ESAB WARRIOR EDGE 500 Instruction manual

WARRIOREDGE500

Instruction manual

0463 772 001  GB  20230224

Valid for: Serial number:

OP137YY-XXXXXX

TABLE OF CONTENTS

1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

2.1 Equipment

3 TECHNICAL DATA

4 INSTALLATION

4.1 Location

4.2 Lifting instructions

4.3 Mains supply

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4.4 Recommended fuse sizes and minimum cable area

5 OPERATION

5.1 Connections and control devices

5.2 Symbols

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5.3 Connection of welding and return cable

5.4 Turning the mains power ON/OFF

5.5 Fan control

5.6 Usage of cooling unit

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5.6.1 Operation of cooling unit after welding

5.7 Cooling unit connection

5.8 Cooling unit pressure controller

5.9 USB Connection

6 CONTROL PANEL

6.1 Overview

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6.2 LED indicators description

6.3 Functions and symbols

6.3.1 TIG welding

6.3.2 Arc air gouging

6.3.3 MMA welding

6.3.4 MMA cel 6010 welding

6.3.5 MIG/MAG

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6.4 Measured or set values

7 MAINTENANCE

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7.1 Routine maintenance

7.1.1 Cleaning procedure

7.2 Cooling unit

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7.2.1 Filling the coolant

8 EVENT CODES

8.1 Application fault

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8.2 Supply voltage fault

8.3 Temperature fault

8.4 Battery warning

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8.5 Internal voltage error

8.6 Wire feed speed fault

8.7 Communication fault

8.8 Short circuit detected

8.9 High open circuit voltage fault

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TABLE OF CONTENTS

8.10 Lost contact with another unit

8.11 Internal memory fault

8.12 Memory fault

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8.13 User management fault

8.14 Incompatible units

8.15 Timing fault

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8.16 No coolant flow

8.17 Gas pressure fault

8.18 Gas flow fault

8.19 USB fault

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8.20 Software runtime fault

8.21 External stop

9 TROUBLESHOOTING

10 ORDERING SPARE PARTS

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11 CALIBRATION AND VALIDATION

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11.1 Measurement methods and tolerances

11.2 Requirements, specifications and standards

WIRING DIAGRAM

ORDERING NUMBERS

ACCESSORIES

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1  SAFETY

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

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1  SAFETY

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

If equipped with ESAB cooler

Use ESAB approved coolant only. Non-approved coolant might damage the equipment and jeopardize
product safety. In case of such damage, all warranty undertakings from ESAB cease to apply.

For ordering information, see the "ACCESSORIES" chapter in the instruction manual.

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.

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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.

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1  SAFETY

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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.

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1  SAFETY

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.

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2  INTRODUCTION

2 INTRODUCTION

The Warrior Edge 500 is integrated with a cooling unit and offers a complete multi-process package
supporting MIG/MAG, MMA, Live TIG and gouging. It is intended for use in combination with

RobustFeed Edge.

The power source is equipped with gateway to connect to the WeldCloud suite of applications,
including WeldCloud Productivity for production monitoring and WeldCloud Fleet for managing your
fleet of welding equipment.

For more information about the wire feed units, refer to the Instruction manual 0463 773 001.

For more information about WeldCloud, refer to the Quick start guide 0463 778 001.

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.

2.1 Equipment

The power source is supplied with:

• 5 m (16 ft) 95mm2return cable with earth clamp

• 5 m (16 ft) mains cable

• Instruction manual

• Quick start guide

• Safety instruction

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3  TECHNICAL DATA

3 TECHNICAL DATA

WARRIOR EDGE 500

Mains voltage 380–460V, ±10%, 3~ 50/60Hz

Mains supply S

Primary current I

scmin

max

6.8 MVA

380 V 400 V 460 V

MIG/MAG 36 A 36 A 31 A

MMA 38 A 37 A 32 A

TIG 29 A 29 A 25 A

Idle power with fans OFF 41 W 43 W 43 W

Setting range (DC)

MIG/MAG 16A/14.8V – 500A/39V

MMA 16A/20.6V – 500A/40V

TIG 4A/10.2V – 500A/30V

Permissible load at MIG/MAG

60% duty cycle 500A/39V

100% duty cycle 400A/34V

Permissible load at MMA

60% duty cycle 500A/40V

100% duty cycle 400A/36V

Permissible load at TIG

60% duty cycle 500A/30V

100% duty cycle 400A/26V

Power factor

at maximum current (MMA) 0.91

MIG/MAG welding 0.93

Efficiency

at maximum current (MMA) 89%

MIG/MAG welding 88%

Open-circuit voltage 55V

Operating temperature -20to+55°C

Transportation temperature -40to+80°C

Constant sound pressure when idling < 70dB(A)

