ESAB EWH 50 FSW User manual

Brand: ESAB

Model: EWH 50 FSW

Type: User manual

Service manual

0463 625 001 GB 20190318

Valid for: serial no. 840-, 904-xxx-xxxx

EWH50FSW

Friction stir welding head

TABLE OF CONTENTS

0463 625 001 © ESAB AB 2019

READ THIS FIRST.................................................................................... 3

BEFORE STARTING SERVICE................................................................ 4

Service aid .............................................................................................. 4

INTRODUCTION....................................................................................... 5

Main components of the welding head ................................................ 6

WIRING DIAGRAM................................................................................... 7

Component description ......................................................................... 7

Valid from serial no. 840-xxx-xxxx ........................................................ 7

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

TROUBLESHOOTING .............................................................................. 9

Cooling liquid leakage ........................................................................... 9

REPLACEMENT INSTRUCTIONS ........................................................... 10

Replacing the front bearing................................................................... 10

Replacing the rear bearing .................................................................... 16

SPARE PARTS AND ACCESSORIES ..................................................... 19

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 625 001

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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.

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 AND

ACCESSORIES" 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: EWH50FSW with serial numbers 840- and 904-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.

EWH50FSW 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.

BEFORE STARTING SERVICE

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BEFORE STARTING SERVICE

Service aid

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

Tool kit bearing exchange

Ordering no. 0905 825 880

The tool kit includes tools

needed for replacement of the

front and rear bearings of the

welding head.

INTRODUCTION

0463 625 001

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INTRODUCTION

EWH 50 FSW is an electromechanical friction stir welding head intended for use on a

welding robot or other welding carrier. It is designed for welding plates up to 10 mm in Al6000

alloys. EWH 50 FSW is equipped with an integrated liquid cooling system of the motor

spindle and the FSW tool to secure high volume production and a long lifetime.

INTRODUCTION

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Main components of the welding head

Serial no. 840-xxx-xxxx:

From serial no. 904-xxx-xxxx:

1. Welding head 6. Inlet tool cooling

2. Load cell 15 kN 7. Outlet tool cooling

3. Tool holder 8. Leak alarm holes

4. Inlet motor cooling 9. Power cable

5. Outlet motor cooling 10. Signal and temperature cable

For further information about the components included in the welding head, see the spare

parts list.

WIRING DIAGRAM

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WIRING DIAGRAM

The names of the components included in the EWH50FSW friction steer welding head are

listed in the component description below.

Component description

Component Description

E1.1/M Spindle motor

E2.1/G Hall sensor

E2.2 Temperature sensor

E3 Load cell

E1/X1 Motor power supply connector

XE2 Connector for motor sensors

XE3 Connector for load cell

Valid from serial no. 840-xxx-xxxx

TECHNICAL DATA

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TECHNICAL DATA

EWH50 FSW, from serial no. 840-xxx-xxxx

Rated power supply voltage 400VAC

Rated supply input frequency AC with 50to 400Hz ±5% orDC

Rated input current:

Continuous 40.4A

Peak 93.5A

Maximum spindle rotation 4000 rpm

Spindle power 20 kW

Number of poles 10

Torque 50Nmat0–3200rpm,

15Nmat4000rpm

Tool holder Weldon 25

Axial force 15 kN

Radial force 4.5 kN

Connection motor cooling 2hosesockets,

6mmhoseinnerdiameter

Connection tool cooling 2hosesockets,

6mmhoseinnerdiameter

Force sensor for axial force (capacity load cell type) Resolution20kN/1000,

Accuracy0.1%

Operating temperature +5 to +50°C

Certification mark Declaration of Incorporation

Dimensions Length=297mm, Diameter=232mm

Weight 60kg

TROUBLESHOOTING

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TROUBLESHOOTING

Cooling liquid leakage

If liquid is dripping or running from any of the two leak alarm holes next to the in- and outlet

for the motor cooling, welding must be stopped immediately and the welding head must be

exchanged! Never start welding until the welding head has been exchanged!

If liquid is dripping or running from the leak alarm hole next to the in- and outlet for the tool

cooling, welding must be stopped immediately! If liquid is leaking through this hole, there is a

possibility to repaire the equipment by exchanging the cooling water cap and the seal at the

back end of the welding head.

Serial no. 840-xxx-xxxx: From serial no. 904-xxx-xxxx:

REPLACEMENT INSTRUCTIONS

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REPLACEMENT INSTRUCTIONS

Replacing the front bearing

Equipment required

• Tool kit bearing exchange (ESAB ordering no. 0905 825 880)

• Open end wrenches 46mm, 67mm, 80mm

• Allen keys 4mm, 5mm

• Torx key TX20

• Rubber hammer

• Silicone based lubricating grease, Q8Rubens WBNLGI2, NLGI2.5 or equivalent

NOTE!

The welding head must be mounted onto a gantry or robot while replacing the front

bearing.

1. Using a 4 mm Allen key, unscrew and remove the cover in front of the load cell.

2. Using a TX20 Torx key, unscrew and remove the load cell cable cover.

3. Using a 5 mm Allen key, unscrew and remove the load cell.

4. Loosen the three Allen screws in the nut, unscrew the nut and remove the inner seal

ring.

