ESAB Warrior™ Feed 304, Warrior™ Feed 304w User manual

Category
Welding System
Type
User manual

This manual is also suitable for

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
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.......................................................
© ESAB AB 2013
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bm55d1e
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.
GB
© ESAB AB 2013
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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.
GB
© ESAB AB 2013
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bm55d1e
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.
GB
© ESAB AB 2013
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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.
GB
© ESAB AB 2013
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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.
GB
© ESAB AB 2013
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bm55d1e
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.
GB
© ESAB AB 2013
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bm55d1e
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.
GB
© ESAB AB 2013
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bm55d1e
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.
GB
© ESAB AB 2013
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bm55d1e
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.
GB
© ESAB AB 2013
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bm55d1e
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.
GB
© ESAB AB 2013
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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.
GB
© ESAB AB 2013
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bm55d1e
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
© ESAB AB 2013
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
Not used
Not used
42 VAC
13C3
13RP2
R
13XS3-1
13XS20
1335
13R1
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bm55e11a
© ESAB AB 2013
A04
13AP1
A05
A06
A09
A10
0 V
+5 V
0 V
+5 V
+5 V
A08
A07
0 V
13SA1
4stroke
2stroke
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
+5 V
0 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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bm55e11a
© ESAB AB 2013
Warrior™ Feed 304 / Warrior™ Feed 304w
Order number Números de referência Número de pedido
- 47 -
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
© ESAB AB 2013
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bm55whj1
Replacement parts
Item Ordering no. Denomination Notes Wire type Wire dimensions
HI1 0455 072 002
0456 615 001
Intermediate nozzle
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
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
© ESAB AB 2013
- 49 -
bm55whj1
Pict to be replaced
Warrior™ Feed 304 / Warrior™ Feed 304w
© ESAB AB 2013
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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ESAB Warrior™ Feed 304, Warrior™ Feed 304w User manual

Category
Welding System
Type
User manual
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