ESAB Warrior 750i CC/CV Instruction Manual Download

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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

Summary of Contents for Warrior 750i CC/CV

Page 1: ...Instruction manual 0463 730 001 US 20210503 Valid for from serial no 005 xxx xxxx 015 xxx xxxx Warrior 750i CC CV ...

Page 2: ...from power generators 16 4 4 3 Connection instruction 17 4 4 4 Installation of electrical cable 17 5 OPERATION 19 5 1 Overview 19 5 2 Connections and control devices 19 5 3 Connecting welding and return cables 20 5 4 Turning the power on off 21 5 5 Fan control 21 5 6 Symbols and functions 21 6 SHIELDING GAS RECOMMENDATION 24 7 PROCEDURE FOR CAG PROCESS 25 7 1 Parallel operation of CAG process 26 8...

Page 3: ...ury or death PROTECT YOURSELF AND OTHERS Some welding cutting and gouging processes are noisy and require hearing protection The arc like the sun emits ultraviolet UV and other radiation and can injure the skin and eyes Hot metal can cause burns Training in the proper use of the processes and equipment is essential to prevent accidents Therefore 1 Wear a welding helmet fitted with a proper shade o...

Page 4: ...s 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 Do not use equipment beyond its ratings For example an overloaded welding cable can overheat and create a fire hazard 7 After completing work inspect the work area to make sure there are no hot sparks or hot met...

Page 5: ...s galvanized steel stainless steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is provided Do not breathe in the fumes from these materials 3 Do not operate near degreasing and spraying operations The heat or arc can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gases 4 If you develop momentary eye nose or throat i...

Page 6: ... CAN INJURE Only use lifting eye to lift unit Do NOT use running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit Keep cables and cords away from moving vehicles when working from an aerial location WARNING EQUIPMENT MAINTENANCE Faulty or impr...

Page 7: ... and Face Protection Devices 1 3 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...

Page 8: ... 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 wet clothing Insulate yourself from work and ground Ensure your working position is safe ELECTRIC AND MAGNETIC FIELDS Pose health risks Welders with pacemakers fitted sh...

Page 9: ...s spatter can cause a fire Make sure there are no inflammable materials nearby Do not use on closed containers HOT SURFACE Parts can burn Do not touch parts bare handed Allow cooling period before working on equipment To handle hot parts use proper tools and or insulated welding gloves to prevent burns MALFUNCTION Call for expert assistance in the event of malfunction PROTECT YOURSELF AND OTHERS W...

Page 10: ... WARNING This product can expose you to chemicals including lead which are known to the state of California to cause cancer and birth defects or other reproductive harm Wash hands after use For more information go to www P65Warnings ca gov ...

Page 11: ...r filled cored wire FCAW S for GTAW welding and welding with coated electrodes SMAW The power sources are intended for use with the following wire feed units Robust Feed PRO Warrior Feed 304 Warrior Feed 404HD ESAB 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 Instruction manual ...

Page 12: ...6 5 min after welding 34 W Setting range for all modes GMAW MIG flat characteristic GTAW TIG drooping characteristic SMAW MMA drooping characteristic Gouging 16 A 15 V 820 A 44 V 10 A 10 V 820 A 34 V 15 A 15 V 820 A 44 V 100 A 18 V 820 A 44 V Permissible load at GMAW 60 duty cycle 100 duty cycle 820 A 44 V 750 A 44 V Permissible load at GTAW 60 duty cycle 100 duty cycle 820 A 34 V 750 A 34 V Permi...

Page 13: ...lication class Mains supply Ssc min Minimum short circuit power on the network in accordance with IEC 61000 3 12 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 104 F 40 C or below Enclosure class The IP code indicates the enclosure class i e the degree of protection again...

Page 14: ...neral The installation must be carried out by a professional CAUTION This product is intended for industrial use In a domestic environment this product may cause radio interference It is the user s responsibility to take adequate precautions 4 2 Lifting instructions ...

Page 15: ...oint between the user s supply and the public system 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 is connected only to a supply with a short circuit power greater than or equal to Sscmin Refer to the technical data in the TECHNICAL DATA chapter Make sure that the welding power sou...

