ESAB Warrior™ YardFeed 200 User manual

Warrior™ YardFeed 200
ESAB
Brand
ESAB
Model
Warrior™ YardFeed 200
Category
Welding System
Type
User manual

This manual is also suitable for

ESAB Warrior™ YardFeed 200w is a welding wire feeder designed for MIG/MAG (GMAW) welding. It features a four-wheel drive wire feed mechanism and electronic control. It has a wire feed speed range of 1.9 - 25.0 m/min (75 - 985 in/min) and can weld with wire dimensions of 0.6 - 1.2 mm (0.02 - 3/64 in.) for Fe, Ss, and Al and 0.8 - 1.2 mm (1/32 - 3/64 in.) for Cored wire. It also has a gas purging function, wire inching, and a choice of 2-stroke or 4-stroke operation.

ESAB Warrior™ YardFeed 200w is a welding wire feeder designed for MIG/MAG (GMAW) welding. It features a four-wheel drive wire feed mechanism and electronic control. It has a wire feed speed range of 1.9 - 25.0 m/min (75 - 985 in/min) and can weld with wire dimensions of 0.6 - 1.2 mm (0.02 - 3/64 in.) for Fe, Ss, and Al and 0.8 - 1.2 mm (1/32 - 3/64 in.) for Cored wire. It also has a gas purging function, wire inching, and a choice of 2-stroke or 4-stroke operation.

