ESAB Versotrac EWT 1000 User manual

Versotrac
Instruction manual
Original instructions
0463 613 101 US 20200513 Valid for: from serial no. 905-xxx-xxxx
EWT1000

TABLE OF CONTENTS
0463 613 101 © ESAB AB 2020
1SAFETY ....................................................................................................... 5
1.1 Meaning of symbols ............................................................................... 5
1.2 Safety precautions ................................................................................. 5
2INTRODUCTION.......................................................................................... 9
2.1 Welding method...................................................................................... 9
2.1.1 Definitions............................................................................................. 9
2.1.2 Submerged Arc Welding (SAW) ........................................................... 9
2.1.3 GMAW (MIG/MAG) welding ................................................................. 9
2.2 Horizontal welding.................................................................................. 9
2.3 Stability.................................................................................................... 10
3TECHNICAL DATA ...................................................................................... 11
3.1 EWT1000 welding tractor...................................................................... 11
3.2 EAC10 control unit ................................................................................ 12
3.3 Welding head EWH600/EWH1000 ....................................................... 12
4INSTALLATION............................................................................................ 14
4.1 General .................................................................................................... 14
4.2 Lifting instructions ................................................................................. 14
4.3 Main components ................................................................................... 15
4.3.1 Welding cables ..................................................................................... 15
4.4 Assembly ................................................................................................ 15
4.4.1 Bobbin holder ....................................................................................... 16
4.4.2 Adjusting the brake hub........................................................................ 16
4.5 Connections............................................................................................ 17
4.5.1 Connecting to a digital power source ................................................... 18
4.5.2 Connecting to a compatible DC analog power source ......................... 19
5OPERATION ................................................................................................ 21
5.1 General .................................................................................................... 21
5.2 Transportation ........................................................................................ 21
5.3 The clutch................................................................................................ 23
5.4 Loading the welding wire....................................................................... 23
5.5 Changing the feed roller ........................................................................ 24
5.5.1 Single wire............................................................................................ 24
5.5.1.1 Knurled rollers for flux-cored wire...................................................... 24
5.6 Refilling with flux powder ...................................................................... 24
5.7 Changing to three wheeler module....................................................... 25
5.8 EAC10 control panel ............................................................................. 26
5.8.1 Keys and knobs.................................................................................... 26
5.8.2 Initial configuration ............................................................................... 27
5.8.3 Startup.................................................................................................. 28
5.8.4 Measured screen.................................................................................. 28
5.8.5 Set screen, digital power source .......................................................... 29

TABLE OF CONTENTS
0463 613 101 © ESAB AB 2020
5.8.6 Set screen, analog power source......................................................... 30
5.8.7 Welding menu....................................................................................... 30
5.9 Adjustments............................................................................................ 31
5.10 Work piece voltage reference brush..................................................... 32
5.11 Welding applications.............................................................................. 33
6MAINTENANCE........................................................................................... 37
6.1 General .................................................................................................... 37
6.2 Daily......................................................................................................... 37
6.3 Weekly ..................................................................................................... 37
7TROUBLESHOOTING ................................................................................. 38
7.1 EWT1000 ................................................................................................ 38
7.2 EWH600/EWH1000................................................................................ 38
7.3 EAC 10..................................................................................................... 39
8ERROR CODES........................................................................................... 40
9ORDERING SPARE PARTS ........................................................................ 42
DIAGRAM ............................................................................................................ 43
ORDERING NUMBERS....................................................................................... 45
ACCESSORIES ................................................................................................... 46
WEAR PARTS...................................................................................................... 51
Rights reserved to alter specifications without notice.

1 SAFETY
0463 613 101 -5- © ESAB AB 2020
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

1 SAFETY
0463 613 101 -6- © ESAB AB 2020
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use ear defenders or other hearing protection.

1 SAFETY
0463 613 101 -7- © ESAB AB 2020
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.
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 such locations,
due to conducted as well as radiated disturbances.

1 SAFETY
0463 613 101 -8- © ESAB AB 2020
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.

2 INTRODUCTION
0463 613 101 -9- © ESAB AB 2020
2 INTRODUCTION
The EWT 1000 welding equipment is designed for Submerged Arc Welding (SAW) and
GMAW (MIG/MAG) welding of butt and fillet joints.
All other applications are prohibited.
The equipment is intended for use in combination with EAC10 and ESAB digital power
sources LAFxxx1,TAFxxx1, or Aristo 1000 and also through the analog interface LAF635
and LAF1000.
The EAC10 also supports analog-controlled power sources from other suppliers; see
chapter "Connecting to a compatible DC analog power source" for more information about
the interface.
2.1 Welding method
2.1.1 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.
2.1.2 Submerged Arc Welding (SAW)
Use EWH 1000 or EWH 1000 twin welding equipment for Submerged Arc Welding.
EWH1000 permits loads of up to 1000A (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.
2.1.3 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.
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 EWT1000 when welding on inclined planes.
Avoid welding on surfaces with a slope of greater than 3° (>6in/10ft/ >5cm/m) due to risk
of weld defects caused by the large amount of melted metal in the weld pool.

