ESAB Warrior™ Feed 304 User manual

Brand: ESAB

Model: Warrior™ Feed 304

Category: Welding System

Type: User manual

This manual is also suitable for

Warrior™ Feed 304w

ESAB Warrior™ Feed 304w is a wire feed unit designed for GMAW (MIG/MAG) welding, compatible with ESAB's Warrior 400i CC/CV and Warrior 500i CC/CV welding power sources. It features a sealed design with a four-wheel drive wire feed mechanism and electronic controls, allowing precise wire feeding and welding parameter adjustment. With a wire feed speed range of 1.5 to 25 meters per minute, it accommodates various wire diameters, including solid wires from 0.6 to 1.6 mm, stainless steel wires from 0.8 to 1.6 mm, aluminum wires of 1.0 and 1.6 mm, and cored wires from 0.9 to 1.6 mm.

Service manual

0740 800 222 GB 20180927

Valid for: serial no. 246-, 324-, 526-xxx-xxxx

Warrior™ Feed 304 

Warrior™ Feed 304w

TABLE OF CONTENTS

0740 800 222 © ESAB AB 2018

READ THIS FIRST.................................................................................... 3

INTRODUCTION....................................................................................... 5

TECHNICAL DATA ................................................................................... 6

WIRING DIAGRAM................................................................................... 8

4.1 Overview ................................................................................................. 8

4.2 Component description ......................................................................... 9

4.3 Warrior Feed 304, Warrior Feed 304w,

validforserialno.246-xxx-xxxx ...........................................................

4.4 Warrior Feed 304, Warrior Feed 304w,

validfromserialno.324-xxx-xxxx ........................................................

DESCRIPTION OF OPERATION.............................................................. 14

5.1 13AP1 Wire feeder control board.......................................................... 14

5.1.1 13AP1:1 Power supply ......................................................................... 14

5.1.2 13AP1:2 Activation, power source ....................................................... 15

5.1.3 13AP1:3 Voltage adjustment ................................................................ 15

5.1.4 13AP1:4 Gas valve............................................................................... 16

5.1.5 13AP1:5 2-stroke/4-stroke.................................................................... 16

5.1.6 13AP1:6 Wire feed speed .................................................................... 17

5.1.7 13AP1:7 Motor driving / braking ........................................................... 18

5.1.8 13AP1:8 Pulse generator input ............................................................ 19

5.1.9 13AP1:9 Current relay, Creep start / Normal start................................ 19

5.1.10 13AP1:10 Start / Stop........................................................................... 19

5.1.11 13AP1:11 Processor, Starting sequence, Motor type ........................... 20

5.1.12 13AP1:12 Gas purge / Inching ............................................................. 21

5.1.13 13AP1:13 Remote control input ........................................................... 21

5.1.14 13AP1:14 Wire selection ...................................................................... 22

5.1.15 13AP1 Component positions................................................................ 23

5.2 13AP2 Digital display ............................................................................. 24

5.2.1 13AP2 Component positions................................................................ 26

SERVICE INSTRUCTIONS....................................................................... 27

6.1 What is ESD? .......................................................................................... 27

6.2 Service aid .............................................................................................. 27

6.3 Assembly and service information....................................................... 28

6.3.1 Removing the digital display................................................................. 28

6.4 Troubleshooting remote kit Railtrac / Miggytrac ................................. 30

SPARE PARTS AND ACCESSORIES ..................................................... 32

Rights reserved to alter specifications without notice.

1 READ THIS FIRST

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1 READ THIS FIRST

Maintenance and repair work must 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 boards

are divided into numbered blocks, which are described individually in more detail in the

description of operation. Component names in the wiring diagram are listed in the

component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS" chapter

in this manual.

This manual contains details of design changes that have been made up to and including

June 2015.

The manual is valid for: Warrior Feed 304 and Warrior Feed 304w

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for safety and

function, of the specific set-up, lies with the integrator.

