ESAB Warrior 400i CC/CV User manual

Instruction manual

0463 362 201 GB 20221121 Valid for: serial no. 324-, 230-xxx-xxx

Warrior™400iCC/CV

Warrior™500iCC/CV

TABLE OF CONTENTS

0463 362 201 © ESAB AB 2022

1SAFETY ....................................................................................................... 5

1.1 Meaning of symbols ............................................................................... 5

1.2 Safety precautions ................................................................................. 5

2INTRODUCTION.......................................................................................... 8

2.1 Overview ................................................................................................. 8

2.2 Equipment ............................................................................................... 8

3TECHNICAL DATA ...................................................................................... 9

4INSTALLATION............................................................................................ 11

4.1 General .................................................................................................... 11

4.2 Lifting instructions ................................................................................. 11

4.3 Location................................................................................................... 12

4.4 Mains supply........................................................................................... 12

5OPERATION ................................................................................................ 15

5.1 Connections and control devices ......................................................... 15

5.2 Connection of welding and return cables ............................................ 15

5.3 Turning the mains power on/off ............................................................ 16

5.4 Fan control .............................................................................................. 16

5.5 Symbols and functions .......................................................................... 16

6MAINTENANCE........................................................................................... 19

6.1 Routine maintenance ............................................................................. 19

6.2 Cleaning instructions............................................................................. 19

6.2.1 Cleaning procedure .............................................................................. 20

7TROUBLESHOOTING ................................................................................. 21

8ORDERING SPARE PARTS ........................................................................ 22

DIAGRAM ............................................................................................................ 23

ORDERING NUMBERS....................................................................................... 24

ACCESSORIES ................................................................................................... 25

Rights reserved to alter specifications without notice.

1 SAFETY

0463 362 201 -5- © ESAB AB 2022

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and

Safety Data Sheets (SDSs).

1.2 Safety precautions

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.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its 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

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

1 SAFETY

0463 362 201 -6- © ESAB AB 2022

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be 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

wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.

EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to

EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your

body between the torch and work cables. Never coil the torch or work

cable around your body. Keep welding power source and cables as

far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases

away from your breathing zone 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.

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY

0463 362 201 -7- © ESAB AB 2022

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only

qualified people remove covers for maintenance and troubleshooting as

necessary. Reinstall panels or covers and close doors when service is

finished and before starting engine.

• Stop engine before installing 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!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential

locations where the electrical power is provided by the

public low-voltage supply system. There may be

potential difficulties in ensuring electromagnetic

compatibility of class A equipment in those locations,

due to conducted as well as radiated disturbances.

NOTE!

Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/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 information on approved

collection stations.

For further information contact the nearest ESAB dealer.

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.

2 INTRODUCTION

0463 362 201 -8- © ESAB AB 2022

2 INTRODUCTION

2.1 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.

The power sources are intended for use with the following wire feed units:

• RobustFeed PRO

• RobustFeed AVS

• 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 source is supplied with:

• 5 m (16 ft) return cable with earth clamp

• 5 m (16 ft) mains cable

• Instruction manual

• Quick start guide

• Safety instruction

3 TECHNICAL DATA

0463 362 201 -9- © ESAB AB 2022

3 TECHNICAL DATA

Warrior 400i CC/CV Warrior 500i CC/CV

Mains voltage 380-415 V ±10%,

3~ 50/60 Hz

380-415 V ±10%,

3~ 50/60 Hz

Mains supply Sscmin 6.4 MVA 7.2 MVA

Mains supply Zmax 0.025 Ω 0.022 Ω

Primary current I max

MIG/MAG 28 A 37 A

TIG 23 A 30 A

MMA 28 A 38 A

Idle power 22.9W 21.3W

Setting range

MIG/MAG 16 A/15 V - 400 A/34 V 16 A/15 V - 500 A/39 V

TIG 5 A/10 V - 400 A/26 V 5 A/10 V - 500 A/30 V

MMA 16 A/20 V - 400 A/36 V 16 A/20 V - 500 A/40 V

Permissible load at MIG/MAG

60 % duty cycle 400 A/34 V 500 A/39 V

100% duty cycle 300 A/29 V 400 A/34 V

Permissible load at TIG

60 % duty cycle 400 A/26 V 500 A/30 V

100% duty cycle 300 A/22 V 400 A/26 V

Permissible load at MMA

60 % duty cycle 400 A/36 V 500 A/40 V

100% duty cycle 300 A/32 V 400 A/36 V

Power factor at maximum current 0.91 0.91

Efficiency at maximum current 90 % 90 %

Electrode types Basic

Rutile

Cellulosic

Basic

Rutile

Cellulosic

Open-circuit voltage

VRD deactivated 56 V DC peak 56 V DC peak

VRD activated 28 V DC peak 28 V DC peak

Apparent power at maximum

current

18.0 kVA 24.6 kVA

Active power at maximum

current

16.4 kW 22.5 kW

Operating temperature -10 to +40°C -10 to +40°C

Transportation temperature -20 to +55°C -20 to +55°C

Constant sound pressure when

idling

<70 db (A) <70 db (A)

Dimensions l × w × h 712 × 325 × 470 mm 712 × 325 × 470 mm

3 TECHNICAL DATA

Warrior 400i CC/CV Warrior 500i CC/CV

Weight 58.5 kg 58.5 kg

Insulation class H H

Enclosure class IP 23 IP 23

Application class

Mains supply, Ssc min

Minimum short circuit power on the network in accordance with IEC 61000-3-12.

Mains supply, Zmax

Maximum permissible line impedance of the network in accordance 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/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 with increased

electrical hazard.

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