ESAB EAC 10 User manual

Brand: ESAB

Model: EAC 10

Category: Welding System

Type: User manual

Service manual

0463 610 001 GB 20200114

Valid for: serial no. 841- and 905-xxx-xxxx

EAC 10 Control unit

TABLE OF CONTENTS

0463 610 001 © ESAB AB 2020

READ THIS FIRST

....................................................................................

BEFORE STARTING SERVICE

................................................................

Service aid

..............................................................................................

ESAB tools

..............................................................................................

INTRODUCTION

.......................................................................................

ERROR CODES

........................................................................................

Error code description

...........................................................................

WIRING DIAGRAM

...................................................................................

Component description

.........................................................................

EAC 10 Control pendant, from serial number 841- and

905-xxx-xxxx

...........................................................................................

EAC 10 Control unit, from serial number 841- and 905-xxx-xxxx

......

TECHNICAL DATA

...................................................................................

SOFTWARE UPDATE AND CONFIGURATION

.......................................

Motor control board 26AP1

...................................................................

Welding data board 1AP1

......................................................................

Updating software ................................................................................ 25

Reset with reset.txt............................................................................... 25

TROUBLESHOOTING

..............................................................................

INSTALLATION AND CONNECTIONS

....................................................

External connections

.............................................................................

On/Off switch (2)................................................................................... 28

Connection welding head (5)................................................................ 29

Connection for digital power source (7)................................................ 29

Connection for compatible DC analogue power source (8).................. 29

USB connection.................................................................................... 30

CAN, connection for control unit or service tool (3)

...........................

Internal connections

..............................................................................

Emergency stop ................................................................................... 33

Travel limit switches ............................................................................. 33

Motor drive and field supply ................................................................. 34

Motor encoder ...................................................................................... 34

42 V AC output ..................................................................................... 35

DISASSEMBLY AND REASSEMBLY

......................................................

Motor drive unit

......................................................................................

Control pendant

......................................................................................

REPLACEMENT INSTRUCTIONS

...........................................................

Replacing the front plate

.......................................................................

Replacing the rubber pieces

.................................................................

TABLE OF CONTENTS

0463 610 001 © ESAB AB 2020

Replacing the display

............................................................................

DESCRIPTION OF OPERATION

..............................................................

1AP1 Welding data board

......................................................................

1AP1:1 Power supply and CAN bus..................................................... 42

1AP1:2 Display control ......................................................................... 45

1AP1:3 Push button monitoring............................................................ 46

1AP1:4 USB memory ........................................................................... 46

1AP1:5 Encoder monitoring ................................................................. 47

1AP1 Component positions.................................................................. 49

24AP1 Analogue interface board

..........................................................

24AP1:1 Power supply and CAN bus................................................... 50

24AP1:2 Weld data measurement........................................................ 54

24AP1:3 Digital output and voltage reference...................................... 55

Component positions............................................................................ 56

26 Motor control & motor drive

.............................................................

26AP1 Motor control board

...................................................................

Circuit board identity............................................................................. 57

26AP1:1 Power supply ......................................................................... 57

26AP1:2 CAN bus and termination ...................................................... 58

26AP1:3 Encoder for wire feed motor ............................................... 59

26AP1:4 Encoder for travel motor ........................................................ 59

26AP1:5 Travel limit switches............................................................... 60

26AP1:7 External Start/Stop switch ..................................................... 60

26AP1 Component positions................................................................ 61

26AP2 Motor drive board

.......................................................................

26AP2:1 Power supply ......................................................................... 62

26AP2:2 Motor 1 drive (Wire feed at CN7)........................................... 63

26AP2:3 Motor 2 drive (Travel motion at CN6) .................................... 65

26AP2:4 Relay outputs......................................................................... 66

26AP2 Component positions................................................................ 67

SERVICE INSTRUCTIONS

.......................................................................

Tools needed

...........................................................................................

Replacing the battery

.............................................................................

SPARE PARTS AND ACCESSORIES

.....................................................

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 610 001

- 4 -

READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

The circuit boards are divided into numbered blocks. Component names in the wiring

diagram are listed in the component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS" chapter

in this manual.

This manual contains details of design changes that have been made up to and including

January 2019.

The manual is valid for:

• EAC 10 with serial number 841- and 905-xxx-xxxx

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for safety and

function, of the specific set-up, lies with the integrator.

The EAC 10 is designed and tested in accordance with the standards stated in the

instruction manual. 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 involved standards.

