ESAB Warrior™ YardFeed 200w User manual

Brand: ESAB

Model: Warrior™ YardFeed 200w

Category: Welding System

Type: User manual

This manual is also suitable for

Warrior™ YardFeed 200

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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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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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

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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

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

6 A

Settings data

TECHNICAL DATA

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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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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

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Units with ordering numbers 0459 906 898 and 0459 906 899

WIRING DIAGRAM

0463 394 001

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WIRING DIAGRAM

0463 394 001

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Units with ordering numbers 0459 906 900 and 0459 906 901

WIRING DIAGRAM

0463 394 001

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WIRING DIAGRAM

0463 394 001

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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

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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

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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

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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

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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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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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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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13AP01 Component positions

DESCRIPTION OF OPERATION

0463 394 001

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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 200w User manual

Brand: ESAB

Model: Warrior™ YardFeed 200w

Category: Welding System

Type: User manual

This manual is also suitable for

Warrior™ YardFeed 200

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ESAB Warrior™ YardFeed 200w User manual

This manual is also suitable for

ESAB Warrior™ YardFeed 200w User manual

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