Warrior™ 400i CC/CV

Warrior™ 500i CC/CV

Instruction manual

0463 340 030 GB 20181009 Valid for: Serial no. 339-xxx-xxxx

TABLE OF CONTENTS

1 SAFETY ....................................................................................................... 3
1.1 Meaning of symbols ............................................................................... 3
1.2 Safety precautions ................................................................................. 3
1.3 User responsibility ................................................................................. 7
1.4 California Proposition 65 Warning........................................................ 9

2 INTRODUCTION .......................................................................................... 10
2.1 Overview ................................................................................................. 10
2.2 Equipment ............................................................................................... 10

3 TECHNICAL DATA ...................................................................................... 11

4 INSTALLATION............................................................................................ 13
4.1 General .................................................................................................... 13
4.2 Lifting 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
ORDERING NUMBERS ....................................................................................... 27
ACCESSORIES ................................................................................................... 28

Rights reserved to alter specifications without notice.

0463 340 030 © ESAB AB 2018

1 SAFETY

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

WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in Additional Safety Information section.
Before performing any installation or operating procedures, be sure to read and
follow the safety precautions 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 proper use of the processes and equipment is essential
to prevent accidents. Therefore:
1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.
2. Always wear safety glasses with side shields in any work area, even if welding
helmets face shields and goggles are also required.
3. Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.

0463 340 030 -3- © ESAB AB 2018

1 SAFETY

4. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuff less trousers,
high-topped shoes and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.
5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of
clothing.
6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.
7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be
hot and can fly far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS

Heat from flames and arcs can start fires. Hot slag or sparks can also
cause fires and explosions. Therefore:

1. Protect yourself and others from flying sparks and hot metal.
2. Remove all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints and coatings paper, etc.
3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.
4. Do not weld, cut 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. Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
7. After completing operations, inspect the work area to make certain there are no hot
sparks or hot metal which could cause a later fire. Use fire watchers when necessary.

ELECTRICAL SHOCK
Contact with live electrical parts and ground can cause severe injury
or death. DO NOT use AC welding current in damp areas, if movement
is confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the ground system of the
input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.
6. Make sure that all parts of your body are insulated from both the work piece and from
the ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.

0463 340 030 -4- © ESAB AB 2018

1 SAFETY

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may
interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimise exposure to EMF:
a) Route the electrode and work cables together. Secure them with tape when
possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on
the same side of your body.
d) Connect the work cable to the workpiece as close as possible to the area being
welded.
e) Keep welding power source and cables as far away from your body as
possible.

FUMES AND GASES

Fumes and gases, can cause discomfort or 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
provided. Do not breathe 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 irritation while operating, this is an
indication that ventilation is not adequate. Stop work and take necessary steps to
improve ventilation in the work area. Do not continue to operate if physical discomfort
persists.
5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
6. WARNING: This product when used for welding or cutting, produces fumes or gases
which contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:

0463 340 030 -5- © ESAB AB 2018

1 SAFETY

1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
2. Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain
hoses and fittings in good condition. Follow manufacturer's operating instructions for
mounting regulator to a compressed gas cylinder.
3. Always secure cylinders in an upright position by chain or strap to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.
4. When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders 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 service, disconnect negative (-)
battery cable from battery.
5. Keep hands, hair, loose clothing and tools away from moving parts.
6. Reinstall panels or covers and close doors when service is finished and before
starting engine.

WARNING!
FALLING EQUIPMENT 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.

0463 340 030 -6- © ESAB AB 2018

1 SAFETY

WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1. Always have qualified personnel perform the installation,
troubleshooting and maintenance work. Do not perform any electrical
work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source,
disconnect the power source from the incoming electrical power.
3. Maintain cables, earthing wire, connections, power cord and power
supply in safe working order. Do not operate any equipment in faulty
condition.
4. Do not abuse any equipment or accessories. Keep equipment away
from heat sources such as furnaces, wet conditions such as water
puddles, oil or grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good
repair.
6. Use equipment only for its intended purpose. Do not modify it in any
manner.

CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices
for Arc Welding, Cutting and Gouging”, Form 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 29 CFR 1910 - "Safety and health standards"
7. CSA W117.2 - "Code for safety in welding and cutting"
8. NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and
Other Hot Work"
9. CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”
1 ANSI Z87.1, "Occupational and Educational Personal Eye and Face
0. 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
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.

