ESAB 0904 200 880, Instruction Manual

Page 1: ...Versotrac Instruction manual Original instructions 0463 613 001 GB 20181218 Valid for from serial no 841 xxx xxxx EWT 1000 ...

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Page 3: ... Assembly 15 4 4 1 Bobbin holder 15 4 4 1 1 Adjusting the brake hub 15 4 5 Connections 16 4 5 1 Connecting to digital power source 17 4 5 2 Connecting to compatible DC analogue power source 18 5 OPERATION 20 5 1 General 20 5 2 Transportation 20 5 3 Loading the welding wire 22 5 4 Changing the feed roller 23 5 4 1 Single wire 23 5 4 1 1 Knurled rollers for flux cored wire 23 5 5 Refilling with flux...

Page 4: ...g applications 30 6 MAINTENANCE 33 6 1 General 33 6 2 Daily 33 6 3 Weekly 33 7 TROUBLESHOOTING 34 8 ERROR CODES 35 9 ORDERING SPARE PARTS 36 DIAGRAM 37 ORDERING NUMBERS 39 ACCESSORIES 40 WEAR PARTS 43 Rights reserved to alter specifications without notice ...

Page 5: ...ty 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 th...

Page 6: ... 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...

Page 7: ...quipment 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 Direct...

Page 8: ...merged Arc Welding SAW Use EWH 1000 welding equipment for Submerged Arc Welding EWH 1000 permits loads up to 1000 A 100 This version can be equipped with feed rollers for single wire welding 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 Horizontal welding The product descr...

Page 9: ...2 INTRODUCTION 0463 613 001 9 ESAB AB 2018 Avoid welding on surfaces with a slope greater than 3 5 cm m due to risk of weld defects caused by the large size of the melted metal in the weld pool ...

Page 10: ...ng 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 temperatur...

Page 11: ...ons adapted for ESAB motors 6 A 100 Speed control Feedback from pulse encoder Operating temperature 10 to 40 C 14 to 104 F Storage temperature 20 to 55 C 4 to 131 F Relative air humidity Max 95 Dimensions l w h EAC 10 complete control unit 275 300 165 mm 10 8 11 8 6 5 in EAC 10 control pendant 245 225 50 mm 9 7 8 9 2 0 in Weight EAC 10 complete control unit 6 8 kg 15 lb EAC 10 control pendant 1 25...

Page 12: ...mm 0 03 0 20 in SS flux cored 0 8 5 0 mm 0 03 0 20 in Al Solid NA Al Flux Cored NA Type of gas NA Wire feed speed Maximum 9 m min 29 5 feet min Minimum 0 4 m min 1 3 feet min Brake hub braking torque 1 5 Nm 13 3 in lb Flux hopper volume 6 l Dimensions l w h 620 530 832 mm 24 4 20 9 32 8 in Weight welding head excluding wire and flux 17 kg 37 5 lb Enclosure class IPXX EMC classification Class A ...

Page 13: ...io interference It is the user s responsibility to take adequate precautions 4 2 Lifting instructions WARNING The welding tractor must be lifted using the lifting eye 4 Disconnect the power source and remove all consumables flux and welding wire Disconnect and remove welding cables from the welding tractor The welding cables are not to be lifted with the tractor Remove optional air and water hoses...

Page 14: ...t tube 2 EAC 10 Motor drive unit 9 Guide pin 3 Column 10 Wire feed unit 4 Tractor carriage 11 Flux tube 5 Guide bar lock 12 Wire feed motor 6 Guide bar 13 Flux hopper 7 Cable support 14 Wire liner 4 3 1 Welding cables Use different number of welding cables for different welding currents Up to 500 A one 120 mm2 cable 500 1000 A two 120 mm2 cables NOTE With two welding cable setup run the welding ca...

Page 15: ...ub 4 4 1 1 Adjusting the brake hub The brake hub is adjusted at delivery If readjustment is required follow the instructions below Adjust the brake hub so the wire is slightly slack when wire feed stops Adjusting the braking torque 1 Turn the red handle to the locked position 2 Insert a screwdriver into the springs in the hub Turn the springs clockwise to reduce the braking torque Turn the springs...

