ESAB Warrior 400i CC/CV User manual

Instruction manual
0463 362 001 GB 20130618 Valid for: serial no. 324-xxx-xxx
Warrior™ 400i CC/CV
Warrior™ 500i CC/CV

TABLE OF CONTENTS
0463 362 001 © ESAB AB 2013
1 SAFETY ................................................................................................................ 4
2 INTRODUCTION................................................................................................... 7
2.1 Overview ............................................................................................................... 7
2.2 Equipment............................................................................................................. 7
3 TECHNICAL DATA ............................................................................................... 8
4 INSTALLATION................................................................................................... 10
4.1 General................................................................................................................ 10
4.2 Lifting instructions............................................................................................. 10
4.3 Location .............................................................................................................. 10
4.4 Mains supply ...................................................................................................... 11
5 OPERATION ....................................................................................................... 14
5.1 Overview ............................................................................................................. 14
5.2 Connections and control devices.....................................................................14
5.3 Connection of welding and return cables........................................................15
5.4 Turning the mains power on/off........................................................................15
5.5 Fan control.......................................................................................................... 15
5.6 Symbols and functions......................................................................................15
6 MAINTENANCE.................................................................................................. 18
6.1 Overview ............................................................................................................. 18
6.2 Power source...................................................................................................... 18
6.3 Welding torch ..................................................................................................... 18
7 FAULT TRACING................................................................................................ 19
8 ORDERING SPARE PARTS ............................................................................... 20
DIAGRAM ..................................................................................................................21
ORDERING NUMBERS.............................................................................................22
ACCESSORIES .........................................................................................................23
Rights reserved to alter specifications without notice.

1 SAFETY
0463 362 001 -4- © ESAB AB 2013
1 SAFETY
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment when it
is started up
○ no-one is unprotected when the arc is struck or work is started with the equpment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could
become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified electrician
○ Appropriate fire extinquishing equipment must be clearly marked and close at hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation

1 SAFETY
0463 362 001 -5- © ESAB AB 2013
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth the unit in accordance with applicable standards
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
• Insulate yourself from earth and the workpiece
• Ensure your working stance is safe
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes
• Use ventilation, extraction at the arc, or both, to take fumes and gases away
from your breathing zone and the general area
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens and
wear protective clothing
• Protect bystanders with suitable screens or curtains
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
NOISE - Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection. Protect your ears.
Use earmuffs or other hearing protection
• Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
This product is solely intended for arc welding.

1 SAFETY
0463 362 001 -6- © ESAB AB 2013
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of
class A equipment in those locations, due to conducted
as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2002/96/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law, electrical
and/or electronic equipment that has reached the end of
its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION
0463 362 001 -7- © ESAB AB 2013
2 INTRODUCTION
2.1 Overview
The Warrior 400i CC/CV and Warrior 500i CC/CV are welding power sources intended for
MIG/MAG welding, as well as for welding with powder filled cored wire (FCAW-S), for TIG
welding, for welding with coated electrodes (MMA) and for arc air gouging.
The power sources are intended for use with the following wire feed units:
• Warrior Feed 304
• Warrior Feed 304w
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.2 Equipment
The power source is supplied with:
• 5 m return cable with earth clamp
• 3 m mains cable
• instruction manual

3 TECHNICAL DATA
0463 362 001 -8- © ESAB AB 2013
3 TECHNICAL DATA
Warrior 400i CC/CV Warrior 500i CC/CV
Mains voltage 380-415 V ±10%,
3~ 50/60 Hz
380-415 V ±10%,
3~ 50/60 Hz
Mains supply Sscmin 6.4 MVA 7.2 MVA
Mains supply Zmax 0.025 Ω 0.022 Ω
Primary current I max
MIG/MAG
TIG
MMA
28 A
23 A
28 A
37 A
30 A
38 A
No-load power in energy-saving
mode 6.5 min. after welding 30 W 30 W
Setting range
MIG/MAG
TIG
MMA
16 A/15 V - 400 A/34 V
5 A/10 V - 400 A/26 V
16 A/20 V - 400 A/36 V
16 A/15 V - 500 A/39 V
5 A/10 V - 500 A/30 V
16 A/20 V - 500 A/40 V
Permissible load at MIG/MAG
60 % duty cycle
100% duty cycle
400 A/34 V
300 A/29 V
500 A/39 V
400 A/34 V
Permissible load at TIG
60 % duty cycle
100% duty cycle
400 A/26 V
300 A/22 V
500 A/30 V
400 A/26 V
Permissible load at MMA
60 % duty cycle
100% duty cycle
400 A/36 V
300 A/32 V
500 A/40 V
400 A/36 V
Power factor at maximum current 0.91 0.91
Efficiency at maximum current 88 % 89 %
Electrode types Basic
Rutile
Cellulosic
Basic
Rutile
Cellulosic
Open-circuit voltage
without VRD function 78 V DC 78 V DC
Apparent power at maximum
current
18.0 kVA 24.6 kVA
Active power at maximum
current
16.4 kW 22.5 kW
Operating temperature -10 to +40°C -10 to +40°C
Transportation temperature -20 to +55°C -20 to +55°C
Constant sound pressure when
idling
<70 db (A) <70 db (A)
Dimensions l × w × h 712 × 325 × 470 mm 712 × 325 × 470 mm
Weight 58.5 kg 58.5 kg

