ESAB Warrior™ Feed 304 User manual

BR

SA

GB

Valid for serial no. 251-xxx-xxxx0463 343 030 BR SA 20130115

Warrior™ Feed 304

Warrior™ Feed 304w

GB Instruction manual

BR Manual de instruções

SA Manual de instrucciones

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English

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TOCe

1 SAFETY 32...........................................................

2 INTRODUCTION 34...................................................

2.1 Equipment 34................................................................

3 TECHNICAL DATA 35.................................................

4 INSTALLATION 36....................................................

4.1 Lifting instructions 36.........................................................

5 OPERATION 37.......................................................

5.1 Connections and control devices 38............................................

5.2 Water connection 39..........................................................

5.3 Starting procedure 39.........................................................

5.4 Function explanations 40......................................................

5.5 Wire feed pressure 41........................................................

5.6 Changing / loading wire 41....................................................

5.7 Changing feed rollers 42......................................................

6 MAINTENANCE 42....................................................

6.1 Inspection and cleaning 42....................................................

7 ORDERING SPARE PARTS 43.........................................

DIAGRAM 44............................................................

ORDER NUMBER 47.....................................................

ACCESSORIES 50.......................................................

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1 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 can result

in injury to the operator and damage to the equipment.

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

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding and cutting

2. The operator must ensure that:

S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from drafts

4. Personal safety equipment

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

clothing, safety gloves.

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

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

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

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

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

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WARNING

Read and understand the instruction manual before installing or operating.

PROTECT yourself and others. ARC PROCESS can be hazardous.

S Before use, read and follow all labels, the manufacturer's instruction manual,

employer's safety practices, and Material Safety Data Sheets (MSDSs).

S Only qualified persons are to install, use or service the equipment

ELECTRIC SHOCK can kill.

S Do not touch live electrial parts.

S Always wear dry insulating gloves.

S Insulate yourself from work and ground.

S Disconnect input power before servicing unit.

FUMES AND GASES can be hazardous to your health.

S Keep your head out of the fumes.

S Use enough ventilation, exhaust at the arc, or both to keep fumes and gases

from your breathing zone and the general area.

SPARKS AND SPATTER can cause fire or explosion.

S Do not use near flammable material.

S Do not use on closed containers.

ARC RAYS can injure eyes and burn skin. NOISE can damage hearing.

S Wear correct eye, ear and body protection.

MOVING PARTS can injure.

S Keep away from moving parts.

S Keep all doors, panels, covers, and quards closed and securely in place.

DO NOT REMOVE, DISTROY OR COVER THIS LABEL

CAUTION

Read and understand the instruction manual before

installing or operating.

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.

CAUTION

This product is solely intended for arc welding.

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Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/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 can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

The Warrior Feed 304 wire feed unit is intended for MIG/MAG-welding together with

welding power sources:

S Warrior 400i CC/CV

S Warrior 500i CC/CV

They come in different variants, see on page 47.

The wire feed units are sealed and contain four-wheel drive wire feed mechanisms

as well as control electronics.

They can be used together with wire on ESAB's MarathonPac, or on wire bobbin

(standard Ø 200 mm, Ø 300 mm and accessory Ø 440 mm).

The wire feed unit can either be placed on the power source, trolley, suspended

above workplace with lifting eye, on a counter balance or on the floor with or without

wheel set.

ESAB's accessories for the product can be found on page 50.

2.1 Equipment

The Warrior Feed 304, Warrior Feed 304w wire feed unit is supplied with:

S Instruction manual

S Sticker with recommended wear parts.

