Warrior Feed Dual 304 Wire Feeder
Instruction Manual
0558012460 11/2015
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or
inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be
checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper
repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
2
TABLE OF CONTENTS
Contents
Safety - English ...................................................................................................................................................5
Safety - Spanish .................................................................................................................................................................................... 9
Safety - French ....................................................................................................................................................................................13
Warrior Feed Dual 304 Wire Feeder ................................................................................................................17
Specications ...................................................................................................................................................................................... 17
Optional Accessories ........................................................................................................................................................................ 20
Additional Accessories and Features .......................................................................................................................................... 20
Installation ........................................................................................................................................................23
Adjustments and Operation ..........................................................................................................................................................25
Operating Sequence ........................................................................................................................................................................ 25
Maintenance .....................................................................................................................................................27
Replacement Parts ...........................................................................................................................................29
General ..................................................................................................................................................................................................29
Ordering ............................................................................................................................................................................................... 29
3
TABLE OF CONTENTS
4
SAFETY
Safety - English
WARNING: These Safety Precautions are
for your protection. They summarize
precautionary information from the
references listed in Additional Safety
Information section. Before per forming
any installation or operating procedures, be sure
to read and follow the safety precautions listed
below as well as all other manuals, material safety
data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, e mits
ultraviolet (UV) and other radiation and can injure
skin and eyes. Hot metal can cause burns. Training
in the proper use of the processes and equipment
is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield tted with the correct lter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, heavy long-
sleeve shirt, cuess trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A ameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot sparks
with a suitable non-ammable partition or curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective
non-ammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in oors or wall openings and cause a hidden smoldering re or res on the oor below. Make
certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the
work piece has been completely cleaned so that there
are no substances on the work piece which might
produce ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have re extinguishing e quipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and
create a re hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later re. Use re watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec tion
Association, Battery march Park, Quincy, MA 02269.
5
SAFETY
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.
1. Be sure the Power Source frame (chassis) is connected to the ground system of the input power.
2. Connect the work piece to a good electrical ground.
3. Connect the work cable to the work piece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and Power
Source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommendations. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current owing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding and cutting current creates EMF around
welding cables and welding machines. Therefore:
1. Welders having pacemakers should
consult their physician before welding. EMF may interfere with some
pacemakers.
2. Exposure to EMF may have other health eects
which are unknown.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the work piece as close
as possible to the area being welded.
E. Keep welding Power Source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. D o not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.
6
SAFETY
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder,
valve, or relief device can injure or kill.
Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.
2. Before performing any maintenance work inside a
Power Source, disconnect the Power Source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and Power Source in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more
information on safe practices for electric
arc welding and cutting equipment, ask
your supplier for a copy of "Precautions
and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed G ases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.
The following publications, which are available from
the American Welding Societ y, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal
Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting
and Allied Processes.
7
SAFETY
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your
safety is involved.
DANGER
CAUTION
WARNING
Enclosure Class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not
intended to be used outside during precipitation unless sheltered.
CAUTION
CAUTION
If equipment is placed on a surface that slopes more
than 15°, toppling over may occur. Personal injury and
/ or signicant damage to equipment is possible.
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could result in personal injury or loss of life.
Means hazards which could result in minor personal injury.
This product is solely intended for plasma cutting. Any other use may
result in personal injury and / or equipment damage.
CAUTION
CAUTION
CAUTION
To avoid personal injury and/or equipment damage,
lift using method and attachment points shown here.
8
Maximum Tilt
15°
SAFETY
Safety - Spanish
ADVERTENCIA: Estas Precauciones de
Seguridad son para su protección. Ellas
hacen resumen de información proveniente de las referencias listadas en la sección
"Información Adicional Sobre La Seguridad". Antes
de hacer cualquier instalación o procedimiento de
operación , asegúrese de leer y seguir las precaucio nes de seguridad listadas a continuación así como
también todo manual, hoja de datos de seguridad
del material, calcomanias, etc. El no observar las
Precauciones de Seguridad puede resultar en daño
a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco, como
el sol , emite rayos ultravioleta (UV) y otras radiaciones
que pueden dañar la piel y los ojos. El metal caliente
causa quemaduras. EL entrenamiento en el uso propio
de los equipos y sus procesos es esencial para prevenir
accidentes. Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando esté
usando careta de soldar, protector para su cara u otro
tipo de protección.
2. Use una careta que tenga el ltro correcto y lente para
proteger sus ojos, cara, cuello, y oídos de las chispas y
rayos del arco cuando se esté operando y observando
las operaciones. Alerte a todas las personas cercanas
de no mirar el arco y no exponerse a los rayos del arco
eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa pesada
de mangas largas, pantalón de ruedo liso, zapato alto
al tobillo, y careta de soldar con capucha para el pelo,
para proteger el cuerpo de los rayos y chispas calientes
provenientes del metal fundido. En ocaciones un delantal
a prueba de fuego es necesario para protegerse de l calor
radiado y las chispas.
4. Chispas y partículas de metal caliente puede alojarse en
las mangas enrolladas de la camisa , el ruedo del pantalón
o los bolsillos. Mangas y cuellos deberán mantenerse
abotonados, bolsillos al frente de la camisa deberán ser
cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas
calientes con una cortina adecuada no-amable como
división.