Service manual
0463 394 001 GB 20180115
Valid for: serial no. 427-, 528-, 802-xxx-xxxx
Warrior™YardFeed200
Warrior™YardFeed200w
TABLE OF CONTENTS
0463 394 001 © ESAB AB 2018
READ THIS FIRST.................................................................................... 3
INTRODUCTION....................................................................................... 4
TECHNICAL DATA ................................................................................... 5
WIRING DIAGRAM ................................................................................... 7
General .................................................................................................... 7
Units with ordering numbers 0459 906 898 and 0459 906 899 ........... 8
Units with ordering numbers 0459 906 900 and 0459 906 901 ........... 10
Component description ......................................................................... 12
DESCRIPTION OF OPERATION.............................................................. 13
13AP01 Control Board ........................................................................... 13
13AP01:1 Power supply ....................................................................... 13
13AP01:2 2-stroke / 4-stroke................................................................ 13
13AP01:3 Start / Stop........................................................................... 14
13AP01:4 Current relay........................................................................ 14
13AP01:5 Motor driving / braking ......................................................... 15
13AP01:6 Pulse generator input .......................................................... 15
13AP01:7 Wire selection / Burnback.................................................... 16
13AP01:8 Wire feed speed .................................................................. 16
13AP01:9 Gas valve............................................................................. 16
13AP01:10 Activation, contactor .......................................................... 17
13AP01:11 Gas purge / Inching............................................................ 17
13AP01:12 Display setting meter / inch ............................................... 17
13AP01:13 Processor, Starting sequence............................................ 17
13AP01 Component positions.............................................................. 19
13AP02 Digital display V/A .................................................................... 20
13AP02 Component positions.............................................................. 22
13AP03 Digital display Wire feed speed............................................... 22
13AP03 Component positions.............................................................. 23
Circuit diagram ..................................................................................... 24
SERVICE INSTRUCTIONS....................................................................... 25
What is ESD? .......................................................................................... 25
Removing the cover of the Warrior YardFeed ..................................... 26
Tigthening torques................................................................................ 27
Maintenance............................................................................................ 29
SPARE PARTS ......................................................................................... 30
Rights reserved to alter specifications without notice.
READ THIS FIRST
0463 394 001
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© ESAB AB 2018
READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and electrical
work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit board
is divided into numbered blocks, which are described individually in more detail in the
description of operation. All component names in the wiring diagram are listed in the
component description.
This manual contains details of all design changes that have been made up to and including
January 2018.
The manual is valid for:
• Warrior™ YardFeed 200
• Warrior™ YardFeed 200w
The Warrior™ YardFeed 200 and Warrior™ YardFeed 200w are designed and tested in
accordance with international and European standards IEC/EN 60974-5 and IEC/EN
60974-10, Canadian standard CAN/CSA-E60974-5 and US standard 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 standards.
INTRODUCTION
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© ESAB AB 2018
INTRODUCTION
The wire feed units Warrior™ YardFeed 200 and Warrior™ YardFeed 200w are intended for
MIG/MAG (GMAW) welding together with welding power sources:
• Warrior 400i CC/CV
• Warrior 500i CC/CV
They come in different variants, see chapter "ORDERING NUMBERS" in the instruction
manual.
The wire feed units are sealed and contains a four-wheel drive wire feed mechanism as well
as control electronics.
They can be used together with wire from ESAB, standard ØS200mm / Ø8inch,
7.5kg/15lbs.
Design structure of the wire feeding unit
The wire feeding unit consists of a drive unit and an electronic unit. The drive unit is the
mechanical unit that actually feeds the wire and the electronic unit is communicating with the
power source and controlling the drive unit.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
TECHNICAL DATA
0463 394 001
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© ESAB AB 2018
TECHNICAL DATA
For serial number 427-xxx-xxxx
Warrior™ YardFeed 200
Mains voltage 42 V, 50-60 Hz
Power requirement 252 VA
Rated supply current I
1
6 A
Settings data
Wire feed speed 1.9 - 25.0 m/min (75 - 985 in/min)
2/4 stroke 2 stroke or 4 stroke
Wire selection / Burnback Solid or Cored
Creep start Always on
Gas purging Yes
Wire inching Yes
Torch connection EURO
Wire bobbin: Type, Max. diameter, Max
weight
S200, 200 mm (8 in.), 5kg (10lb)
Wire dimension
Fe 0.6-1.2 mm (0.02-3/64 in.)
Ss 0.6-1.2 mm (0.02-3/64 in.)
Al 1.0-1.2 mm (0.04-3/64 in.)
Cored wire 0.8 - 1.2 mm (1/32 - 3/64in.)
Weight
WYF 200 11.6 kg (25.6 lb)
WYF 200w 11.8 kg (26.0 lb)
Dimensions (l × w × h) 593 × 210 × 302 mm (23,3 × 8,3 × 11,9 in.)
Operating temperature -10 to +40°C (+14 to +104°F)
Transport and storage temperature -20 to +55°C (-4 to +131°F)
