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Warrior YardFeed 200
Instruction Manual
28 pgs2.82 Mb0
Instruction Manual
28 pgs2.41 Mb0
Table of contents
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ESAB Warrior YardFeed 200, Warrior YardFeed 200w Instruction Manual

Warrior™ YardFeed 200 Warrior™YardFeed200w
Instruction manual
0463 387 131 US 20150918 Valid for: serial no. 528-xxx-xxxx

TABLE OF CONTENTS

1 SAFETY PRECAUTIONS ..................................................................................... 3
2 INTRODUCTION...................................................................................................9
3 TECHNICAL DATA ............................................................................................. 10
4 INSTALLATION................................................................................................... 12
5 OPERATION ....................................................................................................... 13
6 MAINTENANCE.................................................................................................. 18
7 ORDERING SPARE PARTS............................................................................... 19
DIAGRAM ..................................................................................................................20
ORDERING NUMBERS .............................................................................................22
WEAR PARTS............................................................................................................23
ACCESSORIES .........................................................................................................27
Rights reserved to alter specifications without notice.
0463 387 131 © ESAB AB 2015

1 SAFETY PRECAUTIONS

1 SAFETY PRECAUTIONS
WARNING!
These Safety Precautions are for your protection. They summarise precautionary information from the references listed in the Additional Safety Information section. Before performing 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 the Safety Precautions could result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require hearing protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure the 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 fitted with the correct filter 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 look at the arc and not to expose themselves to the rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes and a welding helmet or cap for protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned and open pockets eliminated from the front of the clothing.
5. Protect other personnel from arc rays and hot sparks using a suitable nonflammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly for long distances. Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS
The heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coating paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor 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 workpiece has been completely cleaned, to ensure there are no substances on the workpiece which might produce flammable or toxic vapors. Do not perform hot work on closed containers. They may explode.
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1 SAFETY PRECAUTIONS
4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire 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 fire hazard.
6. After completing work, inspect the work area to make sure there are no hot sparks or hot metal that could cause a fire later. Use fire 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 Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK
Contact between live electrical parts and earth can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the earth system of the input power.
2. Connect the workpiece to a good electrical earth.
3. Connect the work cable to the workpiece. 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 the workpiece and from earth.
7. Do not stand directly on metal or the ground 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 off the power, before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific earthing recommendations. Do not mistake the work lead for a earth cable.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor causes localised Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:
1. Welders with pacemakers fitted should consult their doctor before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimise 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 workpiece as close as possible to the area being
welded.
e) Keep the welding power source and cables as far away from your body as possible.
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1 SAFETY PRECAUTIONS
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in confined 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 galvanised steel, stainless steel, copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is provided. Do not breathe in the fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc can react with chlorinated hydrocarbon vapours 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 the ventilation is not adequate. Stop work and take the 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 specific ventilation recommendations.
5. WARNING: This product when used for welding or cutting, produces fumes or gases that 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 fittings in good condition. Follow the manufacturer's operating instructions for mounting a regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position, by chain or strap, to suitable hand trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.
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.
4. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.
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1 SAFETY PRECAUTIONS
WARNING! EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting and maintenance work. Do not perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.
3. Maintain cables, earthing wire, connections, power cord and power supply 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.
CAUTION! 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.
The following publications, which are available from the American Welding Society, 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"
MEANING OF SYMBOLS As used throughout this manual: Means Attention! Be Alert!
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1 SAFETY PRECAUTIONS
DANGER! Means immediate hazards that, 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.
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed, in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the equipment. Incorrect operation of the equipment may lead to hazardous situations, which could result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with: ○ its operation ○ the location of emergency stops ○ its function ○ the relevant safety precautions ○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that: ○ no unauthorised person is within the working area of the equipment when it is started
up
○ no-one is unprotected when the arc is struck or work is started with the equpment
3. The workplace must: ○ be suitable for the purpose ○ be free from drafts
4. Personal safety equipment: ○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could
become trapped or cause burns
5. General precautions: ○ Make sure the return cable is connected securely ○ Work on high voltage equipment may only be carried out by a qualified electrician ○ Appropriate fire extinquishing equipment must be clearly marked and close at hand ○ Lubrication and maintenance must not be carried out on the equipment during
operation
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1 SAFETY PRECAUTIONS
CAUTION!
Read and understand the instruction manual before installing or operating.
CAUTION!
Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in such locations, due to conducted as well as radiated disturbances.
CAUTION!
This product is solely intended for arc welding.
NOTE! Dispose of electronic equipment at a recycling
facility!
To conform with the European Directive 2012/19/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary welding protection and accessories.
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2 INTRODUCTION

2 INTRODUCTION
The Warrior™ YardFeed 200 and Warrior™ YardFeed 200w wire feed units are intended for MIG/MAG (GMAW) welding together with welding power sources:
• Warrior 400i CC/CV
• Warrior 500i CC/CV
They are available in different versions, see chapter "ORDERING NUMBERS".
The wire feed units are sealed and contain a four-wheel drive wire feed mechanism as well as control electronics.
They can be used together with wire from ESAB, standard S200 Ø 200 mm / Ø 8 inch —
7.5kg/15lbs.
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of this manual.
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