6. Use careta protectora además de sus gafas de seguridad
cuando esté removiendo escoria o puliendo.
La escoria puede estar caliente y desprenderse
con velocidad. Personas cercanas deberán usar
gafas de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
las amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1
. Remueva todo material combustible lejos del área de
trabajo o cubra los materiales con una cobija a prueba de
fuego. Materiales combustibles incluyen madera, ropa,
líquidos y gases amables, solventes, pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en las
grietas y agujeros de pisos y paredes causando fuegos
escondidos en otros niveles o espacios. Asegúrese de
que toda grieta y agujero esté cubierto para proteger
lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo relacionado
hasta que la pieza de trabajo esté totalmente limpia y
libre de substancias que puedan producir gases inamables o vapores tóxicos. No trabaje dentro o fuera de
contenedores o tanques cerrados. Estos pueden explotar
si contienen vapores inamables.
4. Tenga siempre a la mano equipo extintor de fuego para
uso instantáneo, como por ejemplo una manguera con
agua, cubeta con agua, cubeta con arena, o extintor
portátil. Asegúrese que usted esta entrenado para su
uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en los
cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione
el área de trabajo para cerciorarse de que las chispas o
metal caliente ocasionen un fuego más tarde. Tenga
personal asignado para vigilar si es necesario.
7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of
Cutting and Welding Processes", disponible a través de la
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo
o muerte. NO use so ldadura de corriente
alterna (AC) en áreas húmedas, de movimiento connado en lugares estrechos
o si hay posibilidad de caer al suelo.
9
SAFETY
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5 . Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones especícas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente
eléctrica uye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2. Exponerse a campos electromagnéticos (EMF) puede
causar otros efectos de salud aún desconocidos.
3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique sub-
stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones especícas en la ventilación.
10
SAFETY
5. ADVERTENCIA-- Este producto cuando se utiliza para
soldaduras o cortes, produce humos o gases,
los cuales contienen químicos conocidos por
el Estado de California de causar defectos en el
nacimiento, o en algunos casos, Cancer. (California
Health & Safety Code §25249.5 et seq.)
MANEJO DE CILINDROS-- Los cilindros, si no son
manejados correctamente, pueden
romperse y liberar violentamente
gases. Rotura repentina del cilindro,
válvula, o válvula de escape puede
causar daño o muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:
1. Siempre tenga personal cualicado para efec-
tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGURIDAD -- Para
más información sobre las prácticas de seguridad de los equipos de arco eléctrico para
soldar y cortar, pregunte a su suplidor por
una copia de "Precautions and Safe Practices
for Arc Welding, Cutting and Gouging-Form
52-529.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal
Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting
and Allied Processes.
11
SAFETY
SIGNIFICADO DE LOS SIMBOLOS -- Según usted avanza en la lectura de este folleto: Los Símbolos
Signican ¡Atención! ¡Esté Alerta! Se trata de su seguridad.
Signica riesgo inmediato que, de no ser evadido, puede resultar inmediata-
PELIGRO
mente en serio daño personal o la muerte.
ADVERTENCIA
CUIDADO
Signica el riesgo de un peligro potencial que puede resultar en serio daño
personal o la muerte.
Signica el posible riesgo que puede resultar en menores daños a la persona.
Clase de envolvente
El código IP indica la clase de envolvente, es decir, el grado de protección contra la penetración de objetos
sólidos o agua. Se provee protección contra el toque con un dedo, penetración de objetos sólidos de un tamaño
superior a 12 mm y contra rocío de agua de hasta 60 grados de la vertical. El equipo marcado IP21S se puede
almacenar, pero no se debe usar en el exterior durante periodos de precipitaciones a menos que esté protegido.
ADVERTENCIA
Este producto sólo se debe usar para corte por plasma Cualquier otro uso
puede causar lesiones físicas y/o daños en los equipos.
ADVERTENCIA
Si el equipo se coloca sobre una supercie con una
inclinación superior a 15°, se puede producir un volcamiento. Es posible que se produzcan lesiones físicas y/o daños importantes en los equipos.
Inclinación
máxima permitida
ADVERTENCIA
Para evitar lesiones físicas y/o daños en los equipos,
levante mediante el método y los puntos de sujeción
que se indican en esta ilustración.
12
15°
SAFETY
Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection.
Ils récapitulent les informations de pré-
caution provenant des références dans
la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser
l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les
ches d'information sur la sécurité du matériel et
sur les étiquettes, etc. Tout défaut d'observer ces
précautions de sécurité peut entraîner des blessures
graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive.
L'arc, tout comme le soleil, émet des rayons ultraviolets
en plus d'autre rayons qui peuvent causer des blessures
à la peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les
accidents. Par conséquent:
1. Por tez des lunettes protec trices munies d'écrans latéraux lorsqu e
vous êtes dans l'aire de travail, même si vous devez porter un
casque de soudeur, un écran facial ou des lunettes étanches.
2. Por tez un écran facial muni de verres ltrants et de plaqu es protectrices approp riées an de protéger vos yeux , votre visage, votre
cou et vos oreilles des étincelles et des rayons de l'arc lors d'une
opération ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas regarder l'arc
et de ne pas s'exposer aux rayons de l'arc électrique ou le métal
incandescent.