Dimensions l × w × h 700×325×680mm

Weight 85kg (including cooler)

Insulation class H

Enclosure class IP23

Application class

Coolant ESAB's coolant (0465 720 002)

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3  TECHNICAL DATA

WARRIOR EDGE 500

Cooling power 1.4kW

Cooling volume 4.7l

Maximum flow 2l/min

Maximum pressure 4.5bar



Mains supply, S

sc min

Minimum short circuit power on the network in accordance with IEC 61000-3-12.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a certain
load without overloading.

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid
objects or water.

Equipment marked IP23 is intended for indoor and may be used outdoors if sheltered during
precipitation.

Application class

The symbol indicates that the power source is suitable for welding in an environment with an
increased risk of electric shock.

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4  INSTALLATION

4 INSTALLATION

The installation must be carried out by a professional.

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 Location

Position the welding power source in such a way that its cooling air inlets and outlets are not
obstructed.

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4  INSTALLATION

4.2 Lifting instructions

Mechanical lifting must be done with both outer handles.

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4  INSTALLATION

4.3 Mains supply

NOTE!
Mains supply requirements

This equipment complies with IEC 61000-3-12 provided that the short-circuit power is greater
than or equal to S

It is the responsibility of the installer or user of the equipment to ensure, by consultation with
the distribution network operator if necessary, that the equipment is connected only to a supply
with a short-circuit power greater than or equal to S

TECHNICAL DATA chapter.

at the interface point between the user's supply and the public system.

scmin

. Refer to the technical data in the

scmin

1. Rating plate with supply connection data.

4.4 Recommended fuse sizes and minimum cable area

WARRIOR EDGE 500

Mains voltage 380 V 3~ 50/60Hz 400 V 3~ 50/60Hz 460 V 3~ 50/60 Hz

Mains cable area 4×6 mm

Maximal current I

I

1eff

max

2

4×6 mm

38 A 37 A 32 A

MIG/MAG 29 A 28 A 24 A

MMA 30 A 29 A 25 A

TIG 24 A 22 A 19 A

Fuse

Anti-surge 35 A 35 A 35 A

Type C MCB 32 A 32 A 32 A

2

4×6 mm

2

NOTE!

The mains cable areas and fuse sizes as shown above are in accordance with Swedish
regulations. For other regions, supply cables must be suitable for the application and meet
local and national regulations.

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4  INSTALLATION

Supply from power generators

The power source can be supplied from different types of generators. However, some generators may
not provide sufficient power for the welding power source to operate correctly. Generators with
Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power
≥40kW, are recommended.

Connection instruction

WARNING!

The mains supply must be disconnected during installation.

WARNING!

Wait until the DC bus capacitors are discharged. The DC bus capacitor discharge time is at
least 2 minutes!

The power source is factory set to 400 V AC. If another mains voltage setting is required, the cable on
the printed circuit board has to be moved and put in the correct position. Also, the label at the rear of
the power source, marked with the mains voltage setting must be updated. This operation must be
done by a person who has the appropriate electrical knowledge.

NOTE!

This power source version is designed for a nominal input voltage from 380 to 460VAC. This
means that the hardware to support 575V input is not available, 575V tab is not connected.

If the mains cable needs to be changed, the earth connection to the bottom plate and the ferrites must
be installed correctly. See the picture below for the installation order of the ferrites, washers, nuts and
screws.

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4  INSTALLATION

Connections Cable colour (CE)

L1 Brown

L2 Black

L3 Grey

GND Yellow/Green

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5  OPERATION

5 OPERATION

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.

WARNING!

Electric shock! Do not touch the workpiece or the welding head during operation!

5.1 Connections and control devices

1. Mains power supply switch, O/I 8. Connection BLUE for coolant from cooling unit

2. Connection for remote control unit 9. USB connection ports

3. Power connection to wire feed unit 10. Current/Voltage encoder knob

4. Negative welding terminal: Return cable 11. Process selection knob

5. Fuse (10A) for supply voltage for wire feeder

unit

6. Positive welding terminal: Welding cable 13. Mains cable

7. Connection RED for coolant (return) to cooling

unit

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12. WeldCloud Ethernet connection

14. Coolant tank

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5  OPERATION

5.2 Symbols

WeldCloud connection USB connection

Protective earth Position for mechanized lifting

5.3 Connection of welding and return cable

The power source has two outputs, a positive terminal (+) and a negative terminal (-), for connecting
welding and return cables.

