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4 INSTALLATION

0463 362 001

- 10 -

© ESAB AB 2013

4

INSTALLATION

4.1

General

The installation must be carried out by a professional.

4.2

Lifting instructions

WARNING!

Secure the equipment -
particularly if the ground is
uneven or sloping.

4.3

Location

Position the welding power source such that its cooling air inlets and outlets are not
obstructed.

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Summary of Contents for Warrior 400

Page 1: ...Instruction manual 0463 362 001 GB 20130618 Valid for serial no 324 xxx xxx Warrior 400i CC CV Warrior 500i CC CV ...

Page 2: ......

Page 3: ... OPERATION 14 5 1 Overview 14 5 2 Connections and control devices 14 5 3 Connection of welding and return cables 15 5 4 Turning the mains power on off 15 5 5 Fan control 15 5 6 Symbols and functions 15 6 MAINTENANCE 18 6 1 Overview 18 6 2 Power source 18 6 3 Welding torch 18 7 FAULT TRACING 19 8 ORDERING SPARE PARTS 20 DIAGRAM 21 ORDERING NUMBERS 22 ACCESSORIES 23 Rights reserved to alter specific...

Page 4: ...function relevant safety precautions welding and cutting or other applicable operation of the equipment 2 The operator must ensure that no unauthorised person is stationed within the working area of the equipment when it is started up no one is unprotected when the arc is struck or work is started with the equpment 3 The workplace must be suitable for the purpose be free from drafts 4 Personal saf...

Page 5: ...e and the general area ARC RAYS Can injure eyes and burn skin Protect your eyes and body Use the correct welding screen and filter lens and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing Protect your ears Use earmuffs o...

Page 6: ... of electronic equipment at the recycling facility In observance of European Directive 2002 96 EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law electrical and or electronic equipment that has reached the end of its life must be disposed of at a recycling facility As the person responsible for the equipment it is your responsibility to obtain in...

Page 7: ...d cored wire FCAW S for TIG welding for welding with coated electrodes MMA and for arc air gouging The power sources are intended for use with the following wire feed units Warrior Feed 304 Warrior Feed 304w ESAB s accessories for the product can be found in the ACCESSORIES chapter of this manual 2 2 Equipment The power source is supplied with 5 m return cable with earth clamp 3 m mains cable inst...

Page 8: ...00 duty cycle 400 A 34 V 300 A 29 V 500 A 39 V 400 A 34 V Permissible load at TIG 60 duty cycle 100 duty cycle 400 A 26 V 300 A 22 V 500 A 30 V 400 A 26 V Permissible load at MMA 60 duty cycle 100 duty cycle 400 A 36 V 300 A 32 V 500 A 40 V 400 A 36 V Power factor at maximum current 0 91 0 91 Efficiency at maximum current 88 89 Electrode types Basic Rutile Cellulosic Basic Rutile Cellulosic Open c...

Page 9: ...ordance with IEC 61000 3 11 Duty cycle The duty cycle refers to the time as a percentage of a ten minute period that you can weld or cut at a certain load without overloading The duty cycle is valid for 40 C Enclosure class The IP code indicates the enclosure class i e the degree of protection against penetration by solid objects or water Equipment marked IP23 is intended for indoor and outdoor us...

Page 10: ...al The installation must be carried out by a professional 4 2 Lifting instructions WARNING Secure the equipment particularly if the ground is uneven or sloping 4 3 Location Position the welding power source such that its cooling air inlets and outlets are not obstructed ...

Page 11: ... short circuit power greater than or equal to Sscmin Refer to the technical data in the Technical data section 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 Warrior 400i CC CV Mains voltage 380 V 3 50 60 Hz 400 V 3 50 60 Hz 415 V 3 50 60...

Page 12: ...ith Swedish regulations Use the power source in accordance with the relevant national regulations Connection instruction The power source is factory set to 400 V AC If another mains voltage setting is required the cable on the printed circuit board has to be moved and put in the correct position Also the label at the rear of the power source marked with the mains voltage setting must be updated Th...

Page 13: ...13 ESAB AB 2013 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 ...