The Warrior Feed 304 and Warrior Feed 304w are designed and tested in accordance

with international and European standards IEC/EN 60974-5 and IEC/EN 60974-10

Class A, 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 standards.

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

1 READ THIS FIRST

0740 800 222

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2 INTRODUCTION

0740 800 222

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2 INTRODUCTION

The Warrior Feed 304 and Warrior Feed 304w wire feed units are intended for GMAW

(MIG/MAG) welding together with either of the following welding power sources:

• Warrior 400i CC/CV

• Warrior 500i CC/CV

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

12 inch / 300 mm, accessory Ø 17 inch / 440 mm).

The wire feed unit can either be placed on the trolley, suspended above the workplace with a

lifting eye, on a counter balance or on the floor with or without wheel set.

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.

3 TECHNICAL DATA

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3 TECHNICAL DATA

Warrior Feed 304, Warrior Feed 304w

Power Supply voltage 42 V AC, 50–60 Hz

Power requirement 252 VA

Rated supply current I

6 A

Settings data

Wire feed speed

Creep start

2/4 stroke

Wire selection

1.5–25.0 m/min (4.9–82 ft/min)

OFF or ON

2 stroke or 4 stroke

Solid or Cored

Torch connection EURO

Max. diameter wire bobbin 300 mm (*440 mm), 12 inch (*17 inch)

Wire dimension

Cored wire

0.6–1.6 mm (0.023 – 1/16 inch)

0.8–1.6 mm (0.030 – 1/16 inch)

1.0 & 1.6 mm (0.40 & 1/16 inch)

0.9–1.6 mm (0.035 – 1/16 inch)

Weight

WF 304 with bobbin cover

WF 304w with bobbin cover

14.4 kg (31.7 Ibs)

14.7 kg (32.4 Ibs)

Weight wire spool (ESAB standard)

Ø 200 mm

Ø 300 mm

Ø 440 mm

5 kg (11.0 lbs)

18 kg (39.7 lbs)

30 kg (66.1 lbs)

Dimensions (l × w × h)

basic



675×265×418mm (26.6×10.4×16.5

inch)

Operating temperature -10° to +40°C (+14° to +104°F)

Transport and storage temperature -20° to +55°C (-4° to +131°F)

Shielding gas

max pressure

All types intended for MIG/MAG welding

5 bar (0.5 Mpa)

Coolant(Warrior Feed 304w)

max pressure

ESAB's ready mixed coolant

5 bar (0.5 Mpa)

Permissible load at

60% duty cycle

100% duty cycle



500 A

400 A

Enclosure class

with the Ø 440 mm (Ø 17 inch) bobbin and/or

the counter balance device

IP23



IP2X

* See the "ACCESSORIES" chapter in the instruction manual.

3 TECHNICAL DATA

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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 intended for indoor and outdoor use.

Equipment marked IP2X is intended for indoor use.

4 WIRING DIAGRAM

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4 WIRING DIAGRAM

4.1 Overview

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

4 WIRING DIAGRAM

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4.2 Component description

Component Description

13AP1 Main circuit board with control electronics, see the description in "13AP1 Wire

feeder control board", page14.

13AP2 Circuit board with display, see the description in "13AP2 Digital display", page

24.

13C1, 13C3 Capacitor 0.1 μF, decoupling.

13G1 Pulse generator (encoder) built into motor 13M1, see the description in

"13AP1:8 Pulse generator input", page19.

13M1 Motor, rated voltage 42 V.

13R1 Resistor, 2.2 kΩ for adaptation of the start signal between the feeder and the

power source.

13R2 Resistor, 2.2 kΩ, 5 W.

13RP1 Potentiometer, 10 kΩ for setting the wire feed speed.

13RP2 Potentiometer, 10 kΩ for setting the welding voltage.

13SA1 Switch, 2/4-stroke changeover. When the switch is closed, 4-stroke control

mode is selected.

13SA2 Switch, Creep start function On/Off. When the switch is open, creep start

function is operative.

