ESAB EWH 1000 Arc Air Instruction manual

Versoarc

EWH1000Arc Air

Instruction manual

0463 731 001 GB 20230419

Valid for: 910-xxx-xxxx

TABLE OF CONTENTS

1

SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2

INTRODUCTION

2.1 Equipment

3

TECHNICAL DATA

4

INSTALLATION

4.1 Main components of Gouging head

4.2 Mechanical assembly

4.3 Electrical connections

4.4 Electrodes

4.5 Gouging Operation Settings

4.6 Selecting the Proper Electrode Diameter

4.7 Keeping Electrodes Dry

4.8 Compressed Air

5

OPERATION

5.1 Positioning the Torch head

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4

4

4

7

7

8

9

9

10

11

11

12

13

13

13

14

14

5.1.1 Insert the Electrode .............................................................................. 15

5.2 EAC 10 settings

6

MAINTENANCE

6.1 Daily

6.2 Monthly

7

ORDERING NUMBERS

8

ORDERING SPARE PARTS
SPARE PARTS LIST
ACCESSORIES

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23

Rights reserved to alter specifications without notice.

0463 731 001 © ESAB AB 2023

1 SAFETY

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

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© ESAB AB 2023

1 SAFETY

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.

0463 731 001

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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© ESAB AB 2023

1 SAFETY

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.

0463 731 001

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© ESAB AB 2023

2 INTRODUCTION

2 INTRODUCTION

The EWH1000Arc Air gouging system is designed for use with the EAC 10 control unit and
EWT 1000 tractor.

2.1 Equipment

EWH1000Arc Air is supplied with:

• Instruction manual

• Welding cable kit

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© ESAB AB 2023

3 TECHNICAL DATA

3 TECHNICAL DATA

EWH1000Arc Air

Duty Cycle 1600Aat100%

Rated Input

Rated Input Amperage 1600A

488×580×805mm

Dimensions l×w×h

(19.21×22.83×31.69in.)

Enclosure class IPXX

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.

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© ESAB AB 2023

4 INSTALLATION

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.

4.1 Main components of Gouging head

1. Positioner lever 5. Cable connector

2. Positioner lever 6. Versotrac N7500i head

3. Molded locking nut 7. Electrode guide

4. Air hose connection

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© ESAB AB 2023

4 INSTALLATION

4.2 Mechanical assembly

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

Adjust the welding head with the two leveler (3 and 4).

Insert the electrode (5) and connect the OKC cables to the connector (6).

NOTE!

Check if the connection is fixed and mount if needed.

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© ESAB AB 2023

4 INSTALLATION

4.3 Electrical connections

Position of the mounted OKC cables

4.4 Electrodes

The most important part of the Gouging head is the electrode. Since the Gouging head uses
only DC power, the electrodes must be formulated and manufactured for use exclusively with
Direct Current.

The use of Arc Air Jointed Jetrods Copperclad DC Electrodes is highly recommended. These
electrodes are manufactured to Arc Air specifications to provide the best electrical
conductivity, to maintain proper electrode diameter at the point of the arc, and to minimize
carbon sublimation. A male/female joint enables electrodes to be joined together while the
gouging operation is taking place.

Electrode diameter Gouge width Amperage

mm inch mm inch min max

7.9 5/16 11.1 7/16 400 450

9.5 3/8 12.7 1/2 450 600

12.7 1/2 20.7 13/16 800 1000

15.9 5/8 24.9 15/16 1000 1250

19.1 3/4 27.0 11/16 1250 1600

CAUTION!

When 1000A or higher current is used, three cables are needed!

The formulation and design of the Jetrods Electrodes embody numerous laboratory-proven
advantages under the user’s production conditions. Among these advantages are:

• Cooler operation due to a small incandescent area at the tip and joint

• Excellent arc stability

• High metal-removal rates

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© ESAB AB 2023

4 INSTALLATION

• Uniformity of diameter

• Clean grooves or cuts

4.5 Gouging Operation Settings

Operating Parameters shows recommended operating amperage by electrode sizes.

Results may vary depending on the arc current, voltage and other parameters used.

