ESAB Warrior 500i CV Instruction Manual
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Summary of Contents for ESAB Warrior 500i CV
- Page 1 Warrior™ 500i CC/CV Instruction manual Valid for: 339-xxx-xxx, 405-xxx-xxx 0463 341 231 US 20200610...
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Page 2: Table Of Contents
Symbols and functions ................MAINTENANCE ................... Overview ....................Power source ..................Welding torch ..................TROUBLESHOOTING ................. ORDERING SPARE PARTS ................ DIAGRAM ......................ORDER NUMBERS ..................... 27 ACCESSORIES ....................28 Rights reserved to alter specifications without notice. 0463 341 231 © ESAB AB 2020... -
Page 3: Safety
A flameproof apron may also be desirable as protection against radiated heat and sparks. 0463 341 231 - 3 - © ESAB AB 2020... - 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 341 231 - 4 - © ESAB AB 2020...
- 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 341 231 - 5 - © ESAB AB 2020...
- 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 341 231 - 6 - © ESAB AB 2020...
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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 341 231 - 8 - © ESAB AB 2020...
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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
The power sources are intended for use with the following wire feed units: • Warrior Feed 304 • Warrior Feed 304w ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual. Equipment The power source is delivered with: •... -
Page 11: Technical Data
Active power at maximum current 22.6 kW Operating temperature -50 to 104°F (-10 to 40°C) Transportation temperature -68 to 131°F (-20 to 55°C) Constant sound pressure when idling <70 db (A) 0463 341 231 - 11 - © ESAB AB 2020... - Page 12 Equipment marked IP23 is intended for indoor and outdoor use. Application class The symbol indicates that the power source is designed for use in areas with increased electrical hazard. 0463 341 231 - 12 - © ESAB AB 2020...
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Page 13: Installation
4 INSTALLATION INSTALLATION General The installation must be carried out by a professional. Lifting instructions 0463 341 231 - 13 - © ESAB AB 2020... -
Page 14: Location
Mains voltage 380V 3~ 50/60 Hz 440V 3~ 50/60 Hz Mains cable area 4C 8Awg / 4G 6mm 4C 8Awg / 4G 6mm Phase current I Fuse anti-surge type C MCB 0463 341 231 - 14 - © ESAB AB 2020... - Page 15 If a different mains voltage is required, the cable on the printed circuit board must be moved and placed on the correct pin. See picture above. This operation must be carried out by personnel with the appropriate electrical knowledge. 0463 341 231 - 15 - © ESAB AB 2020...
- 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 341 231 - 16 - © ESAB AB 2020...
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Page 17: Operation
The power source has two outputs, a positive terminal (+) and a negative terminal (-), for connecting welding and return cables. The output to which the welding cable is connected depends on the welding method or type of electrode used. 0463 341 231 - 17 - © ESAB AB 2020... -
Page 18: Turning The Mains Power On/Off
The power source has a time control, this 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 341 231 - 18 - © ESAB AB 2020... -
Page 19: Symbols And Functions
This is indicated by a lit VRD led. The VRD function is blocked when the system detects 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 SMAW welding, the power source must be supplemented with: • welding cable with electrode holder • return cable with clamp 0463 341 231 - 20 - © ESAB AB 2020...
- Page 21 For GMAW and self-shielded, cored wire welding, the power source must be supplemented with: • wire feed unit • welding torch • connection cable between the power source and wire feed unit • gas cylinder • return cable with clamp 0463 341 231 - 21 - © ESAB AB 2020...
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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 341 231 - 22 - © ESAB AB 2020... -
Page 23: Welding Torch
The wire end must not have sharp edges when inserted into the wire liner. For detailed information, see the instruction manuals for welding torches. 0463 341 231 - 23 - © ESAB AB 2020... -
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 341 231 - 24 - © ESAB AB 2020... -
Page 25: 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 26: Diagram
DIAGRAM DIAGRAM 0463 341 231 - 26 - © ESAB AB 2020... -
Page 27: 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 341 231 - 27 - © ESAB AB 2020... -
Page 28: Accessories
With Tweco 4 connector, incl. gas flow meter and heater 0465 250 880 Warrior™ Feed 304 0465 250 881 Warrior™ Feed 304w, with water cooling 0558 005 728 MobileFeed 300 AVS 0463 341 231 - 28 - © ESAB AB 2020... - Page 29 Remote control cable 12 pole - 8 pole 0459 552 880 0459 552 881 10 m 0459 552 882 15 m 0459 552 883 25 m 0465 424 880 Remote outlet kit 0465 416 880 Wheel kit 0463 341 231 - 29 - © ESAB AB 2020...
- Page 30 70 mm², liquid cooled, 10.0 m 0446 160 893 70 mm², liquid cooled, 15.0 m 0446 160 894 70 mm², liquid cooled, 25.0 m 0446 160 895 70 mm², liquid cooled, 35.0 m 0463 341 231 - 30 - © ESAB AB 2020...
- Page 31 Connection set, 95 mm², 19 poles 0459 836 986 0459 836 981 0459 836 982 10 m 0459 836 983 15 m 0459 836 984 25 m 0459 836 985 35 m 0463 341 231 - 31 - © ESAB AB 2020...
- Page 32 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 341 231 - 32 - © ESAB AB 2020...
- Page 33 ACCESSORIES 0463 341 231 - 33 - © ESAB AB 2020...
- Page 34 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...