ESAB EWH 600 / EWH 1000 User manual

Brand: ESAB

Model: EWH 600 / EWH 1000

Category: Welding System

Type: User manual

ESAB EWH 600 / EWH 1000 welding heads offer precise and efficient welding solutions for both SAW and GMAW (MIG/MAG) processes. Designed for use with EAC 10 control unit and compatible power sources, these welding heads excel in submerged arc welding, twin wire welding, and flat fillet welding applications. The EWH 1000 is specifically suited for SAW, while the EWH 600 is ideal for GMAW welding.

Versoarc

Instruction manual

0463 627 101 GB 20200513

Valid for: 905- and 910-xxx-xxxx

EWH600 / EWH1000

Welding head

TABLE OF CONTENTS

0463 627 101 © ESAB AB 2020

SAFETY

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

1.1 Meaning of symbols

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

1.2 Safety precautions

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

INTRODUCTION

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

2.1 Equipment

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

2.2 Welding method

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

2.2.1 Definitions............................................................................................. 7

2.2.2 Submerged Arc Welding (SAW) ........................................................... 7

2.2.3 GMAW (MIG/MAG) welding ................................................................. 7

TECHNICAL DATA

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

INSTALLATION

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

4.1 Main components of the welding head

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

4.1.1 Description of main parts...................................................................... 11

4.2 Mechanical assembly

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

4.3 Electrical connections

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

OPERATION

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

5.1 Wire feed unit

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

5.1.1 Loading the welding wire...................................................................... 15

5.2 Contact equipment for Submerged Arc Welding

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

5.2.1 For single wire 1.6–5.0mm – (D20) ..................................................... 16

5.2.2 For twin wires 2×1.2–1.6mm – High speed twin (D35)........................ 16

5.2.2.1 Accessories ....................................................................................... 16

5.2.2.2 Adjustment of the wires for twin-arc welding ..................................... 16

5.3 Refilling with flux powder - A4

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

MAINTENANCE

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

6.1 Daily

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

TROUBLESHOOTING

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

ORDERING SPARE PARTS

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

ORDERING NUMBERS

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

ACCESSORIES

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

WEAR PARTS

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

Rights reserved to alter specifications without notice.

1 SAFETY

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1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and

Safety Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety

precautions must meet the requirements that apply to this type of equipment. The following

recommendations should be observed in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

1 SAFETY

0463 627 101

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4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions

when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or

wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.

EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to

EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your

body between the torch and work cables. Never coil the torch or work

cable around your body. Keep welding power source and cables as

far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases

away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens

and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY

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MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only

qualified people remove covers for maintenance and troubleshooting as

necessary. Reinstall panels or covers and close doors when service is

finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable

materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential

locations where the electrical power is provided by the

public low-voltage supply system. There may be

potential difficulties in ensuring electromagnetic

compatibility of class A equipment in those locations,

due to conducted as well as radiated disturbances.

NOTE!

Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on

Waste Electrical and Electronic Equipment and its

implementation in accordance with national law,

electrical and/or electronic equipment that has reached

the end of its life must be disposed of at a recycling

facility.

As the person responsible for the equipment, it is your

responsibility to obtain information on approved

collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment

for purchase. For ordering information contact your local ESAB dealer or visit us on

our website.

2 INTRODUCTION

0463 627 101

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2 INTRODUCTION

EWH 1000 is a welding head intended for single SAW, twin SAW and EWH 600 is intended

for GMAW (MIG/MAG) welding.

It is designed for use with the EAC10 control unit and ESAB Aristo 1000, LAF and TAF

welding power sources. It is also designed for use with compatible analogue power sources.

2.1 Equipment

EWH1000 is supplied with:

• Instruction manual

2.2 Welding method

2.2.1 Definitions

SAW The weld bead is protected by a cover of flux during the

welding.

GMAW (MIG/MAG) welding The weld bead is protected by shielding gas during welding.

Twin wire welding Welding with two wires in one torch.

Flat fillet welding Welding in downhand position, on the top side of the joint.

2.2.2 Submerged Arc Welding (SAW)

Use EWH 1000 or EWH 1000 twin welding equipment for Submerged Arc Welding.

EWH 1000 permits loads up to 1000A (100%).

This version can be equipped with feed rollers for single or twin wire welding (twin-arc). A

special knurled feed roller is available for flux-cored wire, which guarantees even wire feed

without the risk of deformation of welding wire due to high feed pressure.

2.2.3 GMAW (MIG/MAG) welding

For GMAW (MIG/MAG) welding use welding equipment EWH 600 gmaw.

EWH 600 gmaw consists of a GMAW torch and gas shielding equipment.

The welding head is water-cooled. The cooling water is supplied by hoses from connections

intended for the purpose.

