ESAB Warrior 500i CV User manual

Instruction manual
0463 341 231 US 20200610 Valid for: 339-xxx-xxx, 405-xxx-xxx
Warrior™ 500i CC/CV

TABLE OF CONTENTS
0463 341 231 © ESAB AB 2020
1SAFETY ....................................................................................................... 3
1.1 Meaning of symbols ............................................................................... 3
1.2 Safety precautions ................................................................................. 3
1.3 User responsibility ................................................................................. 7
1.4 California Proposition 65 Warning........................................................ 9
2INTRODUCTION.......................................................................................... 10
2.1 Overview ................................................................................................. 10
2.2 Equipment ............................................................................................... 10
3TECHNICAL DATA ...................................................................................... 11
4INSTALLATION............................................................................................ 13
4.1 General .................................................................................................... 13
4.2 Lifting instructions ................................................................................. 13
4.3 Location................................................................................................... 14
4.4 Electrical supply..................................................................................... 14
5OPERATION ................................................................................................ 17
5.1 Overview ................................................................................................. 17
5.2 Connections and control devices ......................................................... 17
5.3 Connecting welding and return cables ................................................ 17
5.4 Turning the mains power on/off ............................................................ 18
5.5 Fan control .............................................................................................. 18
5.6 Symbols and functions .......................................................................... 19
6MAINTENANCE........................................................................................... 22
6.1 Overview ................................................................................................. 22
6.2 Power source.......................................................................................... 22
6.3 Welding torch.......................................................................................... 23
7TROUBLESHOOTING ................................................................................. 24
8ORDERING SPARE PARTS ........................................................................ 25
DIAGRAM ............................................................................................................ 26
ORDER NUMBERS ............................................................................................. 27
ACCESSORIES ................................................................................................... 28
Rights reserved to alter specifications without notice.

1 SAFETY
0463 341 231 -3- © ESAB AB 2020
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
WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in 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 Safety Precautions can 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. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.
2. Always wear safety glasses with side shields in any work area, even if welding
helmets, face shields and goggles are also required.
3. 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.
4. Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants,
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.

1 SAFETY
0463 341 231 -4- © ESAB AB 2020
5. 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.
6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.
7. 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. Protect yourself and others from flying sparks and hot metal.
2. Move all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.
3. 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.
4. Do not weld, cut, or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not perform hot work on closed containers, they may
explode.
5. 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.
6. Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
7. 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.
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 both the work piece and from
the ground.
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 for specific grounding recommendations. Do not
mistake the work lead for a earth cable.

1 SAFETY
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ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:
1. Welders having pacemakers should consult their physician 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 welding power source and cables as far away from your body as
possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in
confined spaces. Shielding gases can cause asphyxiation. Therefore:
1. Keep your head out of the fumes. Do not breathe the fumes and gases.
2. Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe in the fumes from these materials.
3. Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other
irritant gases.
4. 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.
5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
6. 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. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:
1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
2. 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 adapters. Maintain
hoses and fittings in good condition. Follow the manufacturer's operating instructions
for mounting a regulator to a compressed gas cylinder.

1 SAFETY
0463 341 231 -6- © ESAB AB 2020
3. 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.
4. 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.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause
injury. Therefore:
1. Keep all doors, panels, guards, and covers closed and securely in place.
2. Stop the engine or drive systems before installing or connecting a unit.
3. Have only qualified people remove covers for maintenance and troubleshooting as
necessary
4. To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.
5. Keep hands, hair, loose clothing and tools away from moving parts.
6. Reinstall panels or covers and close doors when service is finished and before
starting engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any
other accessories.
• Use equipment of adequate capacity to lift and support unit.
• If using lift forks to move unit, be sure forks are long enough to extend beyond
opposite side of unit.
• Keep cables and cords away from moving vehicles when working from an
aerial location.
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.

