ESAB Warrior 400i CC/CV Instruction Manual
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ESAB Warrior 400i CC/CV Instruction Manual

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Warrior™ 400i CC/CV
Warrior™ 500i CC/CV
Instruction manual
Valid for: serial no. 324-, 230-xxx-xxx
0463 362 201 GB 20221121

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Summary of Contents for ESAB Warrior 400i CC/CV

  • Page 1 Warrior™ 400i CC/CV Warrior™ 500i CC/CV Instruction manual Valid for: serial no. 324-, 230-xxx-xxx 0463 362 201 GB 20221121...

  • Page 4: Table Of Contents

    MAINTENANCE ................... Routine maintenance ................Cleaning instructions ................6.2.1 Cleaning procedure ................TROUBLESHOOTING ................. ORDERING SPARE PARTS ................ DIAGRAM ......................ORDERING NUMBERS ..................24 ACCESSORIES ....................25 Rights reserved to alter specifications without notice. 0463 362 201 © ESAB AB 2022...

  • Page 5: Safety

    Safety Data Sheets (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 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. 0463 362 201 - 6 - © ESAB AB 2022...
  • Page 7 For further information contact the nearest ESAB dealer. 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 362 201 - 7 - ©...

  • Page 8: 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 9: Technical Data

    3 TECHNICAL DATA TECHNICAL DATA Warrior 400i CC/CV Warrior 500i CC/CV Mains voltage 380-415 V ±10%, 380-415 V ±10%, 3~ 50/60 Hz 3~ 50/60 Hz Mains supply S 6.4 MVA 7.2 MVA scmin Mains supply Z 0.025 Ω 0.022 Ω...
  • Page 10 3 TECHNICAL DATA Warrior 400i CC/CV Warrior 500i CC/CV Weight 58.5 kg 58.5 kg Insulation class Enclosure class IP 23 IP 23 Application class Mains supply, S sc min Minimum short circuit power on the network in accordance with IEC 61000-3-12.

  • Page 11: Installation

    4 INSTALLATION INSTALLATION General The installation must be carried out by a professional. Lifting instructions 0463 362 201 - 11 - © ESAB AB 2022...

  • Page 12: 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. Recommended fuse sizes and minimum cable area Warrior 400i CC/CV Warrior 400i CC/CV Mains voltage...
  • Page 13 4 INSTALLATION Warrior 400i CC/CV 1eff MIG/MAG 20 A 19 A 18 A 16 A 16 A 14 A 21 A 20 A 19 A Fuse anti-surge 25 A 25 A 20 A type C MCB 25 A 25 A...
  • Page 14 This power source version is designed for a nominal input voltage from 380 to 415 V AC. ESAB does not recommend a connection of the cable on the circuit board in the position of 440 , 460 or 575 V AC.

  • Page 15: Operation

    Connect the return cable to the other output on the power source. Secure the return cable's contact clamp to the work piece and ensure that there is good contact between the work piece and the output for the return cable on the power source. 0463 362 201 - 15 - © ESAB AB 2022...

  • Page 16: Turning The Mains Power On/Off

    The fans start again when welding restarts. Symbols and functions Placement of lifting Voltage Reducing Device Overheating Basic electrode protection 0463 362 201 - 16 - © ESAB AB 2022...
  • Page 17 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 18 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 362 201 - 18 - © ESAB AB 2022...

  • Page 19: 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 0463 362 201 - 19 - © ESAB AB 2022...

  • Page 20: 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 362 201 - 20 - © ESAB AB 2022...

  • Page 21: 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 362 201 - 21 - © ESAB AB 2022...

  • Page 22: 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 23: Diagram

    DIAGRAM DIAGRAM 0463 362 201 - 23 - © ESAB AB 2022...

  • Page 24: Ordering Numbers

    0465 350 886 Welding power source Warrior 400i CC/CV VRD 415 V 0464 254 001 Spare parts list 0464 523 001 Service manual Technical documentation is available on the Internet at www.esab.com 0463 362 201 - 24 - © ESAB AB 2022...

  • Page 25: Accessories

    RobustFeed AVS without Rotameter with Tweco connector 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 0463 362 201 - 25 - © ESAB AB 2022...
  • Page 26 0459 552 880 5 m (16 ft.) 0459 552 881 10 m (33 ft.) 0459 552 882 15 m (49 ft.) 0459 552 883 25 m (82 ft.) 0465 424 880 Remote outlet kit 0463 362 201 - 26 - © ESAB AB 2022...
  • Page 27 0459 836 881 5 m (16 ft.) 0459 836 882 10 m (33 ft.) 0459 836 883 15 m (49 ft.) 0459 836 884 25 m (82 ft.) 0459 836 885 35 m (115 ft.) 0463 362 201 - 27 - © ESAB AB 2022...
  • Page 28 0446 160 891 5 m (16 ft.) 0446 160 892 10 m (33 ft.) 0446 160 893 15 m (49 ft.) 0446 160 894 25 m (82 ft.) 0446 160 895 35 m (115 ft.) 0463 362 201 - 28 - © ESAB AB 2022...
  • Page 29 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 362 201 - 29 - © ESAB AB 2022...
  • Page 30 For contact information visit esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 manuals.esab.com...

This manual is also suitable for:

Warrior 500i cc/cv

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