13SA3 Switch, three way returning to middle. Gas purge is activated in one direction

and Inching (cold wire feed) in the other.

13SA4 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.

13XP1 Panel plug, for connection to the welding power source.

13XP2 Panel plug for welding current connection from the power source.

13XS . . Connectors with the designation 13XS . . are socket connectors.

13XP . . Connectors with the designation 13XP . . are pin connectors.

13XS13 23 pole panel socket for remote control. (only available as an option)

13YV1 Gas valve.

4 WIRING DIAGRAM

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4.3 Warrior Feed 304, Warrior Feed 304w,

validforserialno.246-xxx-xxxx

4 WIRING DIAGRAM

0740 800 222

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4 WIRING DIAGRAM

0740 800 222

- 12 -

4.4 Warrior Feed 304, Warrior Feed 304w,

validfromserialno.324-xxx-xxxx

4 WIRING DIAGRAM

0740 800 222

- 13 -

5 DESCRIPTION OF OPERATION

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5 DESCRIPTION OF OPERATION

This section describes the function of circuit boards and other components in the equipment.

It is divided into sections, numbered to correspond to the circuit board numbers and divisions

into function blocks.

5.1 13AP1 Wire feeder control board

CAUTION!

This circuit board looks identical to the control board used in other wire feed

units, but there may be differences both in hardware and software. If the wrong

board is used, it might be damaged. Make sure that the replacement board has

correct article number, see the spare parts list.

5.1.1 13AP1:1 Power supply

The wire feed unit receives 42 V AC from the control power supply transformer in the welding

power source via connector 13XP1.

42 V AC is supplied to the welding torch trigger switch, the gas valve and the contactor. In

addition, terminals G01 and G02 supply 42 V AC to a Miggytrac or a Railtrac unit if this is

used together with the wire feed unit.

DC power supplies

Diodes D30–D33 rectify the 42 V AC supply to 60 V DC. Capacitor C61 smooths the supply,

which is then used to power the wire feeder motor. Transistor Q2 is a pre-regulator that drops

the voltage from 60 V DC to 20 V DC. Q2 is current-limited to about 200 mA. VR1 and VR2

are voltage regulators, producing 5 V DC and 15 V DC respectively. The circuit board's

microprocessor monitors the voltages. If the 15 V DC supply falls below 13 V DC, the wire

feed unit is stopped.

5 DESCRIPTION OF OPERATION

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5.1.2 13AP1:2 Activation, power source

The start signal is adapted by the resistor 13R1 and connected to the power source via pin F

in connector 13XP1.

5.1.3 13AP1:3 Voltage adjustment

Adjustment on the front panel of the feeder unit

When the wire feed unit is connected to a power source with step-less variable output

voltage, potentiometer 13RP2 on the front of the unit can be used to control the power

source output voltage.

The +15 VB and 0 VB voltages are supplied by the power source via connector XP01. The

voltage adjustment circuits are not galvanically isolated from the other circuits on circuit

board 13AP1.

The remote control unit for voltage control is connected to pins J, K, L, Z and Y in connector

13XS13. A link must be fitted between pins Z and Y in order to activate the unit.

5 DESCRIPTION OF OPERATION

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5.1.4 13AP1:4 Gas valve

The gas valve is connected to connectors F04 and F05.

5.1.5 13AP1:5 2-stroke/4-stroke

Adjustment on the inner panel of the feeder unit

2-stroke

When switch 13SA1 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.

4-stroke

When switch 13SA1 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.

5 DESCRIPTION OF OPERATION

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5.1.6 13AP1:6 Wire feed speed

Adjustment on the front panel of the feeder unit

Potentiometer 13RP1 controls the wire feed speed in the range 4.9–82 ft/min (1.5–25

m/min).

Adjustment using the remote control unit

Wire feed speed reference from the remote control unit

Potentiometer 13RP1 is disengaged when a remote control unit is connected to input

13XS13. The circuit board microprocessor senses that the remote control unit is connected

by means of the voltage drop across diode D35. When the remote control unit is connected,

the voltage on connector E11 cannot drop below about 0.6 V.