3. Portez des gants ignifugiés à crispin, une chemise épaisse à
manches longues, des pantalons sans rebord et des chaussures
montantes an de vous protéger des r ayons de l'arc, des étincelles
et du métal incandescent, en plus d'un casque de soudeur ou
casquette pour protéger vos cheveux. Il est également recommandé de por ter un tablier ininammable an de vous protége r
des étincelles et de la chaleur par rayonnement.
4. Les éti ncelles et les projec tions de métal incandes cent risquent de
se loger dans les manche s retroussées, les rebords de pantalons
ou les poches. Il est recommandé de garder boutonnés le col et
les manches et de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des étincelles
et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininammable.
6. Portez des lunet tes étanches par dessus vos lunettes de s écurité
lors des opérations d'écaillage ou de meulage du laitier. Les
écailles de laitier incandescent peuvent être projetées à des
distances considérables. Les personnes se trouvant à proximité
doivent également po rter des lunettes étanch es par dessus leur
lunettes de sécurité.
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
1. Éloignez susamment tous les matériaux combustibles
de l'aire de travail et recouvrez les matériaux avec un
revêtement protecteur ininammable. Les matériaux
combustibles incluent le bois, les vêtements, la sciure, le
gaz et les liquides combustibles, les solvants, les p eintures
et les revêtements, le papier, etc.
2. Les étincelles et les projections de métal incandescent
peuvent tomber dans les ssures dans les planchers ou
dans les ouvertures des murs et déclencher un incendie
couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal
incandescent.
3. N'exécutez pas de soudure, de coupe ou autre travail à
chaud avant d'avoir complètement nettoyé la surface de
la pièce à traiter de façon à ce qu'il n'ait aucune substance
présente qui pourrait produire des vapeurs inammables
ou toxiques. N'exécutez pas de travail à chaud sur des
contenants fermés car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction d'incendie
est disponible et prêt à servir, tel qu'un tuyau d'arrosage,
un seau d'eau, un seau de sable ou un extincteur portatif.
Assurez-vous d'être bien instruit par rapport à l'usage de
cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage surchargé peut surchauer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection de
métal incandescent ne risque de provoquer un incendie
ultérieurement. Employez des guetteurs d'incendie au
besoin.
7. Pour obtenir des informations supplémentaires, consultez
le NFPA Standard 51B, "Fire Prevention in Use of Cutting
and Welding Processes", disponible au National Fire
Protection Association, Batterymarch Park, Quincy, MA
02269.
CHOC ÉLECTRIQUE -- Le contact avec des pièces élec-
triques ou les pièces de mise à la terre
sous tension peut causer des blessures
graves ou mortelles. NE PAS utiliser un
courant de soudage c.a. dans un endroit
humide, en espace restreint ou si un
danger de chute se pose.
13
SAFETY
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à la
terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de terre
électrique.
3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion an d'éviter le risque de
choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endommagés.
5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé de la
pièce à traiter et des pièces de la mise à la terre.
7. Si vous devez eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des
planches sèches ou une plate-forme isolée et portez
des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever vos
gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à la page
suivante) pour des recommandations spéciques
concernant les procédures de mise à la terre. Ne pas
confondre le câble de masse avec le câble de mise à
la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel conducteur
produit des champs électriques et
magnétiques localisés. Le soudage
et le courant de coupage créent des
champs électriques et magnétiques
autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des eets néfastes inconnus pour
la santé.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A. Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'eectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation.
Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une ir ritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail an
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spéciques
concernant la ventilation.
14
SAFETY
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de coupage,
dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme
étant une cause des malformations congénitales
et dans certains cas, du cancer. (California Health
& Safety Code §25249.5 et seq.)
MANIPULATION DES CYLINDRES -- La manipula-
tion d'un cylindre, sans observer
les précautions nécessaires, peut
produire des ssures et un échappement dangereux des gaz. Une brisure
soudaine du cylindre, de la soupape
ou du dispositif de surpression peut causer
des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération et le
détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur.
Maintenez en bon état les tuyaux et les raccords. Observez
les instructions d'opération du fabricant pour assembler
le détendeur sur un cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à l'aide
d'une chaîne ou une sangle, sur un chariot manuel, un
châssis de roulement, un banc, un mur, une colonne ou
un support convenable. Ne xez jamais un cylindre à un
poste de travail ou toute autre dispositif faisant partie
d'un circuit électrique.
3. Lorsque les cylindres ne ser vent pas, gardez les soupapes
fermées. Si le détendeur n'est pas branché, assurez-vous
que le bouchon de protection de la soupape est bien en
place. Fixez et déplacez les cylindres à l'aide d'un chariot
manuel approprié. Toujours manipuler les cylindres avec
soin.
4. Placez les cylindres à une distance appropriée de toute
source de chaleur, des étincelles et des ammes. Ne jamais
amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez CGA
Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par
le Compressed Gas Association, 1235 Jeerson Davis
Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. Eorcez-vous de toujours coner les tâches d'installation,
de dépannage et d'entretien à un personnel qualié.
N'eectuez aucune réparation électrique à moins d'être
qualié à cet eet.
2. Avant de procéder à une tâche d'entretien à l'intérieur
de la source d'alimentation, débranchez l'alimentation
électrique.