1 SAFETY
0463 341 231 -7- © ESAB AB 2020
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 are recommended:
• ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
• AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
• AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
• AWS SP - “Safe practices” - Reprint, Welding Handbook
• ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of
Containers That Have Held Hazardous Substances”
• OSHA 29 CFR 1910 - "Safety and health standards"
• CSA W117.2 - "Code for safety in welding and cutting"
• NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other Hot
Work"
• CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in
Cylinders”
• ANSI Z87.1, "Occupational and Educational Personal Eye and Face
Protection Devices"
1.3 User responsibility
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 unauthorized 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
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0463 341 231 -8- © ESAB AB 2020
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 may cause injury 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 - Pose health risks
• Welders with pacemakers fitted should consult their doctor 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 the 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 your 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 ear defenders or other hearing protection.

1 SAFETY
0463 341 231 -9- © ESAB AB 2020
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 a fire. Make sure 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!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
This product is solely intended for arc welding.
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.
1.4 California Proposition 65 Warning
WARNING!
Welding or cutting equipment produces fumes or gases which contain chemicals
known in the State of Carlifornia to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Section 25249.5 et seq.)
WARNING!
This product can expose you to chemicals including lead, which are known to the
state of California to cause cancer and birth defects or other reproductive harm.
Wash hands after use.
For more information, go to www.P65Warnings.ca.gov.

2 INTRODUCTION
0463 341 231 - 10 - © ESAB AB 2020
2 INTRODUCTION
2.1 Overview
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), for GTAW welding, for welding with
coated electrodes (SMAW) and arc air gouging.
The power sources are intended for use with the following wire feed units:
• 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 delivered with:
• 5 m return cable with ground clamp
• Instruction manual

3 TECHNICAL DATA
0463 341 231 - 11 - © ESAB AB 2020
3 TECHNICAL DATA
Warrior 500i CC/CV
Mains voltage 380 V; 440 V; 460 V; 575 V ±10%,
3~ 50/60 Hz
Primary current
Imax. GMAW - MIG
Imax. GTAW - TIG
Imax. SMAW - MMA
38 A
31 A
38 A
No load power in energy-saving mode 6.5 min. after
welding 40 W
Setting range
GMAW - MIG flat characteristic
GTAW - TIG drooping characteristic
SMAW - MMA drooping characteristic
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 GMAW
60% duty cycle
100% duty cycle
500 A/39 V
400 A/34 V
Permissible load at GTAW
60% duty cycle
100% duty cycle
500 A/30 V
400 A/26 V
Permissible load at SMAW
60% duty cycle
100% duty cycle
500 A/40 V
400 A/36 V
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 84 V 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 <70 db (A)

3 TECHNICAL DATA
0463 341 231 - 12 - © ESAB AB 2020
Warrior 500i CC/CV
Dimensions l × w × h 28.1 x 12.8 x 18.5 inch
(712 x 325 x 470 mm)
Weight (welding power source) 115.7 lbs (52.5 kg)
Insulation class H
Enclosure class IP 23
Application class
Duty cycle
The duty cycle refers to the time, expressed as a percentage of a ten-minute period, during
which you can weld or cut at a certain load without overloading. The duty cycle is valid for
104°F (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 341 231 - 13 - © ESAB AB 2020
4 INSTALLATION
4.1 General
The installation must be carried out by a professional.
4.2 Lifting instructions


4 INSTALLATION
0463 341 231 - 14 - © ESAB AB 2020
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 Electrical supply
NOTE!
Mains supply requirements
High power equipment, due to the primary current drawn from the mains supply, may
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, in 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. A protective ground connection must be made in
accordance with regulations.
Warrior 500i CC/CV
Mains voltage 380V 3~ 50/60 Hz 440V 3~ 50/60 Hz
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
Recommended fuse sizes and minimum cable area Warrior 500i CC/CV

4 INSTALLATION
0463 341 231 - 15 - © ESAB AB 2020
Warrior 500i CC/CV
Mains voltage 460V 3~ 50/60 Hz 575V 3~ 50/60 Hz
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.
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 an equivalent or better
type of regulation, with rated power ≥40kW, are recommended.
Connection instruction
The power source Warrior 500i CC/CV (0465 350 881) for USA is connected to 460 V from
the factory. The power source Warrior 500i CC/CV (0465 350 887) for Canada is connected
to 575 V 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 with the appropriate electrical knowledge.

