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Versoarc
Service manual
0463 656 001 GB 20191016
Valid for: serial no. 841- and 905-xxx-xxxx
EWH1000
Weldinghead
TABLE OF CONTENTS
0463 656 001 © ESAB AB 2019
READ THIS FIRST
....................................................................................
3
BEFORE STARTING SERVICE
................................................................
4
Service aid
..............................................................................................
4
INTRODUCTION
.......................................................................................
5
WIRING DIAGRAM
...................................................................................
6
Serial number 841-xxx-xxxx
..................................................................
7
Serial number 905-xxx-xxxx
..................................................................
8
TECHNICAL DATA
...................................................................................
9
DISASSEMBLY AND REASSEMBLY
......................................................
10
REPLACEMENT INSTRUCTIONS
...........................................................
13
Replacing wire straightener with memory
...........................................
13
Replacing the clamp
..............................................................................
13
Replacing the welding current clamp
...................................................
14
SPARE PARTS AND ACCESSORIES
.....................................................
15
Rights reserved to alter specifications without notice.
READ THIS FIRST
0463 656 001
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© ESAB AB 2019
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
February 2019.
The manual is valid for EWH1000 with serial no. 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.
EWH1000 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 656 001
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© ESAB AB 2019
BEFORE STARTING SERVICE
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 610×610mm /
24×24in)
• A 1.5m (3.28ft) long ground cable with
a crocodile clip
• An adjustable wrist strap and cable with
a built-in protective resistor
Antistatic service kit
INTRODUCTION
0463 656 001
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© ESAB AB 2019
INTRODUCTION
EWH1000 is a welding head intended for single SAW, twin SAW and GMAW (MIG/MAG)
welding.
It is designed for use with the EAC10 control unit and ESAB digital power sources
Aristo1000, LAFxxx1 or TAFxxx1 and through the analogue interface also LAF 635,
LAF800 and LAF 1000. It also supports analogue controlled power sources from other
suppliers.
WIRING DIAGRAM
0463 656 001
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© ESAB AB 2019
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.
The control unit EAC10 detects the welding head in use by a specific resistance (R1) in
accordance with the list below:
56 Ohm EWH 1000 single
100Ohm EWH 1000 twin
220Ohm EWh 1000 gmaw
NOTE!
Wire feeder motor encoder supply voltage: 24VDC.
WIRING DIAGRAM
0463 656 001
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© ESAB AB 2019
Serial number 841-xxx-xxxx
WIRING DIAGRAM
0463 656 001
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© ESAB AB 2019
Serial number 905-xxx-xxxx
TECHNICAL DATA
0463 656 001
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© ESAB AB 2019
TECHNICAL DATA
EWH 1000, from serial no. 841-xxx-xxxx
EWH1000 EWH1000twin EWH1000gmaw
Supply voltage 42 V AC 42 V AC 42 V AC
Permissible load at
100%
1000 A 1000 A 600 A
Wire dimensions
Fe solid single 1.6–5.0 mm
(0.06–0.20in.)
NA 0.8–2.5 mm
(0.03–0.10in.)
Fe solid twin
2×1.2–3.2 mm
1)
(2×0.05–0.09in.
1)
)
2×1.2–1.6 mm
(2×0.05–0.06in.)
NA
Fe flux cored 1.6–5.0 mm
(0.06–0.20in.)
NA 1.2–3.2 mm
(0.05–1/8in.)
Fe flux cored twin
2×1.2–3.2 mm
1)
(2×0.05–0.09in.
1)
)
NA NA
SS solid 1.6–5.0 mm
(0.06–0.20in.)
NA 0.8–1.6 mm
(0.03–0.06in.)
SS solid twin
2×1.2–2.4 mm
1)
(2×0.05–0.09in.
1)
)
2×1.2–1.6 mm
(2×0.05–0.06in.)
NA
SS flux cored 1.6–5.0 mm
(0.06–0.20in.)
NA 1.2–3.2 mm
(0.05–1/8in.)
SS flux cored twin
2×1.2–2.4 mm
1)
(2×0.05–0.09in.
1)
)
NA NA
Al Solid NA NA 2.5 mm (0.10in.)
Al Flux Cored NA NA NA
Type of gas NA NA CO
2
, Ar
Maximum wire feed speed
Maximum (≤ 4 mm wire) 9.0 m/min
(29.5feet/min)
16 m/min
(52.5feet/min)
16 m/min
(52.5feet/min)
Maximum (5 mm wire) 2.5 m/min (8.2
feet/min)
Brake hub braking
torque
1.5 Nm (13.3in.lb)
Flux hopper volume 6 l 6 l N/A
Dimensions l×w×h 620×530×832mm
(24.4×20.9×32.8in.)
600×530×805mm
(23.6×20.9×31.7in.)
600×500×760mm
(23.6×19.7×29.9in.)
Weight welding head,
excluding wire and flux
17 kg (37.5lb) 19kg (41.9lb) 16.5kg (36.4lb)
Enclosure class IPXX
EMC classification Class A
1)
with optional twin kit accessory
DISASSEMBLY AND REASSEMBLY
0463 656 001
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© ESAB AB 2019
DISASSEMBLY AND REASSEMBLY
The image shows serial number 905-xxx-xxxx. The disassembly and reassembly of serial
number 841-xxx-xxxx is the same, although a few parts have different location.
DISASSEMBLY AND REASSEMBLY
0463 656 001
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© ESAB AB 2019
Twin head:
DISASSEMBLY AND REASSEMBLY
0463 656 001
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© ESAB AB 2019
Gmaw head:
REPLACEMENT INSTRUCTIONS
0463 656 001
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© ESAB AB 2019
REPLACEMENT INSTRUCTIONS
Replacing wire straightener with memory
Replacing the clamp
REPLACEMENT INSTRUCTIONS
0463 656 001
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© ESAB AB 2019
Replacing the welding current clamp
SPARE PARTS AND ACCESSORIES
0463 656 001
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© ESAB AB 2019
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
Spare parts list 0463 628 001 EWH1000
Instruction manual 0463 627 * EWH 1000
The three last digits in the document number of the manual show the version of the manual.
Therefore they are replaced with * here. Make sure to use a manual with a serial number or
software version that corresponds with the product, see the front page of the manual.
/