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3 TECHNICAL DATA

Warrior Feed 304, Warrior Feed 304w

Power Supply voltage 42 V AC, 50 - 60 Hz

Power requirement 42 x 6 = 252 VA

Rated supply current I

1

6 A

Settings data

Wire feed speed

Creep start

2/4 stroke

1.5-25.0 m/min

ON/OFF

2 stroke or 4 stroke

Torch connection EURO

Max. diameter wire bobbin 300 mm (*440 mm)

Wire dimension

Fe

SS

Al

Cored wire

0.6-1.6 mm

0.8-1.6 mm

1.0 & 1.6 mm

0.9-1.6 mm

Weight

WF 304 with bobbin cover

WF 304w with bobbin cover

14.4 kg

14.7 kg

Weight wire spool (ESAB standard)

Ø 200 mm

Ø 300 mm

Ø 440 mm

11,0 lbs (5 kg)

39,7 lbs (18 kg)

66,1 lbs (30 kg)

Dimensions (l x w x h)

basic 675 x 265 x 418 mm

Operating temperature -10 to +40° C

Transport and storage temperature -20 to +55° C

Shielding gas

max pressure

All types intended for

MIG/MAG welding

0.5 Mpa (5 bar)

Coolant (Warrior Feed 304w)

max pressure

50% water / 50% glycol

5 bar

Permissible load at

60% duty cycle

100% duty cycle

500 A

400 A

Enclosure class

with the bobbin Ø 440 mm and/or the counter balance device

IP23

IP2X

* Accessories, see page 50.

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.

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 designed for indoor and outdoor use.

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4 INSTALLATION

The installation must be carried out by a professional.

WARNING

When welding in an environment with increased electrical danger, only power

sources intended for this environment may be used. These power sources are

marked with the symbol

4.1 Lifting instructions

CAUTION

Mounting a large (Ø 440 mm) bobbin change the gravity and tipping and

crushing hazard exists when lifting. Protect yourself and warn bystanders

of the risk!

To avoid personal injury and / or equipment damage, lift using method and

attachment points shown here.

Ordering number for the lifting eye can be found on page 50.

Note! If another mounting device is used, this should be insulated from the wire feed

unit.

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5 OPERATION

General safety regulations for handling the equipment can be found on

page 32. Read through before you start using the equipment!

TO AVOID SHOCK, DO NOT TOUCH ELECTRODE WIRE OR PARTS IN

CONTACT WITH IT, OR UNINSULATED CABLE OR CONNECTIONS.

When moving the equipment use intended handle. Never pull on the torch.

AH 0935

WARNING

Assure that the side panels are closed during operation.

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WARNING

To prevent the reel from sliding off the hub: Lock the

reel in place by turning the red knob as shown on the

warning label attached next to the hub.

Before threading welding wire, make sure the chisel point and burrs have been

removed from the end of the wire to prevent the wire from jamming in the torch

liner.

WARNING

Rotating parts can cause injury, take great care.

WARNING

There is a risk of tipping if the wire feed unit is fitted with a counterbalance arm.

Secure the equipment, especially if used on an uneven or sloping surface.

5.1 Connections and control devices

1 Display voltage (V) 9 Switch for creep start (inside)

2 Display current (A) 10 Switch for 2-stroke / 4-stroke (inside)

3 Knob for setting the wire feed speed 11 Connection for welding current from power

source (OKC)

4 Knob for setting the voltage 12 Connection for control cable from power

source

5 Switch for wire inching or gas purge 13 Connection for shielding gas

6 Connection RED for cooling water from

welding torch *

)

14 Connection BLUE for cooling water from

power source (cooling unit) *

)

7 Connection BLUE for cooling water to the

welding torch *

)

15 Connection RED for cooling water to

power source (cooling unit) *

)

8 Connection for the welding gun

*

)

NOTE! Cooling water connections only available on certain models.

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5.2 Water connection

When connecting a water-cooled welding gun, the power source's main power

supply switch must be in the OFF position and the cooling unit switch must be in

position 0.

A water connection kit can be orderred as accessory, see on page 50.

5.3 Starting procedure

When the wire feed starts, the power source generates welding voltage.

If there is no welding current flow within three seconds, the power source switches

the welding voltage off. The wire feed continues until the welding gun's switch is

switched off.