3. Maintenez les câbles, les ls de mise à la terre, les
branchements, le cordon d'alimentation et la source
d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques d'eau,
de l'huile ou de la graisse, des atmosphères corrosives et
des intempéries.
5. Laissez en place tous les dispositifs de sécurité et tous les
panneaux de la console et maintenez-les en bon état.
6. Utilisez l'équipement conformément à son usage prévu
et n'eectuez aucune modication.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA
SÉCURITÉ -- Pour obtenir de l'information
supplémentaire sur les règles de sécurité à
observer pour l'équipement de soudage à
l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for
Arc Welding, Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal
Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting
and Allied Processes.
15
SAFETY
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel, signie "Attention" ! Soyez vigilant ! Votre sécurité
est en jeu.
DANGER
AVERTISSEMENT
ATTENTION
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
Signie un danger qui peut entraîner des blessures
corporelles mineures.
Classe de protection de l’enveloppe
L’indice de protection (codication IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de
protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration
d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de
la verticale. Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont pas
conçus pour être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.
AVERTISSEMENT
Ce produit a été conçu pour la découpe au plasma seulement. Toute autre
utilisation pourrait causer des blessures et/ou endommager l’appareil.
AVERTISSEMENT
L’équipement pourrait basculer s’il est placé sur une
surface dont la pente dépasse 15°. Vous pourriez
vous blesser ou endommager l’équipement de façon
importante.
AVERTISSEMENT
Soulevez à l’aide de la méthode et des points
d’attache illustrés an d’éviter de vous blesser ou
d’endommager l’équipement.
Angle
d’inclinaison
maximal
15°
16
description
Warrior Feed Dual 304 Wire Feeder
The Warrior Feed Dual 304 Wire Feeder described in this
manual is designed for short arc, spray arc or cored wire
welding with a constant potential (CP) welding power source.
Secondary input from the power source can be DC "+" or DC "-"
depending on the requirements of the wire type being used.
The Warrior Feed Dual 304 Wire Feeder uses drive motors designed to feed wires from .023 to 3/32-inches diameter. Rate
of wire feed (75 to 950 inches per minute (1.3-19 m/min)) is
precisely controlled by a solid-state, Pulse Width Modulated
(PWM) governor printed circuit board housed in the control
assembly. The Gun Switch is energized by 12 volts DC for operator safety.
The Warrior Feed Dual 304 Wire Feeder is designed to sit on at surfaces. The standard features of the Warrior Feed Dual
304 Wire Feeder include:
• 4-roll drive stands, each with two driven rolls and two pressure rolls
• 2 Internal gas solenoids
• "Euro" style torch connections and TWECO (NAS)
• Power ON/OFF switch
• Gas Purge/Jog switch
• Remote power source voltage control
• Right/Left side "Active" lights
• Cored/Solid Selection
• Independent Left/Right Voltage/Current Controls
Specications
Table 2-1. ESAB Warrior Wire Feeder Specications
Input Power Required ....................................................................42 V ac, 5A, 50/60 Hz, 1-phase
Wire Feed Speed Range .....................................................................75 - 950 ipm(2.0-24 m/min)
Wire Sizes Accommodated:
Hard/Soft ........................................................................023 thru 1/16 in. (0.6 thru 1.6 mm)
Flux Cored ..................................................................... .035 thru 5/64 in. (0.9 thru 2.0 mm)
Length ................................................................................................................................. 24 in. (61 cm)
Width .................................................................................................................................... 16 in. (41 cm)
Height .................................................................................................................................. 14 in. (36 cm)
Weight ................................................................................................................................. 53 lbs (24 kg)
17
description
WATER OUT (WATER KIT OPTIONAL)
WIRE FEED SPEED
VOLTS
AMPS
POWER SWITCH
RIGHT/LEFT SIDE "ACTIVE" LIGHTS
CORED/SOLID WIRE
SELECTOR SWITCH
MIG TORCH
CONNECTOR
RECEPTACLE
WIRE FEED
SPEED
CONTROL
SLOW RUN IN
ON (LEFT)
OFF (RIGHT)
2 STROKE/
4 STROKE
JOG/PURGE
VOLTAGE CONTROL
18
description
Controls and Features
Power Switch
Press this switch to turn ON or turn OFF the Wire feeder.
AMPS Display
Displays welding current and holds last value unless setting value is changed.
Wire Feed Speed Display
Displays wire feed speed and holds last value unless setting value is changed.
Volts Display
Displays preset welding voltage and holds last value unless setting value is changed.
Wire Feed Speed Control (Right and Left)
The Wire Feed Speed control knob adjusts Wire Feed Speed (WFS) (which in turn adjusts the output current by changing
the amount of MIG wire delivered to the welding arc). The optimum WFS required is dependent on the type of welding
application. The value may also be adjusted while a weld is in progress. Turn the knob either clockwise to increase WFS
or counterclockwise to decrease WFS by increments of 1.0 IPM (0.1MPM).
Voltage Control (Right and Left)
The Voltage control knob adjusts the output voltage of the power source. The welding voltage is increased by turning
the knob clockwise or decreased by turning the knob counter-clockwise. The value may also be adjusted while a weld is
in progress. Turn the knob either clockwise to increase voltage or counterclockwise to decrease voltage by increments
of 0.1V.