0463 340 030 -7- © ESAB AB 2018

1 SAFETY

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
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.

0463 340 030 -8- © ESAB AB 2018

1 SAFETY

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.

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!

WARNING!
Do not use the power source for thawing frozen pipes.

CAUTION!
This product is solely intended for arc welding.

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.

1.4 California Proposition 65 Warning

WARNING!
Welding or cutting equipment produces fumes or gases which contain chemicals
known in the State of Carlifornia to cause birth defects and, in some cases,
cancer. (California Health & Safety Code Section 25249.5 et seq.)

WARNING!
This product contains chemicals, including lead, known to the state of California
to cause cancer, birth defects, or other reproductive harm. Wash hands after use.

0463 340 030 -9- © ESAB AB 2018

2 INTRODUCTION

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:
• 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
• instruction manual

0463 340 030 - 10 - © ESAB AB 2018

3 TECHNICAL DATA

3 TECHNICAL DATA
Warrior 400i CC/CV Warrior 500i CC/CV
Mains voltage 380-460 V ±10%, 380-460 V ±10%,
3~ 50/60 Hz 3~ 50/60 Hz
Primary current I max
MIG/MAG 27 A 37 A
TIG 23 A 30 A
MMA 29 A 38 A
No-load power in energy-saving
mode 6.5 min. after welding 30 W 30 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
MIG/MAG 0.84 0.88
TIG 0.75 0.85
MMA 0.82 0.88
Efficiency at maximum current
MIG/MAG 91 % 90 %
TIG 88 % 87 %
MMA 91 % 91 %
Electrode types Basic Basic
Rutile Rutile
Cellulosic Cellulosic
Open-circuit voltage
without VRD function 71 V DC 84 V DC
Operating temperature -10 to +40°C -10 to +40°C
Transportation temperature -20 to +55°C -20 to +55°C
Constant sound pressure when <70 db (A) <70 db (A)
idling
Dimensions l × w × h 712 × 325 × 470 mm 712 × 325 × 470 mm
Weight 52.5 kg 52.5 kg

0463 340 030 - 11 - © ESAB AB 2018

3 TECHNICAL DATA

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

Insulation class H H
Enclosure class IP 23 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 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.

0463 340 030 - 12 - © ESAB AB 2018

4 INSTALLATION

4 INSTALLATION
4.1 General
The installation must be carried out by a professional.

4.2 Lifting instructions

0463 340 030 - 13 - © ESAB AB 2018

4 INSTALLATION

WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.

4.3 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.

4.4 Mains supply

NOTE!
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. A protective earth connection must be made in
accordance with regulations.

Table 1. Recommended fuse sizes and minimum cable area Warrior 400i CC/CV
Warrior 400i CC/CV
Mains voltage 380 V 3~ 50/60 Hz 440 V 3~ 50/60 Hz 460 V 3~ 50/60 Hz
Mains cable area 4C 8Awg / 4G 6mm2 4C 8Awg / 4G 6mm2 4C 8Awg / 4G 6mm2
Ieff 22 A 21 A 21 A
Fuse
anti-surge 25 A 25 A 25 A
type C MCB 25 A 25 A 25 A

0463 340 030 - 14 - © ESAB AB 2018

4 INSTALLATION

Table 2. Recommended fuse sizes and minimum cable area Warrior 500i CC/CV
Warrior 500i CC/CV
Mains voltage 380 V 3~ 50/60 Hz 440 V 3~ 50/60 Hz 460 V 3~ 50/60 Hz
Mains cable area 4C Awg / 4G 6mm2 4C 8Awg / 4G 6mm2 4C 8Awg / 4G 6mm2
Ieff 29 A 27 A 26 A
Fuse
anti-surge 35 A 35 A 35 A
type C MCB 32 A 32 A 32 A

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.

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

The power source is connected to 440 V from the factory. If a different mains voltage is
required, the cable on the printed circuit board must be moved and placed on the correct pin.
See picture above. This operation must be carried out by personnel having appropriate
electrical knowledge.

0463 340 030 - 15 - © ESAB AB 2018

4 INSTALLATION

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.

0463 340 030 - 16 - © ESAB AB 2018

5 OPERATION

5 OPERATION
5.1 Overview
General safety regulations for handling the equipment can be found in the chapter
"Safety". Read it through before you start the equipment.

