ESAB Warrior 500i CC/CV User manual

US CAN
SA
Valid for serial no. 251-xxx-xxxx0463 341 031 20130115
Warrior™500i CC/CV
US Instruction manual
CAN Manuel d'instructions SA Manual de instrucciones

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Rights reserved to alter specifications without notice.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Sous réserve de modifications sans avis préalable.
English US 3.............................................
Canadian français 19.......................................
Español SA 36.............................................

English US
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1 SAFETY 5...........................................................
2 INTRODUCTION 7...................................................
2.1 Equipment 7................................................................
3 TECHNICAL DATA 8.................................................
4 INSTALLATION 9....................................................
4.1 Lifting instructions 9.........................................................
4.2 Location 9..................................................................
4.3 Mains supply 10..............................................................
5 OPERATION 12.......................................................
5.1 Connections and control devices 13............................................
5.2 Connection of welding and return cable 14.......................................
5.3 Turning on/off the mains power source 14.......................................
5.4 Fan control 14...............................................................
5.5 Symbols and functions 15.....................................................
6 MAINTENANCE 17....................................................
6.1 Power source 17.............................................................
6.2 Welding gun and torch 17.....................................................
7 FAULT-TRACING 18..................................................
8 ORDERING SPARE PARTS 18.........................................
SCHEMATIC DIAGRAM 53................................................
ORDERING NUMBER 54.................................................
ACCESSORIES 55.......................................................

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1 SAFETY
Users of ESAB welding 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 welding equipment. The following recommen
dations 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 welding
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 welding equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is
started up.
Sno-one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the ground cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
6 Reference
SCAN/CSA-W117.2-06 Safety in Welding, Cutting and Allied Processes
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READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES
WHICH SHOULD BE BASED ON MANUFACTURERS' HAZARD DATA.
ELECTRIC SHOCK - CAN KILL
SINSTALL AND EARTH (GROUND) THE WELDING UNIT IN ACCORDANCE WITH
APPLICABLE STANDARDS.
SDO NOT TOUCH LIVE ELECTRICAL PARTS OR ELECTRODES WITH BARE SKIN,
WET GLOVES OR WET CLOTHING.
SINSULATE YOURSELF FROM EARTH AND THE WORKPIECE.
SENSURE YOUR WORKING STANCE IS SAFE.
FUMES AND GASES - CAN BE DANGEROUS TO HEALTH
SKEEP YOUR HEAD OUT OF THE FUMES.
SUSE 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.
SPROTECT YOUR EYES AND BODY. USE THE CORRECT WELDING SCREEN AND
FILTER LENS AND WEAR PROTECTIVE CLOTHING.
SPROTECT BYSTANDERS WITH SUITABLE SCREENS OR CURTAINS.
FIRE HAZARD
SSPARKS (SPATTER) CAN CAUSE FIRE. MAKE SURE THEREFORE THAT THERE ARE
NO INFLAMMABLE MATERIALS NEARBY.
NOISE - EXCESSIVE NOISE CAN DAMAGE HEARING
SPROTECT YOUR EARS. USE EARMUFFS OR OTHER HEARING PROTECTION.
SWARN BYSTANDERS OF THE RISK.
MALFUNCTION - CALL FOR EXPERT ASSISTANCE IN THE EVENT OF MALFUNCTION.
PROTECT YOURSELF AND OTHERS!
REFERENCE TO CAN/CSA-W117.2-06
DO NOT USE THE POWER SOURCE FOR THAWING FROZEN PIPES.
Read and understand the instruction manual
before installing or operating.
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This product is solely intended for arc welding. Any other use may result in personal
injury and / or equipment damage.
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.
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
The Warrior 500i CC/CV is a welding power source intended for GMAW welding, as
well as for welding with powder filled cored wire (FCAW-S), GTAW welding, welding
with coated electrodes (SMAW) and arc air gouging.
The power source is intended for use with the following wire feed units:
SWarrior Feed 304
SMobile Feed 300
ESAB's accessories for the product can be found on page 55.
2.1 Equipment
The power source is supplied with:
S5 m return cable with clamp
Sinstruction manual
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3 TECHNICAL DATA
Warrior 500i CC/CV
Mains voltage 380V; 440V; 460V: 575V
$10%, 350/60Hz
Primary current
Imax. GMAW - MIG
Imax. GTAW - TIG
Imax. SMAW - MMA
38A
31A
38A
No-load power in energy-saving mode
6.5 min. after welding 40W
Setting range
GMAW - MIG flat characteristic
GTAW - TIG drooping characteristic
SMAW - MMA drooping characteristic
16A/15V-500A/39V
5A/10V-500A/30V
16A/20V-500A/40V
Permissible load at GMAW
60% duty cycle
100% duty cycle
500A/39V
400A/34V
Permissible load at GTAW
60% duty cycle
100% duty cycle
500A/30V
400A/26V
Permissible load at SMAW
60% duty cycle
100% duty cycle 500A/40V 400A/36V
Power factor at maximum current
GMAW
GTAW
SMAW
0.87
0.83
0.87
Efficiency at maximum current
GMAW
GTAW
SMAW
90%
88%
90%
Electrode types Basic
Rutile
Cellulosic
Open-circuit voltage without VRD function 84V DC
Apparent power at maximum current 31.7 kVA
Active power at maximum current 22.6 kW
Operating temperature - 50 to 104°F ( -10 to 40°C)
Transportation temperature - 68 to 131°F (-20 to 55°C)
Constant sound pressure when idling <70db (A)
Dimensions lxwxh 28.1 x 12.8 x 18.5"
(712 x 325 x 470mm)
Weight (welding power source) 115.7lbs (52.5kg)
Insulation class H
Enclosure class IP 23
Application class
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 104°F (40°C) .
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Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 23 is designed 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
The installation must be done by a professional.
4.1 Lifting instructions
FASTEN THE EQUIPMENT –PARTICULARLY IF
THE GROUND IS UNEVEN OR SLOPING.
If equipment is placed on a surface that slopes more
than 10°, toppling over may occur. Personal injury
and/or significant damage to equipment is possible.
4.2 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
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4.3 Mains supply
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case 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 may be connected.
Make sure that the welding power source is connected to the correct supply voltage
and that it is protected by the correct fuse rating. Before connection and usage a
protective earth connection must be created in accordance with regulations.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable area
Warrior 500i CC/CV
Mains voltage 380V 350/60Hz 440V 350/60Hz
Mains cable area 4C 8Awg / 4G 6mm24C 8Awg / 4G 6mm2
Phase current Ieff 30A 28A
Fuse
anti-surge
type C MCB 35A 32A 35A 32A
Warrior 500i CC/CV
Mains voltage 460V 350/60Hz 575V 350/60Hz
Mains cable area 4C 8Awg / 4G 6mm24C 8Awg / 4G 6mm2
Phase current Ieff 28A 24A
Fuse
anti-surge
type C MCB 35A 32A 25A 25A
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.
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