ESAB Warrior YardFeed 200 User manual

Instruction manual
0463 387 201 GB 20180115 Valid for: serial no. 802-xxx-xxxx
Warrior™ YardFeed 200
Warrior™YardFeed200w

TABLE OF CONTENTS
0463 387 201 © ESAB AB 2018
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols ............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 8
3TECHNICAL DATA ...................................................................................... 9
4INSTALLATION............................................................................................ 10
4.1 Lifting instructions ................................................................................. 10
5OPERATION ................................................................................................ 11
5.1 Connections and control devices ......................................................... 12
5.2 Function .................................................................................................. 13
5.3 Wire feed pressure ................................................................................. 14
5.4 Replacing and inserting wire................................................................. 15
5.5 Changing feed rollers............................................................................. 15
6MAINTENANCE........................................................................................... 16
6.1 Inspection and cleaning......................................................................... 16
7ORDERING SPARE PARTS ........................................................................ 17
DIAGRAM ............................................................................................................ 18
ORDERING NUMBERS....................................................................................... 20
WEAR PARTS...................................................................................................... 21
ACCESSORIES ................................................................................................... 26
Rights reserved to alter specifications without notice.

1 SAFETY
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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 387 201 -5- © ESAB AB 2018
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!
Wire feeders are intended to be used with power sources in MIG/MAG mode
only.
If used in any other welding mode, such as MMA, the welding cable between wire
feeder and power source must be disconnected, or else the wire feeder becomes
live or energized.
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• 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

1 SAFETY
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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.
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 therefore 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.
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.

1 SAFETY
0463 387 201 -7- © ESAB AB 2018
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 387 201 -8- © ESAB AB 2018
2 INTRODUCTION
The wire feed units Warrior™ YardFeed 200 and Warrior™ YardFeed 200w are intended for
MIG/MAG (GMAW) welding together with welding power sources:
• Warrior 400i CC/CV
• Warrior 500i CC/CV
They come in different variants, see chapter "ORDERING NUMBERS".
The wire feed units are sealed and contains a four-wheel drive wire feed mechanism as well
as control electronics.
They can be used together with wire from ESAB, standard S200 Ø 200 mm / Ø 8 in.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.

3 TECHNICAL DATA
0463 387 201 -9- © ESAB AB 2018
3 TECHNICAL DATA
Warrior™ YardFeed 200
Mains voltage 42 V, 50-60 Hz
Power requirement 252 VA
Rated supply current I16 A
Settings data
Wire feed speed 1.9-25.0 m/min (75-985 in/min)
2/4 stroke 2 stroke or 4 stroke
Wire selection / Burnback Solid or Cored
Creep start Always on
Gas purging Yes
Wire inching Yes
Torch connection EURO
Wire bobbin: Type, Max. diameter S200, 200 mm (8 in.)
Wire dimension
Fe 0.6-1.2 mm (0.023-0.045 in.)
Ss 0.6-1.2 mm (0.023-0.045 in.)
Al 1.0-1.2 mm (0.040-0.045 in.)
Cored wire 0.8-1.6 mm (0.030-1/16 in.)
Weight
WYF 200 12 kg (26.5 lb)
WYF 200w 12.2 kg (26.9 lb)
Dimensions (l × w × h) 593 × 210 × 312 mm
(23.3×8.3×12.28in.)
Operating temperature -10 to +40°C (+14 to +104°F)
Transport and storage temperature -20 to +55°C (-4 to +131°F)
Shielding gas All types intended for MIG/MAG welding
max pressure 0.5 MPA (5 bar / 72.5 psi)
Maximum permissible load at
60% duty cycle 365 A
100% duty cycle 280 A
Enclosure class IP23
Standard factory settings
Standard factory settings for Warrior™ YardFeed 200 are in/min and fully open gas valve.
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).
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.

4 INSTALLATION
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4 INSTALLATION
The installation must be carried out by a professional.
WARNING!
When welding in an environment with increased electrical danger, only power
sources intended for this environment may be used. These power sources are
marked with the symbol .
4.1 Lifting instructions

5 OPERATION
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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!
WARNING!
To avoid shock, do not touch electrode wire or parts in contact with it, or
uninsulated cable or connections.
NOTE!
When moving the equipment, use handle intended for transportation. Never pull
the equipment by the welding torch.
WARNING!
Assure that the side panels are closed during operation.
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
Risk of crushing when replacing the wire bobbin!
Do not use safety gloves when inserting the welding
wire between the feed rollers.
CAUTION!
Before threading welding wire, make sure the chisel point and burrs have been
removed from the end of the wire to prevent the wire from jamming in the torch
liner.

5 OPERATION
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5.1 Connections and control devices
1 Safety contact switch 9 Connection RED for cooling water
to power source (cooling unit) **
2 Connection for welding torch (Euro
connector)
10 Toggle switch for gas purging / wire
inching
3 Display wire feed speed (in/min or
m/min)*
11 Switch for 2 stroke/ 4 stroke
4 Knob for setting the voltage 12 Connection for welding current from
power source (OKC)
5 Display current (A) 13 Connection for shielding gas
6 Display voltage (V) 14 Connection for control cable from
power source
7 Knob for setting the wire feed
speed (m/min or in/min)
15 Connection RED, for coolant to
power source (cooling unit)
8 Connection BLUE for cooling water
from power source (cooling unit) **
16 Connection BLUE, for coolant from
power source (cooling unit)
*For setting of display wire feed speed unit, see the "Function" section.
** Cooling water connections are only available on certain models.