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5.4 Function explanations

Open the lid for access of the 2-4 stroke and the creep start functions.

2 stroke

With 2 stroke, wire feed starts when the trigger switch is pressed in and ends when

it is released.

4 stroke

With 4 stroke, the gas flow starts when the trigger switch is pressed in and the wire

feed starts when it is released. The welding process continues until the switch is

pressed in again, the wire feed stops and when the switch is released the gas stops

flowing.

Creep start

Creep start means that the wire is fed at low speed (1.5 m/min) until it comes into

electrical contact with the workpiece and then the speed increases to the set speed.

Burnback time

Burnback time is not adjustable delay between the time when the wire starts to

brake, until the time when the power source switches off the welding power.

Wire inching

Wire inching is used when one needs to feed wire without welding voltage being

applied. The wire is fed with a fixed speed of 9 m/min as long as the switch is held to

the left.

Gas purging

Gas purging is used when measuring the gas flow or to flush any air or moisture

from the gas hoses before welding starts. Gas purging occurs for as long as the

switch is held to the right and occurs without voltage or wire feed starting.

Wire feed speed

This sets the required feed speed of the filler wire in m/minute or in inch/minute.

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5.5 Wire feed pressure

Start by making sure that the wire moves smoothly through the wire guide. Then

set the pressure of the wire feeder's pressure rollers. It is important that the

pressure is not too great.

Fig 1 Fig 2

To check that the feed pressure is set correctly, you can feed out the wire against

an insulated object, e.g. a piece of wood.

When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed

rollers should slip.

If you hold the gun approx. 50 mm from the piece of wood, the wire should be

fed out and bend (fig. 2).

5.6 Changing / loading wire

S Open the side panel.

S Disconnect the pressure sensor by folding it backwards, the pressure rollers

slide up.

S Straighten out the new wire 10-20 cm. File away burrs and sharp edges from the

end of the wire before inserting it into the wire feed unit.

S Make sure that the wire goes properly into the feed roller's track and into the

outlet nozzle or wire guide.

S Secure the pressure sensor.

S Close the side panel.

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5.7 Changing feed rollers

S Open the side panel.

S Disconnect the pressure sensor (1) by folding it

backwards.

S Disconnect the pressure rollers (2) by turning the

axle (3) 1/4 turn clockwise and pulling out the axle.

The pressure rollers disconnect

S Disconnect the feed rollers (4) by unscrewing the

nuts (5) and pulling out the rollers.

During installation, repeat the above in the reverse order.

Choice of track in the feed rollers

Turn the feed roller with the dimensioning mark for the required track towards you.

6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts any

work to rectify any faults in the product during the guarantee period.

6.1 Inspection and cleaning

Wire feed unit

Check regularly that the wire feed unit is not clogged with dirt.

S Cleaning and replacement of the wire feed unit mechanism's worn parts should

take place at regular intervals in order to achieve trouble-free wire feed. Note

that if pre-tensioning is set too hard, this can result in abnormal wear on the

pressure roller, feed roller and wire guide.

The brake hub

The hub is adjusted when delivered, if

readjustment is required, follow the instructions

below. Adjust the brake hub so that wire is slightly

slack when wire feed stops.

S Adjusting the braking torque:

S Turn the red handle to the locked position.

S Insert a screwdriver into the springs in the hub.

Turn the springs clockwise to reduce the braking torque

Turn the springs counter-clockwise to increase the braking torque. NB: Turn

both springs the same amount.

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Welding torch

S Cleaning and replacement of the welding torch wear parts should take place at

regular intervals in order to achieve trouble-free wire feed. Blow the wire guide

clean regularly and clean the contact tip.

7 ORDERING SPARE PARTS

Repair and electrical work should be performed by an authorised ESAB service

technician. Use only ESAB original spare and wear parts.

