ESAB WARRIOR EDGE 500 Instruction Manual
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ESAB WARRIOR EDGE 500 Instruction Manual

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WARRIOR EDGE 500
Instruction manual
Valid for: Serial number:
OP137YY-XXXXXX
0463 772 001   GB   20230224

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Summary of Contents for ESAB WARRIOR EDGE 500

  • Page 1 WARRIOR EDGE 500 Instruction manual Valid for: Serial number: OP137YY-XXXXXX 0463 772 001   GB   20230224...

  • Page 3: Table Of Contents

    Supply voltage fault ......................Temperature fault ......................Battery warning ....................Internal voltage error ....................Wire feed speed fault ....................Communication fault ....................Short circuit detected ................... High open circuit voltage fault 0463 772 001 - 3 - © ESAB AB 2023...
  • Page 4 ....................... TROUBLESHOOTING ...................... ORDERING SPARE PARTS ..................... CALIBRATION AND VALIDATION ..............11.1 Measurement methods and tolerances ............11.2 Requirements, specifications and standards ..........................WIRING DIAGRAM ......................... ORDERING NUMBERS ............................. ACCESSORIES 0463 772 001 - 4 - © ESAB AB 2023...

  • Page 5: Safety

    (SDSs). 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.
  • Page 6 If equipped with ESAB cooler Use ESAB approved coolant only. Non-approved coolant might damage the equipment and jeopardize product safety. In case of such damage, all warranty undertakings from ESAB cease to apply. For ordering information, see the "ACCESSORIES" chapter in the instruction manual.
  • Page 7 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. 0463 772 001 - 7 - © ESAB AB 2023...
  • Page 8 1   SAFETY 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. 0463 772 001 - 8 - © ESAB AB 2023...

  • Page 9: Introduction

    2   INTRODUCTION INTRODUCTION The Warrior Edge 500 is integrated with a cooling unit and offers a complete multi-process package supporting MIG/MAG, MMA, Live TIG and gouging. It is intended for use in combination with RobustFeed Edge. The power source is equipped with gateway to connect to the WeldCloud suite of applications, including WeldCloud Productivity for production monitoring and WeldCloud Fleet for managing your fleet of welding equipment.

  • Page 10: Technical Data

    Constant sound pressure when idling < 70 dB (A) Dimensions l × w × h 700×325×680 mm Weight 85 kg (including cooler) Insulation class Enclosure class IP23 Application class Coolant ESAB's coolant (0465 720 002) 0463 772 001 - 10 - © ESAB AB 2023...
  • Page 11 3   TECHNICAL DATA WARRIOR EDGE 500 Cooling power 1.4 kW Cooling volume 4.7 l Maximum flow 2 l/min Maximum pressure 4.5 bar   Mains supply, S sc min Minimum short circuit power on the network in accordance with IEC 61000-3-12. Duty cycle The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a certain load without overloading.

  • Page 12: Installation

    It is the user's responsibility to take adequate precautions. Location Position the welding power source in such a way that its cooling air inlets and outlets are not obstructed. 0463 772 001 - 12 - © ESAB AB 2023...

  • Page 13: Lifting Instructions

    4   INSTALLATION Lifting instructions Mechanical lifting must be done with both outer handles. 0463 772 001 - 13 - © ESAB AB 2023...

  • Page 14: Mains Supply

    . Refer to the technical data in the scmin TECHNICAL DATA chapter. 1. Rating plate with supply connection data. Recommended fuse sizes and minimum cable area WARRIOR EDGE 500 Mains voltage 380 V 3~ 50/60 Hz 400 V 3~ 50/60 Hz 460 V 3~ 50/60 Hz Mains cable area 4×6 mm...
  • Page 15 If the mains cable needs to be changed, the earth connection to the bottom plate and the ferrites must be installed correctly. See the picture below for the installation order of the ferrites, washers, nuts and screws. 0463 772 001 - 15 - © ESAB AB 2023...
  • Page 16 4   INSTALLATION Connections Cable colour (CE) Brown Black Grey Yellow/Green 0463 772 001 - 16 - © ESAB AB 2023...

  • Page 17: Operation

    5. Fuse (10 A) for supply voltage for wire feeder 12. WeldCloud Ethernet connection unit 6. Positive welding terminal: Welding cable 13. Mains cable 7. Connection RED for coolant (return) to cooling 14. Coolant tank unit 0463 772 001 - 17 - © ESAB AB 2023...

  • Page 18: Symbols

    Regardless the mains supply is interrupted abnormally, or the power source is switched off in the normal manner, the welding data will be stored, so it will be available next time the unit is turned on. 0463 772 001 - 18 - © ESAB AB 2023...

  • Page 19: Fan Control

    The fans start again when welding restarts. Usage of cooling unit ELP (ESAB Logic Pump) The cooling unit is equipped with detection system called ELP (ESAB Logic Pump), which checks that the coolant hoses are connected. When connecting a liquid cooled torch, cooling starts. NOTE!

  • Page 20: Usb Connection

    1. IoT Gateway USB port 1 3. USB port 3, which enables the user to upgrade the software and to export the error log report. 2. IoT Gateway USB port 2 0463 772 001 - 20 - © ESAB AB 2023...