2 INTRODUCTION
0463 613 101 - 10 - © ESAB AB 2020
2.3 Stability
NOTE!
Always check the welding equipment for stability before welding.
The EWT1000 is designed to be flexible and cover many different welding applications and
setups. Stability can be improved by moving the horizontal slide, moving the wire bobbin to
the opposite side, etc.

3 TECHNICAL DATA
0463 613 101 - 11 - © ESAB AB 2020
3 TECHNICAL DATA
3.1 EWT1000 welding tractor
1. Tractor carriage 4. EAC10, control pendant
2. Bobbin holder 5. EWH1000, welding head
3. Column with EAC10
EWT1000, from serial no. 841-xxx-xxxx
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 13.3in-lb (1.5Nm)
Minimum turning radius for circumferential welding
Inside object diameter 9ft 10.11in (3000mm)
Outside object diameter, four
wheels
12ft 9.54in (3900 mm)
Minimum pipe diameter for
internal joint welding
3ft 7.31in (1100mm)
Maximum weight of wire 66lb (30 kg)
Weight
Total, excluding wire and flux 148lb (67 kg)
Tractor carriage 48.7lb (22.1 kg)
Bobbin holder, without wire 4.2lb (6kg)
Column with EAC10 55.1lb (25kg)
Relative air humidity Max 95%
Operating temperature -14to+104 °F (-10to+40 °C)
Storage temperature -4to+131 °F (-20to+55 °C)

3 TECHNICAL DATA
0463 613 101 - 12 - © ESAB AB 2020
EWT1000, from serial no. 841-xxx-xxxx
EWT1000
Maximum surface
temperature
140°F (60°C)
EMC classification Class A
Enclosure class IPXX
3.2 EAC10 control unit
EAC 10, from serial no. 841-xxx-xxxx and 905-xxx-xxxx
Supply voltage 60VDC or 42VAC, 50/60Hz
Supply voltage to control
pendant
12VDC
Power requirement Max 900VA
Motor connections adapted
for ESAB motors
6A 100%
Speed control Feedback from pulse encoder
Operating temperature -14to+104°F (-10to+40°C)
Storage temperature -4to+131°F (-20to+55°C)
Relative air humidity Max 95%
Dimensions l×w×h
EAC10, complete control unit 10.8×11.8×6.5in (275×300×165mm)
EAC10 control pendant 9.7×8.9×2.0in (245×225×50mm)
Weight
EAC10, complete control unit 15lb (6.8kg)
EAC10 control pendant 2.8 lb (1.25 kg)
Enclosure class IP23
3.3 Welding head EWH600/EWH1000
EWH 1000, for serial no. 841-xxx-xxxx, 905-xxx-xxxx and 910-xxx-xxxx
EWH1000 EWH1000twin EWH600gmaw
Supply voltage 42VAC 42VAC 42VAC
Permissible load at
100%
1000 A 1000 A 600 A
Wire dimensions
Fe solid single 0.06–0.20in
(1.6–5.0mm)
N/A 0.03-0.10in (0.8-2.5
mm)
Fe solid twin 2×1.2–3.2 mm1)
(2×0.05–0.09in.1))
2×1.2-1.6 mm
(2×0.05-0.06in.)
N/A
Fe flux cored 0.06–0.20in
(1.6–5.0mm)
N/A 1.2–3.2 mm
(0.05–1/8in.)
Fe flux cored twin 2×1.2–3.2 mm1)
(2×0.05–0.09in.1))
N/A N/A

