Versoarc
EWH600/EWH1000
Welding head
Instruction manual
Translation of the manual in original
0463 627 101 US 20221206
Valid for: 905- and 910-xxx-xxxx
TABLE OF CONTENTS
1
SAFETY
1.1 Meaning of symbols
1.2 Safety precautions
2
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
3
TECHNICAL DATA
4
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
5
OPERATION
5.1 Wire feed unit
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4
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7
7
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8
9
9
12
14
15
15
5.1.1 Loading the welding wire...................................................................... 15
5.2 Contact equipment for Submerged Arc Welding
5.2.1 For single wire 1.6–5.0mm – (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
6
MAINTENANCE
6.1 Daily
7
TROUBLESHOOTING
8
ORDERING SPARE PARTS
ORDERING NUMBERS
ACCESSORIES
WEAR PARTS
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24
Rights reserved to alter specifications without notice.
0463 627 101 © ESAB AB 2022
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
could result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ the location of emergency stops
○ its function
○ the relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorized person is 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
0463 627 101
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© ESAB AB 2022
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 may cause injury 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 - Pose health risks
• Welders with pacemakers fitted should consult their doctor 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 the 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 your 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 627 101
NOISE - Excessive noise can damage hearing
Protect your ears. Use ear defenders or other hearing protection.
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© ESAB AB 2022
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 a fire. Make sure 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 such locations,
due to conducted as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
To conform with the 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 2022
2 INTRODUCTION
2 INTRODUCTION
EWH 1000 is a welding head intended for single SAW and twin SAW; 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 analog 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 covering 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 the 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.
EWH1000 permits loads of 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 an even wire
feed without risk of deformation of the 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.
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© ESAB AB 2022
3 TECHNICAL DATA
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 DC 42 V DC 42 V DC
Permissible load at
1000 A 1000 A 600 A
100%
Wire dimensions
Fe solid single 0.06–0.20in
(1.6–5.0mm)
Fe solid twin
2×1.2–3.2 mm
(2×0.05–0.09in.1))
Fe flux cored 0.06–0.20in
(1.6–5.0mm)
Fe flux cored twin
2×1.2–3.2 mm
(2×0.05–0.09in.1))
SS solid 1.6–4.0 mm
(0.06–0.20in.)
SS solid twin
2×1.2–2.4 mm
(2×0.05–0.09in.1))
SS flux cored 1.6–4.0 mm
(0.06–0.20in.)
SS flux cored twin
2×1.2–2.4 mm
(2×0.05–0.09in.1))
N/A 0.8–2.5 mm
(0.03–0.10in.)
1)
2×1.2–1.6 mm
N/A
(2×0.05–0.06in.)
N/A 1.2–3.2 mm
(0.05–1/8in.)
1)
N/A N/A
N/A 0.8–1.6 mm
(0.03–0.06in.)
1)
2×1.2–1.6 mm
N/A
(2×0.05–0.06in.)
N/A 1.2–3.2 mm
(0.05–1/8in.)
1)
N/A N/A
Al Solid N/A N/A 2.5 mm (0.10in.)
Type of gas N/A N/A CO2, Ar
Maximum wire feed speed
Maximum (≤4mm wire) 9.0 m/min
(29.5feet/min)
16 m/min
(52.5feet/min)
16 m/min
(52.5feet/min)
Maximum (5mm wire) 2.5 m/min (8.2
feet/min)
Brake hub braking
1.5 Nm (13.3in.lb)
torque
Flux hopper volume 6 l 6 l N/A
Dimensions l×w×h 620×530×832mm
(24.4×20.9×32.8in.)
Weight welding head,
17 kg (37.5lb) 19kg (41.9lb) 16.5kg (36.4lb)
600×530×805mm
(23.6×20.9×31.7in.)
600×500×760mm
(23.6×19.7×29.9in.)
excluding wire and flux
Enclosure class IPXX
EMC classification Class A
1)
with optional twin kit accessory
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© ESAB AB 2022
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