The Warrior Feed 304 is designed and tested in accordance with international standards

IEC 609745. Canadian standards CAN/CSA-E60974-5 and US standards ANSI/IEC 60974-5.

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

standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

GB

Diagram Esquema Esquema

1309

13AP2

1331

1330

1332

4 1

3

13XS12

13XS17

M

1316 1317

13XS16

13XS6

13G113M1

7

H01

H02

+60 V

0 V

Qd

+5 V = M1

M2

0 V = M3

8

13XS3-2

1313

1312

13XP2

13C1

Current relay

1310

Welding gun

C06

C05

9

+5 V

10

C02

C01

0 V

B_42VAC

1333

1334

1340

1336

1337

1338

1339

H

S

B

A

F

M

L

K

J

U

D

E

V

T

19 pole

13XP1

Digital display

13XS11

1301

1302

1303

1304

1305

01 SCK

03 0 V

02 +24 V

04 LOAD

05 SDA

1391

1390

From 13XS13

F01

F02

F03

F06

F07

F08

F09

F04

B_42VAC

A_42VAC

B_42VAC

Crater fill

0VB

Voltage ref.

15VB

A_42VAC

1 2

3

Arc voltage

0 VB

Voltage REF

15 VB

Clock display

+24 V display

0 V display

Load display

Data display

Power source

13YV1

1314

1315

F05

B_42VAC

TC2

4

13AP1

13XS5

3

A02

Voltage ref.

A01

0VB

A03

15VB

Voltage

13XS1

1340

1341

1342

1

2

3

1311

Not used

42 VAC

13C3

13RP2

R

13XS3-1

13XS20

1335

13R1

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A04

13AP1

A05

A06

A09

A10

0 V

+5 V

0 V

+5 V

A08

A07

0 V

13SA1

4−stroke

2−stroke

5

1351

1352

1353

A14

0 V

A15

Wire ref.

A16

+5 V

A17

Wire ref. 0-10V

1

2

3

G02

G01

1

E09

E11

E10

6

E12

E08

E07

E06

E04

E03

E02

Wire feed speed

E01

E05

13RP1

1364

1363

1362

1361

1360

1359

U

V

E

D

Y

Z

L

K

J

M

3

7

4

A

B

F

G

1388

1389

To 1310

To 1309

1391

1390

Remote connection

(Option)

13

Wire ref.

Voltage ref.

+15 V

0VB

+15 V

0VB

+60 V

0 V

A_42VAC

B_42VAC

0 V

-

+

Ref

Ref Wire feed

A_42VAC

B_42VAC

Start / Stop

+ 15 V

Voltage

Miggytrac

Railtrac

13XS4

13XS13

K04

K03

0 V

+5 V

IC1

K02

K01

0 V

+5 V

IC1

12

BY1:2

BY1:1

RS6

RS5

RS4

RS3

RS2

RS1

Processor

+5 V

0 V

11

B03

B02

B01

0 V

+5 V

9

13XS2

OFF

ON

Creep start

13SA2

Gas purgeInching

A_42VAC

B_42VAC

13XS10

1401

1402

1403

13SA3

1

2

3

1328

2

1327

3

1325

2

1326

3

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Warrior™ Feed 304 / Warrior™ Feed 304w

Order number Números de referência Número de pedido

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bm55o11a

1.

