ESAB Warrior 400i CC/CV, Warrior 500i CC/CV Instruction Manual
Instruction manual
0463 362 001 GB 20130618 Valid for: serial no. 324-xxx-xxx
Warrior™ 400i CC/CV
Warrior™ 500i CC/CV
TABLE OF CONTENTS
0463 362 001 © ESAB AB 2013
1 SAFETY ................................................................................................................ 4
2 INTRODUCTION...................................................................................................7
2.1 Overview ............................................................................................................... 7
2.2 Equipment............................................................................................................. 7
3 TECHNICAL DATA ............................................................................................... 8
4 INSTALLATION................................................................................................... 10
4.1 General................................................................................................................ 10
4.2 Lifting instructions.............................................................................................10
4.3 Location .............................................................................................................. 10
4.4 Mains supply ...................................................................................................... 11
5 OPERATION ....................................................................................................... 14
5.1 Overview ............................................................................................................. 14
5.2 Connections and control devices..................................................................... 14
5.3 Connection of welding and return cables........................................................15
5.4 Turning the mains power on/off........................................................................15
5.5 Fan control.......................................................................................................... 15
5.6 Symbols and functions......................................................................................15
6 MAINTENANCE.................................................................................................. 18
6.1 Overview ............................................................................................................. 18
6.2 Power source...................................................................................................... 18
6.3 Welding torch .....................................................................................................18
7 FAULT TRACING................................................................................................ 19
8 ORDERING SPARE PARTS............................................................................... 20
DIAGRAM ..................................................................................................................21
ORDERING NUMBERS .............................................................................................22
ACCESSORIES .........................................................................................................23
Rights reserved to alter specifications without notice.
1 SAFETY
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© ESAB AB 2013
1 SAFETY
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 equpment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
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 extinquishing equipment must be clearly marked and close at hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
1 SAFETY
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WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth the unit in accordance with applicable standards
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
• Insulate yourself from earth and the workpiece
• Ensure your working stance is safe
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
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
NOISE - Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection. Protect your ears.
Use earmuffs or other hearing protection
• Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
This product is solely intended for arc welding.
1 SAFETY
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© ESAB AB 2013
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 2002/96/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 can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
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2 INTRODUCTION
2.1 Overview
The Warrior 400i CC/CV and Warrior 500i CC/CV are welding power sources intended for
MIG/MAG welding, as well as for welding with powder filled cored wire (FCAW-S), for TIG
welding, for welding with coated electrodes (MMA) and for arc air gouging.
The power sources are intended for use with the following wire feed units:
• Warrior Feed 304
• Warrior Feed 304w
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.2 Equipment
The power source is supplied with:
• 5 m return cable with earth clamp
• 3 m mains cable
• instruction manual
3 TECHNICAL DATA
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© ESAB AB 2013
3 TECHNICAL DATA
Warrior 400i CC/CV Warrior 500i CC/CV
Mains voltage 380-415 V ±10%,
3~ 50/60 Hz
380-415 V ±10%,
3~ 50/60 Hz
Mains supply S
scmin
6.4 MVA 7.2 MVA
Mains supply Z
max
0.025 Ω 0.022 Ω
Primary current I
max
MIG/MAG
TIG
MMA
28 A
23 A
28 A
37 A
30 A
38 A
No-load power in energy-saving
mode 6.5 min. after welding 30 W 30 W
Setting range
MIG/MAG
TIG
MMA
16 A/15 V - 400 A/34 V
5 A/10 V - 400 A/26 V
16 A/20 V - 400 A/36 V
16 A/15 V - 500 A/39 V
5 A/10 V - 500 A/30 V
16 A/20 V - 500 A/40 V
Permissible load at MIG/MAG
60 % duty cycle
100% duty cycle
400 A/34 V
300 A/29 V
500 A/39 V
400 A/34 V
Permissible load at TIG
60 % duty cycle
100% duty cycle
400 A/26 V
300 A/22 V
500 A/30 V
400 A/26 V
Permissible load at MMA
60 % duty cycle
100% duty cycle
400 A/36 V
300 A/32 V
500 A/40 V
400 A/36 V
Power factor at maximum current 0.91 0.91
Efficiency at maximum current 88 % 89 %
Electrode types Basic
Rutile
Cellulosic
Basic
Rutile
Cellulosic
Open-circuit voltage
without VRD function 78 V DC 78 V DC
Apparent power at maximum
current
18.0 kVA 24.6 kVA
Active power at maximum
current
16.4 kW 22.5 kW
Operating temperature -10 to +40°C -10 to +40°C
Transportation temperature -20 to +55°C -20 to +55°C
Constant sound pressure when
idling
<70 db (A) <70 db (A)
Dimensions l × w × h 712 × 325 × 470 mm 712 × 325 × 470 mm
Weight 58.5 kg 58.5 kg
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