5 OPERATION
0463 387 201 - 13 - © ESAB AB 2018
NOTE!
The display for wire feed speed is activated a few seconds after the safety
contact switch is set to "Welding ON" mode (1).
NOTE!
Coolant connections are only available on certain models.
5.2 Function
Water connection
When connecting a water-cooled welding torch, the main power supply switch of the power
source must be in the OFF position and the cooling unit switch must be in position 0.
A water connection kit can be ordered as an accessory, see chapter "Accessories".
Strain relief
Hook the strain relief onto the hook on the rear
side of the feeder unit and the connection cable.
Safety contact switch
0 Welding OFF
1 Welding ON
Heat ON (accessory) and welding OFF
The bobbin area is heated so that the
welding wire is kept dry when welding.
Gasflow control and solid/cored wire
Open the lid for access to the gasflow control
and selection of the solid/cored wire.
A= Gas flow meter
B= Setting solid or cored wire
C= Display setting, in/min or m/min
Wire selection – Solid wire
Short Circuit Termination (SCT) behavior is selected when the trigger is released
to adapt to welding with solid wire.
SCT is a way to stop the welding with some small short circuits to reduce the
end crater and oxidation. It also gives the advantage of a good start
performance with solid wire.

5 OPERATION
0463 387 201 - 14 - © ESAB AB 2018
Wire selection – Cored wire
A constant burnback time is selected when the trigger is released to adapt to
welding with cored wire.
Gas purging
Gas purging is used when measuring the gas flow or to flush any air or moisture
from the gas hoses before welding starts. Gas purging occurs for as long as the
button is held depressed and occurs without voltage or wire feed starting.
Wire inching
Wire inching is used when one needs to feed wire without welding voltage being
applied. The wire is fed as long as the button is depressed.
2-stroke
With 2-stroke, gas pre-flow starts when the welding torch trigger switch is
pressed. The welding process then starts. Releasing the trigger switch stops
welding entirely and starts gas post-flow.
4-stroke
With 4 stroke, the gas pre-flow starts when the welding torch trigger switch is
pressed in and the wire feed starts when it is released. The welding process
continues until the switch is pressed in again, the wire feed then stops and when
the switch is released the gas post-flow starts.
Voltage
Higher voltage increases the arc length and produces a hotter, wider arc.
Wire feed speed
This sets the required feed speed of the filler wire in inches per minute (in/min)
or meters per minute (m/min).
5.3 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then set the
pressure of the wire feeder's pressure rollers. It is important that the pressure is not too high.
Figure A Figure B

5 OPERATION
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To check that the feed pressure is set correctly, you can feed out the wire against an
insulated object, e.g. a piece of wood.
When you hold the welding torch approx. 5 mm from the piece of wood (figure A) the feed
rollers should slip.
If you hold the welding torch approx. 50 mm from the piece of wood, the wire should be fed
out and bend (figure B).
5.4 Replacing and inserting wire
1. Open the side panel.
2. Disconnect the pressure sensor by folding it backwards, the pressure rollers slide up.
3. Straighten out the new wire 10-20 cm. File away burrs and sharp edges from the end
of the wire before inserting it into the wire feed unit.
4. Make sure that the wire goes properly into the feed roller's track and into the outflow
nozzle or wire guide.
5. Secure the pressure sensor.
6. Close the side panel.
5.5 Changing feed rollers
1. Open the side panel.
2. Disconnect the pressure sensor (1) by
folding it backwards, the pressure rollers
slide up.
3. Disconnect the pressure rollers (2) by
turning the axle (3) 1/4 turn clockwise and
pulling out the axle. The pressure rollers
disconnect.
4. Disconnect the feed rollers (4) by
unscrewing the nuts (5) and pulling out
the rollers.
During installation, repeat the above in reverse order.
Choice of track in the feed rollers
Turn the feed roller with the dimensioning mark for the required track towards you.

6 MAINTENANCE
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6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
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.
6.1 Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
Cleaning and replacement of the wire feed unit mechanism's worn parts should take place at
regular intervals in order to achieve trouble-free wire feed. Note that if pre-tensioning is set
too hard, this can result in abnormal wear on the pressure roller, feed roller and wire guide.
The brake hub
The hub is adjusted when delivered.
Adjust the brake hub so that the wire is
slightly slack when wire feed stops.
Welding torch
The welding torch's wear parts should be cleaned and replaced at regular intervals in order
to achieve trouble-free wire feed. Blow the wire guide clean regularly and clean the contact
tip.

7 ORDERING SPARE PARTS
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7 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
The Warrior™ YardFeed 200 and Warrior™ YardFeed 200w are designed and tested in
accordance with international and European standards IEC/EN 60974-5 and IEC/EN
60974-10, Canadian standard CAN/CSA-E60974-5 and US standard ANSI/IEC 60974-5.
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 standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list. This facilitates dispatch and
ensures correct delivery.

DIAGRAM
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DIAGRAM
Warrior™ Yard Feed 200

DIAGRAM
0463 387 201 - 19 - © ESAB AB 2018

ORDERING NUMBERS
0463 387 201 - 20 - © ESAB AB 2018
ORDERING NUMBERS
Ordering no. Denomination Type
0459 906 900 Warrior™ YardFeed 200
0459 906 901 Warrior™ YardFeed 200w with water cooling
0463 390 001 Spare parts list
Instruction manuals and the spare parts list are available on the Internet at: www.esab.com