Connect the return cable to the negative terminal on the power source. Secure the return cable's
contact clamp to the work piece and ensure that there is good contact between the work piece and the
output for the return cable on the power source.

Recommended maximum current values for connection set cables

At an ambient temperature of +25 °C and normal 10 minutes cycle:

Duty cycle

Cable area

Voltage loss/10m

100% 60%

50mm

70mm

95mm

2

2

2

290 320 0.35V / 100A

360 400 0.25V / 100A

430 500 0.19V / 100A

At an ambient temperature of +40 °C and normal 10 minutes cycle:

Duty cycle

Cable area

Voltage loss/10m

100% 60%

50mm

70mm

95mm

2

2

2

250 280 0.37V / 100A

310 350 0.27V / 100A

370 430 0.20V / 100A

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a certain
load without overloading.

5.4 Turning the mains power ON/OFF

Turn ON the mains power by turning switch to the ”I” position.

Turn the power source OFF by turning the switch to the ”O” position.

Regardless the mains supply is interrupted abnormally, or the power source is switched off in the
normal manner, the welding data will be stored, so it will be available next time the unit is turned on.

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5  OPERATION

5.5 Fan control

The power source has a time control that means that the fans continue to run for 4 minutes after
welding has stopped. The fans start again when welding restarts.

5.6 Usage of cooling unit

ELP (ESAB Logic Pump)

The cooling unit is equipped with detection system called ELP (ESAB Logic Pump), which checks that
the coolant hoses are connected. When connecting a liquid cooled torch, cooling starts.

NOTE!

The cooling unit starts as soon as the ELP is activated!

For liquid cooled torches, the cooling unit will start only if the torch cooling hoses are
connected to the wire feeder.

When the cooling hoses are disconnected from the wire feeder, the cooling stops immediately.

NOTE!

The cooling unit will be applicable only for MIG/MAG welding.

The power source automatically detects the need of cooling unit based on welding applications and
operates the cooling unit accordingly.

When liquid cooled torch is connected, if the coolant temperature exceeds 45 °C, the cooler fan and
pump will start even if there is no welding operation.

5.6.1 Operation of cooling unit after welding

If the coolant temperature is below 55°C, the cooler fan and pump will continue to run for three
minutes and then stop.

If the coolant temperature is at 65°C or above, the cooler fan and pump will continue to run for seven
minutes and then stop.

In a long weld, if the coolant temperature has not decreased to 55°C within seven minutes, the cooler
fan and pump will continue to run for another three minutes and then stop.

5.7 Cooling unit connection

For trouble free operation, it is recommended that the height from the cooling unit to the liquid-cooled
torch is 25m or less.

5.8 Cooling unit pressure controller

The pump has an enclosed pressure relief valve. The valve opens gradually when the pressure is too
high. This can occur if a hose is folded, which causes the flow to fail or stop.

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5  OPERATION

5.9 USB Connection

1. IoT Gateway USB port 1 3. USB port 3, which enables the user to upgrade

the software and to export the error log report.

2. IoT Gateway USB port 2

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6  CONTROL PANEL

6 CONTROL PANEL

6.1 Overview

1. LED Indicators 4. Current/voltage encoder knob

2. Display, shows set or measured current 5. Application selection knob

3. Display, shows set or measured

voltage/dynamics

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6  CONTROL PANEL

6.2 LED indicators description

Indicator Description

WeldCloud

An online management system that connects welding power supplies to a software
platform that manages data to be analysed for maximum productivity.

WeldCloud productivity provides the production manager tools to improve welding
productivity and increase traceability by keeping track of each weld, operator, part
number and more.

The indicator is lit in green when it is connected.

VRD (Voltage Reducing Device)

The VRD function ensures that the open-circuit voltage does not exceed 35 V when
welding is not being carried out. The VRD function must be activated by a qualified
service technician, by means of Edge ESAT (ESAB Software Administration Tool, a
kit for technical service including a software to manage settings, update of software
etc.).

The VRD function is blocked when the system senses that welding has started.

When VRD function is active, the indicator is lit in green.