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

BEFORE STARTING SERVICE

0463 610 001

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BEFORE STARTING SERVICE

NOTE!

Follow the instructions when performing service work on the equipment!

Service aid

ESAB can offer a number of service tools that will simplify the service.

Antistatic service kit

Ordering no. 0740 511 001

The kit makes it easier to protect sensitive

components from electrostatic discharge.

Contents:

• A conductive mat (size 610×610mm /

24×24in.)

• A 1.5m (3.28ft) long ground cable with

a crocodile clip

• An adjustable wrist strap and cable with

a built-in protective resistor

ESAB tools

ESAT Service kit

The software update is made from a PC, it has to be managed by a trained service

technician. For this, a PC program called ESAT (ESAB Software Administration Tool) is

needed. The PC is connected to the welding equipment by a cable connector and a CAN

reader. From the ESAT it is possible to update the software. ESAT also contains service

functions by which it is possible to control, change or read the different functions of the

equipment.

For the installation and use of the ESAT a PC with Windows operating system is needed.

The ESAT service kit contents:

• CAN adapter with connection cables

• Software

• Instruction manual for ESAT

Ordering no:

0458847881 USB2CAN for connection to the USB port of the PC

INTRODUCTION

0463 610 001

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INTRODUCTION

Block diagram of the EAC 10 control unit

Design structure of the control unit

EAC 10 is a control unit for power sources intended for submerged arc welding (SAW) and

for gas metal arc welding (GMAW). The control unit includes a motor control for use together

with automatic welding machines.

It has connections for:

• welding power source

• emergency stop

• CAN bus

• USB memory

• motors

• control of flux/gas

• encoders

• limit switches (on the board only)

ERROR CODES

0463 610 001

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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.

Error code description

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

described in the manuals for these units.

Code Description

1 Program memory error (EPROM)

The program memory is damaged. This error does not disable any functions.

Action: Restart the equipment. If the error persists, update the unit with new control

program software. If the error still persists, replace welding data board 1AP1 that

carries the memory chip.

2 Microprocessor RAM error

The microprocessor is unable to read/write from/to a particular memory address in its

internal memory. This test is preformed only as part of initiation after power-up. This

error does not disable any functions.

Action: Restart the equipment. If the error persists, replace the welding data board

1AP1.

3 Error in the external RAM

Read/write test of the processor's external RAM. This test is performed only on

initiation after power-up. The microprocessor is unable to read/write from/to a

particular memory address in its external memory. This error does not disable any

functions.

Action: Restart the equipment. If the error persists, replace the welding data board

1AP1.

4 +5V power supply too low

The unregulated power supply voltage for the processor is too low: the smoothing

capacitors cannot keep the voltage up enough for the processor to continue to

operate. The processor stops all normal activities, expecting to be shut down.

Action: Turn off the mains power supply to reset the unit. If the error persists, check

the power supply to welding data board 1AP1.

6 High temperature

Error code from external source

Action: Check manual for connected units

7 Low current

Error code from external source. To low current detected during 0.3 sec and welding

is interrupted.

Action: Check if something obstruct the welding arc, check for faulty cables. Check

manual for connected units

ERROR CODES

0463 610 001

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Code Description

8 Low battery voltage +3V

The voltage must not be less than 2.4 V. This test is preformed only as part of

initiation after power-up. This error does not disable any functions.

Action: Replace the battery on welding data board 1AP1. If it is not replaced, the

entire contents of the battery-backed memory will be lost at power off.

9 Power supply 2

Error code from external source.

Action: Check manual for connected units.

10 Power supply 3

Error code from external source.

Action: Check manual for connected units.

11 Current servo / wire feed speed servo

Error code from external source.

Action: Check manual for connected units. Check connections and cables to the

motors.

12 Communication error (warning)

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

Action: Check the equipment to ensure that only one wire feed unit and/or remote

control unit is connected.

14 Communication error (bus off)

The system's internal CAN bus has temporarily ceased to work due to excessive

load. The current welding process is stopped.

Action: Check that there are no faulty units connected to the CAN bus. Check the

cables. Turn off the mains power supply to reset the unit.

15 Lost messages

The bus CAN controller indicates that a message has been lost. No functions are

disabled by this error.

Action: Check that all units are correctly connected to the CAN bus.

16 High open circuit voltage

Error code from external source.

Action: Check manual for connected units.

17 Lost contact with other unit

The current activities are stopped and welding start is prevented.