Page 16: ...n tractor carriage 2 On Off switch 7 Connection digital power source 3 Work piece voltage reference input 8 Connection anlogue power source 4 Accessory cable entries 9 Cable to control pendant 5 Connection welding head NOTE Connect only digital power source or analogue power source at a time ...

Page 17: ...terconnection cable between CAN based ESAB power source and EAC 10 are available as accessories in different lengths ESAB CAN based power sources are LAF xxx1 TAF xxx1 and Aristo 1000 For further information about connecting welding power source see separate instruction manual Always use the dust cover on the connections where no cable is connected ...

Page 18: ...ble is connected Requirements on the analogue power source Supply voltage 60 V DC or 42 V AC 50 60 Hz from welding power source or by external means Voltage feedback from negative welding terminal for welding voltage measurement for display in pendant Start input 0 10 V input for setting welding parameter control signal Shunt output or scaled 0 10 V 1 V per 100 arc Amp output for welding current m...

Page 19: ...t Open collector output L 0 V common for power source start and reference M 0 10 V reference N Current shunt negative mV P Current shunt positive mV R Emergency stop Y Emergency stop S 24 V AC torch input For non ESAB power sources T Weld start torch common For non ESAB power sources U Current feedback 1 V 100 A For non ESAB power sources ...

Page 20: ...he equipment NOTE When moving the equipment use intended handle Never pull the cables 5 2 Transportation It is possible to transport the welding tractor EWT 1000 following the instructions in section Lifting instructions Follow these instructions to dismount the welding tractor EWT 1000 into four separate modules before transportation When transporting the welding tractor EWT 1000 on the wheels pl...

Page 21: ...5 OPERATION 0463 613 001 21 ESAB AB 2018 NOTE Make sure the welding head has cooled down before dismounting ...

Page 22: ...semble in backwards order Make sure to lock the welding head 6 5 3 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 EAC 10 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 t...

Page 23: ...ring no 0212 901 101 Tighten the pressure screw 4 with moderate pressure to ensure that the flux cored wire does not deform 5 5 Refilling with flux powder 1 Close the flux valve 1 on the flux hopper 2 Remove the optional cyclone on the flux recovery unit 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 Pos...

Page 24: ... AC mode 5 6 1 Keys and knobs The buttons are used for Up Down Right Left and Confirm middle button during configuration and setting Up Left Right Down Welding stop 1 Stops all travel motions all motors and welding current Welding start 2 The LED is lit when welding is in progress The OK button 5 is used to confirm a selected choice The Back button 6 is used to go back one step inte the menu Press...

Page 25: ... voltage offset voltage knob1 4 is used for increasing or decreasing set values The travel speed frequency knob1 13 is used for increasing or decreasing set values 1 Only with Aristo 1000 in AC mode 5 6 2 Initial configuration At first startup after delivery after program update and after a completed reset the control panel requires initial configuration The initial configuration starts automatica...

Page 26: ...n 3 seconds to open the menu and change analogue power source using the buttons Up Down and OK If no button is pressed the startup will proceed with no changes on power source 3 Previously selected wire type and wire dimension is shown Press any button within 7 seconds to open the menu Select wire type and wire dimension using the buttons Up Down and OK If no button is pressed the control panel co...

Page 27: ...ny of the knobs during welding to open the SET screen from the MEASURED screen The values are shown during 2 seconds before returning to the MEASURED screen unless any adjustments are made If the SET screen is opened without ongoing welding it will stay active When welding starts the MEASURED screen is activated Change the welding settings by using the knob next to the value shown on the display I...

Page 28: ... 7 Welding menu When any of the screens SET or MEASURED is shown press long on OK to open the extended WELDING MENU The information on the display depends on the authorisation level attached power source and welding head The authorisation level is shown with an icon in the upper right corner of the display Example of welding menu for Aristo 1000 AC DC WELDING MENU METHOD REGULATION TYPE START TYPE...

Page 29: ...ed settings with Back or the Left button 5 7 Adjustments 1 Vertical adjustment of the welding head see scale on the column 2 Adjust the guide roller device distance both in front and back of welding tractor 3 Adjust the horizontal column location see scale next to the column 4 Adjust the rotation angle of the column NOTE Always keep handle in locked position when not adjusting 5 Adjust the rotatio...