TRUEARC compensate

To achieve a good welding result, the arc voltage is a crucial factor. In MIG/MAG
welding, the power source is prepared to sense the arc voltage in the wire feeder.
Prerequisite for this functionality is that an ESAB wire feeder and an ESAB
interconnection cable is used.

In compensation mode, when the torch is triggered on the workpiece (avoid wire
contact), it measures the inductance and resistance to compensate for the voltage
drop in the interconnection cable, torch and return cable.

The indicator is lit in yellow when compensation is required and it blinks during the
compensation process. If the compensation process is a success, the indicator is lit
in green.

Warning/Error

• Warning
The indicator is lit in yellow and displays an "Err" message. If warning
occurs, completion of ongoing weld is possible, but start of a new weld
is prevented as long as the warning remains.

• Error
The indicator is lit in red and displays an "Err" message. The ongoing
welding is stopped as long as the error remains.

Lock

Green - This indicates when the system has limited access or Job limits are active.

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Red - This indicates the system is locked, and to be able to use the system, it is
required to unlock.

Red (blink) - This indicates when the user is trying to access the restricted features.

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6  CONTROL PANEL

6.3 Functions and symbols

6.3.1 TIG welding

TIG welding melts the metal of the workpiece, with an arc initiated from a
non-consuming tungsten electrode. The weld pool and electrode are protected by
shielding gas.

For TIG welding, the welding power source shall be supplemented with:

• a TIG torch with gas valve

• an argon gas cylinder

• an argon gas regulator

• tungsten electrode

This power source performs Live TIG start (TIG Live).

The tungsten electrode is placed against the workpiece. When lifted away from workpiece the arc is
struck at a limited current level.

6.3.2 Arc air gouging

With arc air gouging, a special electrode comprising a carbon rod with a copper casing
is used.

An arc is formed between the carbon rod and the workpiece, which melts the material.
Compressed air is supplied so that the melted material is blown away.

For arc air gouging the power source shall be supplemented with:

• ARCAIR torches

• return cable with clamp

• air pressure

Recommended voltage setting for ARCAIR gouging electrodes

Electrode

size

Voltage V 35-38 36-40 38-42 40-46 44-50 46-54

NOTE!

The minimum and maximum settings are starting points for the rods indicated, with relatively
clean metal, an acceptable gouge groove should be expected. These specific
recommendations are based on the result of test carried out on A36/ASME mild steel.

in 1/8 5/32 3/16 1/4 5/16 3/8

mm 3.2 4.0 4.8 6.4 7.9 9.5

For different types of metal, adjust the volt setting and air flow for better performance.

For any gouging issues other than performance, see the TROUBLESHOOTING section.

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6  CONTROL PANEL

6.3.3 MMA welding

MMA welding may also be referred to as welding with coated electrodes. Striking the arc
melts the electrode, and its coating forms protective slag.

For MMA welding the power source shall be supplemented with:

• welding cable with electrode holder

• return cable with clamp

6.3.4 MMA cel 6010 welding

Optimized arc characteristic for cellulosic electrodes such as 6010 and similar.

6.3.5 MIG/MAG

An arc melts a continuously supplied wire. The weld pool is protected by shielding gas.

For MIG/MAG welding, the power source shall be supplemented with:

• wire feed unit

• welding torch

• connection cable between power source and wire feed unit

• gas cylinder

• return cable with clamp

6.4 Measured or set values

Measured or set voltage

Measured or set value in the display for arc voltage V is an average arithmetic value.

Measured or set amperage

Measured or set value in the display for welding current A is an average arithmetic
value.

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7  MAINTENANCE

7 MAINTENANCE

WARNING!

The mains supply must be disconnected during cleaning and maintenance.

CAUTION!

Only persons with the appropriate electrical knowledge (authorised personnel) may remove
the safety plates.

CAUTION!

The product is covered by manufacturer's warranty. Any attempt to carry out repair work by
non-authorised service centers or personnel will invalidate the warranty.

NOTE!

Regular maintenance is important for safe and reliable operation.

NOTE!

Perform maintenance more often during severe dusty conditions.

Before each use - make sure that:

• Product and cables are not damaged

• The torch is clean and not damaged

7.1 Routine maintenance

Maintenance schedule during normal conditions. Check equipment prior to every use.

Interval Area to maintain

Every 3 months

Every 12 months or
depending on
environmental
conditions (by
authorised service
technician)

Clean or replace

unreadable labels.

