ESAB EWT 1000 User manual

Versotrac

Service manual

0463 653 001 GB 20190322

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

EWT1000

TABLE OF CONTENTS

0463 653 001 © ESAB AB 2019

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

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

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

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

ERROR CODES........................................................................................ 6

TECHNICAL DATA ................................................................................... 7

WIRING DIAGRAM................................................................................... 9

Serial number 841-xxx-xxxx .................................................................. 10

Serial number 905-xxx-xxxx .................................................................. 11

DISASSEMBLY AND REASSEMBLY ...................................................... 12

Tractor carriage ...................................................................................... 12

Column .................................................................................................... 13

Bobbin holder ......................................................................................... 14

REPLACEMENT INSTRUCTIONS ........................................................... 15

Replacing the wheel shaft ..................................................................... 15

Replacing the drive motor ..................................................................... 15

Replacing the column ............................................................................ 16

SPARE PARTS AND ACCESSORIES ..................................................... 17

Rights reserved to alter specifications without notice.

READ THIS FIRST

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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.

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 EWT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.

EWT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

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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

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INTRODUCTION

The EWT 1000 automatic welding equipment is designed for Submerged Arc Welding

(SAW) and MIG/MAG welding of butt and fillet joints.

All other applications are prohibited.

EWT 1000 is roughly divided into these four modules:

• Tractor carriage

• Bobbin holder

• Welding head EWH 1000, covered in service manual 0463 656 001.

• Column including the control unit EAC10, covered in service manual 0463 610 001

NOTE!

For service instruction to the welding head and control unit, see the separate

manuals.

ERROR CODES

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ERROR CODES

Error codes are used in order to indicate and identify a fault in the equipment.

All faults that occur when using the welding equipment are documented as error messages in

the error log in the control unit EAC10. For further information about error codes, refer to the

EAC10 service manual (0463610001).

TECHNICAL DATA

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TECHNICAL DATA

1. Tractor carriage 4. EAC 10, control pendant

2. Bobbin holder 5. EWH 1000, welding head

3. Column with EAC 10

EWT1000, from serial no. 841-xxx-xxxx

EWT1000

Supply voltage 60VDC or 42VAC, 50/60Hz

Max power requirement 900 VA

Travel speed 0.1–2.0 m/min (0.3–6.6 feet/min)

Brake hub braking torque 3 Nm (26.6 in. lb)

Minimum turning radius for circumferential welding

Inside object diameter 3000 mm (9ft 10.11in.)

Outside object diameter, four

wheels

3900 mm (12ft 9.54in.)

Minimum pipe diameter for

internal joint welding

1100 mm (3 ft 7.31 in.)

Maximum weight of wire 30 kg (66lb)

Weight

Total, excluding wire and flux 67 kg (148lb)

Tractor carriage 22.1 kg (48.7lb)

Bobbin holder, without wire 6 kg

Column with EAC 10 25 kg

Relative air humidity Max 95%

Operating temperature -10 to +40 °C (-14 to +104 °F)

Storage temperature -20 to +55 °C (-4 to +131 °F)

Maximum surface

temperature

60 °C

TECHNICAL DATA

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EWT1000, from serial no. 841-xxx-xxxx

EWT1000

EMC classification Class A

Enclosure class IPXX

WIRING DIAGRAM

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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 EWT 1000 automatic welding equipment consists of a number of function modules. The

circuit board and component names and the wire numbers in the wiring diagram, show to

which module each board/component/wire belongs. The function modules, circuit boards and

components are listed in the component description below.

Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors

XS1 - XS99 (S = socket), XT1 - XT99 (T = terminal).

Circuit boards within each module have names such as 20AP1 - 20AP99.

20 = module association, 1-69

AP = circuit board

1 = individual identification number, 0-99

Transistors within particular modules have identification numbers such as 15Q1 - 15Q99.

15 = module association, 1-69

Q = transistor

1 = individual identification number, 0-99

NOTE!

Travel motor encoder supply voltage: 5VDC.

WIRING DIAGRAM

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Serial number 841-xxx-xxxx

WIRING DIAGRAM

0463 653 001

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Serial number 905-xxx-xxxx

DISASSEMBLY AND REASSEMBLY

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DISASSEMBLY AND REASSEMBLY

Tractor carriage

DISASSEMBLY AND REASSEMBLY

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Column

DISASSEMBLY AND REASSEMBLY

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Bobbin holder

REPLACEMENT INSTRUCTIONS

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REPLACEMENT INSTRUCTIONS

Replacing the wheel shaft

1. Remove the roll pin (1) and remove the wheel (2).

2. Remove the lock ring (3) and the bearing (4).

3. Loosen the screws (5) and remove the bearing housing (6).

4. Repeat the steps on the other side to be able to replace the wheel shaft (7).

5. During reassembly, position the mounting screws (5) with slot facing towards

connecting plate to lock the bearing housing.

Replacing the drive motor

1. Disconnect the mains connector and other cables.

2. Remove all harness connections from the motor by unplugging the connectors.

REPLACEMENT INSTRUCTIONS

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3. Remove all modules from the tractor base.

NOTE!

For detailed instruction about how to disassembly the modules, see section

"Transportation" in the instruction manual.

4. Remove the clutch knob (1).

5. Remove roll pin (2) and wheel (3) on both sides.

6. Remove lock ring (4), ball bearing (5) and the screws (6) from the side slider. Remove

the front cover.

7. Place the tractor base module upside down.

8. Remove screws on both sides.

9. Replace the drive motor (7).

10. Reconnect cables.

Replacing the column

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 614 001 EWT 1000 Welding tractor

Instruction manual 0463 613 * EWT 1000 Welding tractor

Spare parts list 0463 628 001 EWH 1000 Welding head

Service manual 0463 656 001 EWH 1000 Welding head

Instruction manual 0463 627 * EWH 1000 Welding head

Spare parts list 0463 611 001 EAC 10 Control unit

Service manual 0463 610 001 EAC 10 Control unit

Instruction manual 0463 609 * EAC 10 Control unit

Instruction manual 0463 612 * EAC 10 Control panel

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 EWT 1000 User manual

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