Warrior Edge 500 CX - Welding machine Esab - Free user manual and instructions

Product Type	Arc welding power source
Brand	Esab
Model	Warrior Edge 500 CX
Mains Voltage	380–460 V, ±10%, 3~ 50/60 Hz
Setting Range (MIG/MAG)	16 A / 14.8 V – 500 A / 39 V
Setting Range (MMA)	16 A / 20.6 V – 500 A / 40 V
Setting Range (TIG)	4 A / 10.2 V – 500 A / 30 V
Duty Cycle (MIG/MAG)	60% @ 500 A / 39 V; 100% @ 400 A / 34 V
Duty Cycle (MMA)	60% @ 500 A / 40 V; 100% @ 400 A / 36 V
Duty Cycle (TIG)	60% @ 500 A / 30 V; 100% @ 400 A / 26 V
Open-Circuit Voltage	55 V
Power Factor (max MMA)	0.91
Efficiency (max MMA)	89%
Operating Temperature	−20 °C to +55 °C
Dimensions (l × w × h)	700 × 325 × 680 mm
Weight (including cooler)	85 kg
Enclosure Class	IP23
Insulation Class	H
Cooling Unit	Integrated, 1.4 kW cooling power, 4.7 L volume, max flow 2 L/min, max pressure 4.5 bar
Coolant	ESAB ready mixed coolant (0465 720 002)
Processes	MIG/MAG, MMA, Live TIG, Arc Air Gouging
Fan Control	Time control: runs 4 minutes after welding stops
VRD (Voltage Reducing Device)	Optional, reduces open-circuit voltage below 35 V when not welding
Connectivity	WeldCloud (Ethernet), USB ports (3)
Recommended Fuse	35 A anti-surge or 32 A Type C MCB
Standards Compliance	EN IEC 60974-1, -2, -10 Class A; CSA & ANSI equivalents
Application Class	S (increased electric shock risk)
Maintenance Interval	Every 12 months: clean interior with dry compressed air at 4 bar; every 3 months: check cables and labels

Frequently Asked Questions - Warrior Edge 500 CX Esab

What welding processes can the Warrior Edge 500 CX perform?

The Warrior Edge 500 CX supports MIG/MAG, MMA (including cellulosic electrodes), Live TIG (lift start), and Arc Air Gouging. It is a complete multi-process package requiring appropriate accessories for each process.

What is the duty cycle of this welding machine?

The duty cycle is the percentage of a 10-minute period you can weld at a given load without overheating. For MIG/MAG: 60% at 500 A (39 V) and 100% at 400 A (34 V). For MMA: 60% at 500 A (40 V) and 100% at 400 A (36 V). For TIG: 60% at 500 A (30 V) and 100% at 400 A (26 V).

How do I connect this machine to WeldCloud?

The power source includes a WeldCloud Ethernet connection and an IoT Gateway with two USB ports. Connect via Ethernet cable to your network, then use WeldCloud Productivity for monitoring or WeldCloud Fleet for fleet management. Refer to the Quick start guide 0463 778 001.

What coolant should I use for the cooling unit?

Use only ESAB ready mixed coolant (order number 0465 720 002). Using non-approved coolant may damage the equipment and void the warranty. The coolant tank holds 4.7 liters.

How do I clean the Warrior Edge 500 CX?

Disconnect from mains and wait 2 minutes for capacitors to discharge. Remove side and top panels and the plastic cover between heatsink and fan. Use dry compressed air at 4 bar to blow dust from PCBs, heatsinks, transformer, and fans. Reassemble and test per IEC 60974-4. Perform cleaning every 12 months or more often in dusty conditions.

What does the VRD (Voltage Reducing Device) do?

The VRD ensures that the open-circuit voltage does not exceed 35 V when welding is not in progress. It must be activated by a qualified service technician using Edge ESAT software. When active, the green VRD indicator lights up; it automatically disables when welding starts.

How do I interpret event codes on the control panel?

Event codes have three digits. The first digit indicates the subsystem: 0=System, 1=Communication, 2=Power source, 3=Wire feed unit, 4=Cooling unit, 6=Gas unit, 7=External. For example, code 205 means supply voltage fault. Refer to the event code table in the manual for corrective actions. If the fault persists, contact a service technician.

How should I lift the welding machine?

Always use both outer handles for mechanical lifting. Do not pull the cables. The machine weighs 85 kg including cooler, so use appropriate lifting equipment.

What are the mains power requirements?

The power source requires a 3-phase supply of 380–460 V AC, ±10%, 50/60 Hz. The minimum short-circuit power (S_min) is 6.8 MVA. Recommended fuse: 35 A anti-surge or 32 A Type C MCB. Cable area: 4×6 mm².

How do I fill the coolant in the cooling unit?

Use only ESAB ready mixed coolant. Open the tank filling hole and fill until the fluid level is between the upper and lower markings. If connecting a torch with hoses longer than 5 m, top up accordingly. Dispose of coolant as chemical waste.

USER MANUAL Warrior Edge 500 CX Esab

Technical line drawing of a computer rack unit with visible internal components and mounting brackets (no text or symbols)

Instruction manual

EU DECLARATION OF CONFORMITY

According to:

The Low Voltage Directive 2014/35/EU;

The EMC Directive 2014/30/EU;

The RoHS Directive 2011/65/EU;

The Ecodesign Directive 2009/125/EC

Type of equipment

Arc welding power source

Type designation

Warrior Edge 500, from serial number OP 137 YY XX XXXX

X and Y represents digits, 0 to 9 in the serial number, where YY indicates year of production.

