ESAB Warrior 400i CC/CV User manual

Instruction manual
0463 362 201 GB 20221121 Valid for: serial no. 324-, 230-xxx-xxx
Warrior™400iCC/CV
Warrior™500iCC/CV

TABLE OF CONTENTS
0463 362 201 © ESAB AB 2022
1SAFETY ....................................................................................................... 5
1.1 Meaning of symbols ............................................................................... 5
1.2 Safety precautions ................................................................................. 5
2INTRODUCTION.......................................................................................... 8
2.1 Overview ................................................................................................. 8
2.2 Equipment ............................................................................................... 8
3TECHNICAL DATA ...................................................................................... 9
4INSTALLATION............................................................................................ 11
4.1 General .................................................................................................... 11
4.2 Lifting instructions ................................................................................. 11
4.3 Location................................................................................................... 12
4.4 Mains supply........................................................................................... 12
5OPERATION ................................................................................................ 15
5.1 Connections and control devices ......................................................... 15
5.2 Connection of welding and return cables ............................................ 15
5.3 Turning the mains power on/off ............................................................ 16
5.4 Fan control .............................................................................................. 16
5.5 Symbols and functions .......................................................................... 16
6MAINTENANCE........................................................................................... 19
6.1 Routine maintenance ............................................................................. 19
6.2 Cleaning instructions............................................................................. 19
6.2.1 Cleaning procedure .............................................................................. 20
7TROUBLESHOOTING ................................................................................. 21
8ORDERING SPARE PARTS ........................................................................ 22
DIAGRAM ............................................................................................................ 23
ORDERING NUMBERS....................................................................................... 24
ACCESSORIES ................................................................................................... 25
Rights reserved to alter specifications without notice.

1 SAFETY
0463 362 201 -5- © ESAB AB 2022
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
1.2 Safety precautions
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0463 362 201 -6- © ESAB AB 2022
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0463 362 201 -7- © ESAB AB 2022
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0463 362 201 -8- © ESAB AB 2022
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:
• RobustFeed PRO
• RobustFeed AVS
• Warrior Feed 304
• Warrior Feed 304w
ESAB 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 (16 ft) return cable with earth clamp
• 5 m (16 ft) mains cable
• Instruction manual
• Quick start guide
• Safety instruction

3 TECHNICAL DATA
0463 362 201 -9- © ESAB AB 2022
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 28 A 37 A
TIG 23 A 30 A
MMA 28 A 38 A
Idle power 22.9W 21.3W
Setting range
MIG/MAG 16 A/15 V - 400 A/34 V 16 A/15 V - 500 A/39 V
TIG 5 A/10 V - 400 A/26 V 5 A/10 V - 500 A/30 V
MMA 16 A/20 V - 400 A/36 V 16 A/20 V - 500 A/40 V
Permissible load at MIG/MAG
60 % duty cycle 400 A/34 V 500 A/39 V
100% duty cycle 300 A/29 V 400 A/34 V
Permissible load at TIG
60 % duty cycle 400 A/26 V 500 A/30 V
100% duty cycle 300 A/22 V 400 A/26 V
Permissible load at MMA
60 % duty cycle 400 A/36 V 500 A/40 V
100% duty cycle 300 A/32 V 400 A/36 V
Power factor at maximum current 0.91 0.91
Efficiency at maximum current 90 % 90 %
Electrode types Basic
Rutile
Cellulosic
Basic
Rutile
Cellulosic
Open-circuit voltage
VRD deactivated 56 V DC peak 56 V DC peak
VRD activated 28 V DC peak 28 V DC peak
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

3 TECHNICAL DATA
0463 362 201 - 10 - © ESAB AB 2022
Warrior 400i CC/CV Warrior 500i CC/CV
Weight 58.5 kg 58.5 kg
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/104°F, or below.
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 362 201 - 11 - © ESAB AB 2022
4 INSTALLATION
4.1 General
The installation must be carried out by a professional.
4.2 Lifting instructions

4 INSTALLATION
0463 362 201 - 12 - © ESAB AB 2022
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.
4.4 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 chapter.
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
Recommended fuse sizes and minimum cable area Warrior 400i CC/CV

4 INSTALLATION
0463 362 201 - 13 - © ESAB AB 2022
Warrior 400i CC/CV
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
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
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.
Supply from power generators
The power source can be supplied from different types of generators. However, some
generators may not provide sufficient power for the welding power source to operate
correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better
type of regulation, with rated power ≥40kW, are recommended.
Connection instruction
The power source is factory set to 400 V AC (415VAC for 0465350885 and 0465350886).
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.