Automatic Gouging Operating Data

Electrode Diameter Desired Depth DC Current Travel Speed Per Min.

mm inch mm inch A mm/min inch/min

7.9 5/16 3.2 1/8 400 1651 65

7.9 5/16 4.8 3/16 400 1143 45

7.9 5/16 6.4 1/4 450 914 36

7.9 5/16 7.9 5/16 450 838 33

7.9 5/16 11.1 7/16 500 572 22.5

9.5 3/8 3.2 1/8 500 1778 70

9.5 3/8 4.8 3/16 500 1118 44

9.5 3/8 6.4 1/4 500 889 35

9.5 3/8 9.5 3/8 500 508 20

9.5 3/8 14.3 9/16 500 445 17.5

12.7 1/2 3.2 1/8 850 2438 96

12.7 1/2 6.4 1/4 850 1448 57

12.7 1/2 9.5 3/8 850 889 35

12.7 1/2 12.7 1/2 850 610 24

12.7 1/2 19.1 3/4 850 445 17.5

15.9 5/8 6.4 1/4 1250 1829 72

15.9 5/8 9.5 3/8 1250 1219 48

15.9 5/8 12.7 1/2 1250 940 37

15.9 5/8 15.9 5/8 1250 762 30

15.9 5/8 23.8 15/16 1250 495 19.5

19.1 3/4 6.4 1/4 1400 1829 72

19.1 3/4 9.5 3/8 1400 1068 42

19.1 3/4 12.7 1/2 1400 865 34

19.1 3/4 15.9 5/8 1400 687 27

19.1 3/4 19.1 3/4 1400 560 22

19.1 3/4 28.6 1 1/8 1400 330 13

0463 731 001

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© ESAB AB 2023

4 INSTALLATION

4.6 Selecting the Proper Electrode Diameter

NOTE!

If you want a groove depth that is greater than 1-1/2 times the diameter of the
electrode being used, make the groove in two or more passes.

Your choice should be based on the depth and width of the gouge you need. If you
want a gouge 1-1/2 times greater than the diameter of the electrode being used, make
the groove in two or more passes or oscillate the Torch Head.

WARNING!

Direct current/electrode positive (reverse po larity) is required for the N7500 System.
Use direct current/electrode negative (straight polarity) for special applications. DO
NOT use alternating current with the system.

CAUTION!

Power Supplies must be rated for 100% duty cycle at the amperage required for the
size (diameter) electrode used. Contact the manufacturer of the Power Supply for
paralleling procedures or with questions concerning amperage ratings and duty
cycles.

NOTE!

Recommendations are based on a 4 volt DC drop per 30.48 m (100 ft.) length given is
one-half the sum of lengths of electrode and ground leads. Inadequate grounding may
cause cable overheating. There should be at least 6.45 cm2 (1 square in.) of contact
per 1000 A.

Your choice should be based on the depth and width of the gouge you need. If you want a
gouge 1-1/2 times greater than the diameter of the electrode being used, make the groove in
two or more passes or oscillate the Torch Head.

4.7 Keeping Electrodes Dry

Keep electrodes dry. Damp electrodes should be dried before using. (Ten hours at 176.7°C
[300°F]) Wet electrodes may shatter from internal steam pressure when an arc is struck.

4.8 Compressed Air

Compressed air flows from an air nozzle in the Gouging Head, travels parallel along the axis
of the electrode, and is directed into the molten puddle. An air regulator should be supplied
by the user. Use at least 60 psi, but not greater than 100 psi input of compressed air to the
regulator.

Compressed Air Requirements

Air Pressure Air Volume

psi*

kg/cm

2

CFM

m3/min.

60 4.2 46 1.3

80 5.6 63 1.8

100 7.0 81 2.3

0463 731 001

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© ESAB AB 2023

5 OPERATION

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 Positioning the Torch head

This part should be reviewed

1. Position the torch head above the work piece you want to start gouging.

2. Using the angle gauge supplied with the EWH1000Arc Air, adjust the torch head to
the work piece. The angle gauge sets the torch angle, electrode stick-out and aligns
the air nozzle.

3. The air should flow between the electrode and the work piece.

Charts, graphics and other data in this manual are based on a 45° electrode angle, but you
can use electrode angles from 45° to 60°. Users should develop their own standards based
on shop conditions and application.

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© ESAB AB 2023

5 OPERATION

5.1.1 Insert the Electrode

1. Push the electrode release (clamping) lever down and insert the electrode FEMALE
END FIRST into the rear of the torch head until it protrudes through the nozzle. The
two-legged spring and protective shield should rest squarely on top of the electrode.
To check their positions, look down the rear of the torch. If the spring and shield are
pushed to either side, withdraw the electrode and insert it again. Release the clamping
lever.

2. The electrode will retract for several seconds and stop.

5.2 EAC 10 settings

When the EWH1000Arc Air is connected to the tractor, the EAC10 Control unit detects it
automatically.

NOTE!

New wires have to set on the panel before welding.

On the control panel the following settings can be adjusted:

• Travel speed setting,

• voltage setting,

• current setting,

• and electrode dimension setting.

For further information of the available settings, see the EAC 10 control unit instruction
manual.

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© ESAB AB 2023

6 MAINTENANCE

6 MAINTENANCE

WARNING!

The mains supply must be disconnected during cleaning and maintenance.

CAUTION!

Only persons with the appropriate electrical knowledge (authorised personnel) may
remove the safety plates.