JOG Switch
After turning the power ON, press this switch to the left and hold it to start cold feeding. JOG is used when you need to
feed wire without welding voltage being applied. The wire is fed at the set speed for as long as the switch is energized.
PURGE Switch
This switch is used to initiate gas line purge function to ll the gas line with the shielding gas from the connected gas
cylinder. Press this switch to the right and hold it to start gas purge function. You can stop the gas purge any time by
releasing the switch. PURGE is used when measuring the gas ow or to ush any air or moisture from the gas hoses
before welding starts. Gas purging occurs for as long as the switch is held to the right and occurs without voltage or
wire feed starting.
MIG Torch Connector Receptacles (Right and Left)
The MIG Torch adaptor is the connection point for the MIG welding Torch. Connect the MIG Torch by pushing the MIG
Torch connector into the brass MIG Torch adaptor rmly and tightening the plastic MIG Torch nut clockwise to secure
in position. To remove the MIG Torch simply reverse these directions.
Right/Left side "Active" lights
Illuminates to indicate which side of feeder is active.
19
description
4 Pin Trigger Socket (TWECO (NAS) Connection Version)
The 4 pin Trigger Socket is used to connect remote control devices to the welding power source. To make connections, align
keyway, insert plug, and rotate threaded collar fully clockwise.
3
4
Socket Pin
1
2
Figure 3-3 4 Pin Trigger Socket
1
2
3
4
Function
Trigger Switch
1 Trigger Switch Input
2 Trigger Switch Input
3 Not connected
4 Not connected
Table 3-2 Pin Function in 4 Pin Trigger Socket
Slow Run-In Switch - when activated, means that the wire is fed at low speed (1.9 m/min / 75 in/min) until it comes into
electrical contact with the workpiece, or 3 sec. has elapsed after which the speed increases to the set speed.
Solid/Cored Wire Switch
Wire selection – Solid wire
Short Circuit Termination (SCT) behavior is selected when the trigger is released to adapt to welding with solid wire.
SCT is a new way to stop the welding with some small short circuits to reduce the end crater and oxidation. It also gives
the advantage of a good start performance with solid wire.
Wire selection – Cored wire
A constant burnback time is selected when the trigger is released to adapt to welding with cored wire.
2 Stroke/4 Stroke Switch
2 stroke
With 2-stroke gas pre-ow (if used) starts when the welding torch trigger switch is pressed. The welding process then
starts. Releasing the trigger switch stops welding entirely and starts gas post-ow (if selected).
4 stroke
With 4 stroke, the gas pre-ow starts when the welding torch trigger switch is pressed in and the wire feed starts when
it is released. The welding process continues until the switch is pressed in again, the wire feed then stops and when the
switch is released the gas post-ow starts (if selected).
20
description
WELDING POWER
INPUT STUD
CONTROL CABLE
DOOR LATCH
Gas Inlet
Gas inlet allows to connect the shield gas.
GAS INLET
WATER IN ( WATER KIT OPTIONAL)
WIRE SPOOL HUB
REEL STAND
WIRE GUIDE
5 A CIRCUIT BREAKER
Welding Power Input Stud
This connector allows to connect welding cable with Wire feeder. Please make sure that it is secured rmly, or it will heat
and generate arc.
Control Cable Socket (NOTE: Connect only to an ESAB Warrior power source)
The control cable connects to the power source at this 19-pin amphenol connector. It contains the signals required to
allow the welding power source and the wire feeder to work together as a system.
WATER KIT OPTION
The optional water kit provides a convenient way of connecting water cooled torches close to the power connection
while allowing connections to the cooler/recirculator at the rear of the unit.
21
Keyway
WARNING
description
The protective earth ground (pin G) of the control cable is established ONLY when
the power source is properly grounded. See the power source owner’s manual for
proper grounding methods.
L
KUNB
HS RD
A
M
CPVTJ
EFG
Figure 3-5 Pin Identication
Control Cable Pin Function
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
42VAC Hot
42VAC Neutral
Not Used
+24 VDC
24 VDC Common
Contactor Control
Not Used
Voltage Feedback to P/S
+15 VDC
Voltage Control REF to P/S
0 VDC
Not Used
Not Used
Not Used
Not Used
Not Used
Serial Communication V/A
Serial Communication Clock
Serial Communication Load
22
Table 3-3 Control Cable Pin Functions
description
Optional Accessories
The following options are available from ESAB or your supplier.
• Water Kit (P/N 0465276881). Convenient way of using water cooled guns. Kit consists of inlet/outlet ttings, mount-
ing hardware and quick action connectors for the gun hoses and connecting to the Cooler/Recirculator.
Additional Accessories and Features
NOTE:
Drive Rolls and Guide Tubes must be purchased separately to match the desired application.
A. Constant potential Mig power source. Use with Warrior 400i and 500i power sources.
B. Shielding gas regulator/owmeter and tted hose to bring gas from owmeter to wire feeder. Such as:
Regulator/Flowmeters:
R-5007 Argon/Helium/Nitrogen, P/N 998124.
R-5008 CO2, P/N 998125.
