ESAB EWH 1000 User manual

Brand: ESAB

Model: EWH 1000

Type: User manual

This manual is also suitable for

EWH 600 / EWH 1000

ESAB EWH 600 / EWH 1000 welding heads are designed for single SAW, twin SAW, and GMAW (MIG/MAG) welding. These versatile machines offer precise control and reliable operation, making them ideal for a wide range of welding applications. With their robust construction and user-friendly interface, the EWH 600 / EWH 1000 are perfect for demanding industrial environments.

Versoarc

Service manual

0463 656 001 GB 20191016

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

EWH1000

Weldinghead

TABLE OF CONTENTS

0463 656 001 © ESAB AB 2019

READ THIS FIRST

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

BEFORE STARTING SERVICE

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

Service aid

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

INTRODUCTION

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

WIRING DIAGRAM

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

Serial number 841-xxx-xxxx

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

Serial number 905-xxx-xxxx

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

TECHNICAL DATA

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

DISASSEMBLY AND REASSEMBLY

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

REPLACEMENT INSTRUCTIONS

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

Replacing wire straightener with memory

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

Replacing the clamp

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

Replacing the welding current clamp

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

SPARE PARTS AND ACCESSORIES

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

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 656 001

- 3 -

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 EWH1000 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.

EWH1000 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

- 4 -

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 610×610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

Antistatic service kit

INTRODUCTION

0463 656 001

- 5 -

INTRODUCTION

EWH1000 is a welding head intended for single SAW, twin SAW and GMAW (MIG/MAG)

welding.

It is designed for use with the EAC10 control unit and ESAB digital power sources

Aristo1000, LAFxxx1 or TAFxxx1 and through the analogue interface also LAF 635,

LAF800 and LAF 1000. It also supports analogue controlled power sources from other

suppliers.

WIRING DIAGRAM

0463 656 001

- 6 -

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 EAC10 detects the welding head in use by a specific resistance (R1) in

accordance with the list below:

56 Ohm EWH 1000 single

100Ohm EWH 1000 twin

220Ohm EWh 1000 gmaw

NOTE!

Wire feeder motor encoder supply voltage: 24VDC.

WIRING DIAGRAM

0463 656 001

- 7 -

Serial number 841-xxx-xxxx

WIRING DIAGRAM

0463 656 001

- 8 -

Serial number 905-xxx-xxxx

TECHNICAL DATA

0463 656 001

- 9 -

TECHNICAL DATA

EWH 1000, from serial no. 841-xxx-xxxx

EWH1000 EWH1000twin EWH1000gmaw

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

(0.06–0.20in.)

NA 0.8–2.5 mm

(0.03–0.10in.)

Fe solid twin

2×1.2–3.2 mm

(2×0.05–0.09in.

)

2×1.2–1.6 mm

(2×0.05–0.06in.)

Fe flux cored 1.6–5.0 mm

(0.06–0.20in.)

NA 1.2–3.2 mm

(0.05–1/8in.)

Fe flux cored twin

2×1.2–3.2 mm

(2×0.05–0.09in.

)

NA NA

SS solid 1.6–5.0 mm

(0.06–0.20in.)

NA 0.8–1.6 mm

(0.03–0.06in.)

SS solid twin

2×1.2–2.4 mm

(2×0.05–0.09in.

)

2×1.2–1.6 mm

(2×0.05–0.06in.)

SS flux cored 1.6–5.0 mm

(0.06–0.20in.)

NA 1.2–3.2 mm

(0.05–1/8in.)

SS flux cored twin

2×1.2–2.4 mm

(2×0.05–0.09in.

)

NA NA

Al Solid NA NA 2.5 mm (0.10in.)

Al Flux Cored NA NA NA

Type of gas NA NA CO

, Ar

Maximum wire feed speed

Maximum (≤ 4 mm wire) 9.0 m/min

(29.5feet/min)

16 m/min

(52.5feet/min)

16 m/min

(52.5feet/min)

Maximum (5 mm wire) 2.5 m/min (8.2

feet/min)

Brake hub braking

torque

1.5 Nm (13.3in.lb)

Flux hopper volume 6 l 6 l N/A

Dimensions l×w×h 620×530×832mm

(24.4×20.9×32.8in.)

600×530×805mm

(23.6×20.9×31.7in.)

600×500×760mm

(23.6×19.7×29.9in.)

Weight welding head,

excluding wire and flux

17 kg (37.5lb) 19kg (41.9lb) 16.5kg (36.4lb)

Enclosure class IPXX

EMC classification Class A

with optional twin kit accessory

DISASSEMBLY AND REASSEMBLY

0463 656 001

- 10 -

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

- 11 -



Twin head:



DISASSEMBLY AND REASSEMBLY

0463 656 001

- 12 -

Gmaw head:

REPLACEMENT INSTRUCTIONS

0463 656 001

- 13 -

REPLACEMENT INSTRUCTIONS

Replacing wire straightener with memory

Replacing the clamp

REPLACEMENT INSTRUCTIONS

0463 656 001

- 14 -

Replacing the welding current clamp

SPARE PARTS AND ACCESSORIES

0463 656 001

- 15 -

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 EWH1000

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.

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 1000 User manual

Brand: ESAB

Model: EWH 1000

Type: User manual

This manual is also suitable for

EWH 600 / EWH 1000

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ESAB EWH 1000 User manual

This manual is also suitable for

ESAB EWH 1000 User manual

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