CAUTION!

The product is covered by manufacturer's warranty. Any attempt to carry out repair
work by non-authorised service centers or personnel will invalidate the warranty.

NOTE!

Regular maintenance is important for safe and reliable operation.

NOTE!

Perform maintenance more often during severe dusty conditions.

6.1 Daily

• Check that the electrical cables are connected.

• Check the compressed air hoses.

• Check that electrical cables are not damaged.

• Check that all bolted joints are tight.

• Replace worn or damaged components.

6.2 Monthly

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

0463 731 001

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© ESAB AB 2023

7 ORDERING NUMBERS

7 ORDERING NUMBERS

Ordering number Denomination Type Notes

0908 904 880 Welding head EWH1000ArcAir With 95mm*2 cables

0908 904 881 Welding head EWH1000ArcAir With 120mm*2 cables

0463 731 * Instruction manual

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.

Technical documentation is available on the Internet at: http://manuals.esab.com.

0463 731 001

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© ESAB AB 2023

8 ORDERING SPARE PARTS

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1000Arc Air is designed and tested in accordance with the international and
European standards IEC/EN 60974-5, IEC/EN 60974-10 and EN 12100:2010. 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 standards.

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.

0463 731 001

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© ESAB AB 2023

SPARE PARTS LIST

SPARE PARTS LIST

Item Qty. Ordering no. Denomination Notes

1 1 Torch Housing

2 1 Cover

3 1 Locknut

4 1 94‐013‐098 Electrode Tube Adapter

5 1 94‐096‐132 Vee Block

6 1 94‐784‐076 Nozzle Sleeve

7 1 94‐636‐001 Air Plenum

8 1 94‐556‐071 Air Nozzle w/ Insulator

9 1 96‐070‐030 Interconnect Bar

10* 1 0440 240 880 Filter Board

11 1 96‐070‐029 Bus Bars

12 1 96‐458‐025 Tinned Flat Copper Braid

13 1 96‐168‐028 Jumper Clamp

14 1 96‐774‐097 Shoe

15 1 94‐949‐053 Wheel Assembly

16 1 94‐800‐184 Shoe Spring

17 1 94‐476‐067 Clamping Lever Assembly

18 1 94‐949‐051 Drive Wheel Assembly

19 1 Motor Housing

20 1 Drive Motor Complete

21 1 94‐893‐082 Electrode Holder Tube

22* 1 94‐105‐016 Cable Boot

23 1 94‐306‐151 Air Inlet Fitting

24 1 94‐777‐110 Shield

25 1 94‐079‐013 Mounting Beam

Components

26* 1 Motor Housing Cap

27 1 94‐800‐186 Nozzle Spring and Guard

28 1 0908 780 880 Cable Assembly

29* 1 0561 007 031 Voltage Sense Cable

*Not shown in illustration.

0463 731 001

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© ESAB AB 2023

SPARE PARTS LIST

0463 731 001

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© ESAB AB 2023

SPARE PARTS LIST

Item Qty. Ordering no. Denomination Notes

0908 558 880 Mounting arm for gouging

head

1 1 0905 736 880 Welding head arm complete

2 1 Upper front frame

3 1 0908 556 880 Arm mounting plate

4 1 Scale rotation

5 1 Roll pin

6 4 Clamp Rubber/steel D=22

7 1 0908 550 001 Head plate

8 1 0908 549 001 Link

9 2 Nut M5

10 1 Screw M6S 8X25

11 1 Spring washer D18.1x10.2

12 1 Washer D26/8.4X5

13 2 Locking arm

14 2 Shoulder bolt H12X16

15 4 Washer D24/13X2 M12

16 2 Screw M5X16

17 2 Screw M6X12

18 2 Locknut M10

19 1 Clamp

0463 731 001

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© ESAB AB 2023

SPARE PARTS LIST

0463 731 001

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© ESAB AB 2023

ACCESSORIES

ACCESSORIES

EWH 1000

0160 360 882 OKC connector Male, 70-120mm²

0160 361 882 OKC connector Female, 70-120mm²

Welding cable with OKC

0446 134 880 95 mm², 15 m (49ft)

0446 134 881 95 mm², 25 m (82ft)

0446 134 882 95 mm², 35 m (115ft)

0446 134 883 95 mm², 50 m (164 ft)

0446 134 884 95 mm², 75 m (246ft)

0446 134 885 95 mm², 100 m (328 ft)

0446 134 890 120mm², 15 m (49ft)

0446 134 891 120mm², 25 m (82ft)

0446 134 892 120mm², 35 m (115ft)

0446 134 893 120mm², 50 m (164 ft)

0463 731 001

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© ESAB AB 2023

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone [phone]

manuals.esab.com

For contact information visit esab.com