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ESAB Warrior 400i CC Instruction Manual Download Page 24

7 TROUBLESHOOTING

0463 340 030

- 24 -

© ESAB AB 2018

7

TROUBLESHOOTING

Try these recommended checks and inspections before sending for an authorized service
technician.

Type of fault

Corrective action

No arc.

• Check that the mains power supply

switch is turned on.

• Check that the mains, welding and

return cables are correctly connected.

• Check that the correct current value is

set.

• Check the mains power supply fuses.

The welding current is interruppted during
welding.

• Check whether the overloading

protection has deployed (indicated on
the front).

• Check the mains power 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 used.

• Check the mains power supply fuses.
• Check the gas pressure in the

equipment connected to the power
source.

"Err" on display in open circuit mode

• Check the mains power supply fuses.
• 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.

Summary of Contents for Warrior 400i CC

Page 1: ...Instruction manual 0463 340 030 GB 20181009 Valid for Serial no 339 xxx xxxx Warrior 400i CC CV Warrior 500i CC CV ...

Page 2: ...ifting instructions 13 4 3 Location 14 4 4 Mains supply 14 5 OPERATION 17 5 1 Overview 17 5 2 Connections and control devices 17 5 3 Connection of welding and return cable 18 5 4 Turning the mains power on off 18 5 5 Fan control 18 5 6 Symbols and functions 19 6 MAINTENANCE 22 6 1 Overview 22 6 2 Power source 22 6 3 Welding torch 23 7 TROUBLESHOOTING 24 8 ORDERING SPARE PARTS 25 DIAGRAM 26 ORDERIN...

Page 3: ...recautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result in injury or death PROTECT YOURSELF AND OTHERS Some welding cutting and gouging processes are noisy and require ear protection The arc like the sun emits ultraviolet UV and other radiation and can injure skin and eyes Hot metal can cause burns Training in the...

Page 4: ...ut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors Do not do hot work on closed containers they may explode 5 Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use 6...

Page 5: ... harm particularly in confined spaces Shielding gases can cause asphyxiation Therfore 1 Keep your head out of the fumes Do not breathe the fumes and gases 2 Always provide adequate ventilation in the work area by natural or mechanical means Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is ...

Page 6: ... by using suitable hand trucks MOVING PARTS Moving parts such as fans rotors and belts can cause injury Therefore 1 Keep all doors panels guards and covers closed and securely in place 2 Stop engine or drive systems before installing or connecting unit 3 Have only qualified people remove covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting of equipment during se...

Page 7: ...m 52 529 The following publications are recommended to you 1 ANSI ASC Z49 1 Safety in Welding and Cutting 2 AWS C5 5 Recommended Practices for Gas Tungsten Arc Welding 3 AWS C5 6 Recommended Practices for Gas Metal Arc welding 4 AWS SP Safe practices Reprint Welding Handbook 5 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances 6 OSHA ...

Page 8: ...clearly marked and close at hand Lubrication and maintenance must not be carried out on the equipment during operation WARNING Arc welding and cutting can be injurious to yourself and others Take precautions when welding and cutting ELECTRIC SHOCK Can kill Install and ground the unit in accordance with instruction manual Do not touch live electrical parts or electrodes with bare skin wet gloves or...

Page 9: ...alling or connecting unit Keep hands hair loose clothing and tools away from moving parts FIRE HAZARD Sparks spatter can cause fire Make sure that there are no inflammable materials nearby Do not use on closed containers MALFUNCTION Call for expert assistance in the event of malfunction PROTECT YOURSELF AND OTHERS WARNING Do not use the power source for thawing frozen pipes CAUTION This product is...

Page 10: ...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 accessories for the product can be found in the ACCESSORIES chapter of this manual 2 2 Equipment The power sources are supplied with 5 m return cable with earth clamp 3 m mains cable inst...

Page 11: ...0 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 MIG MAG TIG MMA 0 84 0 75 0 82 0 88 0 85 0 88 Efficiency at maximum current MIG MAG TIG MMA 91 88 91 90 87 91 Electrode types Basic ...

Page 12: ...riod that you can weld or cut at a certain load without overloading The duty cycle is valid for 40 C 104 F or below 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 use Application class The symbol indicates that the power source is designed for use in areas ...

Page 13: ...4 INSTALLATION 0463 340 030 13 ESAB AB 2018 4 INSTALLATION 4 1 General The installation must be carried out by a professional 4 2 Lifting instructions ...

