ESAB EAC 10 is a versatile control panel designed for various welding processes with submerged arc welding (SAW) and gas metal arc welding (GMAW) capabilities. This user-friendly control panel offers customizable welding parameters, allowing you to adjust settings like arc voltage, wire feed speed, travel speed, and welding direction to achieve precise and high-quality welds.
ESAB EAC 10 is a versatile control panel designed for various welding processes with submerged arc welding (SAW) and gas metal arc welding (GMAW) capabilities. This user-friendly control panel offers customizable welding parameters, allowing you to adjust settings like arc voltage, wire feed speed, travel speed, and welding direction to achieve precise and high-quality welds.
Instruction manual
0463 612 001 US 20190305
Valid for: From software version: 1.01A
EAC 10 Control panel
TABLE OF CONTENTS
0463 612 001 © ESAB AB 2019
1
INTRODUCTION.......................................................................................... 4
1.1 Language................................................................................................. 4
1.2 Control panel .......................................................................................... 4
1.3 Initial configuration ................................................................................ 6
2
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................................................................. 12
3
SUBMERGED ARC WELDING (SAW)........................................................ 13
3.1 Settings for Submerged Arc Welding................................................... 13
4
GAS METAL ARC WELDING (GMAW)....................................................... 14
4.1 Settings for Gas Metal Arc Welding...................................................... 14
5
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
6
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 Authorization profiles ............................................................................ 19
TABLE OF CONTENTS
0463 612 001 © ESAB AB 2019
7
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
By default, the control panel is set to English. 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!
There may be differences in the way the panel functions, depending on the product
in which 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 downward
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 upward 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.
Up
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 selection.
The Back button (6) is used to go back one step in the menu.
Press the Manual wire feed upward button (7) to feed the wire upward. The
wire is fed as long as the button is pressed.
Press the Travel motion (8) button to drive in the welding direction of the
symbol indicated on the weld equipment.
The Fast motion button (9) is used together with other buttons to increase
speed. Press the button to activate fast motion and then press the manual
wire feed button (7, 10) or the 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 the Manual wire feed downward button (10) to feed the wire
downward. The wire is fed as long as the button is pressed.
Press the Travel motion (11) button to drive in the welding direction of the
symbol indicated on the weld equipment.
Three different welding data memories per welding head can be stored in the
control panel memory using soft keys 1, 2, and 3 (12). The soft keys also have
various functions depending on which menu is currently in use. The current
function is displayed in the text in the bottom row of the display.
The welding current/ wire feed speed/ balance knob
1
(3) is used to increase
or decrease set values.
The arc voltage/ offset voltage knob
1
(4) is used to increase or decrease set
values.
The travel speed/ frequency knob
1
(13) is used to increase or decrease set
values.
1
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 authorized user to change the configuration in the GENERAL SETTINGS
menu.
1. Select a language using the Up/Down/Right/Left buttons. Confirm with OK or with the
middle button.
2. Select a measurement unit using the Right/Left buttons. Confirm with OK or with the
middle button.
3. Set the 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 the 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 a 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 a 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 either the SET or MEASURED screen is shown, long press OK to open the
extended WELDING MENU. The information on the display depends on the
authorization level. The authorization level is shown with an icon in the upper-right
corner of the display, and explained in section "Authorization 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 an ESAB original spare part to continue using this feature.
2. If no digital power source is attached, a menu for selecting the type of analog power
source is shown.
The previously used analog power source is shown if on/off switch is in positionII.
Press any button within 3seconds to open the menu and change the analog power
source using the Up/Down and OK buttons.
If no button is pressed, startup will proceed with no changes to the power source.
3. The previously selected wire type and wire dimension are shown. Press any button
within 7seconds to open the menu. Select a wire type and wire dimension using the
Up/Down and OK buttons.
If no button is pressed, the control panel continues to the SET menu with no changes
to the 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 of the OK button when an AC power source is connected will open
the AC settings screen. A long press of the OK button 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 of the 1, 2, or 3 key 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 the selected welding method.
SET MEASURED
The SET screen is used to change welding settings and save settings to the memory slots
using the 1, 2, and 3 keys.
2 MENUS
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Turn any of the knobs during welding to open the SET screen from the MEASURED screen.
The values are shown for 2seconds before returning to the MEASURED screen unless any
adjustments are made.
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 is
possible to save settings for easy access.
A short press of the 1, 2, or 3 key will display the saved welding data memory
settings, set the values, and show 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 an AC power source: A short press of the OK button opens the AC
SETTINGS screen.