Brand name or trademark

ESAB

Manufacturer or his authorised representative established within the EEA

ESAB AB

Lindholmsallén 9, Box 8004, SE-402 77 Göteborg, Sweden

Phone: [phone], www.esab.com

The following EN standards and regulations in force within the EEA has been used in the design:

EN IEC 60974-1:2018/A1:2019	Arc Welding Equipment - Part 1: Welding power sources
EN IEC 60974-2:2019	Arc welding equipment - Part 2: Liquid cooling systems
EN 60974-10:2014	Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC) requirements

Additional Information:

Restrictive use, Class A equipment, intended for use in locations other than residential.

By signing this document, the undersigned declares as manufacturer, or the manufacturer's authorised representative established within the EEA, that the equipment in question complies with the safety and environmental requirements stated above.

Place/Date

Göteborg

2021-10-07

Signature

Standard Equipment Director

CE

1 SAFETY 5

1.1 Meaning of symbols 5
1.2 Safety precautions 5

2 INTRODUCTION 9

2.1 Equipment 9

3 TECHNICAL DATA 10

4 INSTALLATION 12

4.1 Location 12
4.2 Lifting instructions 13
4.3 Mains supply 14
4.4 Recommended fuse sizes and minimum cable area 14

5 OPERATION 17

5.1 Connections and control devices 17
5.2 Symbols 18
5.3 Connection of welding and return cable 18
5.4 Turning the mains power ON/OFF 18
5.5 Fan control 19
5.6 Usage of cooling unit 19

5.6.1 Operation of cooling unit after welding 19

5.7 Cooling unit connection 19
5.8 Cooling unit pressure controller 19
5.9 USB Connection 20

6 CONTROL PANEL 21

6.1 Overview 21
6.2 LED indicators description 22
6.3 Functions and symbols 23

6.3.1 TIG welding 23
6.3.2 Arc air gouging 23
6.3.3 MMA welding 24
6.3.4 MMA cel 6010 welding 24
6.3.5 MIG/MAG 24

6.4 Measured or set values 24

7 MAINTENANCE 25

7.1 Routine maintenance 25
7.1.1 Cleaning procedure 26
7.2 Cooling unit 27
7.2.1 Filling the coolant 27

8 EVENT CODES 29

8.1 Application fault 29
8.2 Supply voltage fault 29
8.3 Temperature fault 29
8.4 Battery warning 30
8.5 Internal voltage error 30
8.6 Wire feed speed fault 30
8.7 Communication fault 30
8.8 Short circuit detected 31
8.9 High open circuit voltage fault 31

8.10 Lost contact with another unit 31
8.11 Internal memory fault 31
8.12 Memory fault 31
8.13 User management fault 32
8.14 Incompatible units 32
8.15 Timing fault 32
8.16 No coolant flow 32
8.17 Gas pressure fault 32
8.18 Gas flow fault 32
8.19 USB fault 33
8.20 Software runtime fault 33
8.21 External stop 33

9 TROUBLESHOOTING 34
10 ORDERING SPARE PARTS 35
11 CALIBRATION AND VALIDATION 36

11.1 Measurement methods and tolerances 36
11.2 Requirements, specifications and standards 36

WIRING DIAGRAM 37

ORDERING NUMBERS 38

ACCESSORIES 39

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual and follow all labels, employer's safety practices and Safety Data Sheets (SDSs).

1.2 Safety precautions

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:

2. its operation

3. location of emergency stops
4. its function
   • relevant safety precautions

5. welding and cutting or other applicable operation of the equipment

6. The operator must ensure that:

7. no unauthorised person is stationed within the working area of the equipment when it is started up

8. no-one is unprotected when the arc is struck or work is started with the equipment

9. The workplace must:

10. be suitable for the purpose

11. be free from drafts

12. Personal safety equipment:

13. Always wear recommended personal safety equipment, such as safety glasses, flame-proof clothing, safety gloves

14. Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns

15. General precautions:

16. Make sure the return cable is connected securely
    • Work on high voltage equipment may only be carried out by a qualified electrician

17. Appropriate fire extinguishing equipment must be clearly marked and close at hand
18. Lubrication and maintenance must not be carried out on the equipment during operation

If equipped with ESAB cooler

Use ESAB approved coolant only. Non-approved coolant might damage the equipment and jeopardize product safety. In case of such damage, all warranty undertakings from ESAB cease to apply.

For ordering information, see the "ACCESSORIES" chapter in the instruction manual.

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
• Insulate yourself from work and ground.
- Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to EMF:

- Route the electrode and work cables together on the same side of your body. Secure them with tape when possible. Do not place your body between the torch and work cables. Never coil the torch or work cable around your body. Keep welding power source and cables as far away from your body as possible.

- Connect the work cable to the workpiece as close as possible to the area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.
• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

MOVING PARTS - Can cause injuries

- Keep all doors, panels and covers closed and securely in place. Have only qualified people remove covers for maintenance and troubleshooting as necessary. Reinstall panels or covers and close doors when service is finished and before starting engine.

- Stop engine before installing or connecting unit.

- Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

- Sparks (spatter) can cause fire. Make sure that there are no inflammable materials nearby.

- Do not use on closed containers.

HOT SURFACE - Parts can burn

- Do not touch parts bare handed.

- Allow cooling period before working on equipment.