Page 16: ... Mains voltage 460 V 3 50 60 Hz 575 V 3 50 60 Hz Mains cable area 4x12 mm2 4x8 mm2 Phase current Ieff 54 A 43 A Fuse anti surge type C MCB 63 A 63 A NOTE The power cable areas and fuse sizes as shown above are in accordance with Swedish regulations Use the power source in accordance with the relevant national regulations 4 4 2 Supply from power generators The power source can be supplied from diff...

Page 17: ...source Warrior 750i CC CV 0445 555 881 for North America is connected to 460 V from the factory If a different voltage is required switch off the mains then remove the cover plate and the selector switch can be positioned for the required voltage 4 4 4 Installation of electrical cable ...

Page 18: ...01 18 ESAB AB 2021 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 ...

Page 19: ...c force MMA 11 Lug connection MIG MAG Welding cable TiG return cable MMA Welding cable or return cable Gouging Welding torch 4 Display current A and voltage V 12 Voltage selector switch 5 Knob for setting SMAW GTAW current A and Gouging voltage V 13 Power socket for grinding machine CO2 heater lighting 115 VAC 6 Process selection knob SMAW GMAW GTAW Mobile feed Gouging 14 Circuit breaker 20 A 115 ...

Page 20: ...ed on the electrode packaging Recommended maximum current values for connection cables set At an ambient temperature of 25 C and a normal 10 minute cycle Cable area Duty cycle Voltage loss 10 m 100 60 35 0 08 in 50 mm2 280 A 310 A 370 A 0 35 V 100 A 0 11 in 70 mm2 350 A 400 A 480 A 0 25 V 100 A 0 15 in 95 mm2 430 A 500 A 600 A 0 19 V 100 A 0 19 in 120 mm2 500 A 580 A 720 A 0 15 V 100 A 2 70 mm2 70...

Page 21: ...e is switched off in the normal manner the welding data will be stored so it is available the next time the unit is started CAUTION Do not turn off the power source during welding with load 5 5 Fan control 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 wh...

Page 22: ...only applies to SMAW welding Inductance Higher inductance results in a wider weld pool and less spatter Lower inductance produces a harsher sound but a stable concentrated arc It only applies to GMAW welding GTAW welding GTAW welding melts the metal of the workpiece using an arc struck from a tungsten electrode that does not itself melt The weld pool and electrode are protected by shielding gas Li...

Page 23: ...t types of metal adjust the volt setting and air flow for better performance For any gouging issues other than performance see the TROUBLESHOOTING section SMAW welding SMAW welding may also be referred to as welding with coated electrodes Striking the arc melts the electrode and its coating forms protective slag For SMAW welding the power source must be supplemented with Welding cable with electro...

Page 24: ...steel Wire Ø 12 FCAW 100 CO2 Stainless steel Wire Ø 12 TIG DC 100 Ar Carbon steel Cup size or nozzle number 1 2 TIG DC 100 Ar Stainless steel Cup size or nozzle number 1 2 TIG DC 100 Ar Stainless steel Cup size or nozzle number 1 2 TIG AC 100 Ar Aluminum Cup size or nozzle number 1 2 The general rule to be followed for shielding gas flow rate is 10 to 12 times of the wire size It may increase for ...

Page 25: ...ensure the compressed air is pointing toward the work area to ensure proper blowing 5 Set the voltage on the power source by referring to the gouging table in the manual or on the power source 6 Initiate the arc by scratching the metal with the gouging rod 7 Maintain the gouging rod at an angle of 30 40 degrees for most of the gouging application A steeper angle or lower travel speed may be requir...

Page 26: ...ts carried out on A36 ASME mild steel For different types of metal adjust the voltage setting and air flow for better performance For any gouging issues other than performance see the TROUBLESHOOTING section 7 1 Parallel operation of CAG process 1 Connect 2 70 mm2 cable for each terminal if the ambient temperature is 25 C 2 Connect 2 95 mm2 cable for each terminal if the ambient temperature is 40 ...

Page 27: ...atory to clean the product regularly How often depends on The welding process The arc time and 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 earplugs safety glasses masks gloves and safety shoes CAUTION Make sure that the cleaning proce...