3 TECHNICAL DATA

0463 627 101

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3 TECHNICAL DATA

EWH 1000, for serial no. 841-xxx-xxxx, 905-xxx-xxxx and 910-xxx-xxxx

EWH1000 EWH1000twin EWH600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.)

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

4 INSTALLATION

0463 627 101

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4 INSTALLATION

The installation must be carried out by a professional.

CAUTION!

This product is intended for industrial use. In a domestic environment this product may

cause radio interference. It is the user's responsibility to take adequate precautions.

WARNING!

Rotating parts can cause injury, take great care.

4.1 Main components of the welding head

EWH1000

1. Flux hopper 6. Wire straightener memory function

2. Flux valve 7. Contact tip

3. Wire feed motor 8. Contact tube

4. Wire feed pressure 9. Welding current connection (OKC)

5. Wire straightener

4 INSTALLATION

0463 627 101

- 10 -

EWH1000twin

1. Wire feed pressure 4. Welding current connection (OKC)

2. Wire straightener memory function 5. Wire feed motor

3. Contact tips

4 INSTALLATION

0463 627 101

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EWH600gmaw

1. Contact tip 5. Wire feed motor

2. Wire straightener memory function 6. Solenoid valve

3. Wire feed unit 7. Gas valve

4. Wire feed pressure 8. Welding current connection

4.1.1 Description of main parts

Flux hopper

The welding flux is poured into the flux hopper and is then directed to the work piece through

the flux hose and the flux nozzle. The welding flux which is released via the flux valve which

is fitted on the flux hopper.

Wire feed unit

The wire feed unit is used to feed the welding wire down into the weld pool through the

contact tube.

Wire feed unit, wire feed pressure roll, wire straightener

The wire feed mecahnism is used to straighten and feed the wire.

Wire straightener memory function

The wire straightener memory function makes it possible to change wire roll without adjusting

the wire feed mechanism as long as same dimension of wire is used.

Contact tip

The contact tip transmits the energy to the welding wire during welding.

Welding current connection

The connector lets you connect the welding cables with quick connectors (OKC connectors).

Both connectors needs to be used when welding over 500A.

4 INSTALLATION

0463 627 101

- 12 -

Wire feed motor

The motor with gear is used to feed the welding wire.

Solenoid

A solenoid valve is used to regulate the supply of the insert gases.

Gas

The gas is used to create a gas shield, to protect the weld bead during welding.

4.2 Mechanical assembly

For single and twin welding heads:

Mount the welding head on the carrier (1) and lock in into position (2).

The wire guide is delivered in assembled position (3).

NOTE!

Check if the connection is fixed and mount if needed.

4 INSTALLATION

0463 627 101

- 13 -

For gmaw welding head:

Mount the welding head on the carrier (1) and lock in into position (2).

The wire guide is delivered in assembled position (3).

NOTE!

Check if the connection is fixed and mount if needed.

Connect the solenoid and gas source (4).

4 INSTALLATION

0463 627 101

- 14 -

4.3 Electrical connections

Connection to the welding head

Connect the control unit EAC10.

Connect the welding cable or welding cables between the power source and the welding

head.

Maximum 500 A per 120 mm

welding cable (AWG: 4/0 (0000) ).

Connection to the EAC 10 motor drive unit

5 OPERATION

0463 627 101

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5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY"

chapter of this manual. Read it through before you start using the equipment!

5.1 Wire feed unit

5.1.1 Loading the welding wire

NOTE!

The feed rollers are marked with their respective groove diameter (D) on the side of

the roller.

1. Turn off EAC10 using the On/Off

switch.

2. Check that feed roller (1) and

contact nozzle (2) have the correct

dimension for the selected welding

wire.

3. Turn the knob (3) to release the wire

straightener.

4. Lift up the wire straightener with

memory (4). There will be no

change in the settings.

5. Feed the welding wire (5) into the

contact nozzle.

6. Lower the wire straightener with

memory (4) back to its position.

Lock by turning the knob (3) fully.

7. Turn on EAC10 and select the

welding wire when prompted on the

display.

8. With control unit EAC10: Feed the

welding wire through the contact

nozzle until it is visible below the

contact nozzle.

9. When needed, adjust wire feed

pressure with knob (6).

10. When needed, adjust wire

straightness with knob (7).

NOTE!

Do not tighten feed pressure knob (6) too hard. This can result in overheating the

wire feeder.

5 OPERATION

0463 627 101

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5.2 Contact equipment for Submerged Arc Welding

5.2.1 For single wire 1.6–5.0mm – (D20)

The following are included:

• Wire feed unit (1),

• Connector D20 (2),

• Contact tip (3) (M12 thread).

Tighten the contact tip (3) with a key in order to

ensure that a good contact is achieved.