- To handle hot parts, use proper tools and/or insulated welding gloves to prevent burns.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

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.

Simple line drawing of a house with two crossed lines forming an X shape (no text or symbols)

NOTE!

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2012/19/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.

Symbol of a trash bin crossed with a diagonal line, no text or numbers present

ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website.

2 INTRODUCTION

The Warrior Edge 500 is integrated with a cooling unit and offers a complete multi-process package supporting MIG/MAG, MMA, Live TIG and gouging. It is intended for use in combination with RobustFeed Edge.

The power source is equipped with gateway to connect to the WeldCloud suite of applications, including WeldCloud Productivity for production monitoring and WeldCloud Fleet for managing your fleet of welding equipment.

For more information about the wire feed units, refer to the Instruction manual 0463 773 001.

For more information about WeldCloud, refer to the Quick start guide 0463 778 001.

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.

2.1 Equipment

The power source is supplied with:

• 5 m (16 ft) 95mm return cable with earth clamp
• 5 m (16 ft) mains cable
• Instruction manual
• Quick start guide
• Safety instruction

3 TECHNICAL DATA

WARRIOR EDGE 500
Mains voltage 380-460 V, ±10%, 3~ 50/60 Hz
Mains supply S_min	6.8 MVA
Primary current I_max	380 V 400 V 460 V
MIG/MAG 36 A 36 A 31 A
MMA 38 A 37 A 32 A
TIG 29 A 29 A 25 A
Idle power with fans OFF	41 W 43 W 43 W
Setting range (DC)
MIG/MAG	16 A/14.8 V - 500 A/39 V
MMA	16 A/20.6 V - 500 A/40 V
TIG	4 A/10.2 V - 500 A/30 V
Permissible load at MIG/MAG
60% duty cycle	500 A/ 39 V
100% duty cycle	400 A/ 34 V
Permissible load at MMA
60% duty cycle	500 A/40 V
100% duty cycle	400 A/36 V
Permissible load at TIG
60% duty cycle	500 A/30 V
100% duty cycle	400 A/26 V
Power factor
at maximum current (MMA)	0.91
MIG/MAG welding	0.93
Efficiency
at maximum current (MMA)	89%
MIG/MAG welding	88%
Open-circuit voltage	55 V
Operating temperature	-20 to +55 °C
Transportation temperature	-40 to +80 °C
Constant sound pressure when idling	< 70 dB (A)
Dimensions l x w x h	700×325×680 mm
Weight	85 kg (including cooler)
Insulation class	H
Enclosure class	IP23
Application class	S
Coolant	ESAB's coolant (0465 720 002)
Cooling power 1.4 kW
Cooling volume 4.7 l
Maximum flow 2 l/min
Maximum pressure 4.5 bar

Mains supply, \$ min

Minimum short circuit power on the network in accordance with IEC 61000-3-12.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a certain load without overloading.

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 may be used outdoors if sheltered during precipitation.

Application class

The symbol indicates that the power source is suitable for welding in an environment with an increased risk of electric shock.

4 INSTALLATION

The installation must be carried out by a professional.

CAUTION!

This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the user's responsibility to take adequate precautions.

4.1 Location

Position the welding power source in such a way that its cooling air inlets and outlets are not obstructed.

4.2 Lifting instructions

Mechanical lifting must be done with both outer handles.

4.3 Mains supply

NOTE!

Mains supply requirements

This equipment complies with IEC 61000-3-12 provided that the short-circuit power is greater than or equal to S_semin at the interface point between the user's supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power greater than or equal to S Refer to the technical data in the TECHNICAL DATA chapter.

1. Rating plate with supply connection data.

4.4 Recommended fuse sizes and minimum cable area

WARRIOR EDGE 500
Mains voltage 380 V	3~ 50/60 Hz 400 V 3~	50/60 Hz 460 V 3~ 50/60 Hz
Mains cable area 4×6 mm2		4×6 mm2	4×6 mm2
Maximal currentmax	38 A 37 A 32 A
I1eff
MIG/MAG 29 A 28 A 24 A
MMA 30 A 29 A 25 A
TIG 24 A 22 A 19 A
Fuse
Anti-surge	35 A 35 A 35 A
Type C MCB	32 A 32 A 32 A

NOTE!

The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations. For other regions, supply cables must be suitable for the application and meet local and national regulations.

Supply from power generators

The power source can be supplied from different types of generators. However, some generators may not provide sufficient power for the welding power source to operate correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power ≥ 40 kW, are recommended.

Connection instruction

WARNING!

The mains supply must be disconnected during installation.

WARNING!

Wait until the DC bus capacitors are discharged. The DC bus capacitor discharge time is at least 2 minutes!

The power source is factory set to 400 V AC. If another mains voltage setting is required, the cable on the printed circuit board has to be moved and put in the correct position. Also, the label at the rear of the power source, marked with the mains voltage setting must be updated. This operation must be done by a person who has the appropriate electrical knowledge.

NOTE!

This power source version is designed for a nominal input voltage from 380 to 460 V AC. This means that the hardware to support 575 V input is not available, 575 V tab is not connected.

If the mains cable needs to be changed, the earth connection to the bottom plate and the ferrites must be installed correctly. See the picture below for the installation order of the ferrites, washers, nuts and screws.

Connections Cable colour (CE)
L1 Brown
L2 Black
L3 Grey
GND Yellow/Green

5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY" chapter of this manual. Read it through before you start using the equipment!

NOTE!

