ESAB Versotrac EWT 1000 User manual

Versotrac Cadet
EWT1000 Weldingtractor
Instruction manual
0463 893 001  GB  20230313
Valid for: Serial number:
xx23422xxxxxx

TABLE OF CONTENTS
0463 893 001 -3- © ESAB AB 2023
1 SAFETY ...................................................................................................................................... 5
1.1 Meaning of symbols .................................................................................................... 5
1.2 Safety precautions ...................................................................................................... 5
2 INTRODUCTION ......................................................................................................................... 8
2.1 Welding methods......................................................................................................... 8
2.2 Horizontal welding....................................................................................................... 8
2.3 Stability ........................................................................................................................ 8
3 TECHNICAL DATA ..................................................................................................................... 9
3.1 Versotrac Cadet EWT 1000 Welding tractor ............................................................. 9
4 INSTALLATION........................................................................................................................... 11
4.1 Lifting instruction ........................................................................................................ 11
4.2 Main components ........................................................................................................ 12
4.2.1 Welding cables ................................................................................................... 13
4.2.2 Bobbin holder ..................................................................................................... 14
4.3 Connections................................................................................................................. 14
4.3.1 Connecting to power source............................................................................... 15
5 OPERATION ............................................................................................................................... 16
5.1 Transportation ............................................................................................................. 16
5.1.1 Dismount the carriage ........................................................................................ 17
5.2 The clutch..................................................................................................................... 18
5.3 Loading the welding wire............................................................................................ 18
5.4 Changing the feed roller ............................................................................................. 19
5.5 Refilling with flux powder ........................................................................................... 19
5.6 Upgrading the tractor to 4 wheel drive...................................................................... 19
5.7 Control panel EAC 10.................................................................................................. 21
5.7.1 Keys and knobs.................................................................................................. 22
5.7.2 Initial configuration ............................................................................................. 23
5.7.3 Startup................................................................................................................ 23
5.7.4 Measured screen................................................................................................ 24
5.7.5 Set screen, power source................................................................................... 24
5.7.6 Welding menu..................................................................................................... 25
5.8 Adjustments................................................................................................................. 26
5.9 Welding positions........................................................................................................ 26
5.10 Work piece voltage reference brush.......................................................................... 27
5.11 Welding applications................................................................................................... 28
5.11.1 Basic version ...................................................................................................... 29
5.11.2 Idling rollers (0446 151 880)............................................................................... 29
5.11.3 Laser lamp (0821 440 984) ................................................................................ 30
5.11.4 Guide wheel bogey (0413 542 880) ................................................................... 30
5.11.5 Grooved wheels (0443 682 881) ........................................................................ 31
5.11.6 Flat fillet welding (0904 586 880) ....................................................................... 31
6 MAINTENANCE.......................................................................................................................... 32
6.1 Daily.............................................................................................................................. 32
6.2 Weekly .......................................................................................................................... 32
7 TROUBLESHOOTING ................................................................................................................ 33
7.1 Versotrac Cadet EWT 1000 ......................................................................................... 33
7.2 Welding head ............................................................................................................... 33

TABLE OF CONTENTS
0463 893 001 -4- © ESAB AB 2023
7.3 Versotrac Cadet Control unit...................................................................................... 34
8 EVENT CODES........................................................................................................................... 35
8.1 High DC voltage........................................................................................................... 35
8.2 High temperature......................................................................................................... 35
8.3 Low welding current.................................................................................................... 35
8.4 Low battery voltage..................................................................................................... 35
8.5 Speed error on a motor (wire feed, travel motor) ..................................................... 35
8.6 Internal communication error (warning) ................................................................... 35
8.7 Communication error .................................................................................................. 36
8.8 Lost contact with the unit ........................................................................................... 36
8.9 No gas flow .................................................................................................................. 36
8.10 High welding current................................................................................................... 36
8.11 Current servo saturation ............................................................................................ 36
8.12 High welding current................................................................................................... 36
8.13 High inductance........................................................................................................... 36
8.14 Internal communication error (warning) ................................................................... 36
8.15 Communication error .................................................................................................. 37
8.16 Current servo saturation ............................................................................................ 37
8.17 A motor has stopped................................................................................................... 37
8.18 A motor has stopped................................................................................................... 37
8.19 Current servo saturation ............................................................................................ 37
8.20 High DC voltage........................................................................................................... 37
8.21 High temperature......................................................................................................... 37
8.22 High temperature......................................................................................................... 37
8.23 High temperature......................................................................................................... 38
8.24 High inductance........................................................................................................... 38
8.25 Lost contact with the unit ........................................................................................... 38
8.26 Speed error on a motor (wire feed, travel motor) ..................................................... 38
8.27 A motor has stopped................................................................................................... 38
9 ORDERING SPARE PARTS ....................................................................................................... 39
WIRING DIAGRAM ................................................................................................................................ 40
ORDERING NUMBERS ......................................................................................................................... 41
ACCESSORIES ..................................................................................................................................... 42
WEAR PARTS........................................................................................................................................ 45