Clean inside

equipment. Use dry

compressed air with

4bar pressure.

Clean weld terminals. Check or replace weld

cables.

0463 772 001

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© ESAB AB 2023

7  MAINTENANCE

7.1.1 Cleaning procedure

To maintain the performance and increase the lifetime of the power source it is mandatory to clean the
product regularly. How often depends on:

• the welding process

• the arc time

• the working environment

• the surrounding environment, that is grinding etc

Tools needed for the cleaning procedure:

• torx screwdriver, T25 and T30

• dry compressed air at a pressure of 4 bar

• protective equipment like ear plugs, safety glasses, masks, gloves and safety shoes

CAUTION!

Make sure that the cleaning procedure is done in a suitable prepared workspace.

CAUTION!

The cleaning procedure should be carried out by authorised service technician.

1. Disconnect the power source from the mains supply.

WARNING!

Wait until the DC bus capacitors are discharged. The DC bus capacitor
discharge time is at least 2 minutes!

2. Remove the side panels on the power source.

3. Remove the top panel on the power source.

4. Remove the plastic cover between the heat sink and fan.

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© ESAB AB 2023

7  MAINTENANCE

5. Clean the power source with dry compressed air (4 bar) as follows:

• The upper rear part.

• From the rear panel through the secondary heat sink.

• The inductor, transformer and current sensor.

• The power components side, from the rear side behind PCB15AP1.

• The PCBs at both sides.

• Current brake resistors

• Radiator and fans

6. Make sure that there is no dust left on any part of the power source.

7. Install the plastic cover between the heat sink and the fan and make sure it is
correctly fitted against the heat sink.

8. Reassemble the power source after cleaning and perform testing according to
IEC60974-4.
Follow the procedure in section “After repair, inspection and test” in the Service
manual.

7.2 Cooling unit

Dust, grinding, swarf etc

The airstream through the cooling unit carries particles that become trapped in the cooling element,
particularly in dirty working environments. This results in reduced cooling capacity.

The coolant system

The recommended coolant must be used in the system. Otherwise, clumps that block the pump,
coolant connections or elements can be created. Flushing can only be performed via red coolant
connection. Then drain the tank manually, i.e. empty via the tank's filling hole.

7.2.1 Filling the coolant

Use only ESAB's ready mixed coolant. See chapter "ACCESSORIES".

• Fill with coolant. (The fluid level must not exceed the upper marking, but neither must
it be below lower marking.)

CAUTION!

The coolant must be handled as chemical waste.

NOTE!

Coolant must be topped up if connecting a welding torch or coolant hoses that are 5 m in
length or longer. When adjusting the coolant level by topping up, the coolant hoses do not
need to be disconnected.

0463 772 001

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© ESAB AB 2023

7  MAINTENANCE

0463 772 001

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© ESAB AB 2023

8  EVENT CODES

8 EVENT CODES

Event codes are used in order to indicate and identify an error in the equipment. Event codes provide
information about the equipment.

Fault log

All faults that occur when using the welding equipment are documented as error messages in the fault
log. When the fault log is full, the oldest message will automatically erase when the next fault occurs.

The most recent fault message is displayed on the control panel. The entire fault log as well as
corrective action can be read on the internal control panel.

List of event codes

The control panel displays an event code with three digits and the first digit indicates the type of event.
The type of event (first digit of the event code) are as follows:

0 = System 1 = Communication 2 = Power source

3 = Wire feed unit 4 = Cooling unit 6 = Gas unit

7 = External

NOTE!

The last two digits indicate the event description at which the user can take corrective action. If
the error code persist or any other code is shown, contact a service technician.

The example presented in the graphic to the left,
indicates that the Supply voltage fault in the power
source.

x01

This event code is displayed due to one of the following:

• 001 - Application checksum error.

1. Acknowledge by pressing any buttons on the control panel.

2. Restart the system.

x05

This event code is displayed due to one of the following:

Application fault

Supply voltage fault

• 205 - Mains over/under voltage or phase error.

1. Make sure that the supply voltage is stable.

2. Restart the system.

x06

This event code is displayed due to one of the following:

• 406 - Return coolant temperature warning/error.

• 206 - Overtemperature.

• 306 - High wire motor temperature warning/error.