5.2 Connections and control devices

1. Mains power supply switch, O/I 9. Connection (-): MIG/MAG: Return cable
TIG: Welding torch MMA: Return cable or
welding cable
2. Indicator lamp, yellow, overheating 10. Connection (+): MIG/MAG: Welding cable
TIG: Return cable MMA: Welding cable or
return cable
3. Indicator lamp, green, VRD function 11. Circuit breaker, 10 A, 42 V
(reduced open-circuit voltage)
4. Display, current (A) and voltage (V) 12. Connection of wire feed unit
5. Knob for setting: MMA/TIG/Arc air 13. Connection of remote control unit (option)
gauging: Current (A) Mobile Feed mode:
Voltage (V)
6. Knob for choice of electrode type 14. Connection of mains power supply
7. Knob for inductance (MIG/MAG) and arc 15. Lifting eye bolt
force (MMA)
8. Knob for welding method

0463 340 030 - 17 - © ESAB AB 2018

5 OPERATION

5.3 Connection of welding and return cable

The power source has two outputs, a positive terminal (+) and a negative terminal (-), for
connecting welding and return cables. The output to which the welding cable is connected
depends on the welding method or type of electrode used.
Connect the return cable to the other output on the power source. Secure the return cable's
contact clamp to the work piece and ensure that there is good contact between the work
piece and the output for the return cable on the power source.
For MMA welding, the welding cable can be connected to the positive terminal (+) or
negative terminal (-) depending on the type of electrode used. The connecting polarity is
stated on the electrode packaging.
Recommended maximum current values for connection set cables
Imax Cable area Cable length Note
450 A (60% duty cycle) 2 - 35 m
70 mm2 19 pole
350 A (100% duty cycle) (6.6 ft - 114.8 ft)
550 A (60% duty cycle) 2 - 35 m
95 mm2 19 pole
430 A (100% duty cycle) (6.6 ft - 114.8 ft)
450 A (60% duty cycle) 2 - 35 m
70 mm2 19 pole, water
350 A (100% duty cycle) (6.6 ft - 114.8 ft)
550 A (60% duty cycle) 2 - 35 m
95 mm2 19 pole, water
430 A (100% duty cycle) (6.6 ft - 114.8 ft)

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.

5.4 Turning the mains power on/off

Turn on the mains power by turning switch to the ”I” position, see 1 on the picture above.
Turn the unit off by turning the switch to the ”O” position.
Whether the mains power supply is interrupted or the power source is switched off in the
normal manner, welding data will be stored so that it is available 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 that 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 when welding restarts.

0463 340 030 - 18 - © ESAB AB 2018

5 OPERATION

5.6 Symbols and functions

Placement of lifting Voltage Reducing
eye Device

Overheating Basic electrode

protection

Rutile electrode Cellulosic electrode

Arc force Inductance

TIG welding (Live Arc air gouging

TIG)

MMA welding MIG/MAG welding

Wire feed unit Protective earth

Mobile feed CV
(Constant voltage)

Voltage reducing device (VRD)

The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding
is not being carried out. This is indicated 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 overheating protection resets automatically when the temperature has fallen, within
normal working temperature.
Arc force
The arc force is important in determining how the current changes in response to a change in
the arc length. A lower value gives a calmer arc with less spatter.
It only applies to MMA welding.

0463 340 030 - 19 - © ESAB AB 2018

5 OPERATION

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 MIG/MAG welding.
TIG welding
TIG welding melts the metal of the workpiece, using an arc struck from a tungsten electrode,
which does not itself melt. The weld pool and the electrode are protected by shielding gas.
"Live TIG-start"
At a ”Live TIG-start” the tungsten electrode is placed against the workpiece. When the
electrode is lifted away from workpiece, the arc is struck at a limited current level.

For TIG welding, the welding power source shall be supplemented with:
• a TIG torch with gas 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:
• arc air torches
• compressed air
• return cable with clamp

Table 3. Recommended for gouging

Electrode Ø Voltage min. Voltage max. Electrode Extension
6 mm (1/4") 36 V 49 V 50 - 76 mm
8 mm (5/16") 39 V 52 V (2 - 3")
10 mm (3/8") 43 V 52 V
MMA welding
MMA welding may also be referred to as welding with coated electrodes. Striking the arc
melts the electrode, and its coating forms protective slag.
For MMA welding the power source shall be supplemented with:
• welding cable with electrode holder
• return cable with clamp

0463 340 030 - 20 - © ESAB AB 2018

5 OPERATION

MIG/MAG and self shielded cored wire welding

An arc 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

0463 340 030 - 21 - © ESAB AB 2018

6 MAINTENANCE

6 MAINTENANCE
6.1 Overview
Regular maintenance is important for safe, reliable operation.
Only personnel with the appropriate electrical skills (authorized staff) may remove safety
plates.

CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.

6.2 Power source

To maintain the performance and increase the lifetime of the power source it is 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 procedure is done in a suitable prepared workspace.

Cleaning procedure

1. Disconnect the mains supply.

2. Wait for 4 minutes to discharge the capacitors.
3. Remove the side panels on the power source.
4. Remove the top panel on the power source.
5. Remove the plastic cover between the heat sink and fan (b).

0463 340 030 - 22 - © ESAB AB 2018

6 MAINTENANCE

6. Clean the power source with dry compressed air (4 bar) as follows:
a) The upper rear part.
b) From the rear panel through the secondary heat sink.
c) The inductor, transformer and current sensor.
d) The power components side, from the rear side behind PCB 15AP1.
e) The PCBs at both sides.
7. Make sure that there is no dust left on any part.
8. Install the plastic cover between the heat sink and the fan (2) and make sure it is
correctly fitted 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.
Each time a wire bobbin is changed, the welding torch should be removed from the power
source and blown clean with compressed air.
The wire end must not have sharp edges when inserted into the wire liner.
For detailed information see instruction manuals for welding torches.

0463 340 030 - 23 - © ESAB AB 2018

7 TROUBLESHOOTING

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 • Check whether the overloading
welding. 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.

0463 340 030 - 24 - © ESAB AB 2018

8 ORDERING SPARE PARTS

8 ORDERING SPARE PARTS

CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.

Warrior 400i CC/CV and Warrior 500i CC/CV are designed and tested in accordance with
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 number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.

0463 340 030 - 25 - © ESAB AB 2018

 DIAGRAM

DIAGRAM

0463 340 030 - 26 - © ESAB AB 2018

 ORDERING NUMBERS

ORDERING NUMBERS

Ordering number 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

0463 340 030 - 27 - © ESAB AB 2018

 ACCESSORIES

ACCESSORIES
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

0463 340 030 - 28 - © ESAB AB 2018

 ACCESSORIES

0349 090 886 Foot control FS002

MMA and TIG: current

Remote control cable 12 pole - 8 pole

0459 552 880 5m
0459 552 881 10 m
0459 552 882 15 m
0459 960 883 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

0463 340 030 - 29 - © ESAB AB 2018

 ACCESSORIES

0465 427 880 Cooling unit

Connection set, 70 mm², 19 poles

0459 836 880 2m
0459 836 881 5m
0459 836 882 10 m
0459 836 883 15 m
0459 836 884 25 m
0459 836 885 35 m
Connection set water, 70 mm², 19 poles
0459 836 890 2m
0459 836 891 5m
0459 836 892 10 m
0459 836 893 15 m
0459 836 894 25 m
0459 836 895 35 m
Connection set, 95 mm², 19 poles
0459 836 980 2m
0459 836 981 5m
0459 836 982 10 m
0459 836 983 15 m
0459 836 984 25 m
0459 836 985 35 m
Connection set water, 95 mm², 19 poles
0459 836 990 2m
0459 836 991 5m
0459 836 992 10 m
0459 836 993 15 m
0459 836 994 25 m
0459 836 995 35 m

0463 340 030 - 30 - © ESAB AB 2018

 ACCESSORIES

TIG torches
0700 300 539 TXH™ 151 V, OKC 50, 4 m
0700 300 545 TXH™ 151 V, OKC 50, 8 m
0700 300 553 TXH™ 201 V, OKC 50, 4 m
0700 300 556 TXH™ 201 V, OKC 50, 8 m

Arc air torches

0468 253 036 Flair 600 incl monocable 2.5 m
0468 253 016 Torch only
0468 253 015 Monocable only
0468 253 881 Flair 1600 incl monocable 2.5 m
0468 253 036 Torch only
0468 253 035 Monocable only

0463 340 030 - 31 - © ESAB AB 2018

 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