5 DESCRIPTION OF OPERATION

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5.1.7 13AP1:7 Motor driving / braking

The motor is powered by the smoothed +60 V supply. Pulse width modulation, controlled by

transistor Qd, is used to vary the motor voltage. The pulse frequency is 39 kHz. The

maximum conducting time of the pulses is 99% of the pulse cycle time. Freewheel diode

D11 maintains motor current during the pulse breaks.

At a drive roller speed of 265 rpm, the wire feed speed is 82 ft/min (25 m/min).

If the wire speed deviates from the set value by more than 2.6 ft/min (0.8 m/min) for more

than three seconds, wire feed will be stopped.

Current limit

The voltage drop across resistor R92 provides a signal that is proportional to the motor

current. When the current exceeds the current limit, IC6:2 turns off the gate pulse to Qd.

When the current drops, Qd conducts again at the next gate pulse.

The control board has a dynamic current limit controlled by the processor. The current limit

is 20 A on starting. When the set speed is achieved, this is reduced to 13 A.

Braking

When the motor starts, capacitor C60 charges up to 15 V DC, with Zener diodes D20 and

D43 limiting the voltage across it. Braking is activated by the optocoupler IC3. When the

transistor in IC3 is turned on by the LED, 15 V DC from capacitor C60 is connected to the

gate of transistor Qb. Transistor Qb turns on and short circuits the motor through the

resistors R85–R87. The resistors limit the braking current to about 20 A.

5 DESCRIPTION OF OPERATION

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5.1.8 13AP1:8 Pulse generator input

The pulse generator (encoder), 13G1, is fitted to drive motor 13M1. It generates 60 pulses

per revolution.

At a wire feed speed of 82 ft/min (25 m/min), the pulse generator produces a pulse frequency

of 9940 Hz.

5.1.9 13AP1:9 Current relay, Creep start / Normal start

Adjustment on the inner panel of the feeder unit

Current relay

The current relay operates if the welding current exceeds 20 A.

Creep Start

The creep start function is activated when switch 13SA2 is open. Creep start means that the

motor runs at a speed of 4.9 ft/min (1.5 m/min) until the current relay is activated. When the

relay operates, the speed increases to the set speed.

If the current relay does not operate within three seconds after starting, the motor speed

increases to the set speed in any case.

5.1.10 13AP1:10 Start / Stop

The trigger switch in the welding torch is supplied at 42 V AC. Closing the switch energises

optocoupler IC10, pulling down the voltage across C46.

When the Miggytrac or the Railtrac is used, the start signal to the feed unit is supplied by the

remote input.

When 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 switch is released.

5 DESCRIPTION OF OPERATION

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5.1.11 13AP1:11 Processor, Starting sequence, Motor type

Processor

The processor stores the machine program. It monitors the power supply voltages: if the

voltages drop to too low a level, wire feed is stopped, as described in section 13AP1:1

above.

The processor also monitors speed. If the wire speed deviates from the set value by more

than 4.9 ft/min (1.5 m/min) for more than five seconds, wire feed will be stopped.

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 continuously with a green light. The board is initiated, and the wire feed

unit is in the application program.

The starting sequence above applies to boards with software version 2.00A and later.

The software version is indicated by a label on the processor, IC1.

LEDs on circuit board 13AP1

Motor type

When the board is tested, the software is set up for motor with pulse generator and the wire

feeder mechanism MEM 30. See the spare parts list for ordering numbers.

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ESAB Warrior™ Feed 304 User manual

Brand: ESAB

Model: Warrior™ Feed 304

Category: Welding System

Type: User manual

This manual is also suitable for

Warrior™ Feed 304w

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ESAB Warrior™ Feed 304 User manual

This manual is also suitable for

ESAB Warrior™ Feed 304 User manual

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