Versoarc
Instruction manual
0463 627 101 GB 20200513
Valid for: 905- and 910-xxx-xxxx
EWH600 / EWH1000
Welding head
TABLE OF CONTENTS
0463 627 101 © ESAB AB 2020
1
SAFETY
.......................................................................................................
4
1.1 Meaning of symbols
...............................................................................
4
1.2 Safety precautions
.................................................................................
4
2
INTRODUCTION
..........................................................................................
7
2.1 Equipment
...............................................................................................
7
2.2 Welding method
......................................................................................
7
2.2.1 Definitions............................................................................................. 7
2.2.2 Submerged Arc Welding (SAW) ........................................................... 7
2.2.3 GMAW (MIG/MAG) welding ................................................................. 7
3
TECHNICAL DATA
......................................................................................
8
4
INSTALLATION
............................................................................................
9
4.1 Main components of the welding head
................................................
9
4.1.1 Description of main parts...................................................................... 11
4.2 Mechanical assembly
.............................................................................
12
4.3 Electrical connections
...........................................................................
14
5
OPERATION
................................................................................................
15
5.1 Wire feed unit
..........................................................................................
15
5.1.1 Loading the welding wire...................................................................... 15
5.2 Contact equipment for Submerged Arc Welding
................................
16
5.2.1 For single wire 1.6–5.0mm – (D20) ..................................................... 16
5.2.2 For twin wires 2×1.2–1.6mm – 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
..............................................................
17
6
MAINTENANCE
...........................................................................................
18
6.1 Daily
.........................................................................................................
18
7
TROUBLESHOOTING
.................................................................................
19
8
ORDERING SPARE PARTS
........................................................................
20
ORDERING NUMBERS
.......................................................................................
21
ACCESSORIES
...................................................................................................
22
WEAR PARTS
......................................................................................................
24
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
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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
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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 EAC10 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
EWH1000 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 1000A (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
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3 TECHNICAL DATA
EWH 1000, for serial no. 841-xxx-xxxx, 905-xxx-xxxx and 910-xxx-xxxx
EWH1000 EWH1000twin EWH600gmaw
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.)
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
4 INSTALLATION
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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
EWH1000
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
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EWH1000twin
1. Wire feed pressure 4. Welding current connection (OKC)
2. Wire straightener memory function 5. Wire feed motor
3. Contact tips
4 INSTALLATION
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EWH600gmaw
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
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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
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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
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4.3 Electrical connections
Connection to the welding head
Connect the control unit EAC10.
Connect the welding cable or welding cables between the power source and the welding
head.
Maximum 500 A per 120 mm
2
welding cable (AWG: 4/0 (0000) ).
Connection to the EAC 10 motor drive unit
5 OPERATION
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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 EAC10 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 EAC10 and select the
welding wire when prompted on the
display.
8. With control unit EAC10: 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
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5.2 Contact equipment for Submerged Arc Welding
5.2.1 For single wire 1.6–5.0mm – (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 2×1.2–1.6mm – High speed twin (D35)
Use automatic welding equipment EWH1000twin, 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
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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
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© ESAB AB 2020
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 30kg wire reel should be 1.5Nm.
To adjust the braking torque, see section "Adjusting the brake hub".
• Replace worn or damaged components.
7 TROUBLESHOOTING
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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
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© ESAB AB 2020
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.
EWH600 and EWH1000 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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