4 INSTALLATION
0463 362 201 - 14 - © ESAB AB 2022
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.
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 362 201 - 15 - © ESAB AB 2022
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
NOTE!
When moving the equipment use intended handle. Never pull the cables.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
5.1 Connections and control devices
1. Mains power supply switch, O/I 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
5.2 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.

5 OPERATION
0463 362 201 - 16 - © ESAB AB 2022
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.
Recommended maximum current values for connection set cables
At an ambient temperature of +25 °C and normal 10 minutes cycle:
Cable area Duty cycle Voltage loss/10m
100% 60%
70mm2360 400 0.25V/100A
95mm2430 500 0.19V/100A
At an ambient temperature of +40 °C and normal 10 minutes cycle:
Cable area Duty cycle Voltage loss/10m
100% 60%
70mm2310 350 0.27V/100A
95mm2370 430 0.20V/100A
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.
5.3 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).
5.4 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.
5.5 Symbols and functions
Placement of lifting
eye
Voltage Reducing
Device
Overheating
protection
Basic electrode

5 OPERATION
0463 362 201 - 17 - © ESAB AB 2022
Rutile electrode Cellulosic electrode
Arc force Inductance
TIG welding (Live
TIG)
Arc air gouging
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"

5 OPERATION
0463 362 201 - 18 - © ESAB AB 2022
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
• 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
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
0463 362 201 - 19 - © ESAB AB 2022
6 MAINTENANCE
WARNING!
The mains supply must be disconnected during cleaning and maintenance.
CAUTION!
Only persons with the appropriate electrical knowledge (authorised personnel) may
remove the safety plates.
CAUTION!
The product is covered by manufacturer's warranty. Any attempt to carry out repair
work by non-authorised service centers or personnel will invalidate the warranty.
NOTE!
Regular maintenance is important for safe and reliable operation.
NOTE!
Perform maintenance more often during severe dusty conditions.
Before each use - make sure that:
• Product and cables are not damaged
• The torch is clean and not damaged
6.1 Routine maintenance
Maintenance schedule during normal conditions. Check equipment prior to every use.
Interval Area to maintain
Every 3 months
Clean or replace
unreadable labels.
Clean weld terminals. Check or replace weld
cables.
Every 12 months or
depending on
environmental
conditions (by
authorised service
technician) Clean inside
equipment. Use dry
compressed air with
4bar pressure.
6.2 Cleaning instructions
To maintain the performance and increase the lifetime of the power source it is mandatory to
clean the product regularly. How often depends on:
• the welding process
• the arc time

6 MAINTENANCE
0463 362 201 - 20 - © ESAB AB 2022
• the working environment
• the surrounding environment, that is grinding etc.
Tools needed for the cleaning procedure:
• torx screwdriver, T25 and T30
• dry compressed air at a pressure of 4 bar
• protective equipment like ear plugs, safety glasses, masks, gloves and safety shoes
CAUTION!
Make sure that the cleaning procedure is done in a suitable prepared workspace.
6.2.1 Cleaning procedure
CAUTION!
The cleaning procedure should be carried out by authorised service technician.
1. Disconnect the mains supply.
2. Wait for 4 minutes to discharge the capacitors.
3. Remove the side panels on the power source.
4. Remove the top panel on the power source.
5. Remove the plastic cover between the heat sink and fan (b).
6. Clean the power source with dry compressed air (4 bar) as follows:
a) The upper rear part.
b) From the rear panel through the secondary heat sink.
c) The inductor, transformer and current sensor.
d) The power components side, from the rear side behind PCB 15AP1.
e) The PCBs at both sides.
7. Make sure that there is no dust left on any part.
8. Install the plastic cover between the heat sink and the fan (2) and make sure it is
correctly fitted against the heat sink.
9. Do a test of the power source according to IEC 60974-4, follow the procedure in
section "After repair, inspection and test" in the Service manual.
10. Install the top panel on the power source.
11. Install the side panels on the power source.
12. Connect the mains supply.