1  SAFETY
0463 893 001 -5- © ESAB AB 2023
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

1  SAFETY
0463 893 001 -6- © ESAB AB 2023
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1  SAFETY
0463 893 001 -7- © ESAB AB 2023
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.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
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.

2  INTRODUCTION
0463 893 001 -8- © ESAB AB 2023
2 INTRODUCTION
The VersotracCadetEWT1000 Welding tractor is designed for Submerged Arc Welding (SAW) of
butt and fillet joints.
All other applications are prohibited.
The equipment is intended for use in combination with an ESAB digital power sources LAFxxx1,
TAFxxx1 or Aristo1000.
2.1 Welding methods
SAW
The weld bead is protected by a cover of flux during the welding.
2.2 Horizontal welding
The product described in this manual is designed for horizontal welding. The welding tractor can be
used for flat fillet welding when welding a tilted fillet joint with the optional flat fillet welding kit.
NOTE!
Do not use VersotracCadetEWT1000 when welding on inclined planes.
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.
2.3 Stability
NOTE!
Always check the welding equipment for stability before welding.
The Versotrac Cadet EWT 1000 is designed to be flexible and cover many different welding
applications and setups. The stability can be improved by moving the pillar holder sideways, the
position of the flux container, etc.

3  TECHNICAL DATA
0463 893 001 -9- © ESAB AB 2023
3 TECHNICAL DATA
3.1 Versotrac Cadet EWT 1000 Welding tractor
1. Tractor carriage 3. EAC10, control pendant
2. Bobbin holder, column and welding head
Versotrac Cadet 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 1.5 Nm (13.3 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, excluding wire and flux 65 kg (143.3lb)
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
on weld object (wheel)
150 °C
EMC classification Class A
Enclosure class IPXX

3  TECHNICAL DATA
0463 893 001 - 10 - © ESAB AB 2023
Welding head
Supply voltage 42 V DC
Permissible load at 100% 1000 A
Wire dimensions
Fe solid single 1.6–4.0 mm (0.06–0.15in.)
SS solid 1.6–3.2 mm (0.06–0.12in.)
Maximum wire feed speed (≤ 4 mm wire) 9.0 m/min (29.5feet/min)
Brake hub braking torque 1.5 Nm (13.3in.lb)
Flux hopper volume 6 l
EMC classification Class A

4  INSTALLATION
0463 893 001 - 11 - © ESAB AB 2023
4 INSTALLATION
The installation must be carried out by a professional.
WARNING!
Rotating parts can cause injury, take great care.
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 Lifting instruction
WARNING!
The welding tractor must be lifted using the lifting eye (3).
• 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.
• Make sure the column is in locked position (1and 2), directed forward as shown in
illustration.

4  INSTALLATION
0463 893 001 - 12 - © ESAB AB 2023
4.2 Main components
Versotrac CadetEWT1000Welding tractor
1. EAC 10 Control pendant 6. Guide bar
2. Versotrac Cadet Control unit 7. Cable support
3. Column 8. Guide pin
4. Tractor carriage 9. Welding head
5. Guide bar lock 10. Wire liner

4  INSTALLATION
0463 893 001 - 13 - © ESAB AB 2023
Welding head
1. Flux hopper 6. Wire straightener memory function
2. Flux valve 7. Contact tip
3. Wire feed motor 8. Contact tube
4. Wire feed pressure roll 9. Welding current connection
5. Wire straightener
4.2.1 Welding cables
Use different number of welding cables for different welding currents:
Up to 500A one 120mm2cable
500 - 1000A two 120mm2cables
NOTE!
With two welding cable setup, run the welding cables close to each other in parallel, but do not
twist them around each other.