When moving the equipment use intended handle. Never pull the cables.

WARNING!

Electric shock! Do not touch the workpiece or the welding head during operation!

5.1 Connections and control devices

Technical line drawing of a mechanical device with internal ventilation duct and labeled component (13), no readable text or symbols beyond the label.

1. Mains power supply switch, O/I 8. Connection BLUE for coolant from cooling unit
2. Connection for remote control unit 9. USB connection ports
3. Power connection to wire feed unit 10. Current/Voltage encoder knob
4. Negative welding terminal: Return cable 11. Process selection knob
5. Fuse (10 A) for supply voltage for wire feeder2. WeldCloud Ethernet connection unit
6. Positive welding terminal: Welding cable 13. Mains cable
7. Connection RED for coolant (return) to cooling. Coolant tank unit

5.2 Symbols

	WeldCloud connection USB	connection
	Protective earth Position for m ized		lifting

5.3 Connection of welding and return cable

The power source has two outputs, a positive terminal (+) and a negative terminal (-), for connecting welding and return cables.

Connect the return cable to the negative terminal on the power source. Secure the return cable's contact clamp to the work piece and ensure that there is good contact between the work piece and the output for the return cable on the power source.

Recommended maximum current values for connection set cables

At an ambient temperature of +25 °C and normal 10 minutes cycle:

Cable area	Duty cycle		Voltage loss / 10 m
	100% 60%
50 mm2	290 320 0.35	V / 100 A
70 mm2	360 400 0.25	V / 100 A
95 mm2	430 500 0.19	V / 100 A

At an ambient temperature of +40 °C and normal 10 minutes cycle:

Cable area	Duty cycle		Voltage loss / 10 m
	100% 60%
50 mm2	250 280 0.37	V / 100 A
70 mm2	310 350 0.27	V / 100 A
95 mm2	370 430 0.20	V / 100 A

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a certain load without overloading.

5.4 Turning the mains power ON/OFF

Turn ON the mains power by turning switch to the "I" position.

Turn the power source OFF by turning the switch to the "O" position.

Regardless the mains supply is interrupted abnormally, or the power source is switched off in the normal manner, the welding data will be stored, so it will be available next time the unit is turned on.

5.5 Fan control

The power source has a time control that means that the fans continue to run for 4 minutes after welding has stopped. The fans start again when welding restarts.

5.6 Usage of cooling unit

ELP (ESAB Logic Pump)

The cooling unit is equipped with detection system called ELP (ESAB Logic Pump), which checks that the coolant hoses are connected. When connecting a liquid cooled torch, cooling starts.

NOTE!

The cooling unit starts as soon as the ELP is activated!

For liquid cooled torches, the cooling unit will start only if the torch cooling hoses are connected to the wire feeder.

When the cooling hoses are disconnected from the wire feeder, the cooling stops immediately.

NOTE!

The cooling unit will be applicable only for MIG/MAG welding.

The power source automatically detects the need of cooling unit based on welding applications and operates the cooling unit accordingly.

When liquid cooled torch is connected, if the coolant temperature exceeds 45 ^ , the cooler fan and pump will start even if there is no welding operation.

5.6.1 Operation of cooling unit after welding

If the coolant temperature is below 55^ C, the cooler fan and pump will continue to run for three minutes and then stop.

If the coolant temperature is at 65^ C or above, the cooler fan and pump will continue to run for seven minutes and then stop.

In a long weld, if the coolant temperature has not decreased to 55^ C within seven minutes, the cooler fan and pump will continue to run for another three minutes and then stop.

5.7 Cooling unit connection

For trouble free operation, it is recommended that the height from the cooling unit to the liquid-cooled torch is 25 m or less.

5.8 Cooling unit pressure controller

The pump has an enclosed pressure relief valve. The valve opens gradually when the pressure is too high. This can occur if a hose is folded, which causes the flow to fail or stop.

5.9 USB Connection

1. IoT Gateway USB port 1 3. USB port 3, which enables the user to upgrade
   the software and to export the error log report.
2. IoT Gateway USB port 2

6 CONTROL PANEL

6.1 Overview

1. LED Indicators 4. Current/voltage encoder knob
2. Display, shows set or measured current 5. Application selection knob
3. Display, shows set or measured voltage/dynamics

6.2 LED indicators description

Indicator Description
	WeldCloudAn online management system that connects welding power supplies to a software platform that manages data to be analysed for maximum productivity.WeldCloud productivity provides the production manager tools to improve welding productivity and increase traceability by keeping track of each weld, operator, part number and more.The indicator is lit in green when it is connected.
	VRD (Voltage Reducing Device)The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding is not being carried out. The VRD function must be activated by a qualified service technician, by means of Edge ESAT (ESAB Software Administration Tool, a kit for technical service including a software to manage settings, update of software etc.).The VRD function is blocked when the system senses that welding has started.When VRD function is active, the indicator is lit in green.
	TRUEARC compensateTo achieve a good welding result, the arc voltage is a crucial factor. In MIG/MAG welding, the power source is prepared to sense the arc voltage in the wire feeder. Prerequisite for this functionality is that an ESAB wire feeder and an ESAB interconnection cable is used.In compensation mode, when the torch is triggered on the workpiece (avoid wire contact), it measures the inductance and resistance to compensate for the voltage drop in the interconnection cable, torch and return cable.The indicator is lit in yellow when compensation is required and it blinks during the compensation process. If the compensation process is a success, the indicator is lit in green.
	Warning/ErrorWarningThe indicator is lit in yellow and displays an "Err" message. If warning occurs, completion of ongoing weld is possible, but start of a new weld is prevented as long as the warning remains.ErrorThe indicator is lit in red and displays an "Err" message. The ongoing welding is stopped as long as the error remains.
	LockGreen - This indicates when the system has limited access or Job limits are active.Red - This indicates the system is locked, and to be able to use the system, it is required to unlock.Red (blink) - This indicates when the user is trying to access the restricted features.