5. Lubricate the area of contact between the bearing exchange tool and the welding

head axle, by putting some grease on the front edge of the axle.

REPLACEMENT INSTRUCTIONS

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6. Fit the bearing exchange tool to the pull ring, by means of the 8 screws.

7. Pull out the bearing housing from the welding head housing, using the tool.

8. Continue screwing using the tool, until the complete bearing housing comes out of the

welding head housing.

CAUTION!

Be prepared to catch the bearing housing to prevent it from getting damaged or

injuring any persons in the vicinity.

9. Unscrew the 8 screws and remove the bearing exchange tool from the pull ring.

REPLACEMENT INSTRUCTIONS

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10. Unscrew the 8 outer screws in the pull ring and remove the pull ring and the outer seal

ring from the bearing housing.

11. Remove the bearing from the bearing housing. If the bearing runs is stuck, use a

rubber hammer to knock carefully around the inner bearing ring.

12. Insert the new bearing into the bearing housing. Knock carefully around the bearing

using a rubber hammer to get the bearing into the correct position.

13. Attach the pull ring containing the outer seal ring and fasten the 8 screws using the

correct tightening torque according to the illustration.

REPLACEMENT INSTRUCTIONS

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14. Apply grease onto the O-ring on the inside of the welding head and to the outer

surface of the bearing housing.

15. Screw on the nut included in the bearing exchange tool onto the welding head axle.

You should now use the nut to push the bearing housing onto the axle.

Do not insert the inner seal ring before starting to push the bearing housing onto the

axle.

Hold the axle fixed with a wrench while screwing the tool on using another wrench.

When the bearing housing has moved approximately 10mm onto the axle, remove

the nut tool, insert the seal ring, screw on the nut tool again and continue pushing the

bearing housing onto the axle.

When the bearing housing has moved approximately two third of its way onto the axle,

remove the nut tool.

REPLACEMENT INSTRUCTIONS

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16. To push the bearing housing the last millimeters into the correct position, use the

original nut that was attached to the welding head from the beginning. Hold the axle

fixed as before while screwing the nut on using another wrench.

NOTE!

Be careful not to rotate the axle.

Tighten the nut.

NOTE!

Be careful not to damage the threads.

Lock the nut by means of the three Allen screws.

After tightening the nut, make sure that the bearing is in correct position properly. Use

the provided gauge.

○ If the gauge rests on the axle and leaves a small gap between the gauge and

the nut, the bearing is in correct position. Move on to the next step.

○ If the gauge rests on the nut, the bearing is not in correct position and the nut

must be tightened further.

REPLACEMENT INSTRUCTIONS

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17. Reattach the load cell and insert all inner and outer screws into the load cell. Make

sure all inner and outer screws align before fastening any screws!

Fasten all screws very gentle!

Then tighten the 8 inner screws crosswise in steps!

Finally tighten all inner and outer screws using the correct tightening torque according

to the illustration.

Check that the axle is able to rotate.

18. Reattach the load cell cable cover and the cover in front of the load cell, using the

correct tightening torques according to the illustration.

REPLACEMENT INSTRUCTIONS

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Replacing the rear bearing

Equipment required

• Tool kit bearing exchange (ESAB ordering no. 0905 825 880)

• Bearing puller tool fitting bearing size6208

• Allen key 4mm

• Rubber hammer

1. Using a 4mm Allen key, remove the cooling water cap and the seal.

2. Attach the tool included in the tool kit bearing exchange, using the four screws for the

cooling water cap. Remove the spring retaining ring, by depressing the tool and hence

the bearing, using the screws.

Then remove the tool.

3. To be able to attach a bearing puller tool to the bearing to be replaced, remove the

sealing in the bearing.

4. Remove the old bearing using the bearing puller tool (fitting bearing size6208).

5. Before attaching the new bearing, make sure the two spring washers are correctly

located. The spring washers should be positioned against each other according to the

graphic!

6. Use a rubber hammer to carefully wedge the new bearing onto the shaft. Then

continue pressing the bearing into position, using the tool included in the tool kit

(together with the four screws for the cooling water cap).

7. When the bearing is in the correct position, attach the spring retaining ring.

8. Remove the tool included in the tool kit.

9. Attach the cooling water cap and the seal.

REPLACEMENT INSTRUCTIONS

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Serial no. 840-xxx-xxxx:

REPLACEMENT INSTRUCTIONS

0463 625 001

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From serial no. 904-xxx-xxxx:

SPARE PARTS AND ACCESSORIES

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SPARE PARTS AND ACCESSORIES

For spare parts, see the spare parts list for the product. For accessories, see the instruction

manual for the product. These documents can be downloaded from the Internet:

www.esab.com

Document type File name Product Note

Spare parts list 0463 626 001 EWH50FSW

Instruction manual 0463 624 * EWH50FSW

For contact information visit esab.com

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

http://manuals.esab.com

ESAB EWH 50 FSW User manual

ESAB EWH 50 FSW User manual

ESAB EWH 50 FSW User manual

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