Ordering No Description Notes

0465 250 880

Warriort Feed 304

0465 250 881

Warriort Feed 304w

with water cooling

0459 839 085 Spare parts list

Technical documentation is available on the Internet at www.esab.com

Warrior™ Feed 304 / Warrior™ Feed 304w

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Replacement parts

Item Ordering no. Denomination Notes Wire type Wire dimensions

HI1 0455 072 002

0456 615 001

Intermediate nozzle

Fe, SS & cored

Al

Ø 2.0 mm steel for 0.6-1.6 mm

Ø 2.0 mm plastic for 0.8-1.6 mm

HI2 0469 837 880

0469 837 881

Outlet nozzle

Fe, SS & cored

Al

Ø 2.0 mm steel for 0.6-1.6 mm

Ø 2.0 mm plastic for 0.8-1.6 mm

HI3 0191 496 114 Key

HI4 0215 701 007 Locking washer

HI5a 0459 440 001 Motor gear euro Drive gear

Item Ordering no. Denomination Wire type Wire dimensions Groove

typ

Roller

markings

HI5b 0459 052 001 Feed/pressure rollers Fe, SS & cored Ø 0.6 & 0.8 mm V 0.6 S2 & 0.8 S2

0459 052 002 Feed/pressure rollers Fe, SS & cored Ø 0.8 & 1,0 mm V

0.8 S2 & 1.0 S2

0459 052 003 Feed/pressure rollers Fe, SS & cored Ø 0.9/1.0 & 1.2 mm V 1.0 S2 & 1.2 S2

0459 052 013 Feed/pressure rollers Fe, SS & cored Ø 1.4 & 1.6 mm V 1.4 S2 & 1.6 S2

0458 825 001 Feed/pressure rollers Cored Ø 0.9/1.0 & 1.2 mm V-Knurled 1.0 R2 & 1.2 R2

0458 825 010 Feed/pressure rollers Cored Ø 1.2/1.2 mm V-Knurled 1.2 R2 & 1.2 R2

0458 825 002 Feed/pressure rollers Cored Ø 1.2 & 1.4 mm V-Knurled 1.2 R2 & 1.4 R2

0458 825 003 Feed/pressure rollers Cored Ø 1.6 mm V-Knurled 1.6 R2 & 2.0 R2

0458 824 001 Feed/pressure rollers Al Ø 0.8 & 0.9/1.0 mm U 0.8 A2 & 1.0 A2

0458 824 002 Feed/pressure rollers Al Ø 1.0 & 1.2 mm U 1.0 A2 & 1.2 A2

0458 824 003 Feed/pressure rollers Al Ø 1.2 & 1.6 mm U 1.2 A2 & 1.6 A2

Use only pressure and feed rollers marked A2, R2 or S2.

The rollers are marked with wire dimension in mm, some are also marked with inch.

Item Ordering no. Denomination Notes

HI6 Washer Ø 16/5x1

HI7 Screw M4x12

HI8 Screw M6x12

HI9 Washer Ø 16/8.4x1.5

HI10 0469 838 001 Cover

HI11 0458 722 880 Axle and Nut

HI12 0459 441 880 Gear adapter

HI13 0455 049 001 Inlet nozzle Ø 3mm for 0.6-1.6mm Fe, SS, Al and cored wire

HI14 0458 999 001 Shaft

HI15 Nut M10

HI16 0458 748 002 Insulating washer

HI17 0458 748 001 Insulating bushing

Item Ordering no. Denomination Wire type Wire dimensions

HI18 0156 602 001 Inlet nozzle Fe, SS, Al &

Cored

Ø 2 mm plastic for 0.6-1.6 mm

Welding with aluminium wire

In order to weld with aluminium wire, proper rollers, nozzles and liners for aluminium wire MUST be

used, It is recommended to use 3 m long welding gun for aluminium wire, equipped with appropriate

wear parts.

Warrior™ Feed 304 / Warrior™ Feed 304w

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Pict to be replaced

Warrior™ Feed 304 / Warrior™ Feed 304w

Accessories Acessórios Accesorios Acessórios Accesorios

- 50 -

bm55a11a

Bobbin cover kit, plastic Ø 300mm ........ 0458 674 980

Wheel kit ................................ 0458 707 880

Wheel kit ................................ 0458 707 881

NOTE! IP23 not valid for wire feeder with

Ø 440 mm bobbin.

Adapter for Ø 440 mm bobbin ............. 0459 233 880

Lifting eye ............................... 0458 706 880

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