6.3 Functions and symbols

6.3.1 TIG welding

TIG welding melts the metal of the workpiece, with an arc initiated from a non-consuming tungsten electrode. The weld pool and electrode are protected by shielding gas.

For TIG welding, the welding power source shall be supplemented with:

• a TIG torch with gas valve
• an argon gas cylinder
• an argon gas regulator
• tungsten electrode

This power source performs Live TIG start (TIG Live).

The tungsten electrode is placed against the workpiece. When lifted away from workpiece the arc is struck at a limited current level.

With arc air gouging, a special electrode comprising a carbon rod with a copper casing is used.

An arc is formed between the carbon rod and the workpiece, which melts the material. Compressed air is supplied so that the melted material is blown away.

For arc air gouging the power source shall be supplemented with:

• ARCAIR torches
• return cable with clamp
• air pressure

Recommended voltage setting for ARCAIR gouging electrodes

Electrode size	in 1/8		5/32	3/16	1/4	5/16	3/8
	mm	3.2	4.0	4.8	6.4	7.9	9.5
Voltage	V		35-38		36-40		38-42	40-46	44-50	46-54

NOTE!

The minimum and maximum settings are starting points for the rods indicated, with relatively clean metal, an acceptable gouge groove should be expected. These specific recommendations are based on the result of test carried out on A36/ASME mild steel.

For different types of metal, adjust the volt setting and air flow for better performance.

For any gouging issues other than performance, see the TROUBLESHOOTING section.

6.3.3 MMA welding

MMA welding may also be referred to as welding with coated electrodes. Striking the arc melts the electrode, and its coating forms protective slag.

For MMA welding the power source shall be supplemented with:

• welding cable with electrode holder
• return cable with clamp

6.3.4 MMA cel 6010 welding

Optimized arc characteristic for cellulosic electrodes such as 6010 and similar.

6.3.5 MIG/MAG

An arc melts a continuously supplied wire. The weld pool is protected by shielding gas.

For MIG/MAG welding, the power source shall be supplemented with:

• wire feed unit
• welding torch
• connection cable between power source and wire feed unit
• gas cylinder
• return cable with clamp

6.4 Measured or set values

Measured or set voltage

Measured or set value in the display for arc voltage V is an average arithmetic value.

Measured or set amperage

Measured or set value in the display for welding current A is an average arithmetic value.

7 MAINTENANCE

WARNING!

The mains supply must be disconnected during cleaning and maintenance.

CAUTION!

Only persons with the appropriate electrical knowledge (authorised personnel) may remove the safety plates.

CAUTION!

The product is covered by manufacturer's warranty. Any attempt to carry out repair work by non-authorised service centers or personnel will invalidate the warranty.

NOTE!

Regular maintenance is important for safe and reliable operation.

NOTE!

Perform maintenance more often during severe dusty conditions.

Before each use - make sure that:

• Product and cables are not damaged
• The torch is clean and not damaged

7.1 Routine maintenance

Maintenance schedule during normal conditions. Check equipment prior to every use.

Interval Area to maintain
Every 3 months	Clean or replace unreadable labels.	Clean weld terminals.	Check or replace weld cables.
Every 12 months or depending on environmental conditions (by authorised service technician)	Clean inside equipment. Use dry compressed air with 4 bar pressure.

7.1.1 Cleaning procedure

To maintain the performance and increase the lifetime of the power source it is mandatory to clean the product regularly. How often depends on:

• the welding process
- the arc time
• the working environment
• the surrounding environment, that is grinding etc

Tools needed for the cleaning procedure:

• torx screwdriver, T25 and T30
- dry compressed air at a pressure of 4 bar
- protective equipment like ear plugs, safety glasses, masks, gloves and safety shoes

CAUTION!

Make sure that the cleaning procedure is done in a suitable prepared workspace.

Technical line drawing of an internal computer chassis showing internal components like CPU, memory, and drive slots (no text or labels)

Technical line drawing of an internal electronic device with visible components and wiring (no text or symbols)

CAUTION!

The cleaning procedure should be carried out by authorised service technician.

1. Disconnect the power source from the mains supply.

WARNING!

Wait until the DC bus capacitors are discharged. The DC bus capacitor discharge time is at least 2 minutes!

1. Remove the side panels on the power source.
2. Remove the top panel on the power source.

3. Remove the plastic cover between the heat sink and fan.

4. Clean the power source with dry compressed air (4 bar) as follows:

5. The upper rear part.

6. From the rear panel through the secondary heat sink.
7. The inductor, transformer and current sensor.
8. The power components side, from the rear side behind PCB 15AP1.
   • The PCBs at both sides.
9. Current brake resistors

10. Radiator and fans

11. Make sure that there is no dust left on any part of the power source.

12. Install the plastic cover between the heat sink and the fan and make sure it is correctly fitted against the heat sink.
13. Reassemble the power source after cleaning and perform testing according to IEC 60974-4.