4  INSTALLATION
0463 893 001 - 14 - © ESAB AB 2023
4.2.2 Bobbin holder
Mount the wire drum on the brake hub in the
bobbin holder.
4.3 Connections
1. On/Off indicator 5. Connection power source
2. On/Off switch 6. Connection tractor carriage
3. Connection work piece voltage reference
brush
7. Cable to control pendant
4. Accessory cable entries

4  INSTALLATION
0463 893 001 - 15 - © ESAB AB 2023
4.3.1 Connecting to power source
Connect the interconnection cable to connector.
Interconnection cable between CAN based ESAB power source and Verotrac Cadet Control unit 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 connection where no cable is connected.

5  OPERATION
0463 893 001 - 16 - © ESAB AB 2023
5 OPERATION
CAUTION!
Read and understand the instruction manual before installing or
operating.
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!
NOTE!
When moving the equipment use intended handle. Never pull the cables.
NOTE!
The tractor is supplied with a strap. It can be used to collect the welding cables behind the
tractor.
5.1 Transportation
It is possible to transport the VersotracCadetEWT1000 Welding tractor by following the
instructions in section "Lifting instructions".
NOTE!
Make sure the welding head has cooled down before transportation.
1) Turn off and disconnect the power source. Disconnect the cables to the welding head and the
tractor carriage (1). Remove the cables from the welding tractor.
NOTE!
If the power source is disconnected without turning off power first, the power source
emergency stop can be activated.
2) Remove wire from wire feed unit and wire liner (2).

5  OPERATION
0463 893 001 - 17 - © ESAB AB 2023
3) Remove the wire bobbin.
5.1.1 Dismount the carriage
1) Make sure the column is positioned in the middle of the tractor carriage.
2) Disconnect the cable (3) between the tractor carriage and the control unit
3) Unlock the column rotation with the handle (4). Rotate to end point. Pull (5) and rotate a few more
degrees.

5  OPERATION
0463 893 001 - 18 - © ESAB AB 2023
5.2 The clutch
Use the clutch knob in the back of the tractor
carriage to lock and unlock the wheels from the
motor. The wheels will be engaged with the motor
when in locked position.
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 the Versotrac Cadet Control unit
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 the wire straightener with memory
(4). There will be no change in the settings.
5. Feed the welding wire (5) into the contact
nozzle.
6. Lower the wire straightener with memory
(4) back to its position. Lock by turning the
knob (3) fully.
7. Turn on the Versotrac Cadet Control unit
and select the welding wire when prompted
on the display.
8. With EAC10 control panel: Feed the
welding wire through the contact nozzle
until it is visible below the contact nozzle.
9. When needed, adjust wire feed pressure
with knob (6).
10.When needed, adjust wire straightness
with knob (7).
NOTE!
Do not tighten feed pressure knob (6) too hard. This can result in overheating the wire feeder.

5  OPERATION
0463 893 001 - 19 - © ESAB AB 2023
5.4 Changing the feed roller
1. Release the knob (3).
2. Release the hand wheel (2).
3. Change the feed roller (1).
The feed rollers are marked with their respective wire
sizes.
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. Position the flux tube without twisting it.
5. Adjust the height of the flux nozzle above the weld so
that the correct amount of flux is delivered.
Flux coverage should be sufficient so that penetration
of the arc does not occur.
5.6 Upgrading the tractor to 4 wheel drive
NOTE!
The following pictures can differ from the Cadet version of the tractor. The pictures are
however correct when it comes to handling the equipment.

5  OPERATION
0463 893 001 - 20 - © ESAB AB 2023
1. Dismount the welding tractor according to the instructions in chapter "Dismount the carriage".
2. Remove the cable support and wheels held
by the roll pins on one side.
3. Mount the sprockets to the wheels using the
included screws.
4. Mount the wheels onto the shafts and lock
them in position using the roll pins.