3 TECHNICAL DATA
0463 362 001 -9- © ESAB AB 2013
Warrior 400i CC/CV Warrior 500i CC/CV
Insulation class H H
Enclosure class IP 23 IP 23
Application class
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
Mains supply, Zmax
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C.
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 outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION
0463 362 001 - 10 - © ESAB AB 2013
4 INSTALLATION
4.1 General
The installation must be carried out by a professional.
4.2 Lifting instructions
WARNING!
Secure the equipment -
particularly if the ground is
uneven or sloping.
4.3 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.

4 INSTALLATION
0463 362 001 - 11 - © ESAB AB 2013
4.4 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 Sscmin at the interface point between the user's
supply and the public system. 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 Sscmin. Refer to the technical data in the Technical
data section.
Make sure that the welding power source is connected to the correct supply voltage and that
it is protected by the correct fuse rating. A protective earth connection must be made in
accordance with regulations.
Warrior 400i CC/CV
Mains voltage 380 V 3~ 50/60 Hz 400 V 3~ 50/60 Hz 415 V 3~ 50/60 Hz
Mains cable area 4 × 6 mm² 4 × 6 mm² 4 × 6 mm²
Maximal current
rating Imax 28 A 27 A 25 A
I1eff
MIG/MAG
TIG
MMA
20 A
16 A
21 A
19 A
16 A
20 A
18 A
14 A
19 A
Fuse
anti-surge
type C MCB
25 A
25 A
25 A
25 A
20 A
20 A
Table 1. Recommended fuse sizes and minimum cable area Warrior 400i CC/CV

4 INSTALLATION
0463 362 001 - 12 - © ESAB AB 2013
Warrior 500i CC/CV
Mains voltage 380 V 3~ 50/60 Hz 400 V 3~ 50/60 Hz 415 V 3~ 50/60 Hz
Mains cable area 4 × 6 mm² 4 × 6 mm² 4 × 6 mm²
Maximal current
rating Imax
38 A 36 A 35 A
I1eff
MIG/MAG
TIG
MMA
28 A
23 A
29 A
27 A
22 A
28 A
26 A
26 A
26 A
Fuse
anti-surge
type C MCB
35 A
32 A
35 A
32 A
35 A
32 A
Table 2. Recommended fuse sizes and minimum cable area Warrior 500i CC/CV
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. Use the power source in accordance with the relevant
national regulations.
Connection instruction
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
415 V AC. ESAB does not recommend a connection of the cable on the circuit
board in the position of 440 , 460 or 575 V AC.

4 INSTALLATION
0463 362 001 - 13 - © ESAB AB 2013
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.

5 OPERATION
0463 362 001 - 14 - © ESAB AB 2013
5 OPERATION
5.1 Overview
General safety regulations for handling the equipment can be found in the chapter
"Safety". Read it through before you start the equipment.
5.2 Connections and control devices
1. Mains power supply switch, O/I 9. Connection (-): MIG/MAG: Return cable
TiG: Welding torch MMA: Return cable or
welding cable
2. Indicator lamp, yellow, overheating 10. Connection (+): MIG/MAG: Welding cable
TIG: Return cable MMA: Welding cable or
return cable
3. Indicator lamp, green, VRD function
(reduced open-circuit voltage)
11. Circuit breaker, 10 A, 42 V
4. Display, current (A) and voltage (V) 12. Connection of wire feed unit
5. Knob for setting: MMA/TIG Arc air
gouging: Current (A) Mobile Feed mode:
Voltage (V)
13. Connection of remote control unit (option)
6. Knob for choice of electrode type 14. Connection of mains power supply
7. Knob for inductance (MIG/MAG) and arc
force (MMA):
15. Lifting eye bolt
8. Knob for welding method