Follow the procedure in section “After repair, inspection and test” in the Service manual.

7.2 Cooling unit

Dust, grinding, swarf etc

The airstream through the cooling unit carries particles that become trapped in the cooling element, particularly in dirty working environments. This results in reduced cooling capacity.

The coolant system

The recommended coolant must be used in the system. Otherwise, clumps that block the pump, coolant connections or elements can be created. Flushing can only be performed via red coolant connection. Then drain the tank manually, i.e. empty via the tank's filling hole.

7.2.1 Filling the coolant

Use only ESAB's ready mixed coolant. See chapter "ACCESSORIES".

- Fill with coolant. (The fluid level must not exceed the upper marking, but neither must it be below lower marking.)

CAUTION!

The coolant must be handled as chemical waste.

NOTE!

Coolant must be topped up if connecting a welding torch or coolant hoses that are 5 m in length or longer. When adjusting the coolant level by topping up, the coolant hoses do not need to be disconnected.

Line drawing of a computer chassis with a digital display showing 10 L (no text or symbols on the device itself)

8 EVENT CODES

Event codes are used in order to indicate and identify an error in the equipment. Event codes provide information about the equipment.

Fault log

All faults that occur when using the welding equipment are documented as error messages in the fault log. When the fault log is full, the oldest message will automatically erase when the next fault occurs.

The most recent fault message is displayed on the control panel. The entire fault log as well as corrective action can be read on the internal control panel.

List of event codes

The control panel displays an event code with three digits and the first digit indicates the type of event. The type of event (first digit of the event code) are as follows:

0 = System 1 = Communication 2 = Power source

3 = Wire feed unit

4 = Cooling unit

6 = Gas unit

7 = External

NOTE!

The last two digits indicate the event description at which the user can take corrective action. If the error code persist or any other code is shown, contact a service technician.

The example presented in the graphic to the left, indicates that the Supply voltage fault in the power source.

x01 | Application fault

This event code is displayed due to one of the following:

• 001 - Application checksum error.

1. Acknowledge by pressing any buttons on the control panel.
2. Restart the system.

x05 Supply voltage fault

This event code is displayed due to one of the following:

• 205 - Mains over/under voltage or phase error.

1. Make sure that the supply voltage is stable.
2. Restart the system.

x06 | Temperature fault

This event code is displayed due to one of the following:

• 406 - Return coolant temperature warning/error.
• 206 - Overtemperature.
• 306 - High wire motor temperature warning/error.

For 406 and 206 - Return coolant temperature warning/error and Overtemperature, perform the following actions:

1. Make sure that the cooling air inlets or outlets are not blocked or clogged by dirt.
2. Check the duty cycle being used, to make sure that the equipment is not being overloaded.
3. Wait until the temperature cools down.

For 306 - High wire motor temperature warning/error, perform the following actions:

1. Check the liner, clean using pressurized air. Replace the liner if damaged or worn out.
2. Check the wire pressure setting and adjust if needed.
3. Check the drive rolls for wear and replace if needed.
4. Make sure the filler metal spool can rotate without much resistance. Adjust the brake hub if needed.
5. Restart the system.
6. If the error persists, check the liner, clean using pressurized air and replace the liner if damaged or worn out.
7. If the error persists despite performing these actions, try replacing the torch.

x08 | Battery warning

This event code is displayed due to one of the following:

• 208 - RTC/SRAM battery low warning.

1. Make sure that the polarity (+, - terminals) of the battery is right.
2. Contact authorised service technician to replace the battery.

x09 | Internal voltage error

This event code is displayed due to one of the following:

• 209 - Internal over/under voltage error.

1. Restart the system.
2. Contact authorised person to check the main inputs.

x11 | Wire feed speed fault

This event code is displayed due to one of the following:

• 311 - Wire saturation warning/error.
• 311 - Wire motor start/work current error.

1. Check the correct liners/contact tip/torch used for types of welding wires.
2. Check the torque tension in the break hub.
3. Make sure that the wire feed speed control is dust free and rotate.
4. Acknowledge by pressing any buttons on the control panel.
5. Contact service technician to check drive motor.

x14 | Communication fault

This event code is displayed due to one of the following:

• 114 - Weld control communication error.
• 114 - Internal communication warning.
• 114 - Connection to main control lost.
• 114 - Fieldbus interface lost.

1. Check that all the equipment is correctly connected.
2. Acknowledge by pressing any buttons on the control panel.
3. Do not turn OFF the system and contact service technician.

x15 | Short circuit detected

This event code is displayed due to one of the following:

• 215 - Weld contact detected at startup.

1. Make sure that the welding cables are properly installed of the weld terminals.
2. Acknowledge by pressing any buttons on the control panel.
3. Contact service technician.

x16 | High open circuit voltage fault

This event code is displayed due to one of the following:

• 216 - Voltage sensor lost.
• 216 - OCV level is too high.
• 216 - Current brake module lost.
• 216 - Current brake function error.

1. In case of voltage sensor lost, contact service technician. Otherwise restart the system.

x17 | Lost contact with another unit

This event code is displayed due to one of the following:

• 017 - Mandatory node missing.
• 017 - Critical node lost.

1. Check the cable connections between the subsystem (wire feeder and power source).
2. Acknowledge by pressing any buttons on the control panel.
3. Contact service technician.

x18 Internal memory fault

This event code is displayed due to one of the following:

• 018 - Partition data storage warning.