3 TECHNICAL DATA
0463 613 101 - 13 - © ESAB AB 2020
EWH 1000, for serial no. 841-xxx-xxxx, 905-xxx-xxxx and 910-xxx-xxxx
EWH1000 EWH1000twin EWH600gmaw
SS solid 0.06–0.20in
(1.6–5.0mm)
N/A 0.03-0.06in (0.8-1.6
mm)
SS solid twin 2×1.2–2.4 mm1)
(2×0.05–0.09in.1))
2×1.2-1.6 mm
(2×0.05-0.06in.)
N/A
SS flux cored 0.06–0.20in
(1.6–5.0mm)
N/A 1.2–3.2 mm
(0.05–1/8in.)
SS flux cored twin 2×1.2–2.4 mm1)
(2×0.05–0.09in.1))
N/A N/A
Al Solid N/A N/A 2.5 mm (0.10in.)
Type of gas N/A N/A CO2, Ar
Maximum wire feed speed
Maximum (≤4mm wire) 29.5feet/min (9.0
m/min)
52.5feet/min (16
m/min)
52.5feet/min (16
m/min)
Maximum (5mm wire) 8.2 feet/min (2.5
m/min)
Brake hub braking
torque
13.3in-lb (1.5Nm)
Flux hopper volume 6 l 6 l N/A
Dimensions l×w×h 24.4×20.9×32.8in
(620×530×832mm)
23.6×20.9×31.7in
(600×530×805mm)
23.6×19.7×29.9in
(600×500×760mm)
Weight welding head,
excluding wire and flux
37.5lb (17 kg) 41.9lb (19kg) 36.4lb (16.5kg)
Enclosure class IPXX
EMC classification Class A
1) with optional twin kit accessory

4 INSTALLATION
0463 613 101 - 14 - © ESAB AB 2020
4 INSTALLATION
4.1 General
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.
4.2 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
must not be lifted with the tractor.
• Remove optional air and water hoses.

4 INSTALLATION
0463 613 101 - 15 - © ESAB AB 2020
• Make sure the column is in the locked position (1), directed forward as shown in the
illustration.
• Make sure the welding head arm is in the locked position (2).
• Remove the bobbin holder or the wire drum from the bobbin holder. Make sure that the
empty bobbin holder is in the locked position (3).
4.3 Main components
1. EAC10 Control pendant 8. Contact 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 a different number of welding cables for different welding currents:
Up to 500A one 120-mm2cable
500–1000A two 120-mm2cables
NOTE!
With a two welding cable setup, run the welding cables close to each other in
parallel, but do not twist them around each other.
4.4 Assembly
For information about assembly of the welding tractor, see chapter "Transportation."

4 INSTALLATION
0463 613 101 - 16 - © ESAB AB 2020
4.4.1 Bobbin holder
Mount the wire drum on the brake hub in the
bobbin holder.
WARNING!
To prevent the reel from sliding off
the hub: Lock the reel in place by
turning the red knob as shown on
the warning label attached next to
the hub.
4.4.2 Adjusting the brake hub
The brake hub is adjusted upon delivery. If readjustment is required, follow the instructions
below. Adjust the brake hub so that 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
counter-clockwise to increase
the braking torque.
NOTE!
Turn both springs the same amount.

4 INSTALLATION
0463 613 101 - 17 - © ESAB AB 2020
4.5 Connections
1. On/Off indicator 6. Tractor carriage connection
2. On/Off switch 7. Digital power source connection
3. Connection work piece voltage
reference brush
8. Analog power source connection
4. Accessory cable entries 9. Cable to control pendant
5. Welding head connection
NOTE!
Only connect one digital power source or one analog power source at a time.

4 INSTALLATION
0463 613 101 - 18 - © ESAB AB 2020
4.5.1 Connecting to a digital power source
Connect the interconnection cable to the connector marked "I".
Interconnection cables between CAN-based ESAB power sources and the 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 a welding power source, see the separate
instruction manual.
Always use the dust cover on connections where no cable is connected.

4 INSTALLATION
0463 613 101 - 19 - © ESAB AB 2020
4.5.2 Connecting to a compatible DC analog power source
Connect the interconnection cable to the connector marked "II".
Interconnection cable between analog-based ESAB power source and EAC10 control unit
are available as accessories in different lengths.
Always use the dust cover on connections where no cable is connected.
Requirements for analog power sources
• Supply 60VDC or 42VAC, 50/60Hz voltage from the welding power source or by
external means.
• Voltage feedback from negative welding terminal (for welding voltage measurement for
display in pendant).
• Start input to initiate welding, analog input (0–10VDC) for setting welding parameters
(control signal).
• 1000A/60mV shunt output for welding current measurement.
Power source connection socket XP2 pinouts
B, C 42VAC
E, F 42VAC return
J Power source negative terminal (U-)
W Power source positive terminal (U+)

4 INSTALLATION
0463 613 101 - 20 - © ESAB AB 2020
Power source connection socket XP2 pinouts
X Arc voltage from welding head
K Power source start
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/trigger input. For non-ESAB power sources.
T Contact closure to pin S/trigger common. For non-ESAB power sources.
U Reserved for future use.
To connect EAC10 with a non-ESAB SAW analog power source, an analog power source
interface box and control cables are available as accessories.
See "ACCESSORIES" chapter.