ESAB Warrior 500i CC/CV Manuel utilisateur

US CAN

Valid for serial no. 251-xxx-xxxx0463 341 031 20130115

Warrior™500i CC/CV

US Instruction manual

CAN Manuel d'instructions SA Manual de instrucciones

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Rights reserved to alter specifications without notice.

Reservado el derecho de cambiar las especificaciones sin previo aviso.

Sous réserve de modifications sans avis préalable.

English US 3.............................................

Canadian français 19.......................................

Español SA 36.............................................

English US

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

2 INTRODUCTION 7...................................................

2.1 Equipment 7................................................................

3 TECHNICAL DATA 8.................................................

4 INSTALLATION 9....................................................

4.1 Lifting instructions 9.........................................................

4.2 Location 9..................................................................

4.3 Mains supply 10..............................................................

5 OPERATION 12.......................................................

5.1 Connections and control devices 13............................................

5.2 Connection of welding and return cable 14.......................................

5.3 Turning on/off the mains power source 14.......................................

5.4 Fan control 14...............................................................

5.5 Symbols and functions 15.....................................................

6 MAINTENANCE 17....................................................

6.1 Power source 17.............................................................

6.2 Welding gun and torch 17.....................................................

7 FAULT-TRACING 18..................................................

8 ORDERING SPARE PARTS 18.........................................

SCHEMATIC DIAGRAM 53................................................

ORDERING NUMBER 54.................................................

ACCESSORIES 55.......................................................

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1 SAFETY

Users of ESAB welding 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 welding equipment. The following recommen

dations 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 welding

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 welding equipment must be familiar with:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorized person is stationed within the working area of the equipment when it is

started up.

Sno-one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from drafts

4. Personal safety equipment

SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the ground cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

6 Reference

SCAN/CSA-W117.2-06 Safety in Welding, Cutting and Allied Processes

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READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE

PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES

WHICH SHOULD BE BASED ON MANUFACTURERS' HAZARD DATA.

ELECTRIC SHOCK - CAN KILL

SINSTALL AND EARTH (GROUND) THE WELDING UNIT IN ACCORDANCE WITH

APPLICABLE STANDARDS.

SDO NOT TOUCH LIVE ELECTRICAL PARTS OR ELECTRODES WITH BARE SKIN,

WET GLOVES OR WET CLOTHING.

SINSULATE YOURSELF FROM EARTH AND THE WORKPIECE.

SENSURE YOUR WORKING STANCE IS SAFE.

FUMES AND GASES - CAN BE DANGEROUS TO HEALTH

SKEEP YOUR HEAD OUT OF THE FUMES.

SUSE 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.

SPROTECT YOUR EYES AND BODY. USE THE CORRECT WELDING SCREEN AND

FILTER LENS AND WEAR PROTECTIVE CLOTHING.

SPROTECT BYSTANDERS WITH SUITABLE SCREENS OR CURTAINS.

FIRE HAZARD

SSPARKS (SPATTER) CAN CAUSE FIRE. MAKE SURE THEREFORE THAT THERE ARE

NO INFLAMMABLE MATERIALS NEARBY.

NOISE - EXCESSIVE NOISE CAN DAMAGE HEARING

SPROTECT YOUR EARS. USE EARMUFFS OR OTHER HEARING PROTECTION.

SWARN BYSTANDERS OF THE RISK.

MALFUNCTION - CALL FOR EXPERT ASSISTANCE IN THE EVENT OF MALFUNCTION.

PROTECT YOURSELF AND OTHERS!

REFERENCE TO CAN/CSA-W117.2-06

DO NOT USE THE POWER SOURCE FOR THAWING FROZEN PIPES.

Read and understand the instruction manual

before installing or operating.

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This product is solely intended for arc welding. Any other use may result in personal

injury and / or equipment damage.

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.

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

The Warrior 500i CC/CV is a welding power source intended for GMAW welding, as

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

with coated electrodes (SMAW) and arc air gouging.

The power source is intended for use with the following wire feed units:

SWarrior Feed 304

SMobile Feed 300

ESAB's accessories for the product can be found on page 55.

2.1 Equipment

The power source is supplied with:

S5 m return cable with clamp

Sinstruction manual

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3 TECHNICAL DATA

Warrior 500i CC/CV

Mains voltage 380V; 440V; 460V: 575V

$10%, 350/60Hz

Primary current

Imax. GMAW - MIG

Imax. GTAW - TIG

Imax. SMAW - MMA

38A

31A

38A

No-load power in energy-saving mode

6.5 min. after welding 40W

Setting range

GMAW - MIG flat characteristic

GTAW - TIG drooping characteristic

SMAW - MMA drooping characteristic

16A/15V-500A/39V

5A/10V-500A/30V

16A/20V-500A/40V

Permissible load at GMAW

60% duty cycle

100% duty cycle

500A/39V

400A/34V

Permissible load at GTAW

60% duty cycle

100% duty cycle

500A/30V

400A/26V

Permissible load at SMAW

60% duty cycle

100% duty cycle 500A/40V

400A/36V

Power factor at maximum current

GMAW

GTAW

SMAW

0.87

0.83

0.87

Efficiency at maximum current

GMAW

GTAW

SMAW

90%

88%

90%

Electrode types Basic

Rutile

Cellulosic

Open-circuit voltage without VRD function 84V DC

Apparent power at maximum current 31.7 kVA

Active power at maximum current 22.6 kW

Operating temperature - 50 to 104°F ( -10 to 40°C)

Transportation temperature - 68 to 131°F (-20 to 55°C)

Constant sound pressure when idling <70db (A)

Dimensions lxwxh 28.1 x 12.8 x 18.5"

(712 x 325 x 470mm)

Weight (welding power source) 115.7lbs (52.5kg)

Insulation class H

Enclosure class IP 23

Application class

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) .

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Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

4 INSTALLATION

The installation must be done by a professional.

4.1 Lifting instructions

FASTEN THE EQUIPMENT –PARTICULARLY IF

THE GROUND IS UNEVEN OR SLOPING.

If equipment is placed on a surface that slopes more

than 10°, toppling over may occur. Personal injury

and/or significant damage to equipment is possible.

4.2 Location

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

obstructed.

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4.3 Mains supply

Mains supply requirements

High power equipment may, due to the primary current drawn from the mains supply, influence the

power quality of the grid. Therefore connection restrictions or requirements regarding the

maximum permissible mains impedance or the required minimum supply capacity at the interface

point to the 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. Before connection and usage a

protective earth connection must be created in accordance with regulations.

Rating plate with supply connection data

Recommended fuse sizes and minimum cable area

Warrior 500i CC/CV

Mains voltage 380V 350/60Hz 440V 350/60Hz

Mains cable area 4C 8Awg / 4G 6mm24C 8Awg / 4G 6mm2

Phase current Ieff 30A 28A

Fuse

anti-surge

type C MCB 35A

32A 35A

32A

Warrior 500i CC/CV

Mains voltage 460V 350/60Hz 575V 350/60Hz

Mains cable area 4C 8Awg / 4G 6mm24C 8Awg / 4G 6mm2

Phase current Ieff 28A 24A

Fuse

anti-surge

type C MCB 35A

32A 25A

25A

NOTE! The mains 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.

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