1. Make sure that network connection is stable with WeldCloud and acknowledge.

x19 | Memory fault

This event code is displayed due to one of the following:

• 019 - Parameter memory read/write error.
• 019 - Log read/write error.

1. Restart the system.
2. Contact service technician.

x20 | User management fault

This event code is displayed due to one of the following:

• 020 - No valid job available.

1. Make sure that the predefined jobs are saved by admin.

x25 Incompatible units

This event code is displayed due to one of the following:

• 025 - System communication version mismatch warning/error.
• 025 - Power converter control module version not valid.

• 025 - Power converter control module power capacity unknown.

• Contact service technician.

• Make sure that the software version should be similar for each connected nodes.
• Connect the correct wire feed unit and restart.

x26 | Timing fault

This event code is displayed due to one of the following:

• 026 - Watchdog timeout.
• 026 - Process control error.

1. Restart the system (recycle power).
2. Acknowledge by pressing any buttons on the control panel.
3. Contact service technician.

x29 | No coolant flow

This event code is displayed due to one of the following:

• 429 - ELP off during welding.

1. Check the coolant hose connections and acknowledge.

x31 | Gas pressure fault

This event code is displayed due to one of the following:

• 631 - Gas input pressure warning/error.

1. Check gas input pressure.
2. Select the appropriate setting of gas flow in control panel.
3. Acknowledge by pressing any buttons on the control panel.
4. Contact service technician.

x32 | Gas flow fault

This event code is displayed due to one of the following:

• 632 - Gas saturation warning/error.
• 632 - No gas out error.

1. Check gas input pressure.
2. Check the gas hoses, gas pressure regulator and connectors and acknowledge.
3. Select the appropriate setting of gas flow in control panel.

x33 | USB fault

This event code is displayed due to one of the following:

• 033 - USB high current.
• 033 - USB read/write error.

1. Make sure that the USB is in good working condition and configured properly.
2. Contact service technician.

x35 Software runtime fault

This event code is displayed due to one of the following:

• 035 - Message allocation error.
• 035 - Driver message allocation error.
• 035 - Event queue overflow.
• 035 - Failed to start microservices.

1. Restart the system.
2. Contact service technician.

x36 | External stop

This event code is displayed due to one of the following:

• 736 - Fieldbus quickstop.
• 736 - Fieldbus superquickstop.

1. Acknowledge by pressing any buttons on the control panel.
2. Restart.

9 TROUBLESHOOTING

Perform these checks and inspections before sending for an authorised service technician.

Check that the mains voltage is disconnected before starting any type of repair action.

Type of fault Corrective action
No arc Check that the mains	power supply switch is turned ON.
	Check that the mains, welding and return cables are correctly connected.
	Check that the correct current value is set.
	Check the mains power supply fuses.
The welding current is interrupted during welding	Check whether the thermal protection trip has operated (indicated by LED on Overtemperature indicator in control panel).
	Check the mains supply fuses.
The thermal protection trips frequently	Make sure that you are not exceeding the rated data for the power source (i.e. that the unit is not being overloaded).
	Check that the ambient temperature is not above the one for the duty cycle 40 °C/104 °F.
Poor welding performance C	Check that the welding current supply and return cables are correctly connected.
	Check that the correct current value is set.
	Check that the correct welding wires are being used.
	Check the main power supply fuses.
Poor cooling effect Clean the	cooling element using compressed air.
	Check the coolant level.
	Check that the ambient temperature is not above the one for the duty cycle 40 °C/104 °F.
Intermittent gouging stops or contact between carbon and metal lost	Air pressure is too high. Reduce the air pressure.
	Check the air pressure whether it is set to the recommended value. Check the manual of the torch used.
Carbon deposit on the gouge metal	Air pressure is too low. Turn on air before striking the arc and air should flow between the electrode and the workpiece.
	Check the air pressure whether it is set to the recommended value. Check the manual of the torch used.
No arc during start or erratic arc during gouging	Check whether the voltage is set to the recommended value.
Intermittent arc action resulting in an irregular groove surface or copper deposition on the metal plate	Check whether the voltage is set to the recommended value.

10 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.

Warrior Edge 500 is designed and tested in accordance with the international and European standards EN IEC 60974-1, EN IEC 60974-2 and EN IEC 60974-10 Class A, Canadian standards CAN/CSA 60974-1, CAN/CSA 60974-2 and US standards ANSI/IEC 60974-1, ANSI/IEC 60974-2.

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.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list. This facilitates dispatch and ensures correct delivery.

11 CALIBRATION AND VALIDATION

WARNING!

Calibration and validation should be performed by a trained service technician, possessing sufficient training in welding and measurement technology. The technician should have knowledge of hazards that may occur during welding and measurement and should take necessary protective actions!

11.1 Measurement methods and tolerances

When calibrating and validating, the reference measuring instrument must use the same measuring method in the DC range (averaging and rectification of the measured values). A number of measurement methods are used for reference instruments, e.g. TRMS (True Root Mean Square), RMS (Root-Mean-Square) and rectified arithmetic mean. Warrior Edge 500 uses the rectified arithmetic mean value and should therefore be calibrated against a reference instrument using the rectified arithmetic mean value.

In the field application it will occur that a measuring device and a Warrior Edge 500 may display different values even though both systems are validated and calibrated. This is due to the measurement tolerances and the method of measurement of the two measurement systems. This can result in a total deviation up to the sum of both measurement tolerances. If the measurement method differ (TRMS, RMS or rectified arithmetic mean), significantly larger deviations are to be expected!

