Related Manuals for ESAB Warrior 400i CC
Summary of Contents for ESAB Warrior 400i CC
- Page 1 Warrior™ 400i CC/CV Warrior™ 500i CC/CV Instruction manual Valid for: Serial no. 339-xxx-xxxx 0463 340 030 GB 20181009...
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Page 2: Table Of Contents
Symbols and functions ................MAINTENANCE ................... Overview ....................Power source ..................Welding torch..................TROUBLESHOOTING ................. ORDERING SPARE PARTS ................ DIAGRAM ......................ORDERING NUMBERS ..................27 ACCESSORIES ....................28 Rights reserved to alter specifications without notice. 0463 340 030 © ESAB AB 2018... -
Page 3: Safety
Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal. 0463 340 030 - 3 - © ESAB AB 2018... - Page 4 Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes. Put on dry, hole-free gloves before turning on the power. 0463 340 030 - 4 - © ESAB AB 2018...
- Page 5 (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: 0463 340 030 - 5 - © ESAB AB 2018...
- Page 6 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. 0463 340 030 - 6 - © ESAB AB 2018...
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Page 7: User Responsibility
Protection Devices" 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. - Page 8 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. 0463 340 030 - 8 - © ESAB AB 2018...
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Page 9: California Proposition 65 Warning
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. California Proposition 65 Warning... -
Page 10: Introduction
INTRODUCTION 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. -
Page 11: Technical Data
3 TECHNICAL DATA TECHNICAL DATA Warrior 400i CC/CV Warrior 500i CC/CV Mains voltage 380-460 V ±10%, 380-460 V ±10%, 3~ 50/60 Hz 3~ 50/60 Hz Primary current I MIG/MAG 27 A 37 A 23 A 30 A 29 A 38 A No-load power in energy-saving mode 6.5 min. - Page 12 3 TECHNICAL DATA Warrior 400i CC/CV Warrior 500i CC/CV Insulation class Enclosure class IP 23 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.
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Page 13: Installation
4 INSTALLATION INSTALLATION General The installation must be carried out by a professional. Lifting instructions 0463 340 030 - 13 - © ESAB AB 2018... -
Page 14: Location
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. Table 1. Recommended fuse sizes and minimum cable area Warrior 400i CC/CV Warrior 400i CC/CV Mains voltage... - Page 15 See picture above. This operation must be carried out by personnel having appropriate electrical knowledge. 0463 340 030 - 15 - © ESAB AB 2018...
- Page 16 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. 0463 340 030 - 16 - © ESAB AB 2018...
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Page 17: Operation
Current (A) Mobile Feed mode: Voltage (V) Knob for choice of electrode type Connection of mains power supply Knob for inductance (MIG/MAG) and arc Lifting eye bolt force (MMA) Knob for welding method 0463 340 030 - 17 - © ESAB AB 2018... -
Page 18: Connection Of Welding And Return Cable
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. 0463 340 030 - 18 - © ESAB AB 2018... -
Page 19: Symbols And Functions
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. - Page 20 For MMA welding the power source shall be supplemented with: • welding cable with electrode holder • return cable with clamp 0463 340 030 - 20 - © ESAB AB 2018...
- Page 21 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 0463 340 030 - 21 - © ESAB AB 2018...
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Page 22: Maintenance
Wait for 4 minutes to discharge the capacitors. Remove the side panels on the power source. Remove the top panel on the power source. Remove the plastic cover between the heat sink and fan (b). 0463 340 030 - 22 - © ESAB AB 2018... -
Page 23: Welding Torch
The wire end must not have sharp edges when inserted into the wire liner. For detailed information see instruction manuals for welding torches. 0463 340 030 - 23 - © ESAB AB 2018... -
Page 24: Troubleshooting
Check that the voltage on the voltage selection label on the rear of the power source is equal to the nominal mains voltage. • Restart the power source with the main switch. 0463 340 030 - 24 - © ESAB AB 2018... -
Page 25: Ordering Spare Parts
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list. -
Page 26: Diagram
DIAGRAM DIAGRAM 0463 340 030 - 26 - © ESAB AB 2018... -
Page 27: Ordering Numbers
0465 350 880 Welding power source Warrior 500i CC/CV 380-460 V 0459 839 084 Spare parts list 0740 800 221 Service manual Technical documentation is available on the Internet at www.esab.com 0463 340 030 - 27 - © ESAB AB 2018... -
Page 28: Accessories
MobileFeed 300 AVS 0459 491 896 Remote control unit AT1 MMA and TIG current 0459 491 897 Remote control unit AT1 CF MMA and TIG: course and fine setting of current 0463 340 030 - 28 - © ESAB AB 2018... - Page 29 0465 416 880 Wheel kit 0465 510 880 Trolley 0465 508 880 Trolley guide pin extension kit Used together with the trolley when the wire feed unit is equipped with wheel kit 0463 340 030 - 29 - © ESAB AB 2018...
- Page 30 Connection set water, 95 mm², 19 poles 0459 836 990 0459 836 991 0459 836 992 10 m 0459 836 993 15 m 0459 836 994 25 m 0459 836 995 35 m 0463 340 030 - 30 - © ESAB AB 2018...
- Page 31 Flair 600 incl monocable 2.5 m 0468 253 016 Torch only 0468 253 015 Monocable only 0468 253 881 Flair 1600 incl monocable 2.5 m 0468 253 036 Torch only 0468 253 035 Monocable only 0463 340 030 - 31 - © ESAB AB 2018...
- Page 32 For contact information visit esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 http://manuals.esab.com...