ESAB EWH 50 FSW Instruction manual

EWH50FSW

Friction stir welding head

Instruction manual

Original instructions

0463 624 001 GB 20211206

Valid for: serial no. 840-, 904-xxx-xxxx

TABLE OF CONTENTS

1

SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2

INTRODUCTION

2.1 Equipment

2.2 Main components of the welding head

3

TECHNICAL DATA

4

INSTALLATION

4.1 Handling of the welding head

4.2 Installation of the cooling water hoses and electrical cables to the

4.3 Installation of the welding head

5

OPERATION

5.1 Leak alarm holes

5.2 Operation at low load

5.3 Noises during operation

5.4 Changing the welding tool

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welding head

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4

4

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7

7

8

9

10

10

10

12

14

14

14

14

15

6

MAINTENANCE

6.1 Validation of the load cell

6.2 Replacing the front and rear bearings

7

TROUBLESHOOTING

8

ORDERING SPARE PARTS

DIAGRAM

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ORDERING NUMBERS
ACCESSORIES

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17

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22

Rights reserved to alter specifications without notice.

0463 624 001 © ESAB AB 2021

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
○ the friction stir welding application

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 work is started with the equipment

3. The workplace must:
○ be suitable for the purpose

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1 SAFETY

4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:
○ 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!

Friction stir welding can be injurious to yourself and others.

Work on the friction stir welding equipment may only be carried out by qualified
personnel trained for this purpose.

Never attempt to perform any type of service or maintenance work on the friction stir
welding equipment when welding is in progress.

WARNING!

Rotating parts can cause injury, take great care.

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.

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1 SAFETY

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.

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© ESAB AB 2021

2 INTRODUCTION

2 INTRODUCTION

EWH50 FSW is an electromechanical friction stir welding head intended for use on a
welding robot or other welding carrier. It is designed for welding plates up to 10mm in Al6000
alloys. EWH50FSW is equipped with an integrated liquid cooling system of the motor
spindle and the FSW tool to secure high volume production and a long lifetime.

NOTE!

Only use cooling liquid made of distilled water and glycol OAT corrosion inhibitor
mixed in a 50/50 percent ratio.

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.

2.1 Equipment

EWH50 FSW is supplied with:

• Instruction manual

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2 INTRODUCTION

2.2 Main components of the welding head

Serial no. 840-xxx-xxxx:

From serial no. 904-xxx-xxxx:

1. Welding head 6. Inlet tool cooling

2. Load cell 15 kN 7. Outlet tool cooling

3. Tool holder 8. Leak alarm holes

4. Inlet motor cooling 9. Power cable

5. Outlet motor cooling 10. Signal and temperature cable

For further information about the components included in the welding head, see the spare
parts list.

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© ESAB AB 2021