4 INSTALLATION
0463 341 231 - 16 - © ESAB AB 2020
Installation of mains cable
A mains cable needs to be installed. It is important that the ground connection to the bottom
plate then be made in the correct way. See the picture above, for the placement order of the
washers, nuts and screws.

5 OPERATION
0463 341 231 - 17 - © ESAB AB 2020
5 OPERATION
5.1 Overview
General safety regulations for handling the equipment can be found in the chapter
"Safety". Read it before you start the equipment.
5.2 Connections and control devices
1. Mains power supply switch, I/O 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 for wire feed unit
5. Knob for setting: SMAW/GTAW:
Current (A)
13. Connection for remote control unit
(option)
6. Knob for selecting electrode type 14. Connection for mains power supply
7. Knob for inductance (MIG/MAG) and
arc force (MMA):
15. Lifting eye bolt
8. Knob for welding method
5.3 Connecting 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.

5 OPERATION
0463 341 231 - 18 - © ESAB AB 2020
Connect the return cable to the other output on the power source. Secure the return cable's
contact clamp to the workpiece and ensure there is a good contact between the workpiece
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 connection polarity is
stated on the electrode packaging.
Recommended maximum current values for connection set cables
Imax Cable area Cable length Note
450 A (60% duty cycle) 70 mm26.6 ft - 114.8 ft
(2 - 35 m) 19 pole
350 A (100% duty cycle)
550 A (60% duty cycle) 95 mm26.6 ft - 114.8 ft
(2 - 35 m) 19 pole
430 A (100% duty cycle)
450 A (60% duty cycle) 70 mm26.6 ft - 114.8 ft
(2 - 35 m) 19 pole, water
350 A (100% duty cycle)
550 A (60% duty cycle) 95 mm26.6 ft - 114.8 ft
(2 - 35 m) 19 pole, water
430 A (100% duty cycle)
Duty cycle
The duty cycle refers to the time, expressed as a percentage of a ten-minute period, during
which you can weld or cut at a certain load without overloading. The duty cycle is valid for
104°F (40°C).
5.4 Turning the mains power on/off
Turn on the mains power by turning switch to the ”I” position, see 1 in 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, the welding data will be stored so it is available the 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, this 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 OPERATION
0463 341 231 - 19 - © ESAB AB 2020
5.6 Symbols and functions
Location of lifting eye Voltage Reducing
Device
Overheating
protection
Basic electrode
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 ground
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 detects that welding has started.
Contact an authorized ESAB service technician to activate this function.
Overheating protection
The welding power source has overheating protection that trips 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 back to the
normal working temperature range.
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 SMAW welding.

5 OPERATION
0463 341 231 - 20 - © ESAB AB 2020
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 GMAW welding.
GTAW welding
GTAW welding melts the metal of the workpiece, using an arc struck from a tungsten
electrode that does not melt. The weld pool and 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 GTAW welding, the welding power source must be supplemented with:
• a TIG torch with gas valve
• an argon gas cylinder
• an argon gas regulator
• tungsten electrode
Arc air gouging
For arc air gouging, a special electrode is used comprised of a carbon rod with a copper
casing.
An arc is formed between the carbon rod and the workpiece, which melts the material.
Compressed air is supplied, so the melted material is blown away.
For arc air gouging the power source must be supplemented with:
• arc air torches
• compressed air
• return cable with clamp
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
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 must be supplemented with:
• welding cable with electrode holder
• return cable with clamp