Shielding gas All types intended for MIG/MAG welding
max pressure 0.5 MPA (5 bar / 72.5 psi)
Maximum permissible load at
60% duty cycle 365 A
100% duty cycle 280 A
Enclosure class IP23
From serial number 528-xxx-xxxx
Warrior™ YardFeed 200
Mains voltage 42 V, 50-60 Hz
Power requirement 252 VA
Rated supply current I
1
6 A
Settings data
TECHNICAL DATA
0463 394 001
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© ESAB AB 2018
Warrior™ YardFeed 200
Wire feed speed 1.9-25.0 m/min (75-985 in/min)
2/4 stroke 2 stroke or 4 stroke
Wire selection / Burnback Solid or Cored
Creep start Always on
Gas purging Yes
Wire inching Yes
Torch connection EURO
Wire bobbin: Type, Max. diameter S200, 200 mm (8 in.)
Wire dimension
Fe 0.6-1.2 mm (0.023-0.045 in.)
Ss 0.6-1.2 mm (0.023-0.045 in.)
Al 1.0-1.2 mm (0.040-0.045 in.)
Cored wire 0.8-1.6 mm (0.030-1/16 in.)
Weight
WYF 200 12 kg (26.5 lb)
WYF 200w 12.2 kg (26.9 lb)
Dimensions (l × w × h) 593 × 210 × 312 mm
(23.3×8.3×12.28in.)
Operating temperature -10 to +40°C (+14 to +104°F)
Transport and storage temperature -20 to +55°C (-4 to +131°F)
Shielding gas All types intended for MIG/MAG welding
max pressure 0.5 MPA (5 bar / 72.5 psi)
Maximum permissible load at
60% duty cycle 365 A
100% duty cycle 280 A
Enclosure class IP23
Standard factory settings
Standard factory settings for Warrior™ YardFeed 200 are in/min and fully open gas valve.
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).
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.
WIRING DIAGRAM
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© ESAB AB 2018
WIRING DIAGRAM
General
The wire feed unit is a function module and is described in the component descriptions on
the following pages. Wire numbers and component names in the wiring diagram show to
which modules the components belong.
Wires/cables within modules are marked 100–6999.
Wires/cables between modules are marked 7000–7999.
Components outside modules – e.g. capacitors – are named such as C1–C99, connectors
XS1–XS99 (S = socket), XP1–XP99 (P = plug), XT1–XT99 (T=terminal).
Circuit boards within each module have names such as 13AP1–13AP99.
13 = module association, 1–69
AP = circuit board
1 = individual identification number, 0–99
Capacitors within particular modules have identification numbers such as 13C1–13C99.
13 = module association, 1–69
C = transistor
1 = individual identification number, 0–99
WIRING DIAGRAM
0463 394 001
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© ESAB AB 2018
Units with ordering numbers 0459 906 898 and 0459 906 899
WIRING DIAGRAM
0463 394 001
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© ESAB AB 2018
WIRING DIAGRAM
0463 394 001
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© ESAB AB 2018
Units with ordering numbers 0459 906 900 and 0459 906 901
WIRING DIAGRAM
0463 394 001
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© ESAB AB 2018
WIRING DIAGRAM
0463 394 001
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© ESAB AB 2018
Component description
Component Description
13AP01 Main circuit board with control electronics, see the description in “13AP01
Control Board”, page13.
13AP02 Digital display V/A, see the description in “13AP02 Digital display V/A”, page
20.
13AP03 Digital display Wire feed speed, see the description in “13AP03 Digital display
Wire feed speed”, page22.
13C4, 13C5 Capacitor, decoupling.
13G1 Pulse generator (encoder) built into motor 13M1, see the description in
“13AP01:6 Pulse generator input”, page15.
13M1 Motor, rated voltage 42 V.
13R1 Resistor, used as a heating element (option).
13R2 Resistor, 2.2 kΩ for adaptation of the start signal between the feeder and the
power source.
13RP1 Potentiometer, 10 kΩ for setting the wire feed speed.
13RP2 Potentiometer, 10 kΩ for setting the welding voltage.
13S2 Safety contact switch, 3 position switch.
13S3 Switch, 2/4-stroke. When the switch is closed, 4-stroke control mode is
selected.
13S4 Switch, three way returning to middle. Gas purge is activated in one direction
and Inching (cold wire feed) in the other.
13S6 Switch, selection of unit for wire speed shown on display, m/min or inch/min.
13S7 Trigger switch on welding torch.
13S8 Switch, wire selection. When the switch is closed, a fixed burnback time is
selected to adapt to welding with cored wire. When the switch is open, Short
Circuit Termination (SCT) behavior is selected to adapt to welding with solid
wire.
13XP . . Plug connectors.
13XS . . Socket connectors.
13YV1 Gas valve.
DESCRIPTION OF OPERATION
0463 394 001
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© ESAB AB 2018
DESCRIPTION OF OPERATION
13AP01 Control Board
The sections 13AP01:1 to 13AP01:13 refers to the wiring diagram in the chapter "WIRING
DIAGRAM".
13AP01:1 Power supply
The power source supplies the wire feeder with 42 V AC. The wire feeder's power demand at
maximum load is 6.0 A.
42 V AC is used for the welding torch trigger switch, the power supply to the gas valve and
for the current relay.
Rectifier BR1 rectifies the 42 V supply to 60 V. Capacitor C28 smooths the voltage, which
then supplies the wire feeder motor.
Transistor Q8 is a pre-regulator which reduces the voltage from 60 V to 20 V. Q8 is
current-limited to about 200 mA. If the 20 V supply drops below 13 V, the wire feed unit
stops.
VR1 and VR2 are 5 V and 15 V voltage regulators respectively.
13AP01:2 2-stroke / 4-stroke
2-stroke
When the switch 13S3 is open, 2-stroke control mode is selected. This means that closing
the welding torch trigger switch starts the wire feed motor, opens the gas valve and closes
the power source contactor. Releasing the switch stops the motor, releases the contactor and
closes the gas valve.
DESCRIPTION OF OPERATION
0463 394 001
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© ESAB AB 2018
4-stroke
When switch 13S3 is closed, 4-stroke control mode is selected. This means that first closure
of the trigger switch operates the gas valve, with the wire feed motor starting, and the power
source contactor operating, when the trigger switch is released.
Closing the trigger switch for the second time stops the motor and de-energises the contactor
in the power source. Releasing the switch closes the gas valve.
13AP01:3 Start / Stop
