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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Connection instruction
The power source is connected to 460V from the factory. If a different mains voltage
is required, the cable on the printed circuit board must be moved and placed on the
correct pin. See picture above. This operation must be carried out by personnel
having appropriate electrical knowledge.
Installation of mains cable
A mains cable needs to be installed. It is then important that the earth connection to
the bottom plate must be made in a correct way. See the picture above for the order
in which the washers, nuts and screws are placed.
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5 OPERATION
General safety regulations for the handling of the equipment can be found on
page 5. Read through before you start using the equipment!
A
H 0935
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5.1 Connections and control devices
1 Mains power supply switch, O/I 8 Knob for welding method
2 Indicating lamp, yellow, overheating 9 Connection (-): GMAW: Return cable
GTAW: Welding torch
SMAW: Return cable or welding cable
3 Indicating lamp, green, VRD function
(reduced open-circuit voltage) 10 Connection (+): GMAW: Welding cable GTAW: Return cable
SMAW: Welding cable or return cable
4 Display, current (A) and voltage (V) 11 Circuit breaker, 10 A, 42 V
5 Knob for setting:
SMAW/GTAW: Current (A)
Mobile Feed mode/Arc Air gauging/GMAW:
Voltage (V)
12 Connection of wire feed unit
6 Knob for choice of electrode type 13 Connection of remote control unit (option)
7 Knob for inductance (GMAW) and arc force
(SMAW) 14 Connection of mains power supply
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5.2 Connection of welding and return cable
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 output on the power source. Secure the return cable
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 SMAW welding, the welding cable can be connected to the positive terminal (+)
or negative terminal (-) depending on the type of electrode used. The connecting po
larity is stated on the electrode packaging.
5.3 Turning on/off the mains power source
Turn on the mains power by turning the switch to the "I" position; see 1 on the
picture in chapter 5.1.
Turn off the mains power 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.
5.4 Fan control
The power source has a time control that means 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.
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5.5 Symbols and functions
Placement of lifting eye VRD Voltage Reducing Device
Overheating protection Basic Basic electrode
Rutile Rutile electrode Cel Cellulosic electrode
Arc force Inductance
GTAW welding (Live TIG) Air arc gouging
SMAW welding GMAW welding
Wire feed unit
Mobile Feed CV
(Constant Voltage) Protective earth
VRD (Voltage Reducing Device)
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 authorized 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 a 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.
This only applies to SMAW welding.
Inductance
Higher inductance results in a wider weld pool and less spatter. Lower inductance
produces a harsher sound but a stable, concentrated arc.
This only applies to GMAW welding.
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GTAW welding
GTAW 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.
For GTAW welding, the welding power source shall be supplemented with:
Sa torch with gas valve
San Argon gas cylinder
San Argon gas regulator
Stungsten electrode
"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.
Arc air gouging
With arc air gouging, a special electrode is used comprising a carbon rod with a
copper casing.
An arc is formed between the carbon rod and the workpiece, which melts the
material. Pressurized air is supplied so that the melted material is blown away.
For Arc air gouging the power source shall be supplemented with:
Sarc air torch
Spressurized air
Recommendation for gouging
Electrode Ø Voltage Min. Voltage Max. Electrode Extension
6mm (1/4") 36V 49V 50  76mm
(2  3")
8mm (5/16") 39V 52V
10mm (3/8") 43V 52V
SMAW welding
SMAW welding may also be referred to as welding with coated electrodes. Striking the
arc melts the electrode, and its coating forms protective slag.
For SMAW welding the power source shall be supplemented with:
Swelding cable with electrode holder
Sreturn cable with clamp
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GMAW and self shielded cored wire welding
An arc melts a continuously supplied wire. The weld pool is protected by shielding
gas.
For GMAW and self shielded cored wire welding, the power source shall be supple
mented with:
Swire feed unit
Swelding gun
Sconnection cable between power source and wire feed unit
Sgas cylinder
Sreturn cable
6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only personnel with the appropriate electrical skills (authorized staff) may remove
safety plates.
Supplier warranty is void if customer attempts any work on product during the
warranty period.
6.1 Power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on:
Sthe welding process
Sthe arc times
Sthe placement
Sthe surrounding environment
It is normally sufficient to blow down the power source with dry compressed air
(reduced pressure) once a year.
Clogged or blocked air inlets and outlets will otherwise result in overheating.
6.2 Welding gun and torch
A regular programme of care and maintenance reduces unnecessary and expensive
downtime.
Each time a wire bobbin is changed, the welding gun should be removed from the
wire feeder 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 guns and torches.
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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. SCheck that the mains power supply switch is
turned on.
SCheck that the mains, welding and return
cables are correctly connected.
SCheck that the correct current value is set.
SCheck the mains power supply fuses.
The welding current is interrupted during welding. SCheck whether the overloading protection
has deployed (indicated on the front).
SCheck the mains power supply fuses.
SCheck that the return cable is correctly
fastened.
The overheating protection trips frequently. SMake sure that you are not exceeding the
rated data for the power source (i.e. that the
unit is not being overloaded).
SCheck that the ventilation is not blocked or
clogged.
Poor welding performance. SCheck that the welding and return cables
are correctly connected.
SCheck that the correct current value is set.
SCheck that the correct wire or electrode is
used.
SCheck the mains power supply fuses.
8 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB service
personnel. Use only ESAB original replacement and wear parts.
The Warrior 500i CC/CV is designed and tested in accordance with international standards
IEC 609741, Canadian standards CAN/CSAE609741:11 and US standards ANSI/IEC
60974-1:2008.
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.
When ordering spare parts, order by part number and part name, as documentet in
the spare parts list. Always provide the series or serial number on the unit on which
the parts will be used. The serial number is tamped on the rating plate.
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Canadian français
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1 SÉCURITÉ 21.........................................................
2 INTRODUCTION 23...................................................
2.1 Équipement 23...............................................................
3 DONNÉES TECHNIQUES 24...........................................
4 INSTALLATION 25....................................................
4.1 Instructions relatives au levage 25..............................................
4.2 Emplacement 25.............................................................
4.3 Alimentation secteur 26.......................................................
5 FONCTIONNEMENT 28................................................
5.1 Connexions et dispositifs de commande 29......................................
5.2 Connexion des câbles de soudage et de retour 30................................
5.3 Mise sous/hors tension de la source d'alimentation principale 30....................
5.4 Commande des ventilateurs 30................................................
5.5 Symboles et fonctions 31......................................................
6 MAINTENANCE 33....................................................
6.1 Source d'alimentation 34......................................................
6.2 Pistolet et chalumeau de soudage 34...........................................
7 DÉTECTION DES DÉFAUTS 35........................................
8 COMMANDE DE PIÈCES DE RECHANGE 35............................
SCHÉMA 53.............................................................
NUMÉRO DE COMMANDE 54.............................................
ACCESSOIRES 55.......................................................

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