C. Wire Reel Adapter (P/N 34323). Use with 60 or 65-lbs. (27 or 30 kg) coils.
D. Spool Spacer (P/N 34330). For adapting 10-in (25.4 cm) spools.
Ordering Information – Accessories
Description Part Number
OKC50 Connectors female cable connector, 1/0-4/0 cable (50 mm²) 13735631 (0160361881)
OKC50 Connectors male cable connector, 1/0-4/0 cable (50 mm²) 13792513 (0160360881)
Marathon Pac Conduit QC Adaptor Kit 899F50
CONN SET 5.6 FT 19/19P 500A 0459836880
CONN SET 16.4 FT 19/19P 500A 0459836881
CONN SET 32.8 FT 19/19P 500A 0459836882
CONN SET 49.2 FT 19/19P 500A 0459836883
CONN SET 82 FT 19/19P 500A 0459836884
CONN SET 115 FT 19/19P 500A 0459836885
CONN SET 5.6 FT 19/19P 500A w/ WATER 0459836890
CONN SET 16.4 FT 19/19P 500A w/ WATER 0459836891
CONN SET 32.8 FT 19/19P 500A w/ WATER 0459836892
CONN SET 49.2 FT 19/19P 500A w/ WATER 0459836893
CONN SET 82 FT 19/19P 500A w/ WATER 0459836894
CONN SET 115 FT 19/19P 500A w/ WATER 0459836895
V350A Spray Master 15 FT Air-cooled MIG Gun (SVM315-116) 1036-1756
V450A Spray Master 15 FT Air-cooled MIG Gun (SVM415-116) 1040-1833
23
description
Table 2.2 Drive Roll & Guide Tube Selection
Wire Type /
Diameter
Hard Wires (“V” groove)**
.023 in. (0.6mm) 21155 2361 2397 2116 3 0558008651 34 612 34615
.030 in. (0.8mm) 21155 2361 2397 2116 4 0558008651 34 612 34615
.035 in. (0.9mm) 21156 2361 2397 21165 0558008650 34612 3 4615
.040 in. (1.0mm) 21156 2361 2397 21165 0558008650 34612 34615
.045 in. (1. 2mm) 21156 2361 2397 21165 0558008650 34612 34615
.052 in. (1.4mm) 21157 2361 2397 21166 0558008649 34612 34615
1/16 in. (1.6mm) 2115 7 2361 2397 2116 6 0558008649 34 612 34615
Soft (aluminum) Wires (“U” groove)**
.030 in. (0.8mm) 21158 2361 2397 0558102450 0558102448 34612 34615
.035 in. (0.9mm) 2115 8 2361 2397 0558102450 0558102448 34612 34615
3/64 in. (1.2mm) 21159 2361 2397 0558102451 0558102449 34612 34615
1/16 in. (1.6mm) 21159 2361 2397 0558102451 0558102449 34612 3 4615
Top and Bottom Grooved- Aluminum
.035 in. (0.9mm) 36860 36860 0558102450 0558102448 34612 34615
3/64 in. (1.2mm) 36860 36860 0558102451 0558102449 34612 34615
1/16 in. (1.6mm) 36861 36861 0558102451 0558102449 34612 34615
Cored Wires (Serrated “V” groove)
.030 in. (0.8mm) 21160 2361 2369 21164 0558008651 34612 34615
.035 in. (0.9mm) 21160 2361 2369 21165 0558008650 34612 34615
.040 in. (1.0mm) 21161 2361 2369 21165 0558008650 34 612 34615
.045 in. (1. 2mm) 21161 2361 2369 21165 0558008650 34612 3 4615
.045 in. (1. 2mm)† 37319 37319 21165 0558008650 34 612 34615
.052 in. (1.4mm) 21161 2361 2369 2116 6 0558008649 34 612 34615
.052 in. (1.4mm)† 37319 37319 21166 0558008649 34612 34615
1/16 in. (1.6mm) 21161 2361 2369 21166 0558008649 34612 34615
1/16 in. (1.6mm)† 37320 37320 2116 6 0558008649 34 612 34615
5/64 in. (2.0mm) 21162 2361 2369 2116 6 0558008649 34 613 34 616
5/64 in. (2.0mm)† 37320 37320 2116 6 0558008649 34 613 34616
Lower
Drive
Roll
Upper
Pressure
Roll
Outlet
Guide
Tub e
EURO NAS
Center
Guide
Tube
Inlet
Guide
Tube
24
† Recommended for use with soft cored wires that are easy to atten. Order both lower drive roll and upper pressure roll.
** If a Geared Pressure Roll is desired, order P/N 23612397.
installation
This wire feeder should NOT be earth or chassis grounded. The feeded has rubber
feet to keep it insulated. In a boom mounted arrangement, there must be an insulator
CAUTION
between the boom and feeder chassis. If not properly insulated and if wire touches
the chassis, such as "bird nesting", current may heat the wire and wire may contact
circuit components, causing the PC board to fail.
Installation
A. Connect the 19 pin control cable to the Power Source.
B. Hose and Electrical Connections. Connect shielding gas supply hose(s). Connect secondary power cable to welding
power input stud and Power Source.
C. Attach a Mig Gun to the mating receptacles on the feeder front panel.
D. Wire Spool.
As with any work area, make sure safety glasses with side shields are worn when
handling or changing wire or clipping wire o at the spool or at the end of the torch.
WARNING
Secure the wire coming o the spool with before clipping. Serious eye injury can
result due to the resilience of the wire which can quickly unravel, or a cut wire end
which may shoot across the room.