The welding torch trigger switch is supplied with 42 V AC. Closing the switch activates
optocoupler IC1, causing the voltage across C35 to go low.
When the wire feed starts, the power source generates welding voltage. If this is not followed
by a flow of welding current within three seconds, the power source shuts down the welding
power supply, although wire feed continues until the welding torch trigger switch is released.
13AP01:4 Current relay
Current relay
The current relay operates if the welding current exceeds 20 A.
Creep start
The creeps start function is always activated.
DESCRIPTION OF OPERATION
0463 394 001
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© ESAB AB 2018
13AP01:5 Motor driving / braking
Driving
The motor is powered from the smoothed +60 V supply. Motor speed is controlled by pulse
width modulation of transistor Qd. The pulse frequency is 39 kHz. The maximum conducting
time of the pulses is 99% of the pulse cycle time. During the pulse spaces, the motor current
freewheels through diode D8.
At 24 V motor supply voltage, the wire feed rollers' speed is 175 r/min. A wire feed speed of
25 m/min. requires a roller speed of 265 r/min.
Current limit
Resistor R19 produces a voltage drop proportional to the motor current. If the current
exceeds the current limit, IC5 turns off the gate pulses to Qd. When the current falls, Qd
conducts again at the next gate pulse.
The control board has a dynamic current limit controlled by the processor. The current limit is
11 A on starting. When the set speed is achieved, this is reduced to 7 A.
Braking
When the motor starts, capacitor C43 charges up via diode D28: the voltage is limited to
15V by zener diodes D10 and D21. When the motor is to brake, the LED in optocoupler IC8
lights, causing the transistor in IC8 to conduct and discharge capacitor C43 (15 V) to the gate
of transistor Qb. The transistor conducts and short-circuits the motor voltage through
resistors R51 and R64, which limit the current to about 20 A.
13AP01:6 Pulse generator input
DESCRIPTION OF OPERATION
0463 394 001
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© ESAB AB 2018
The pulse generator (encoder), 13G1, is fitted to drive motor 13M1. It generates 60 pulses
per revolution.
At a wire feed speed of 20 m/min, the pulse generator produces a pulse frequency of 5093
Hz.
13AP01:7 Wire selection / Burnback
Wire selection – Solid wire
Short Circuit Termination (SCT) behavior is selected when the trigger is released to adapt to
welding with solid wire.
SCT is a way to stop the welding with some small short circuits to reduce the end crater and
oxidation. It also gives the advantage of a good start performance with solid wire.
Wire selection – Cored wire
A constant burnback time is selected when the trigger is released to adapt to welding with
cored wire.
Burnback
The burn-back time is the time from when motor braking starts until the main contactor in the
power source opens.
13AP01:8 Wire feed speed
The wire feed speed range is from 1.9 to 25 m/min for the YardFeed.
A 5 V reference voltage signal at connection A02 represents a speed of 25 m/min.
The processor monitors the wire feed speed. If the wire speed deviates from the set value by
more than 1.5 m/min for more than five seconds, wire feed will be stopped.
13AP01:9 Gas valve
The gas valve is connected to board contacts G04 and G05. The valve is energised via triac
TC1.
DESCRIPTION OF OPERATION
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© ESAB AB 2018
13AP01:10 Activation, contactor
The start signal to the power source is connected to board contact G03. The contactor is
energised via triac TC102.
13AP01:11 Gas purge / Inching
Gas purging, flushes gas without voltage or wire feed starting.
Wire inching is used to feed wire without welding voltage being applied.
13AP01:12 Display setting meter / inch
The setting of wire speed units, meter or inch, shown on the digital display is done with the
switch 13S6. When the switch is open, meter is shown. When the switch is closed, inch is
shown.
13AP01:13 Processor, Starting sequence
Processor
The processor stores the feeder program. It monitors the power supply voltages: if the
voltages drop to too low a level, wire feed is stopped, as described in section "13AP01:1
Power supply".
DESCRIPTION OF OPERATION
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© ESAB AB 2018
Starting sequence
The circuit board displays the starting sequence from power-up.
1. LED1 lights red during 5 seconds. The software is in the boot mode.
2. LED1, LED2 and LED3 lights green. The software has started the application mode.
3. LED1 flashes continously with a green light. The board is initiated, and the wire feed
unit is in the application program.
The software version is indicated by a label on the processor, IC6.
DESCRIPTION OF OPERATION
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© ESAB AB 2018
13AP01 Component positions
DESCRIPTION OF OPERATION
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© ESAB AB 2018
13AP02 Digital display V/A
The display board is intended for use in Warrior YardFeed 200 and Warrior YardFeed 200w
connected to power sources Warrior 500i CC/CV or Warrior 400i CC/CV.
The display unit has two groups of three digits. The left group (DY1–DY3) is used for
displaying set or actual arc voltage and the right group (DY4–DY6) is used to display the
measured welding current.
Data is transmitted to the display board from the power source using a three line serial
interface through the inputs:
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ESAB Warrior™ YardFeed 200 User manual

Warrior™ YardFeed 200
ESAB
Brand
ESAB
Model
Warrior™ YardFeed 200
Category
Welding System
Type
User manual
This manual is also suitable for

ESAB Warrior™ YardFeed 200w is a welding wire feeder designed for MIG/MAG (GMAW) welding. It features a four-wheel drive wire feed mechanism and electronic control. It has a wire feed speed range of 1.9 - 25.0 m/min (75 - 985 in/min) and can weld with wire dimensions of 0.6 - 1.2 mm (0.02 - 3/64 in.) for Fe, Ss, and Al and 0.8 - 1.2 mm (1/32 - 3/64 in.) for Cored wire. It also has a gas purging function, wire inching, and a choice of 2-stroke or 4-stroke operation.

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