Page 14: ...ator lamp yellow overheating 10 Connection MIG MAG Welding cable TIG Return cable MMA Welding cable or return cable 3 Indicator lamp green VRD function reduced open circuit voltage 11 Circuit breaker 10 A 42 V 4 Display current A and voltage V 12 Connection of wire feed unit 5 Knob for setting MMA TIG Arc air gouging Current A Mobile Feed mode Voltage V 13 Connection of remote control unit option ...

Page 15: ...ty is stated on the electrode packaging 5 4 Turning the mains power on off Turn on the mains power by turning switch to the I position see 1 on the picture above Turn the unit off by turning the switch to the O position Whether the mains power supply is interrupted or the power source is switched off in the normal manner welding data will be stored so that it is available next time the unit is sta...

Page 16: ... temperature has fallen within normal working temperature Arc force The arc force is important in determining how the current changes in response to a change in the arc length A lower value gives a calmer arc with less spatter It only applies to MMA welding Inductance Higher inductance results in a wider weld pool and less spatter Lower inductance produces a harsher sound but a stable concentrated...

Page 17: ... 1 4 36 V 49 V 50 76 mm 2 3 8 mm 5 16 39 V 52 V 10 mm 3 8 43 V 52 V Table 3 Recommended for gouging MMA welding MMA welding may also be referred to as welding with coated electrodes Striking the arc melts the electrode and its coating forms protective slag For MMA welding the power source shall be supplemented with welding cable with electrode holder return cable with clamp MIG MAG and self shield...

Page 18: ...logged or blocked air inlets and outlets can result in overheating How often and which cleaning methods apply depend on the welding process the arc times the environment the surrounding environment It is normally sufficient to blow down the power source with dry compressed air reduced pressure once a year 6 3 Welding torch A regular programme of care and maintenance reduces unnecessary and expensi...

Page 19: ... supply fuses Check that the return cable is correctly fastened The overheating protection trips frequently Make sure that you are not exceeding the rated data for the power source i e that the unit is not being overloaded Poor welding performance Check that the welding and return cables are correctly connected Check that the correct current value is set Check that the correct wire or electrode is...

Page 20: ...CC CV and Warrior 500i CC CV are designed and tested in accordance with international and european standards IEC EN 60974 1 and IEC EN 60974 10 On completion of service or repair work it is the responsibility of the person s performing the work to ensure that the product still complies with the requirements of the above standard Spare parts may be ordered through your nearest ESAB dealer see the l...

Page 21: ...DIAGRAM 0463 362 001 21 ESAB AB 2013 DIAGRAM ...

Page 22: ...r Denomination Type Notes 0465 350 884 Welding power source Warrior 400i CC CV 380 415 V 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 ...

Page 23: ...d 304w with water cooling 0558 005 728 MobileFeed 300 AVS 0459 491 896 Remote control unit AT1 MMA and TIG current 0459 491 897 Remote control unit AT1 CF MMA and TIG course and fine setting of current Remote control cable 12 pole 8 pole 0459 552 880 0459 552 881 0459 552 882 0459 552 883 5 m 10 m 15 m 25 m ...

Page 24: ...lley 0465 427 880 Cooling unit Connection set 70 mm 19 poles 0459 836 880 0459 836 881 0459 836 882 0459 836 883 0459 836 884 0459 836 885 1 7 m 5 m 10 m 15 m 25 m 35 m Connection set water 70 mm 19 poles 0459 836 890 0459 836 891 0459 836 892 0459 836 893 0459 836 894 0459 836 895 1 7 m 5 m 10 m 15 m 25 m 35 m ...

Page 25: ...36 992 0459 836 993 0459 836 994 0459 836 995 1 7 m A 5 m C 10 m A 15 m C 25 m C 35 m C TIG torches 0700 300 539 0700 300 545 0700 300 553 0700 300 556 TXH 151 V OKC50 4 m A TXH 151 V OKC 50 8 m A TXH 201 V OKC 50 4 m A TXH 201 V OKC 50 8 m Arc air torches 0468 253 880 0468 253 016 0468 253 015 0468 253 881 0468 253 036 0468 253 035 Flair 600 incl monocable 2 5 m A Torch only A Monocable only A Fl...

Page 26: ...el 34 91 878 3600 Fax 34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB International AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 UKRAINE ESAB Ukraine LLC Kiev Tel 38 044 501 23 24 Fax 38 044 575 21 88 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 5...

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