A long press of the OK button opens the WELDING MENU. Return by pressing the
Back button.
2.4.1 Set screen, AC power source
SET MEASURED
With an AC power source: A short press of the OK button opens the AC
SETTINGS screen.
With an Aristo®1000 power source and SAW welding head: A short press of 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.
2 MENUS
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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.
2.6 Welding menu
When either the SET or MEASURED screen is shown, long press OK to open the
extended WELDING MENU.
The information on the display depends on the authorization level, and the attached power
source and welding head. The authorization level is shown with an icon in the upper-right
corner of the display.
Example welding menu for Aristo®1000 AC/DC
WELDING MENU
METHOD
REGULATION TYPE
START TYPE
CRATER FILL TIME
BURNBACK TIME
DC+
CA
DIRECT
0.0s
0.50s
Example of welding menu for GMAW welding
WELDING MENU
METHOD
REGULATION TYPE
START TYPE
CRATER FILL TIME
BURNBACK TIME
DC+
CA
DIRECT
0.0s
0.50s
Example welding menu for SAW welding with LAF or TAF
WELDING MENU
REGULATION TYPE
START TYPE
CRATER FILL TIME
BURNBACK TIME
CA
DIRECT
0.0s
0.7s
2 MENUS
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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.
Press OK or the middle button to confirm and return to the previous menu
level. The new value is displayed.
Return to the previous menu level WITHOUT changed settings with Back
or the Left button.
2.7 Tools menu
NOTE!
Authorization level: Manager, see section "Authorization 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!
Authorization level: Manager, see section "Authorization 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 MENUS
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2.9 Machine configuration menu
NOTE!
Authorization level: Service, see section "Authorization profiles".
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
1)
14 - 50 V 0.1 V (1V) 30V
Welding current
1)
(CA)
0 - 3200 A 1 A 400 A
Wire feed speed
1)
(CW)
0 - 2500 cm/min 0.33 ft./min (1
cm)
300 cm/min
Travel speed* 0 - 200 cm/min 0.33 ft./min (1
cm)
50 cm/min
Welding direction ▲ - ▲
AC frequency
3)
10 - 100 Hz 1 50 Hz
AC balance
3)
25 - 75% 1 50%>
AC offset
3)
-300 - +300 A/-10 - +10V 1 A/0.1 V 0
Start data
2)
Start type Direct or Scratch - Direct
Stop data
2)
Crater filling time 0 - 10 s 0.1 s 1 s
Burnback time 0 - 10 s 0.01 s
0.55s DC
3)
0.66s AC
3)
1)
The setting range is dependent on the product used.
2)
The menu shows the settings that belong to the selected regulation type.
3)
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 0.33 ft./min (1
cm)
300 cm/min
Travel speed* 0 - 200 cm/min 0.33 ft./min (1
cm)
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 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 a burnback time results in a long
wire stickout after finishing the welding, with a risk of the wire catching 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
1
2
180917
181021
11:24:13
10:15:36
8
8
19
17
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 an 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 = Analog 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.
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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 to transfer. 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
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Unit information is mainly used by service and support.
UNIT INFORMATION
MACHINE ID
47
NODE ID
18
SOFTWARE VERSION
4.65C
SETTING WELD DATA UNIT
UPDATE
6.5 Authorization profiles
Three different authorization 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 authorization level
The equipment starts with authorization level Normal if an authorization level USB is not
available during startup.
To change authorization level, turn off the EAC10 control panel. Insert the USB memory with
the authorization profile. Start the EAC10 control panel. The EAC10 control panel will
confirm the USB memory with a beep during startup.
NOTE!
Change back to authorization level Normal by restarting without the USB memory.
Only removing the USB memory will not change authorization level.
Create authorization profile USB
The authorization profiles are created using a USB memory. The USB memory must be
formatted in FAT32. Create separate authorization 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 the authorization profile Manager
or enter SERVICE to create the authorization profile Service.
NOTE!
The authorization 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 EAC10. 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 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: Contact 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 power supply to reset the unit. If the error persists, send
for a service technician.
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ESAB EAC 10 is a versatile control panel designed for various welding processes with submerged arc welding (SAW) and gas metal arc welding (GMAW) capabilities. This user-friendly control panel offers customizable welding parameters, allowing you to adjust settings like arc voltage, wire feed speed, travel speed, and welding direction to achieve precise and high-quality welds.
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