ABOUT SPAWLAB, MANUFACTURER AND IWE EXPERT
As the owner of the SpawLab brand and a practising IWE engineer, I personally supervise the assembly of high current torches. This gouging torch is not an off the shelf item from a box, it is a Dual-Core current bus that we crimp hydraulically in our Polish assembly shop. I guarantee that this equipment takes a continuous load of 1000A and protects your power source against phase asymmetry and overheating.
SpawLab PRO 1000A Gouging Torch | Dual-Core 190 mm² - 10m
The strongest air carbon arc gouging torch in its class, made for removing casting defects and cutting structures at currents up to 1000A. The supply system based on two parallel 95 mm² cables (Parallel-Core) carries energy without losses and cools passively. A 360° Heavy-Duty rotating head and the Air-Jet nozzle system give the highest metal blowout rate with carbon electrodes up to 16mm.
Complete Specification of the Set (What You Get):
| Torch body | K-4000 PRO |
| Current leads | 2x 10m H01N2-D 95 mm² |
| Machine terminals | 2x LW/LP 70-95 plug |
| Air system | Reinforced hose joined with the handle + barbed connector/quick connector |
| Assembly | Cable ends finished with copper sleeves (tinned) |
Thermal Analysis (Torch at 1000A)
A gouging torch is a part the operator holds in the hands, so thermal safety is critical here. Below is an audit of power losses over a 10m run at a load of 1000A:
| Cable Configuration | Total Cross Section | Heating Power (Losses) | Safety Rating |
|---|---|---|---|
| SpawLab Dual 2×95 mm² | 190 mm² | ~1890 W | SAFE. Handle cool, cable warm. |
| Standard 2×70 mm² | 140 mm² | ~2560 W | BURN RISK. Cable burns after 15 min. |
| Single 120 mm² | 120 mm² | ~3000 W | MELTED INSULATION. Failure certain. |
Loss power calculated from $P=I^2R$ for copper at a working temperature of 60°C.
Engineering of the Dual-Core 1000A Torch
Parallel-Core Technology (2x 95mm²)
Two supply cables instead of one thick conductor follow from ergonomics and thermodynamics. Two 95mm² cables have a cooling surface 40% larger than a single conductor, which carries away close to 2 kW of heat generated at 1000A. The flexibility of two thinner conductors also lets the operator turn the wrist freely, which is impossible with a stiff 185mm² cable.
Hydraulic Crimping of the Terminals (12 Tonnes)
The LW/LP 70-95 plugs are the critical point. At SpawLab we crimp them on hydraulic presses and obtain a uniform copper structure at the contact (diffusion). That removes the transition resistance which in cheap torches melts the welding sockets in the power unit. It is our own way of protecting your equipment.
360° Air-Jet Rotating Head
The torch body carries a system of air nozzles integrated with the electrode clamp. Compressed air not only blows out the molten metal, it also actively cools the copper jaws of the torch. The 360° rotating mechanism lets the angle of attack be changed without twisting the wrist, which matters for comfort when the cabling is heavy.
IMPORTANT: The Mirror-Balance System (Close the Loop.)
Current flows in a closed circuit. For this torch to work at its full 1000A and not overheat, it MUST run with an earth bus of identical parameters. We recommend buying it together with:
SpawLab PRO Dual-Core 190mm² Earth Bus (2x 95mm²)
Only a symmetrical layout (190mm² on the torch plus 190mm² on the earth side) guarantees stable arc parameters and no socket failures in the power unit.
Technical Data (1000A PRO Specification)
| Torch model | SpawLab K-4000 PRO Dual-Core |
| Current supply | 2x 10m H01N2-D 95 mm² (190 mm² total) |
| Load capacity (60% duty cycle) | 1000 A |
| Load capacity (100% duty cycle) | 800 A |
| Connectors to the machine | 2x LW/LP 70-95 plug (hydraulically crimped) |
| Air pressure | 5.0 - 7.0 bar (flow min. 600 l/min) |
| Electrode range | Round: 4-16mm | Flat: 10-20mm |
FAQ - Expert Questions
Why does the torch have two supply cables?
For safety and cooling. Carrying 1000A through one cable would need a 185mm² cross section, which is unmanageable and overheats quickly. Two 95mm² cables are the industrial standard.
Do I have to connect both plugs?
Yes. Connecting only one plug at 800A-1000A will burn the terminal at once and can damage the welder.
