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

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See also: Service Manual , Instruction Manual
Warrior™ 400i CC/CV
Warrior™ 500i CC/CV
Instruction manual
0463 362 001 GB 20130618
Valid for: serial no. 324-xxx-xxx

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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 0463 362 001 GB 20130618 Valid for: serial no. 324-xxx-xxx...

  • Page 3: Table Of Contents

    Overview ......................18 Power source...................... 18 Welding torch ..................... 18 FAULT TRACING....................19 ORDERING SPARE PARTS ................20 DIAGRAM ........................21 ORDERING NUMBERS .....................22 ACCESSORIES ......................23 Rights reserved to alter specifications without notice. 0463 362 001 © ESAB AB 2013...

  • Page 4: Safety

    1 SAFETY SAFETY 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 5 Do not use the power source for thawing frozen pipes. CAUTION! Read and understand the instruction manual before installing or operating. CAUTION! This product is solely intended for arc welding. 0463 362 001 - 5 - © ESAB AB 2013...
  • Page 6 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. ESAB can provide you with all necessary welding protection and accessories. 0463 362 001 - 6 - © ESAB AB 2013...

  • Page 7: 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 8: 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 9 3 TECHNICAL DATA Warrior 400i CC/CV Warrior 500i CC/CV 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. Mains supply, Z Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

  • Page 10: Installation

    WARNING! Secure the equipment - particularly if the ground is uneven or sloping. Location Position the welding power source such that its cooling air inlets and outlets are not obstructed. 0463 362 001 - 10 - © ESAB AB 2013...

  • Page 11: Mains Supply

    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 12 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 13 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 362 001 - 13 - © ESAB AB 2013...

  • Page 14: 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 362 001 - 14 - © ESAB AB 2013...

  • Page 15: Connection Of Welding And Return Cables

    Symbols and functions Placement of lifting Voltage Reducing Device Overheating Basic electrode protection Rutile electrode Cellulosic electrode Arc force Inductance TIG welding (Live Arc air gouging TIG) 0463 362 001 - 15 - © ESAB AB 2013...
  • Page 16 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 17 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 362 001 - 17 - © ESAB AB 2013...

  • Page 18: Maintenance

    The wire end must not have sharp edges when inserted into the wire liner. For detailed information see instruction manuals for welding torches. 0463 362 001 - 18 - © ESAB AB 2013...

  • Page 19: Fault Tracing

    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 362 001 - 19 - © ESAB AB 2013...

  • Page 20: Ordering Spare Parts

    Spare parts may be ordered through your nearest ESAB dealer, see the last page of this document.

  • Page 21: Diagram

    DIAGRAM DIAGRAM 0463 362 001 - 21 - © ESAB AB 2013...

  • Page 22: Ordering Numbers

    0465 350 883 Welding power source Warrior 500i CC/CV 380-415 V 0464 254 001 Spare parts list 0464 523 001 Service manual Technical documentation is available on the Internet at www.esab.com 0463 362 001 - 22 - © ESAB AB 2013...

  • Page 23: Accessories

    MMA and TIG: course and fine setting of current 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 0463 362 001 - 23 - © ESAB AB 2013...
  • Page 24 Connection set water, 70 mm², 19 poles 0459 836 890 1.7 m 0459 836 891 0459 836 892 10 m 0459 836 893 15 m 0459 836 894 25 m 0459 836 895 35 m 0463 362 001 - 24 - © ESAB AB 2013...
  • Page 25 Torch only A 0468 253 015 Monocable only A 0468 253 881 Flair 1600 incl monocable 2.5 m A 0468 253 036 Torch only A 0468 253 035 Monocable only A 0463 362 001 - 25 - © ESAB AB 2013...
  • Page 26 ESAB subsidiaries and representative offices Europe NORWAY North and South America SOUTH KOREA AS ESAB ESAB SeAH Corporation AUSTRIA Larvik ARGENTINA Kyungnam ESAB Ges.m.b.H Tel: +47 33 12 10 00 CONARCO Tel: +82 55 269 8170 Vienna-Liesing Fax: +47 33 11 52 03...

This manual is also suitable for:

Warrior 500i cc/cvWarrior 400

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