ESAB Warrior 750i CC/CV User manual

Instruction manual

0463 730 231 GB 20221128 Valid for: from serial no. 053-, 110-, 246-xxx-xxxx

Warrior™ 750i CC/CV

TABLE OF CONTENTS

0463 730 231 © ESAB AB 2022

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

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

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

2INTRODUCTION.......................................................................................... 9

2.1 Overview ................................................................................................. 9

2.2 Equipment ............................................................................................... 9

3TECHNICAL DATA ...................................................................................... 10

4INSTALLATION............................................................................................ 12

4.1 General .................................................................................................... 12

4.2 Lifting instructions ................................................................................. 12

4.3 Location................................................................................................... 13

4.4 Mains supply........................................................................................... 13

4.4.1 Recommended fuse sizes and minimum cable area

Warrior750iCC/CV..............................................................................

4.4.2 Supply from power generators ............................................................. 14

4.4.3 Connection instruction.......................................................................... 15

4.4.4 Installation of mains cable .................................................................... 15

5OPERATION ................................................................................................ 17

5.1 Overview ................................................................................................. 17

5.2 Connections and control devices ......................................................... 17

5.3 Connection of welding and return cables ............................................ 18

5.4 Turning the mains power on/off ............................................................ 18

5.5 Fan control .............................................................................................. 19

5.6 Symbols and functions .......................................................................... 19

6SHIELDING GAS RECOMMENDATION ..................................................... 21

7PROCEDURE FOR CAG PROCESS .......................................................... 22

7.1 Parallel operation of CAG process ....................................................... 23

8MAINTENANCE........................................................................................... 24

8.1 Overview ................................................................................................. 24

8.2 Power source.......................................................................................... 24

8.3 Welding torch.......................................................................................... 25

9TROUBLESHOOTING ................................................................................. 26

10 ORDERING SPARE PARTS ........................................................................ 28

BLOCK DIAGRAM............................................................................................... 29

ORDERING NUMBERS....................................................................................... 30

ACCESSORIES ................................................................................................... 31

Rights reserved to alter specifications without notice.

1 SAFETY

0463 730 231 -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 730 231 -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

If equipped with ESAB cooler

Use ESAB approved coolant only. Non-approved coolant might damage the equipment and

jeopardize product safety. In case of such damage, all warranty undertakings from ESAB

cease to apply.

For ordering information, see the "ACCESSORIES" chapter in the instruction manual.

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.

1 SAFETY

0463 730 231 -7- © ESAB AB 2022

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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.

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!

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.

1 SAFETY

0463 730 231 -8- © ESAB AB 2022

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 730 231 -9- © ESAB AB 2022

2 INTRODUCTION

2.1 Overview

The Warrior 750i CC/CV is a welding power source intended for arc air gouging, GMAW

welding, as well as for welding with powder filled cored wire (FCAW-S), for TIG welding and

welding with coated electrodes (MMA).

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

• Robust Feed PRO

• 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:

• Quick start guide

• Safety instruction

• 5m return cable with earth clamp

• Instruction manual

• 5m mains cable with 63A plug (5P)

NOTE!

63A plug is intended to use for supply voltage ≥400VAC.

3 TECHNICAL DATA

0463 730 231 - 10 - © ESAB AB 2022

3 TECHNICAL DATA

Warrior 750i CC/CV

Working voltage 380 – 460V,±10%,3~50/60Hz

Mains supply Sscmin 5.4MVA

Mains supply Zmax 0.0319ohm

Primary current 380 V 400 V 415V 440V 460 V

Imax. GMAW - MIG 67A 63A 61A 57A 54A

Imax. TIG 51A 49A 47A 44A 42A

Imax. MMA 67A 63A 61A 57A 54A

Imax. Gouging 67A 63A 61A 57A 54A

No load power in energy-saving

mode 6.5min. after welding 25W

Setting range for all modes

GMAW - MIG flat characteristic

TIG drooping charcteristic

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–850A/44V

Permissible load at GMAW and MMA

60% duty cycle

100% duty cycle

820A/44V

750A/44V

Permissible load at TIG

60% duty cycle

100% duty cycle

820A/34V

750A/34V

Gouging

35% duty cycle

60% duty cycle

100% duty cycle

850A/44V

820A/44V

750A/44V

Power factor at maximum current 0.91

Efficiency at maximum current 91%

Open-circuit voltage without VRD

function (RMS/Peak) 63/89VDC

Open-circuit voltage with VRD

function (RMS/Peak) 25/33VDC

Operating temperature 14to104°F (-10to40°C)

Transport temperature -4to131°F (-20to55°C)

Constant sound pressure when

idling <70dB(A)

Dimensions l × w × h 33.5×16.3×25.1 in. (850×415×637mm)

Weight (welding power source) 222.7lb (101kg)

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