The error may have been caused by an open-circuit in the connection (e.g. in the

CAN cable) between the welding data unit and another unit. The applicable unit is

displayed in the error log.

Action: Check the CAN cabling.

If this error appers directly after installing the EAC 10, check jumper settings inside

the power source. In LAF/TAF power sources: On the AP1 board remove jumper at

CN18 from pin 1-2 and connect it only to pin 3.

ERROR CODES

0463 610 001

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Code Description

19 Memory error in data memory

This error will be detected if the information in the battery-backed-up memory has

become corrupted.

Action: This error corrects itself. Turn off the mains power supply to reset the unit.

Stored data in the current memory section will be lost. If the battery voltage is correct,

and if the error recurs each time the unit is started, there is a error in the persistent

memory. Replace the welding data board 1AP1, in the MMC unit.

26 Program operating error

Something has prevented the processor from performing its normal tasks in the

program. The program restarts automatically. The current welding process will be

stopped. This error does not disable any functions.

Action: This error should not happen. Contact ESAB if the error yet occurs.

27 Faulty wire configuration

Action: PAB user, check wire and dimension settings.

31 No reply from the display unit

The microprocessor has no contact with the display board.

Action: Check the cabling and connectors between the welding data board 1AP1

and the display board 1AP2.

32 No gas flow

External equipment indicates that no gas are flowing.

Action: Check gas flow.

43 High current

The welding power source has measured high current for 0.4 sec and welding is

interrupted.

Action: Check welding power source.

44 Start timeout

If no welding current is detected during the first 10 sec of welding, the welding is

interrupted. The error code is reset at start of the next welding.

Action: Probably no welding arc, check the connections of welding cables and the

return cable from the workpiece.

45 Wire config error

Error code from external equipment.

Action: Check settings against loaded wire.

46 Stop timeout

Secondary power source failed to acknowledge the commando “Stop welding” over

the CAN bus. Only active at master/slave or tandem welding.

Action: If the error is persistant, check CAN bus connections and communications.

47 Current overrun

Welding current set to higher value than power sources (master and slave) can

deliver together.

Action: Decrease welding current.

ERROR CODES

0463 610 001

- 10 -

Code Description

48 Limit switch travel, square direction

Travel has run into limit switch.

54 Exceeded service interval

The limit for exchange of contact tip in the service interval is exceeded.

Action: Change contact tip.

58 Limit switch travel, triangle direction

Travel has run into limit switch.

60 Communication error

Communication error (internal CAN bus)

The system's internal CAN bus has temporarily ceased to work due to excessive

load. The current welding process is stopped.

Action: Check the equipment to ensure that all units are correctly connected. Turn

off the mains power supply to reset the unit.

64 Measuring value limit exceeded

Measured value has exceeded set limit.

Action: Check set limits against registered Q-data.

66 Mixed CAN system

Nodes from Aristo®1000 and LAF/TAF systems are connected in the same system.

Action: Check if the motor card is correctly configured for the system.

67 Primary frequency voltage is outside limits

Applicable to LAF/TAF power sources

Action: Check the voltage frequency.

69 Power source control board processor error

Action: Contact the ESAB Global Service Helpdesk.

71 High current

The welding power source has measured high current for 0.4 sec and welding is

interrupted.

Action: Check welding power source.

88 Inductance to high

Action: Check the length of the welding cables or try welding using a lower current.

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 the equipment to ensure that only one wire feed unit and/or remote

control unit is connected.

95 Communication error (bus off)

The system's internal CAN bus has temporarily ceased to work due to excessive

load. The current welding process is stopped.

Action: Check that there are no faulty units connected to the CAN bus. Check the

cables. Turn off the mains power supply to reset the unit.

ERROR CODES

0463 610 001

- 11 -

Code Description

100 Start timeout

If no welding current is detected during the first 10 sec of welding, the welding is

interrupted. The error code is reset at start of the next welding.

Action: Probably no welding arc, check the connections of welding cables and the

return cable from the workpiece.

168 Motor speed error

Motor speed error code is set for the wire feed motor or the tractor motor.

Action: Check that the wire feeder operates faultlessly, i.e. that the wire and the liner

runs smoothly. If the motor runs uncontrolled at a high speed, check the cables to the

motor. If the cables are OK, replace the encoder or/and the motor. Check the cables

to the tractor motor.

169 Motor speed error

Motor speed error code is set for the wire feed motor or the tractor motor.