Install a spool of welding wire on the hub as follows:
1. Remove "hairpin" clip from spindle.
2. Position the spool of wire so that when it is placed on the spindle, wire will be drawn to the feed roll from the
bottom of the spool. The spool should be held so that the index hole on the back will engage the lug on the
spindle.
3. Slide the spool onto the spindle until it engages the lug. Lock in place with the hairpin clip.
4. When wire coils are to be used instead of spools, reposition the spindle to the highest position and mount wire
reel on spindle as though it were a spool (see 1 and 3 above). Remove thumbnuts and cover plate from reel.
Remove coil from its package, but do not remove its binding wires. Slide coil onto reel so that wire will be drawn
from bottom of coil (starting end for a coil is always the outer end). Replace reel cover plate and thumbnuts. Cut
o coil tie wires and any kinked wire.
E. Drive Rolls. Most drive rolls have grooves for 2 wire sizes. Make sure the grooves are positioned such that they match
on both feed rolls. The groove nearest the gear motor feeds the wire. If the required groove is not correctly positioned,
perform the following:
1. Release the pressure drive roll levers and lift the assemblies upward.
2. Remove retaining screw holding each drive roll to the gear.
3. Reverse the drive roll on the drive roll shaft.
4. Replace the screws and tighten.
5. Secure the pressure drive roll assembly.
25
installation
E. Threading Wire.
1. Turn the front panel power switch to OFF "O". Ensure control cable is disconnected from Power Source or interface
box.
When the control cable is connected to power source or interface box and the power
WARNING
2. Release pressure drive roll assembly and lift upward. Check that proper wire diameter groove is in the inner position.
CAUTION
3. Feed the wire from the spool through the inlet guide, across the drive roll groove and into gun outlet guide.
is on, with the gun trigger depressed, the welding wire becomes electrically hot, and
the wire feed rolls are activated.
Before threading welding wire through liner, make sure chisel point and burrs
have been removed from wire end to prevent wire from jamming in gun or liner.
Make sure that the proper "outlet guide tube" is inserted into the front panel gun tting for the size and type of
wire being used.
To ensure proper wire feeding, it is important that the wire be kept clean and that the drive rolls be periodically
cleaned of any chips or scale that might be carried into the gun liner.
4. Lower pressure roll assembly and secure. Reconnect the control cable. Turn power switch ON "I". Check that the
gears mesh. Feed wire through to gun tip using the JOG switch located on the front panel. Ensure the correct side
is active by checking the indicator light for the desired side is lit. If not lit, pull the torch trigger for the desired side
and release.
F. Brake Drag Adjustment. Brake disc friction should provide enough drag to keep the wire spool or core from spinning
freely after wire feed stops. If adjustment is required, turn adjusting screw (located inside hub) clockwise to increase
drag, counterclockwise to decrease it. Drag should be just low enough to limit wire overrun.
POWER SWITCH
RIGHT/LEFT SIDE "ACTIVE" LIGHTS
26
operation
Adjustments and Operation
A. Selecting the "Active" side (Left/Right).
1. Apply power to wire feeder by turning on the power source and the power switch on the wire feeder front panel.
2. When power is applied to the feeder the default "Active" side is the right side (as viewed from the front of the feeder).
This should be indicated by the right "Active" pilot light being illuminated. If the desired active side is the left, momentarily depress and release the left gun trigger. The right "Active" light will extinguish and the left "Active" light
will be illuminated. The left side will remain the "Active" side until the right gun trigger is depressed. When either
gun trigger is depressed that side automatically becomes the "Active" side and the gun trigger for the opposite side
is disabled until the "Activated" gun trigger is released.
B. Control Setting.
1. Set the wire feed rate and voltage by adjusting the WIRE FEED SPEED and VOLTS control knobs on the front panel.
C. Feeding Wire. Thread wire through torch and contact tip as directed in Installation section, cut o wire so that the wire
extends approximately 1/2" (12.7 mm) beyond the end of the torch nozzle.
D. Shielding Gas Flow Rate. Operate PURGE switch and set desired gas ow rate at the shielding gas regulator-owmeter.
Activate switch for at least 15 seconds to ensure adequate purging of gas hose and torch.
E. Making the Weld. Start to weld by pressing the gun switch lever to actuate the torch switch. This closes the welding
contactor, and starts wire feed and gas ow. The trigger must be depressed for the duration of the weld. Welding action
will be stopped and all services discontinued when the lever is released and returned to its original position. If the gun
is withdrawn from the workpiece during welding, the arc will be interrupted, but shielding gas ow and welding wire
feed will continue until the trigger lever is released.
Do not allow metal-to-metal contact between the wire feeder chassis and a metal
surface connected in any way to a welding ground. With such contact, a poor welding ground connection may create a dierence in potential that sends part of the
WARNING
welding current through the safety ground wiring in the control cable and wire
feeder, resulting in burnout of that wiring and/or damage to wire feeder circuitry.
If the safety ground burns out, the operator may be exposed to 115 V shock hazard.
Operating Sequence
A. Normal.
1. Close torch switch.
-- Gas solenoid opens, weld contactor closes, wire feed motor runs.
2. Release torch switch.
-- Wire feed motor deenergized, brake circuit eective.
-- Burnback circuit deenergized.