0463 772 001

Temperature fault

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© ESAB AB 2023

8  EVENT CODES

For 406 and 206 - Return coolant temperature warning/error and Overtemperature, perform the
following actions:

1. Make sure that the cooling air inlets or outlets are not blocked or clogged by dirt.

2. Check the duty cycle being used, to make sure that the equipment is not being overloaded.

3. Wait until the temperature cools down.

For 306 - High wire motor temperature warning/error, perform the following actions:

4. Check the liner, clean using pressurized air. Replace the liner if damaged or worn out.

5. Check the wire pressure setting and adjust if needed.

6. Check the drive rolls for wear and replace if needed.

7. Make sure the filler metal spool can rotate without much resistance. Adjust the brake hub if

needed.

8. Restart the system.

9. If the error persists, check the liner, clean using pressurized air and replace the liner if damaged

or worn out.

10. If the error persists despite performing these actions, try replacing the torch.

x08

This event code is displayed due to one of the following:

• 208 - RTC/SRAM battery low warning.

1. Make sure that the polarity (+, - terminals) of the battery is right.

2. Contact authorised service technician to replace the battery.

x09

This event code is displayed due to one of the following:

• 209 - Internal over/under voltage error.

1. Restart the system.

2. Contact authorised person to check the main inputs.

x11

This event code is displayed due to one of the following:

• 311 - Wire saturation warning/error.

• 311 - Wire motor start/work current error.

Battery warning

Internal voltage error

Wire feed speed fault

1. Check the correct liners/contact tip/torch used for types of welding wires.

2. Check the torque tension in the break hub.

3. Make sure that the wire feed speed control is dust free and rotate.

4. Acknowledge by pressing any buttons on the control panel.

5. Contact service technician to check drive motor.

x14

This event code is displayed due to one of the following:

• 114 - Weld control communication error.

• 114 - Internal communication warning.

• 114 - Connection to main control lost.

• 114 - Fieldbus interface lost.

0463 772 001

Communication fault

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© ESAB AB 2023

8  EVENT CODES

1. Check that all the equipment is correctly connected.

2. Acknowledge by pressing any buttons on the control panel.

3. Do not turn OFF the system and contact service technician.

x15

This event code is displayed due to one of the following:

• 215 - Weld contact detected at startup.

1. Make sure that the welding cables are properly installed of the weld terminals.

2. Acknowledge by pressing any buttons on the control panel.

3. Contact service technician.

x16

This event code is displayed due to one of the following:

• 216 - Voltage sensor lost.

• 216 - OCV level is too high.

• 216 - Current brake module lost.

• 216 - Current brake function error.

1. In case of voltage sensor lost, contact service technician. Otherwise restart the system.

x17

Short circuit detected

High open circuit voltage fault

Lost contact with another unit

This event code is displayed due to one of the following:

• 017 - Mandatory node missing.

• 017 - Critical node lost.

1. Check the cable connections between the subsystem (wire feeder and power source).

2. Acknowledge by pressing any buttons on the control panel.

3. Contact service technician.

x18

This event code is displayed due to one of the following:

• 018 - Partition data storage warning.

1. Make sure that network connection is stable with WeldCloud and acknowledge.

x19

This event code is displayed due to one of the following:

• 019 - Parameter memory read/write error.

• 019 - Log read/write error.

Internal memory fault

Memory fault

1. Restart the system.

2. Contact service technician.

0463 772 001

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© ESAB AB 2023

8  EVENT CODES

x20

This event code is displayed due to one of the following:

• 020 - No valid job available.

1. Make sure that the predefined jobs are saved by admin.

x25

This event code is displayed due to one of the following:

• 025 - System communication version mismatch warning/error.

• 025 - Power converter control module version not valid.

• 025 - Power converter control module power capacity unknown.

1. Contact service technician.

2. Make sure that the software version should be similar for each connected nodes.

3. Connect the correct wire feed unit and restart.

x26

This event code is displayed due to one of the following:

User management fault

Incompatible units

Timing fault

• 026 - Watchdog timeout.

• 026 - Process control error.

1. Restart the system (recycle power).

2. Acknowledge by pressing any buttons on the control panel.

3. Contact service technician.

x29

This event code is displayed due to one of the following:

• 429 - ELP off during welding.

1. Check the coolant hose connections and acknowledge.

x31

This event code is displayed due to one of the following:

• 631 - Gas input pressure warning/error.

1. Check gas input pressure.

2. Select the appropriate setting of gas flow in control panel.

3. Acknowledge by pressing any buttons on the control panel.

4. Contact service technician.

No coolant flow

Gas pressure fault

x32

This event code is displayed due to one of the following:

• 632 - Gas saturation warning/error.