Page 28: ...ver between the heat sink and the fan b and make sure it is correctly fitted against the heat sink 9 Install the top panel on the power source 10 Install the side panels on the power source 11 Connect the mains supply 8 3 Welding torch A regular program of care and maintenance reduces unnecessary and expensive downtime Each time a wire bobbin is changed the welding torch should be removed from the...

Page 29: ...c Check that the main 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 electrical power supply fuses The welding current is interrupted during welding Check whether the overloading protection has tripped indicated on the front Check the electrical power supply fuses Check that the return ca...

Page 30: ...r pressure Check whether the air pressure is set to the recommended value Check the manual for the torch used Carbon deposit on the gouge metal Air pressure too low Turn on the air before striking the arc air should flow between the electrode and the workpiece Check whether the air pressure is set to the recommended value Check the manual for the torch used No arc during start or erratic arc durin...

Page 31: ...anadian standards CAN CSA E60974 1 11 and US standards ANSI IEC 60974 1 2008 Upon 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 seria...

Page 32: ...BLOCK DIAGRAM 0463 730 001 32 ESAB AB 2021 BLOCK DIAGRAM ...

Page 33: ...ERS Ordering number Denomination Type Notes 0445 555 881 Welding power source Warrior 750i CC CV Factory set voltage 460 VAC 0463 734 001 Spare parts list 0463 733 001 Service manual Technical documentation is available on the Internet at http manuals esab com ...

Page 34: ...8 9 5 mm and 5 8 16 mm flat electrodes Maximum of 1000 A 6108 4008 AirPro X4000 Heavy duty general purpose torch Accepts 3 16 4 8 mm to 1 2 13 mm pointed round 3 8 9 5 mm and 5 8 16 mm flat 5 8 16 mm half round Maximum of 1000 A 6110 4007 K5 Heavy duty general purpose torch Accepts 5 16 7 9 mm to 1 2 13 mm pointed 5 16 7 9 mm to 5 8 16 mm jointed and 5 8 16 mm half round Maximum of 1250 A 6299 141...

Page 35: ...t strain relief Interconnection cable with pre assembled strain relief Use with Robust Feed Pro Must order Lug to OKC adapter along with interconnection cable set Interconnection cable set 70 mm 19 poles 0446 160 880 70 mm gas cooled 2 0 m 0446 160 881 70 mm gas cooled 5 0 m 0446 160 882 70 mm gas cooled 10 0 m 0446 160 883 70 mm gas cooled 15 0 m 0446 160 884 70 mm gas cooled 25 0 m 0446 160 885 ...

Page 36: ...5 mm gas cooled 35 0 m Interconnection cable set 95 mm 19 poles 0446 160 990 95 mm liquid cooled 2 0 m 0446 160 991 95 mm liquid cooled 5 0 m 0446 160 992 95 mm liquid cooled 10 0 m 0446 160 993 95 mm liquid cooled 15 0 m 0446 160 994 95 mm liquid cooled 25 0 m 0446 160 995 95 mm liquid cooled 35 0 m 0446 507 880 Lug to OKC adapter 0459 491 896 Remote control unit AT1 SMAW and GTAW current 0459 49...

Page 37: ...rrent Remote control cable 12 pole 8 pole 0459 552 880 5 m 0459 552 881 10 m 0459 552 882 15 m 0459 552 883 25 m 0446 398 880 Trolley Air cooled 0446 270 880 Trolley Water cooled 0465 427 881 Cool2 Standalone 0465 250 880 Warrior Feed 304 0465 250 881 Warrior Feed 304w with water cooling ...

Page 38: ...et water 70 mm 19 poles 0459 836 890 2 m 0459 836 891 5 m 0459 836 892 10 m 0459 836 893 15 m 0459 836 894 25 m 0459 836 895 35 m Interconnection cable set 95 mm 19 poles 0459 836 980 2 m 0459 836 981 5 m 0459 836 982 10 m 0459 836 983 15 m 0459 836 984 25 m 0459 836 985 35 m Interconnection cable set water 95 mm 19 poles 0459 836 990 2 m 0459 836 991 5 m 0459 836 992 10 m 0459 836 993 15 m 0459 8...

Page 39: ...ACCESSORIES 0463 730 001 39 ESAB AB 2021 ...

Page 40: ...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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