Action: Check that the wire feeder operates faultlessly, i.e. that the wire and the liner

runs smoothly. If the motor runs uncontrolled at a high speed, check the cables to the

motor. If the cables are OK, replace the encoder or/and the motor. Check the cables

to the tractor motor.

173 External stop activated from external equipment via I/O unit

181 Incorrect loading files when a whole system was to be updated via USB

Action: Check loading files and use compatible files.

2105 High primary current

2310 Current servo saturation

The power source has temporarily delivered maximum current.

Action: If the error persists, try lowering the weld data.

2320 Arc lost

An arc was not able to establish.

3201 Power supply 3.3 V outside limits

Action: Replace the power source control board.

3202 Power supply 15 V outside limits

Action: Replace the power source control board.

3203 Power supply 24 V outside limits

Action: Replace the power source control board.

3204 Power supply 5 V outside limits

In a system with Aristo® 1000.

The unregulated power supply voltage for the processor is too low: the smoothing

capacitors cannot keep the voltage up enough for the processor to continue to

operate. The processor stops all normal activities, expecting to be shut down.

Action: Turn off the mains power supply to reset the unit. If the error persists, check

the power supply to welding data board 1AP1.

Replace the power source control board.

ERROR CODES

0463 610 001

- 12 -

Code Description

3205 High DC voltage

Action: Check the internal DCvoltage +60V. This error can also be caused by low or

high supply voltage.

3206 Power supply -15 V outside limits

Action: Replace the power source control board.

3207 Power supply -5 V outside limits

Action: Replace the power source control board.

3208 Low battery voltage +3V

In a system with Aristo® 1000.

The voltage must not be less than 2.4 V. This test is preformed only as part of

initiation after power-up. This error does not disable any functions.

Action: Replace the battery on welding data board 1AP1. If it is not replaced, the

entire contents of the battery-backed memory will be lost at power off.

3209 Power supply 2

In a system with Aristo® 1000.

Error code from external source.

Action: Check manual for connected units.

320A Voltage feedback error

Action: Check that measurement cables are connected in the power source.

4200 High temp in power source cabinet

Action: Clean the air filters in the power source to improve the airflow.

4201 High temp on power source power board

Action: Clean the air filters in the power source to improve the airflow.

4202 High temp in power source power block

Action: Clean the air filters in the power source to improve the airflow.

4203 High temp in power transformer

Action: Clean the air filters in the power source to improve the airflow.

4204 High temp in AC block

Action: Clean the air filters in the power source to improve the airflow.

4205 High temp in AC block 2

Action: Clean the air filters in the power source to improve the airflow.

4206 High temp in power source cabinet (warning)

Action: Clean the air filters in the power source to improve the airflow.

4207 High temp on power source power board (warning)

Action: Clean the air filters in the power source to improve the airflow.

4208 High temp in power source power block (warning)

Action: Clean the air filters in the power source to improve the airflow.

4209 High temp in AC block 1 (warning)

Action: Clean the air filters in the power source to improve the airflow.

ERROR CODES

0463 610 001

- 13 -

Code Description

420A High temp in AC block 2 (warning)

Action: Clean the air filters in the power source to improve the airflow.

420B Cabinet sensor lost

420C Power board sensor lost

420D Power block sensor lost

420E AC block 1 sensor lost

420F AC block 2 sensor lost

5001 Internal flash error in power source control board

Action: Replace the power source control board.

5002 RAM error in power source control board

In a system with Aristo® 1000.

The microprocessor is unable to read/write from/to a particular memory address in its

internal memory. This test is preformed only as part of initiation after power-up. This

error does not disable any functions.

Action: Restart the equipment. If the error persists, replace the welding data board

1AP1.

Replace the power source control board.

5003 External RAM error in power source control board

Error in the external RAM

In a system with Aristo® 1000.

Read/write test of the processor's external RAM. This test is performed only on

initiation after power-up. The microprocessor is unable to read/write from/to a

particular memory address in its external memory. This error does not disable any

functions.

Action: Restart the equipment. If the error persists, replace the welding data board

1AP1.

Replace the power source control board.

5010 Inductance to high

Action: Check the length of the welding cables or try welding using a lower current.

5019 Memory error

Lost messages

In a system with Aristo® 1000.

The bus CAN controller indicates that a message has been lost. No functions are

disabled by this error.

Action: Check that all units are correctly connected to the CAN bus.

6101 Watchdog error

Action: Contact the ESAB Global Service Helpdesk.

ERROR CODES

0463 610 001

- 14 -

Code Description

6103 Program memory error (EPROM)

Flash

In a system with Aristo® 1000.