• 632 - No gas out error.

0463 772 001

Gas flow fault

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© ESAB AB 2023

8  EVENT CODES

1. Check gas input pressure.

2. Check the gas hoses, gas pressure regulator and connectors and acknowledge.

3. Select the appropriate setting of gas flow in control panel.

x33

This event code is displayed due to one of the following:

• 033 - USB high current.

• 033 - USB read/write error.

1. Make sure that the USB is in good working condition and configured properly.

2. Contact service technician.

x35

This event code is displayed due to one of the following:

• 035 - Message allocation error.

• 035 - Driver message allocation error.

• 035 - Event queue overflow.

• 035 - Failed to start microservices.

1. Restart the system.

2. Contact service technician.

x36

USB fault

Software runtime fault

External stop

This event code is displayed due to one of the following:

• 736 - Fieldbus quickstop.

• 736 - Fieldbus superquickstop.

1. Acknowledge by pressing any buttons on the control panel.

2. Restart.

0463 772 001

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© ESAB AB 2023

9  TROUBLESHOOTING

9 TROUBLESHOOTING

Perform these checks and inspections before sending for an authorised service technician.

Check that the mains voltage is disconnected before starting any type of repair action.

Type of fault Corrective action

No arc Check that the mains power supply switch is turned ON.

Check that the mains, welding and return cables are correctly
connected.

Check that the correct current value is set.

Check the mains power supply fuses.

The welding current is
interrupted during welding

The thermal protection trips
frequently

Poor welding performance Check that the welding current supply and return cables are correctly

Poor cooling effect Clean the cooling element using compressed air.

Intermittent gouging stops or
contact between carbon and
metal lost

Check whether the thermal protection trip has operated (indicated by
LED on Overtemperature indicator in control panel).

Check the mains supply fuses.

Make sure that you are not exceeding the rated data for the power
source (i.e. that the unit is not being overloaded).

Check that the ambient temperature is not above the one for the rated
duty cycle 40°C/104°F.

connected.

Check that the correct current value is set.

Check that the correct welding wires are being used.

Check the main power supply fuses.

Check the coolant level.

Check that the ambient temperature is not above the one for the rated
duty cycle 40°C/104°F.

Air pressure is too high. Reduce the air pressure.

Check the air pressure whether it is set to the recommended value.
Check the manual of the torch used.

Carbon deposit on the gouge
metal

No arc during start or erratic
arc during gouging

Intermittent arc action
resulting in an irregular
groove surface or copper
deposition on the metal plate

0463 772 001

Air pressure is too low. Turn on air before striking the arc and air
should flow between the electrode and the workpiece.

Check the air pressure whether it is set to the recommended value.
Check the manual of the torch used.

Check whether the voltage is set to the recommended value.

Check whether the voltage is set to the recommended value.

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© ESAB AB 2023

10  ORDERING SPARE PARTS

10 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service technician.
Use only ESAB original spare and wear parts.

Warrior Edge 500 is designed and tested in accordance with the international and European
standards EN IEC 60974-1, EN IEC 60974-2 and EN IEC 60974-10 Class A, Canadian standards
CAN/CSA 60974-1, CAN/CSA 60974-2 and US standards ANSI/IEC 60974-1, ANSI/IEC 60974-2.
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 standards.

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 part number in accordance
with the spare parts list. This facilitates dispatch and ensures correct delivery.

0463 772 001

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© ESAB AB 2023

11  CALIBRATION AND VALIDATION

11 CALIBRATION AND VALIDATION

WARNING!

Calibration and validation should be performed by a trained service technician, possessing
sufficient training in welding and measurement technology. The technician should have
knowledge of hazards that may occur during welding and measurement and should take
necessary protective actions!

11.1 Measurement methods and tolerances

When calibrating and validating, the reference measuring instrument must use the same measuring
method in the DC range (averaging and rectification of the measured values). A number of
measurement methods are used for reference instruments, e.g. TRMS (True Root Mean Square),
RMS (Root-Mean-Square) and rectified arithmetic mean. Warrior Edge 500 uses the rectified
arithmetic mean value and should therefore be calibrated against a reference instrument using the
rectified arithmetic mean value.

In the field application it will occur that a measuring device and a Warrior Edge 500 may display
different values even though both systems are validated and calibrated. This is due to the
measurement tolerances and the method of measurement of the two measurement systems. This can
result in a total deviation up to the sum of both measurement tolerances. If the measurement method
differ (TRMS, RMS or rectified arithmetic mean), significantly larger deviations are to be expected!

