ESAB Warrior™ 500i cc/cv Руководство пользователя

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Тип
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0463 341 131 20131001 Valid for: 251-xxx-xxx
Warrior™ 500i CC/CV
US Instruction manual
CA Manuel d'instructions
XL Instrucciones de uso
RU Инструкция по эксплуатации
TABLE OF CONTENTS
0463 341 131 © ESAB AB 2013
ENGLISH .................................................................................................................... 3
CANADIAN FRANÇAIS ............................................................................................ 21
ESPAÑOL SA ........................................................................................................... 40
PCСКИЙ ................................................................................................................... 59
TABLE OF CONTENTS
0463 341 131 © ESAB AB 2013
1 WARNINGS........................................................................................................... 4
2 SAFETY ................................................................................................................ 5
3 INTRODUCTION................................................................................................... 8
3.1 Overview ............................................................................................................... 8
3.2 Equipment.............................................................................................................8
4 TECHNICAL DATA ............................................................................................... 9
5 INSTALLATION................................................................................................... 11
5.1 General................................................................................................................ 11
5.2 Lifting instructions............................................................................................. 11
5.3 Location .............................................................................................................. 11
5.4 Mains supply ...................................................................................................... 12
6 OPERATION ....................................................................................................... 14
6.1 Overview ............................................................................................................. 14
6.2 Connections and control devices.....................................................................14
6.3 Connecting welding and return cables ............................................................15
6.4 Turning the mains power on/off........................................................................15
6.5 Fan control..........................................................................................................15
6.6 Symbols and functions......................................................................................15
7 MAINTENANCE.................................................................................................. 18
7.1 Overview ............................................................................................................. 18
7.2 Power source......................................................................................................18
7.3 Welding torch .....................................................................................................18
8 TROUBLESHOOTING........................................................................................ 19
9 ORDERING SPARE PARTS ............................................................................... 20
DIAGRAM ..................................................................................................................78
ORDERING NUMBERS.............................................................................................79
ACCESSORIES .........................................................................................................80
Rights reserved to alter specifications without notice.
1 WARNINGS
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1 WARNINGS
2 SAFETY
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© ESAB AB 2013
2 SAFETY
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
could result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
its operation
the location of emergency stops
its function
the relevant safety precautions
welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
no unauthorised person is 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 equpment
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 extinquishing equipment must be clearly marked and close at hand
Lubrication and maintenance must not be carried out on the equipment during
operation
2 SAFETY
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WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices, which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
Install and earth the unit in accordance with applicable standards
Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
Insulate yourself from earth and the workpiece
Ensure your working stance is safe
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
FIRE HAZARD
Sparks (spatter) can cause fire. Therefore, make sure there are no flammable
materials nearby
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection. Protect your ears.
Use earmuffs or other hearing protection
Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
REFERENCE TO CAN/CSA-W117.2-06
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
This product is solely intended for arc welding.
2 SAFETY
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© ESAB AB 2013
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 such locations, due to conducted as
well as radiated disturbances.
ESAB can provide you with all necessary welding protection and accessories.
3 INTRODUCTION
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3 INTRODUCTION
3.1 Overview
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), for GTAW welding, for welding with
coated electrodes (SMAW) and arc air gouging.
The power sources are intended for use with the following wire feed units:
Warrior Feed 304
Warrior Feed 304w
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
3.2 Equipment
The power source is delivered with:
5 m return cable with ground clamp
Instruction manual
4 TECHNICAL DATA
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4 TECHNICAL DATA
Warrior 500i CC/CV
Mains voltage 380 V; 440 V; 460 V; 575 V ±10%,
3~ 50/60 Hz
Primary current
I
max.
GMAW - MIG
I
max.
GTAW - TIG
I
max.
SMAW - MMA
38 A
31 A
38 A
No load power in energy-saving mode 6.5 min. after
welding 40 W
Setting range
GMAW - MIG flat characteristic
GTAW - TIG drooping characteristic
SMAW - MMA drooping characteristic
16 A/15 V-500 A/39 V
5 A/10 V-500 A/30 V
16 A/20 V-500 A/40 V
Permissible load at GMAW
60% duty cycle
100% duty cycle
500 A/39 V
400 A/34 V
Permissible load at GTAW
60% duty cycle
100% duty cycle
500 A/30 V
400 A/26 V
Permissible load at SMAW
60% duty cycle
100% duty cycle
500 A/40 V
400 A/36 V
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 84 V 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)
Transport temperature -68 to 131°F (-20 to 55°C)
Constant sound pressure when idling <70 db (A)
4 TECHNICAL DATA
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Warrior 500i CC/CV
Dimensions l × w × h 28.1 x 12.8 x 18.5 inch
(712 x 325 x 470 mm)
Weight (welding power source) 115.7 lbs (52.5 kg)
Insulation class H
Enclosure class IP 23
Application class
Duty cycle
The duty cycle refers to the time, expressed as a percentage of a ten-minute period, during
which you can weld or cut at a certain load without overloading. The duty cycle is valid for
104°F (40°C).
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.
5 INSTALLATION
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5 INSTALLATION
5.1 General
The installation must be carried out by a professional.
5.2 Lifting instructions
WARNING!
Secure the equipment -
particularly if the ground is
uneven or sloping.
5.3 Location
Position the welding power source such its cooling air inlets and outlets are not obstructed.