Page 14: ... public grid may apply for some types of equipment see technical data In this case it is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment may be connected 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...

Page 15: ... the relevant national regulations Supply from power generators The power source can be supplied from different types of generators However some generators may not provide sufficient power for the welding power source to operate correctly Generators with Automatic Voltage Regulation AVR or with equivalent or better type of regulation with rated power 40 kW are recommended Connection instruction Th...

Page 16: ... Installation of mains cable A mains cable needs to be installed it is then important that the earth connection to the bottom plate must be made in a correct way See the picture above for the order in which the washers nuts and screws are placed ...

Page 17: ...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 gauging Current A Mobile Feed mode Voltage V 13 Connection of remote control unit option ...

Page 18: ...ty cycle 550 A 60 duty cycle 95 mm2 2 35 m 6 6 ft 114 8 ft 19 pole 430 A 100 duty cycle 450 A 60 duty cycle 70 mm2 2 35 m 6 6 ft 114 8 ft 19 pole water 350 A 100 duty cycle 550 A 60 duty cycle 95 mm2 2 35 m 6 6 ft 114 8 ft 19 pole water 430 A 100 duty cycle 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 overloa...

Page 19: ...ted 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 When this occurs the welding current is interrupted and an overheating indication lamp is lit The overheati...

Page 20: ...s valve an argon gas cylinder an argon gas regulator tungsten electrode Arc air gouging With arc air gouging a special electrode comprising a carbon rod with a copper casing is used An arc is formed between the carbon rod and the workpiece which melts the material Compressed air is supplied so that the melted material is blown away For arc air gouging the power source shall be supplemented with ar...

Page 21: ... melts a continuously supplied wire The weld pool is protected by shielding gas 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 ...

Page 22: ...mandatory to clean the product regularly How often depends on the welding process the arc time the working environment the surrounding environment that is grinding etc Tools needed for the cleaning procedure torx screwdriver T25 and T30 dry compressed air at a pressure of 4 bar protective equipment like ear plugs safety glasses masks gloves and safety shoes CAUTION Make sure that the cleaning proc...

Page 23: ...itted against the heat sink 9 Do a test of the power source according to IEC 60974 4 follow the procedure in section 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 6 3 Welding torch A regular programme of care and maintenance reduces unnecessary and expensive downtime Eac...

Page 24: ...er 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 ...

Page 25: ...h the international standards IEC 60974 1 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 standards 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 n...

Page 26: ...DIAGRAM 0463 340 030 26 ESAB AB 2018 DIAGRAM ...

Page 27: ...r Denomination Type Notes 0465 350 882 Welding power source Warrior 400i CC CV 380 460 V 0465 350 880 Welding power source Warrior 500i CC CV 380 460 V 0459 839 084 Spare parts list 0740 800 221 Service manual Technical documentation is available on the Internet at www esab com ...

Page 28: ...0465 250 880 Warrior Feed 304 0465 250 881 Warrior Feed 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 ...

Page 29: ...control cable 12 pole 8 pole 0459 552 880 0459 552 881 0459 552 882 0459 960 883 5 m 10 m 15 m 25 m 0465 424 880 Remote outlet kit 0465 416 880 Wheel kit 0465 510 880 Trolley 0465 508 880 Trolley guide pin extension kit Used together with the trolley when the wire feed unit is equipped with wheel kit ...

Page 30: ...ion set water 70 mm 19 poles 0459 836 890 0459 836 891 0459 836 892 0459 836 893 0459 836 894 0459 836 895 2 m 5 m 10 m 15 m 25 m 35 m Connection set 95 mm 19 poles 0459 836 980 0459 836 981 0459 836 982 0459 836 983 0459 836 984 0459 836 985 2 m 5 m 10 m 15 m 25 m 35 m Connection set water 95 mm 19 poles 0459 836 990 0459 836 991 0459 836 992 0459 836 993 0459 836 994 0459 836 995 2 m 5 m 10 m 15...

Page 31: ...00 556 TXH 151 V OKC 50 4 m TXH 151 V OKC 50 8 m TXH 201 V OKC 50 4 m TXH 201 V OKC 50 8 m Arc air torches 0468 253 036 0468 253 016 0468 253 015 0468 253 881 0468 253 036 0468 253 035 Flair 600 incl monocable 2 5 m Torch only Monocable only Flair 1600 incl monocable 2 5 m Torch only Monocable only ...

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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