The ESAB Warrior Edge 500 welding power source presents the measured value in rectified arithmetic mean and should therefore not show any significant differences compared to other ESAB welding equipment, due to the measurement method.

11.2 Requirements, specifications and standards

Warrior Edge 500 is designed to meet the accuracy for indication and meters required by IEC/EN 60974-14, by definition Standard grade.

Calibration accuracies of displayed value

Arc voltage ±1.5 V (Umin–U2) under load, resolution 0.25 V (Theoretical measuring range in a Warrior Edge 500 system is 0.25–199 V.)

Welding current ±2.5% of I2 max according to rating plate of the unit under test, resolution 1 A. The measuring range is specified by the rating plate on the used Warrior Edge 500 welding power source.

Recommended method and applicable standard

ESAB recommend calibration and validation to be executed according to IEC/EN 60974-14 (unless another way of execution is communicated from ESAB).

APPENDIX

WIRING DIAGRAM

graph TD
    A["3 x Mains Voltage"] --> B["2QF1"]
    B --> C["2L2"]
    C --> D["Primary Side"]
    D --> E["Bridge Rectifier 15BR1"]
    E --> F["Power Board 15AP1"]
    F --> G["Main Transformer 15T1"]
    G --> H["Secondary Rectifier"]
    H --> I["Switch/Switch"]
    I --> J["+Ve"]
    K["Auxiliary Transformer 2T1"] --> L["IPS Board 15AP2"]
    L --> M["Control Board 20AP1"]
    M --> N["Cooler Board 5AP3"]
    N --> O["IPS Board 5AP2"]
    O --> P["Control Board 20AP1"]
    P --> Q["IoT Board 25AP1"]
    Q --> R["Motor Control"]
    S["MSI"] --> T["Motor Control Board"]
    U["USB"] --> V["Motor Control Board"]
    W["MMC Board 1AP1"] --> X["Motor Control Board"]
    Y["Brake Mosfet"] --> Z["Brake Mosfet Switch"]
    AA["3x Mains Voltage"] --> AB["2QF1"]
    AC["15L1 Secondary Inductor"] --> AD["-Ve"]
    AE["15T2"] --> AF["15T1"]
    AG["15T2"] --> AH["15T1"]
    AI["USB"] --> AJ["Motor Control Board"]
    AK["RJ45"] --> AL["Motor Control Board"]

ORDERING NUMBERS

Technical line drawing of a computer control unit with visible ports, buttons, and ventilation grilles (no text or labels)

Ordering number	Denomination Type Notes
0446 300 880 Power	source Warrior Edge	500 CX I 380-460 V, CE
0446 300 884 Power	source Warrior Edge	500 CX II 380-460 V, CE	Including SPEED
0463 772 * Instruction manual
0463 844 001 Service manual
0463 843 001 Spare parts list

The three last digits in the document number of the manual show the version of the manual. Therefore they are replaced with * here. Make sure to use a manual with a serial number that corresponds with the product, see the front page of the manual.

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

ACCESSORIES

0446 600 880 RobustFeed Edge BX with EURO connector, torch cooling system and NFC.
0446 600 881 RobustFeed Edge CX with EURO connector, torch cooling system, NFC, heater and digital gas control.
0349 313 450 Trolley, compatible with RobustFeed Edge and Warrior Edge 500For assembly instruction, refer to document 0463 357 102
0465 720 002 ESAB ready mixed coolant (10 l/2.64 gal)Use of any other cooling liquid than the prescribed one might damage the equipment.In case of such damage, all warranty undertakings from ESAB cease to apply.
0465 416 880 Edge wheel kitFor assembly instruction, refer to document 0463 360 101

Interconnection cable with pre-assembled strain relief, Air cooled, 70 mm
0446 310 880 2	3 m (7 ft)
0446 310 881 5	m (16 ft)
0446 310 882 10	m (33 ft)
0446 310 883 15	m (49 ft)
0446 310 884 20	m (66 ft)
0446 310 885 25	m (82 ft)
0446 310 886 35	m (115 ft)
0446 310 887 50	m (164 ft)
Interconnection cable with pre-assembled strain relief, Liquid cooled, 70 mm
0446 310 890 2	3 m (7 ft)
0446 310 891 5	m (16 ft)
0446 310 892 10	m (33 ft)
0446 310 893 15	m (49 ft)
0446 310 894 20	m (66 ft)
0446 310 895 25	m (82 ft)
0446 310 896 35	m (115 ft)

Interconnection cable with pre-assembled strain relief, Air cooled, 95 mm
0446 310 980 2	3 m (7 ft)
0446 310 981 5	m (16 ft)
0446 310 982 10	m (33 ft)
0446 310 983 15	m (49 ft)
0446 310 984 20	m (66 ft)
0446 310 985 25	m (82 ft)
0446 310 986 35	m (115 ft)
0446 310 987 50	m (164 ft)

Interconnection cable with pre-assembled strain relief, Liquid cooled, 95 mm
0446 310 990 2	3 m (7 ft)
0446 310 991 5	m (16 ft)
0446 310 992 10	m (33 ft)
0446 310 993 15	m (49 ft)
0446 310 994 20	m (66 ft)
0446 310 995 25	m (82 ft)
0446 310 996 35	m (115 ft)

A WORLD OF PRODUCTS AND SOLUTIONS.

World map outline showing continents and oceans (no text or labels)

For contact information visit http://esab.com

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone [phone]