5 INSTALLATION
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© ESAB AB 2013
5.4 Mains supply
NOTE!
Mains supply requirements
High power equipment, due to the primary current drawn from the mains supply,
may 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, in 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 ground connection must be made in
accordance with regulations.
Warrior 500i CC/CV
Mains voltage 380V 3~ 50/60 Hz 440V 3~ 50/60 Hz
Mains cable area
4C 8Awg / 4G 6mm
2
4C 8Awg / 4G 6mm
2
Phase current I
eff
30A 28A
Fuse
anti-surge
type C MCB
35A
32A
35A
32A
Table 1. Recommended fuse sizes and minimum cable area Warrior 500i CC/CV
Warrior 500i CC/CV
Mains voltage 460V 3~ 50/60 Hz 575V 3~ 50/60 Hz
Mains cable area
4C 8Awg / 4G 6mm
2
4C 8Awg / 4G 6mm
2
Phase current I
eff
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.
5 INSTALLATION
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© ESAB AB 2013
Connection instruction
The power source is connected to 460V 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 with the appropriate
electrical knowledge.
Installation of mains cable
A mains cable needs to be installed. It is then important that the ground connection to the
bottom plate be made in a correct way. See the picture above, for the order in which the
washers, nuts and screws are placed.
6 OPERATION
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© ESAB AB 2013
6 OPERATION
6.1 Overview
General safety regulations for handling the equipment can be found in the chapter
"Safety". Read it before you start the equipment.
6.2 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
(reduced open-circuit voltage)
11. Circuit breaker, 10 A, 42 V
4. Display, current (A) and voltage (V) 12. Connection for wire feed unit
5. Knob for setting: SMAW/GTAW: Current
(A)
13. Connection for remote control unit (option)
6. Knob for selecting electrode type 14. Connection for mains power supply
7. Knob for inductance (MIG/MAG) and arc
force (MMA):
15. Lifting eye bolt
8. Knob for welding method
6 OPERATION
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© ESAB AB 2013
6.3 Connecting welding and return cables
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 workpiece and ensure there is a good contact between the workpiece
and the output for the return cable on the power source.
For SMAW welding, the welding cable can be connected to the positive terminal (+) or
negative terminal (-), depending on the type of electrode used. The connection polarity is
stated on the electrode packaging.
6.4 Turning the mains power on/off
Turn on the mains power, by turning switch to the ”I” position, see 1 in 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, 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).
6.5 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 when welding restarts.
6.6 Symbols and functions
Location of lifting eye Voltage Reducing
Device
Overheating
protection
Basic electrode
Rutile electrode Cellulosic electrode
Arc force Inductance
6 OPERATION
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© ESAB AB 2013
TIG welding (Live
TIG)
Arc air gouging
MMA welding MIG/MAG welding
Wire feed unit
Mobile feed CV
(Constant voltage)
Protective ground
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 detects that welding has started.
Contact an authorized ESAB service technician to activate the function.
Overheating protection
The welding power source has overheating protection that trips 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 back to the
normal working temperature range.
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.
This 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.
This 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 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.
6 OPERATION
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© ESAB AB 2013
For GTAW welding, the welding power source must be supplemented with:
a TIG torch with gas valve
an argon gas cylinder
an argon gas regulator
tungsten electrode
Arc air gouging
For 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 the melted material is blown away.
For arc air gouging the power source must be supplemented with:
arc air torches
compressed air
return cable with clamp
Electrode Voltage min. Voltage max. Electrode Extension
6 mm (1/4") 36 V 49 V 50 - 76 mm
(2 - 3")
8 mm (5/16") 39 V 52 V
10 mm (3/8") 43 V 52 V
Table 2. Recommended for gouging
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 electrode holder
return cable with clamp
GMAW and self-shielded cored wire welding
An arc melts a wire that is fed continuously. The weld pool is protected by shielding gas.
For GMAW and self-shielded core wire welding, the power source must be supplemented
with:
wire feed unit
welding torch
connection cable between the power source and wire feed unit
gas cylinder
return cable with clamp
7 MAINTENANCE
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7 MAINTENANCE
7.1 Overview
Regular maintenance is important for safe, reliable operation.
Only personnel with 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.
7.2 Power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on:
the welding process
the arc times
the placement
the surrounding environment
It is normally sufficient to blow down the power source using dry compressed air (reduced
pressure) once a year.
Clogged or blocked air inlets and outlets will otherwise result in overheating.
7.3 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 power
source and blown clean using compressed air.
The wire end must not have sharp edges when inserted into the wire liner.
For detailed information, see the instruction manuals for welding torches.
8 TROUBLESHOOTING
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8 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 interrupted during
welding.
Check whether the overloading protection
has tripped (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.
9 ORDERING SPARE PARTS
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© ESAB AB 2013
9 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB service technician.
Use only ESAB original spare and wear parts.
The Warrior 500i CC/CV is designed and tested in accordance with international standards
IEC 60974-1, Canadian standards CAN/CSA-E60974-1:11 and US standards ANSI/IEC
60974-1:2008.
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.
When ordering spare parts, order by part number and part name, as documented in the
spare parts list. Always provide the series or serial number on the unit in which the parts will
be used. The serial number is stamped on the rating plate.
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ESAB Warrior™ 500i cc/cv Руководство пользователя

Категория
Сварочные системы
Тип
Руководство пользователя
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