3. Burnback circuit times out.
-- Weld contactor opens.
-- Gas solenoid valve closes.
27
operation
28
Maintenance/troubleshooting
Maintenance
If this equipment does not operate properly, stop work immediately and investigate
CAUTION
Little maintenance is required to keep the wire feeder in top operating condition. It is important, however, that moving parts
such as feed and pressure rolls, wire feed motor, etc., be kept clean and free of dust or dirt. Cleaning is best accomplished
by regularly blowing o these parts with dry compressed air. This should be done once for every eight hours of operating
time, more often if necessary.
A. 42 Volt Wire Feeder and Control Circuits.
CAUTION
the cause of the malfunction. Maintenance work must be performed by an experienced
person, and electrical work by a trained electrician. Do not permit untrained persons
to inspect, clean, or repair this equipment. Use only recommended replacement parts.
If it should become necessary to replace the 5 amp wire feeder circuit breaker or any
other circuit breaker/fuse in the welding machine, ensure that the proper size is used
as a replacement.
The 42-volt circuit is protected by a 5 amp circuit breaker located at the rear of the wire feeder. Failure of this circuit
breaker will shut o the contactor, shielding gas, and wire feeder.
B. Wire Feeder. As soft wire is fed, the drive rolls may pick up metal from the wire surface. Accumulation on the rolls may
score the wire with resulting unwanted friction and improper feeding.
Inspect the rolls regularly and clean them with a ne-wire power brush. Avoid roughening, or removing the hardness
of groove surfaces in grooved rolls. Any roughening may score the wire, just as the accumulation being removed may
do.
NOTE:
Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm
(11” x 17”) paper are included inside the back cover of this manual.
29
Maintenance/troubleshooting
30
Replacement paRts
Replacement Parts
General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.
Ordering
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of
non-ESAB parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers.
NOTE:
Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm
(11” x 17”) paper are included inside the back cover of this manual.
Items listed in the assembly drawing Bill of Materials (included in the back
of this publication) that do not have a part number shown are not avail-
able from ESAB as a replaceable item and cannot be ordered. Descriptions
are shown for reference only. Please use local retail hardware outlets as a
source for these items.
31
Replacement paRts
1, 3, 4
7
8
2
9, 10, 11, 12
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
Qty
Req.
1
1
1
1
1
2
1
1
1
1
1
1
6
Wire Feeder Wire Spool Hub Assembly
Part
No. Description
92044046
634347
92056007
0558003320
948258
948255
36756
23600982
63300136
64302037
64304125
61341133
0558005764
SCREW R.H.M. 3/8-16X1.00
* CLIP, HITCH
WASHER, FLAT 3/8"
* WASHER, D-TYPE
* SPINDLE, MOLDED
* PAD, BRAKING
"D" SHAFT
SPRING
NUT, HEX 3/8-16
WASHER, LOCK 3/8
WASHER, FLAT 3/8
SCREW, HHM 3/8-16 X 1.00
SPINDLE REPLACEMENT KIT
includes items marked *
5
Ckt.
Symbol
32
91
Replacement paRts
99
COMPLETE
96 113104103102
(2)
96 113104103102
COMPLETE
95
(2)
4-Roll Drive Stand, P/N 952940
Item Qty. Part
No. Rec. No. Description
952940 4 ROLL GEARED WIRE DRIVE SYSTEM, CONSISTS OF:
91 1 23612459 PRESSURE ARM COMPLETE, REAR (incls. 96, 102, 103, 104, 113)
92 1 952704 PRESSURE ARM COMPLETE, FRONT(incls. 96, 102, 103, 104, 113)
93 1 23612460 PRESSURE DEVICE WITH SCALE
94 1 34614 FEED PLATE, 4DR.
95 2 23612470 LOCATING PIN,PRESSURE DEVICE
96 2 23612475 PRESSURE ARM
97 2 23612473 LOCATING PIN, PRESSURE ARM
98 4 23612472 Cl RCLIP, LOCATING PIN, PRESSURE ARM
99 2 23612662 SPACER TUBE, PRESSURE ARM
100 1 34607 SPRING, PRESSURE ARM
101 4 0459441880 GEARED ADAPTOR, PRESSURE & DRIVE ROLLS
102 2 23612477 AXLE, PRESSURE ROLL
103 2 23612474 NUT, AXLE, PRESSURE ROLL
104 2 23612368 PRESSURE ROLL, PLAIN
105 1 34615 INLET GUIDE, .023" - .062" WIRE
105A (OPT-1) 34616 INLET GUIDE, .063" - .093" WIRE
106 1 34612 INTERMEDIATE GUIDE, .023" - .062" WIRE
106A (OPT-1) 34613 INTERMEDIATE GUIDE, .062" - .093" WIRE
107 2 34611 AXLE SHAFT, DRIVE ROLL
108 2 34608 WASHER, RETAINING SCREW
109 2 952925 RETAINING SCREW, DRIVE ROLL
110 1 34610 MAIN GEAR DRIVE
111 3 952927 SCREW, THUMB M6X12
112 1 36881 PROTECTIVE GUARD (Not Shown)
113 4 23612476 SPACER, PRESSURE ROLL
33
NOTES
34
1. Originally released -xxxx
REVISION HISTORY
35
ESAB Welding & Cutting Products, Florence, SC
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
36
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