Page 30: ...the joint The guide may be part of the workpiece or a separete guide rail that has been aligned parallel to the joint Circular fillet welding The welding tractor follows the joint using the basic guide arm device Minimum radius 3 9 m Idling rollers 0333 164 880 Idling rollers with adjustable height are supplied as an accessory Required when fillet welding along a low vertical plate the idling roll...

Page 31: ...der to indicate the position of the welding nozzle in the joint See chapter ACCESSORIES Guide wheel bogey 0413 542 880 Use of the guide wheel bogey in a V joint allows the welding tractor to track the joint The welding tractor can pass over tack welds without problems and without losing the track The guide wheel bogey is secured to the contact tube and the welding nozzle is positioned to weld behi...

Page 32: ...t can be fitted with two grooved wheels which will run on an angle iron guide rails can be joined together to make up the required length See chapter ACCESSORIES Flat fillet welding 0904 255 001 The flat fillet welding kit can be used to keep the equipment straight upwards when welding a tilted fillet joint The angle can be set to 0 30 and 45 See chapter ACCESSORIES ...

Page 33: ...he bobbin holder is in locked position Clean flux and dirt off moving parts Clean flux and dirt off slides Check The rotation lock between the carriage and the column The welding head lock The bobbin holder lock Check that the contact tip and all electrical cables are connected Make sure all screwed joints are tightened Check that guides and drive rollers are not worn or damaged Check the brake hu...

Page 34: ...n 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 irregular 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 wir...

Page 35: ...8 ERROR CODES 0463 613 001 35 ESAB AB 2018 8 ERROR CODES For error code information see EAC 10 Instruction manual ...

Page 36: ... 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 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...

Page 37: ...DIAGRAM 0463 613 001 37 ESAB AB 2018 DIAGRAM Digital power source ...

Page 38: ...DIAGRAM 0463 613 001 38 ESAB AB 2018 Analogue power source ...

Page 39: ...cluding welding head EWH 1000 bobbin holder and control unit EAC 10 Feed roller and contact tip not included 0463 627 Instruction manual EWH 1000 welding head 0463 612 Instruction manual EAC 10 control panel 0463 609 Instruction manual EAC 10 control unit 0463 614 001 Spare parts list Technical documentation is available on the Internet at www esab com ...

Page 40: ...880 Bobbin module 0333 164 880 Idling roller 0443 682 881 V wheeltrack in steel 4 pcs 0332 947 880 Bracket suction 0904 223 880 Voltage reference option 0413 542 880 Guide wheel bogey For V joints used for joint tracking For Fitting on the contact tube 0415 857 002 Wheel kit heat resistant 250 C 482 F 0154 203 880 Guide rail with magnets 3 m 9 8 ft Several lenghts of guide rail can be used ...

Page 41: ...tric flux feeding funnel 0413 510 001 0413 510 002 0413 510 003 0413 510 004 Contact tube 260 mm 10 24 in Contact tube 190 mm 7 48 in Contact tube 100 mm 3 94 in Contact tube 500 mm 1 ft 7 7 in 0413 511 001 Contact tube bent 0153 872 880 Wire reel plastic 30 kg 0449 125 880 Wire reel steel flexible width 0671 164 080 Wire reel steel Ø 220 mm EAC 10 Control cable EAC 10 digital power source 0460 91...

Page 42: ... 2018 EAC 10 Control cable EAC 10 analog power source 0449 500 880 15 m 49 ft 0449 500 881 25 m 82 ft 0449 500 882 35 m 115 ft 0449 500 883 50 m 164 ft 0449 500 884 75 m 246 ft 0449 500 885 100 m 328 ft 0462 062 001 USB Memory stick 2 Gb ...

Page 43: ...18 510 287 5 0 0218 510 298 3 0 3 2 Grooved and knurled roller for tubular wire Part no D mm 0146 024 880 0 8 1 6 0146 024 881 2 0 4 0 Pressure rollers Pressure roller groved and knurled for tubular wire Part no D mm 0146 025 880 0 8 1 6 0146 025 881 2 0 4 0 0146 025 882 5 0 7 0 Stub shaft for pressure roller EWH 1000 tubular wire Part no 0212 901 101 ...

Page 44: ...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 ...