  • Page 21: Control Panel

    6   CONTROL PANEL CONTROL PANEL Overview 1. LED Indicators 4. Current/voltage encoder knob 2. Display, shows set or measured current 5. Application selection knob 3. Display, shows set or measured voltage/dynamics 0463 772 001 - 21 - © ESAB AB 2023...

  • Page 22: Led Indicators Description

    To achieve a good welding result, the arc voltage is a crucial factor. In MIG/MAG welding, the power source is prepared to sense the arc voltage in the wire feeder. Prerequisite for this functionality is that an ESAB wire feeder and an ESAB interconnection cable is used.

  • Page 23: Functions And Symbols

    A36/ASME mild steel. For different types of metal, adjust the volt setting and air flow for better performance. For any gouging issues other than performance, see the TROUBLESHOOTING section. 0463 772 001 - 23 - © ESAB AB 2023...

  • Page 24: Mma Welding

    Measured or set value in the display for arc voltage V is an average arithmetic value. Measured or set amperage Measured or set value in the display for welding current A is an average arithmetic value. 0463 772 001 - 24 - © ESAB AB 2023...

  • Page 25: Maintenance

    Clean weld terminals. Check or replace weld unreadable labels. cables. Every 12 months or depending on environmental conditions (by authorised service Clean inside technician) equipment. Use dry compressed air with 4 bar pressure. 0463 772 001 - 25 - © ESAB AB 2023...

  • Page 26: Cleaning Procedure

    2 minutes! 2. Remove the side panels on the power source. 3. Remove the top panel on the power source. 4. Remove the plastic cover between the heat sink and fan. 0463 772 001 - 26 - © ESAB AB 2023...

  • Page 27: Cooling Unit

    Then drain the tank manually, i.e. empty via the tank's filling hole. 7.2.1 Filling the coolant Use only ESAB's ready mixed coolant. See chapter "ACCESSORIES". • Fill with coolant. (The fluid level must not exceed the upper marking, but neither must it be below lower marking.)
  • Page 28 7   MAINTENANCE 0463 772 001 - 28 - © ESAB AB 2023...

  • Page 29: Event Codes

    This event code is displayed due to one of the following: • 406 - Return coolant temperature warning/error. • 206 - Overtemperature. • 306 - High wire motor temperature warning/error. 0463 772 001 - 29 - © ESAB AB 2023...

  • Page 30: Battery Warning

    This event code is displayed due to one of the following: • 114 - Weld control communication error. • 114 - Internal communication warning. • 114 - Connection to main control lost. • 114 - Fieldbus interface lost. 0463 772 001 - 30 - © ESAB AB 2023...

  • Page 31: Short Circuit Detected

    This event code is displayed due to one of the following: • 019 - Parameter memory read/write error. • 019 - Log read/write error. Restart the system. Contact service technician. 0463 772 001 - 31 - © ESAB AB 2023...

  • Page 32: User Management Fault

    Contact service technician. Gas flow fault This event code is displayed due to one of the following: • 632 - Gas saturation warning/error. • 632 - No gas out error. 0463 772 001 - 32 - © ESAB AB 2023...

  • Page 33: Usb Fault

    This event code is displayed due to one of the following: • 736 - Fieldbus quickstop. • 736 - Fieldbus superquickstop. Acknowledge by pressing any buttons on the control panel. Restart. 0463 772 001 - 33 - © ESAB AB 2023...

  • Page 34: Troubleshooting

    Check whether the voltage is set to the recommended value. arc during gouging Intermittent arc action Check whether the voltage is set to the recommended value. resulting in an irregular groove surface or copper deposition on the metal plate 0463 772 001 - 34 - © ESAB AB 2023...

  • Page 35: 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 36: Calibration And Validation

    In the field application it will occur that a measuring device and a Warrior Edge 500 may display different values even though both systems are validated and calibrated. This is due to the measurement tolerances and the method of measurement of the two measurement systems.

  • Page 37: Wiring Diagram

    APPENDIX APPENDIX WIRING DIAGRAM 0463 772 001 - 37 - © ESAB AB 2023...

  • Page 38: Ordering Numbers

    Type Notes 0446 300 880 Power source Warrior Edge 500 CX I 380-460 V, CE 0446 300 884 Power source Warrior Edge 500 CX II 380-460 V, CE Including SPEED 0463 772 * Instruction manual 0463 844 001 Service manual 0463 843 001 Spare parts list The three last digits in the document number of the manual show the version of the manual.

  • Page 39: Accessories

    ESAB ready mixed coolant (10 l / 2.64 gal) Use of any other cooling liquid than the prescribed one might damage the equipment. In case of such damage, all warranty undertakings from ESAB cease to apply. 0465 416 880 Edge wheel kit For assembly instruction, refer to document...
  • Page 40 10 m (33 ft) 0446 310 993 15 m (49 ft) 0446 310 994 20 m (66 ft) 0446 310 995 25 m (82 ft) 0446 310 996 35 m (115 ft) 0463 772 001 - 40 - © ESAB AB 2023...
  • Page 41 APPENDIX 0463 772 001 - 41 - © ESAB AB 2023...
  • Page 42 For contact information visit http://esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 manuals.esab.com...

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