5 OPERATION
0463 362 001 - 15 - © ESAB AB 2013
5.3 Connection of welding and return cables
The power source has two outputs, a positive terminal (+) and a negative terminal (-), for
connecting welding and return cables. The output to which the welding cable is connected
depends on the welding method or type of electrode used.
Connect the return cable to the other output 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.
For MMA welding, the welding cable can be connected to the positive terminal (+) or
negative terminal (-) depending on the type of electrode used. The connecting polarity is
stated on the electrode packaging.
5.4 Turning the mains power on/off
Turn on the mains power by turning switch to the ”I” position, see 1 on the picture above.
Turn the unit off by turning the switch to the ”O” position.
Whether the mains power supply is interrupted or the power source is switched off in the
normal manner, welding data will be stored so that it is available next time the unit is started.
CAUTION!
Do not turn off the power source during welding (with load).
5.5 Fan control
The power source has a time control that means that the fans continue to run for 6.5 minutes
after welding has stopped, and the power source switches to energy-saving mode. The fans
start again when welding restarts.
5.6 Symbols and functions
Placement of lifting
eye
Voltage Reducing
Device
Overheating
protection
Basic electrode
Rutile electrode Cellulosic electrode
Arc force Inductance
TIG welding (Live
TIG)
Arc air gouging

5 OPERATION
0463 362 001 - 16 - © ESAB AB 2013
MMA welding MIG/MAG welding
Wire feed unit
Mobile feed CV
(Constant voltage)
Protective earth
Voltage reducing device (VRD)
The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding
is not being carried out. This is indicated by a lit VRD led.
The VRD function is blocked when the system senses that welding has started.
Contact an authorised ESAB service technician to activate the function.
Overheating protection
The welding power source has overheating protection that operates if the temperature
becomes too high. When this occurs the welding current is interrupted and an overheating
indication lamp is lit.
The overheating protection resets automatically when the temperature has fallen, within
normal working temperature.
Arc force
The arc force is important in determining how the current changes in response to a change in
the arc length. A lower value gives a calmer arc with less spatter.
It only applies to MMA welding.
Inductance
Higher inductance results in a wider weld pool and less spatter. Lower inductance produces
a harsher sound but a stable, concentrated arc.
It only applies to MIG/MAG welding.
TIG welding
TIG welding melts the metal of the workpiece, using an arc struck from a tungsten electrode,
which does not itself melt. The weld pool and the electrode are protected by shielding gas.
"Live TIG-start"
At a ”Live TIG-start” the tungsten electrode is placed against the workpiece. When the
electrode is lifted away from workpiece, the arc is struck at a limited current level.
For TIG welding, the welding power source shall be supplemented with:
• a TIG torch with gas valve
• an argon gas cylinder

5 OPERATION
0463 362 001 - 17 - © ESAB AB 2013
• an argon gas regulator
• tungsten electrode
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:
• arc air torches
• return cable with clamp
• air pressure
Electrode Voltage min. Voltage max. Electrode Extension
6 mm (1/4") 36 V 49 V 50 - 76 mm
(2 - 3")
8 mm (5/16") 39 V 52 V
10 mm (3/8") 43 V 52 V
Table 3. Recommended for gouging
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
MIG/MAG and self shielded cored wire welding
An arc melts a continuously supplied wire. The weld pool is protected by shielding gas.
For MIG/MAG and self shielded core wire 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 MAINTENANCE
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6 MAINTENANCE
6.1 Overview
Regular maintenance is important for safe, reliable operation.
Only personnel with the appropriate electrical skills (authorized staff) may remove safety
plates.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.2 Power source
Check regularly that the welding power source is not clogged with dirt. Clogged or blocked
air inlets and outlets can result in overheating.
How often and which cleaning methods apply depend on:
• the welding process
• the arc times
• the environment
• the surrounding environment
It is normally sufficient to blow down the power source with dry compressed air (reduced
pressure) once a year.
6.3 Welding torch
A regular programme of care and maintenance reduces unnecessary and expensive
downtime.
Each time a wire bobbin is changed, the welding torch should be removed from the power
source and blown clean with compressed air.
The wire end must not have sharp edges when inserted into the wire liner.
For detailed information see instruction manuals for welding torches.

7 FAULT TRACING
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7 FAULT TRACING
Try these recommended checks and inspections before sending for an authorized service
technician.
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 interruppted during
welding.
• Check whether the overloading protection
has deployed (indicated on the front).
• Check the mains power supply fuses.
• Check that the return cable is correctly
fastened.
The overheating protection trips frequently. • Make sure that you are not exceeding the
rated data for the power source (i.e. that
the unit is not being overloaded).
Poor welding performance. • Check that the welding and return cables
are correctly connected.
• Check that the correct current value is
set.
• Check that the correct wire or electrode is
used.
• Check the mains power supply fuses.
• Check the gas pressure in the equipment
connected to the power source.
"Err" on display in open circuit mode • Check the mains power supply fuses.
• Check that the voltage on the voltage
selection label on the rear of the power
source is equal to the nominal mains
voltage.
• Restart the power source with the main
switch

8 ORDERING SPARE PARTS
0463 362 001 - 20 - © ESAB AB 2013
8 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorised ESAB service technician.
Use only ESAB original spare and wear parts.
The Warrior 400i CC/CV and Warrior 500i CC/CV are designed and tested in accordance
with international and european standards IEC/EN 60974-1 and IEC/EN 60974-10. 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 standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of this
document.