5.2.2 For twin wires 2×1.2–1.6mm – High speed twin (D35)

Use automatic welding equipment EWH1000twin, where the

following are included:

• Wire feed unit (1),

• Connector Twin D35 (2),

• Contact tip (3),

Tighten the contact tip (3) with a key in order to ensure that a good contact is achieved.

5.2.2.1 Accessories

• Fine-wire straightener (5) to be fitted on top of the clamp of the

wire feed unit (1).

NOTE!

When mounting the fine-wire straightener, remove the

plate (7) if it exists.

NOTE!

Do not remove the protection plate (8).

5.2.2.2 Adjustment of the wires for twin-arc welding

Position the wires in the joint so as to achieve optimal weld quality by rotating the connector.

The two wires can be rotated so that they are positioned one after the other along the line of

the joint, or in any position up to 90° across the joint, i.e. one wire on each side of the joint.

5 OPERATION

0463 627 101

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5.3 Refilling with flux powder - A4

1. Close the flux valve (1) on the flux hopper.

2. Remove the optional OPC flux recovery on the

flux hopper, if fitted.

3. Fill with flux powder.

NOTE!

The flux powder must be dry. Use

preheated flux powder only when the

flux hopper is designed for that.

4. Position the flux tube without twisting it.

5. Adjust the height of the flux nozzle above the weld

so that the correct amount of flux is delivered.

Flux coverage should be sufficient so that

penetration of the arc does not occur.

6 MAINTENANCE

0463 627 101

- 18 -

6 MAINTENANCE

NOTE!

Regular maintenance is important for safe and reliable operation.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer attempts

any work to rectify any faults in the product during the warranty period.

WARNING!

The mains supply must be disconnected during cleaning and maintenance.

6.1 Daily

• Clean flux and dirt off moving parts.

• Check that the contact tip and all electrical cables are connected.

• Check that electrical cables are not damaged.

• Check that all bolted joints are tight.

• Check that guides and drive rollers are not worn or damaged.

• Check the electrode control, drive rollers and contact tip of the electrode feed unit.

• Check the brake hub braking torque. Tighten if the wire reel continues to rotate when

the wire feed is stopped. Loosen if the feed rollers slip. As a guide, the braking torque

for a 30kg wire reel should be 1.5Nm.

To adjust the braking torque, see section "Adjusting the brake hub".

• Replace worn or damaged components.

7 TROUBLESHOOTING

0463 627 101

- 19 -

7 TROUBLESHOOTING

Perform these checks and inspections before sending for an authorised service technician.

• Check that the welding power source is connected to the correct mains voltage.

• Check that all three phases have live voltage (phase sequence is not significant).

• Check that welding cables and connections are not damaged.

• Check that the controls are correctly set.

• Check that the mains voltage is disconnected before starting any type of repair action.

Type of fault Possible cause Action

Current and

voltage readings

show large

fluctuations

Contact jaws or nozzle are

worn or wrong size.

Replace contact jaws or nozzle.

Wire feed roller pressure is

inadequate.

Increase pressure on wire feed rollers.

Wire feed is

uneven

Pressure on wire feed rollers

is incorrectly set.

Adjust pressure on wire feed rollers.

Wire feed rollers are of the

wrong size.

Replace wire feed rollers.

Grooves in wire feed rollers

are worn.

Replace wire feed rollers.

Wire feed is not

functioning

Wire feed roller pressure is

inadequate.

Adjust pressure on wire feed rollers.

Wrong feed roller is used. Replace feed roller.

Welding cables

are overheating

Poor electrical connection. Clean and tighten all electrical

connections.

Cross-sectional area of

welding cables is too small.

Use cables with a larger cross-section or

use parallel cables.

Incorrect motor

speed

Error in encoder. No feedback

in the system.

Check the electrical connections.

Check cables.

Bad or no start of

welding or arc

ignition

Poor electrical connection in

welding cables.

Tighten the OKC connectors.

Check welding cables.

Poor connection for welding

wire.

Make sure that the welding wire is

straightly cut.

Aristo 1000: Poor connection

for welding wire, no

(+)feedback.

Check the electrical connections. Check

cables.

Poor welding

result

Bad or no feedback to the

system.

Check the electrical connections. Check

cables.

LAF, TAF: No (-)feedback. Check the electrical connections. Check

cables.

8 ORDERING SPARE PARTS

0463 627 101

- 20 -

8 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service

technician. Use only ESAB original spare and wear parts.

EWH600 and EWH1000 are designed and tested in accordance with international ISO

3821:2019, European standards IEC/EN 60974-1, IEC/EN 60974-3, IEC/EN 60974-10,

Canadian standard CAN/CSA-E60974-1 and US standard ANSI/IEC 60974-1. 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 above standard.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures

correct delivery.

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ESAB EWH 600 / EWH 1000 User manual

Brand: ESAB

Model: EWH 600 / EWH 1000

Category: Welding System

Type: User manual

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ESAB EWH 600 / EWH 1000 User manual

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