The program memory is damaged. This error does not disable any functions.

Action: Restart the equipment. If the error persists, update the unit with new control

program software. If the error still persists, replace welding data board 1AP1 that

carries the memory chip.

Replace the power source control board.

6301 Weld data number does not exist

In a system with Aristo® 1000.

Recall of weld data memory that does not exist.

Action: Save a correct weld data setting in that weld data number.

8100 Communication error (warning)

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

Action: Check the equipment to ensure that only one wire feed unit and/or remote

control unit is connected.

8110 Lost messages

The bus CAN controller indicates that a message has been lost. No functions are

disabled by this error.

Action: Check that all units are correctly connected to the CAN bus.

8117 Lost contact with other unit

The current activities are stopped and welding start is prevented.

The error may have been caused by an open-circuit in the connection (e.g. in the

CAN cable) between the welding data unit and another unit. The applicable unit is

displayed in the error log.

Action: Check the CAN cabling.

If this error appers directly after installing the EAC 10, check the jumper settings

inside the power source. In LAF/TAF power sources: On the AP1 board remove

jumper at CN18 from pin 1-2 and connect it only to pin 3.

8120 Communication error (bus off)

The system's internal CAN bus has temporarily ceased to work due to excessive

load. The current welding process is stopped.

Action: Check that there are no faulty units connected to the CAN bus. Check the

cables. Turn off the mains power supply to reset the unit.

8130 Node lost on CAN bus

Action: Check the nodes.

8140 Communication error SPI power source control board

Action: If the error persists, replace the power source control board.

8141 Heart beat check failure

Action: If the error persists, replace the power source control board.

ERROR CODES

0463 610 001

- 15 -

Code Description

8142 Heart beat lost DSP

Action: If the error persists, replace the power source control board.

8146 SCI communication error on power source control board

Action: If the error persists, replace the power source control board.

8160 Communication error

Communication error (internal CAN bus)

In a system with Aristo® 1000.

The system's internal CAN bus has temporarily ceased to work due to excessive

load. The current welding process is stopped.

Action: Check the equipment to ensure that all units are correctly connected. Turn

off the mains power supply to reset the unit.

8411 Motor speed error

Motor speed error code is set for the wire feed motor or the tractor motor.

Action: Check that the wire feeder operates faultlessly, i.e. that the wire and the liner

runs smoothly. If the motor runs uncontrolled at a high speed, check the cables to the

motor. If the cables are OK, replace the encoder or/and the motor. Check the cables

to the tractor motor.

F001 Welding equipment has been stopped because of error

F004 Start weld time out

In a system with Aristo® 1000.

The power source was not able to start welding.

Action: Check that the welding cables are connected correctly. Check that the wire is

running when feeding wire.

F006 Faulty wire configuration

Action: PAB user, check wire and dimension settings.

F007 Invalid values phase shift and balance

F008 AC unit

F009 AC unit warning

F00A Supply voltage dip

Action: Check the stability of the supply voltage.

F00B Power supply fail

Action: Check the stability of the supply voltage.

WIRING DIAGRAM

0463 610 001

- 16 -

WIRING DIAGRAM

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

Component description

Componet Description

1AP1 Welding data board

1AP2 Display

1AP3 Membrane panel

2L2, X3L3, X4L4 Ferrite ring cores

24AP1 Analogue interface board

26AP1 Motor control board

26AP2 Motor driver board

BR1 Rectifier bridge

C2 Filter capacitor

HL1 Power status indicator lamp

S1 Power switch with input selection

X1 Terminal block

XP1 CAN connector (power source communication)

XP2 Analogue connector (power source communication)

XP3 Tractor carriage connector

XP4 Welding head connector

XP5 Voltage feedback connector (work piece)

VG Virtual ground

WIRING DIAGRAM

0463 610 001

- 17 -

EAC 10 Control pendant, from serial number 841- and 905-xxx-xxxx

WIRING DIAGRAM

0463 610 001

- 18 -

EAC 10 Control unit, from serial number 841- and 905-xxx-xxxx

WIRING DIAGRAM

0463 610 001

- 19 -

TECHNICAL DATA

0463 610 001

- 20 -

TECHNICAL DATA

EAC 10, from serial no. 841-xxx-xxxx and 905-xxx-xxxx

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

Supply voltage to control

pendant

12VDC

Power requirement Max 900VA

Motor connections adapted

for ESAB motors

6A 100%

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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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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