The ESAB WarriorEdge 500 welding power source presents the measured value in rectified arithmetic
mean and should therefore not show any significant differences compared to other ESAB welding
equipment, due to the measurement method.

11.2 Requirements, specifications and standards

Warrior Edge 500 is designed to meet the accuracy for indication and meters required by IEC/EN
60974-14, by definition Standard grade.

Calibration accuracies of displayed value

Arc voltage ±1.5V (Umin–U2) under load, resolution 0.25V (Theoretical measuring range in a

WarriorEdge500 system is 0.25–199V.)

Welding current ±2.5% of I2 max according to rating plate of the unit under test, resolution 1A. The

measuring range is specified by the rating plate on the used WarriorEdge500
welding power source.

Recommended method and applicable standard

ESAB recommend calibration and validation to be executed according to IEC/EN60974-14 (unless
another way of execution is communicated from ESAB).

0463 772 001

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© ESAB AB 2023

APPENDIX

APPENDIX

WIRING DIAGRAM

0463 772 001

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© ESAB AB 2023

APPENDIX

ORDERING NUMBERS

Ordering number Denomination Type Notes

0446 300 880 Power source WarriorEdge500 CX I 380-460V, CE

0446 300 884 Power source Warrior Edge 500 CX II 380-460 V, CE

Including SPEED

0463 772 * Instruction manual

0463 844 001 Service manual

0463 843 001 Spare parts list

The three last digits in the document number of the manual show the version of the manual. Therefore
they are replaced with * here. Make sure to use a manual with a serial number that corresponds with
the product, see the front page of the manual.

Technical documentation is available on the Internet at: www.esab.com

0463 772 001

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© ESAB AB 2023

APPENDIX

ACCESSORIES

0446 600 880 RobustFeed Edge BX with EURO connector,

torch cooling system and NFC.

0446 600 881 RobustFeed Edge CX with EURO connector,

torch cooling system, NFC, heater and digital
gas control.

0349 313 450 Trolley, compatible with RobustFeedEdge and

Warrior Edge 500

For assembly instruction, refer to document
0463 357 102

0465 720 002 ESAB ready mixed coolant (10l/2.64gal)

Use of any other cooling liquid than the
prescribed one might damage the equipment.
In case of such damage, all warranty
undertakings from ESAB cease to apply.

0465 416 880 Edge wheel kit

For assembly instruction, refer to document
0463 360 101

Interconnection cable with pre-assembled strain relief, Air cooled, 70 mm

0446 310 880 2.3 m (7 ft)

0446 310 881 5 m (16 ft)

0446 310 882 10 m (33 ft)

0446 310 883 15 m (49 ft)

0446 310 884 20 m (66 ft)

0446 310 885 25 m (82 ft)

0446 310 886 35 m (115 ft)

0446 310 887 50 m (164 ft)

2

0463 772 001

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© ESAB AB 2023

APPENDIX

Interconnection cable with pre-assembled strain relief, Liquid cooled, 70 mm

0446 310 890 2.3 m (7 ft)

0446 310 891 5 m (16 ft)

0446 310 892 10 m (33 ft)

0446 310 893 15 m (49 ft)

0446 310 894 20 m (66 ft)

0446 310 895 25 m (82 ft)

0446 310 896 35 m (115 ft)

Interconnection cable with pre-assembled strain relief, Air cooled, 95 mm

2

0446 310 980 2.3 m (7 ft)

0446 310 981 5 m (16 ft)

0446 310 982 10 m (33 ft)

0446 310 983 15 m (49 ft)

0446 310 984 20 m (66 ft)

0446 310 985 25 m (82 ft)

0446 310 986 35 m (115 ft)

2

0446 310 987 50 m (164 ft)

Interconnection cable with pre-assembled strain relief, Liquid cooled, 95 mm

0446 310 990 2.3 m (7 ft)

0446 310 991 5 m (16 ft)

0446 310 992 10 m (33 ft)

0446 310 993 15 m (49 ft)

0446 310 994 20 m (66 ft)

0446 310 995 25 m (82 ft)

0446 310 996 35 m (115 ft)

2

0463 772 001

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© ESAB AB 2023

APPENDIX

0463 772 001

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© ESAB AB 2023

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone [phone]

manuals.esab.com

For contact information visit http://esab.com