ESAB Warrior 500i CC Instruction Manual
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Summary of Contents for ESAB Warrior 500i CC
- Page 1 Warrior™ 500i CC/CV Instruction manual Valid for: 339-, 405-, 230-xxx-xxx 0463 341 331 US 20220729...
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Page 2: Table Of Contents
MAINTENANCE ................... Routine maintenance ................Cleaning instructions ................6.2.1 Cleaning procedure ................TROUBLESHOOTING ................. ORDERING SPARE PARTS ................ DIAGRAM ......................ORDER NUMBERS ..................... 26 ACCESSORIES ....................27 Rights reserved to alter specifications without notice. 0463 341 331 © ESAB AB 2022... -
Page 3: Safety
A flameproof apron may also be desirable as protection against radiated heat and sparks. 0463 341 331 - 3 - © ESAB AB 2022... - Page 4 Put on dry, hole-free gloves before turning on the power. 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. 0463 341 331 - 4 - © ESAB AB 2022...
- Page 5 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. 0463 341 331 - 5 - © ESAB AB 2022...
- Page 6 Keep all safety devices and cabinet covers in position and in good repair. Use equipment only for its intended purpose. Do not modify it in any manner. 0463 341 331 - 6 - © ESAB AB 2022...
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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 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. 0463 341 331 - 8 - © ESAB AB 2022...
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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
2 INTRODUCTION INTRODUCTION 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. -
Page 11: Technical Data
3 TECHNICAL DATA TECHNICAL DATA Warrior 500i CC/CV Mains voltage 380 V; 440 V; 460 V; 575 V ±10%, 3~ 50/60 Hz Primary current GMAW - MIG max. 38 A GTAW - TIG max. 31 A SMAW - MMA 38 A max. - Page 12 3 TECHNICAL DATA 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 Enclosure class IP 23 Application class...
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Page 13: Installation
4 INSTALLATION INSTALLATION General The installation must be carried out by a professional. Lifting instructions 0463 341 331 - 13 - © ESAB AB 2022... -
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 ground connection must be made in accordance with regulations. Recommended fuse sizes and minimum cable area Warrior 500i CC/CV Warrior 500i CC/CV Mains voltage... - Page 15 ≥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.
- Page 16 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. 0463 341 331 - 16 - © ESAB AB 2022...
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Page 17: Operation
Connect the return cable to the other output on the power source. Secure the return cable’s contact clamp to the workpiece, and make sure that there is a good contact between the workpiece and the output for the return cable on the power source. 0463 341 331 - 17 - © ESAB AB 2022... -
Page 18: Turning The Power On/Off
The fans start again when welding restarts. Symbols and functions Location of lifting eye Voltage Reducing Device Overheating Basic electrode protection 0463 341 331 - 18 - © ESAB AB 2022... - Page 19 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 this function. Overheating protection The welding power source has overheating protection that trips if the temperature becomes too high.
- Page 20 For GMAW and self-shielded, cored wire welding, the power source must be supplemented with: • wire feed unit • welding torch • connection cable between power source and wire feed unit • gas cylinder • Return cable with clamp 0463 341 331 - 20 - © ESAB AB 2022...
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Page 21: Maintenance
To maintain the performance and increase the lifetime of the power source it is mandatory to clean the product regularly. How often depends on: • The welding process, • The arc time, and 0463 341 331 - 21 - © ESAB AB 2022... -
Page 22: Cleaning Procedure
"After repair, inspection and test" in the Service manual. 10. Install the top panel on the power source. 11. Install the side panels on the power source. 12. Connect the mains supply. 0463 341 331 - 22 - © ESAB AB 2022... -
Page 23: 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 341 331 - 23 - © ESAB AB 2022... -
Page 24: Ordering Spare Parts
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. -
Page 25: Diagram
DIAGRAM DIAGRAM 0463 341 331 - 25 - © ESAB AB 2022... -
Page 26: Order Numbers
0465 350 887 Welding power source Warrior 500i CC/CV 575 V Canada 0459 839 084 Spare parts list 0740 800 221 Service manual Technical documentation is available on the Internet at www.esab.com 0463 341 331 - 26 - © ESAB AB 2022... -
Page 27: Accessories
0446 700 883 RobustFeed AVS with Rotameter with Tweco connector 0465 250 880 Warrior™ Feed 304 0465 250 881 Warrior™ Feed 304w, with water cooling 0558 005 728 MobileFeed 300 AVS 0463 341 331 - 27 - © ESAB AB 2022... - Page 28 Remote outlet kit 0465 416 880 Wheel kit 0465 508 880 Trolley guide pin extension kit Used together with the trolley when the wire feed unit is equipped with wheel kit 0463 341 331 - 28 - © ESAB AB 2022...
- Page 29 0459 836 981 5 m (16 ft.) 0459 836 982 10 m (33 ft.) 0459 836 983 15 m (49 ft.) 0459 836 984 25 m (82 ft.) 0459 836 985 35 m (115 ft.) 0463 341 331 - 29 - © ESAB AB 2022...
- Page 30 0446 160 991 5 m (16 ft.) 0446 160 992 10 m (33 ft.) 0446 160 993 15 m (49 ft.) 0446 160 994 25 m (82 ft.) 0446 160 995 35 m (115 ft.) 0463 341 331 - 30 - © ESAB AB 2022...
- 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 341 331 - 31 - © ESAB AB 2022...
- 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...
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