ESAB | ST-16 | Warrior™ 500i with Warrior Feed 304

Warrior™ 500i with Warrior Feed 304
Warrior 500i
with Warrior Feed 304
™
„„Designed with input from real-world welders and
built with ESAB's leading-edge engineering
„„Multi-Process - Warrior is designed for GMAW,
FCAW (Flux-Cored), SMAW, and GTAW applications,
as well as ACAG (Arc Gouging), and delivers up to
500A @ 60% duty cycle
„„ Welds .030-5/64 in. (0.8-2.4 mm) flux cored and solid wires
„„Great short arc performance with 500A
„„Full range of SMAW capabilities with excellent
7018 and 6010 performance
„„Arc gouges with electrodes up to 3/8 in. (5 mm)
„„Inverter technology - increased energy efficiency
and more power from a lighter, smaller, and more
portable unit
„„Generator friendly - compatible to work with
generators when power is not accessible in the field
„„AutoFan feature reduces energy consumption
and dirt intake
™
„„High duty cycle for long runs across a variety
of applications
Ordering Information
„„Automatic Hot Start/Variable Arc Control allows
the welder to fine-tune the arc to get best possible
weld performance and optimize hot start, arc force,
and inductance settings with total arc control
USA
Warrior 500i, 380/460/575V, 3ph, 5.5 ft. (1.7 m)... 0558101760
Warrior 500i, 380/460/575V, 3ph, 32 ft. (9.7 m)... 0558101761
„„Power, gas, and control cables are in an all-in-one
bundle with quick disconnect plugs to reduce setup
time, housed in a tough, protective cover for longer
cable life
„„All controls, including power switch, are located
on the all-in-one front panel
„„Read-anywhere display - easy to read settings
outdoors and from a wide range of angles
„„Ergonomically designed handles, built to
withstand mechanical hoisting
„„Durable and rugged - IP 23 rating for outdoor
and indoor use in rough environments
Ready to Weld Packages
Canada
Warrior 500i, 380/460/575V, 3ph, 5.5 ft. (1.7 m)... 0561000155
Warrior 500i, 380/460/575V, 3ph, 16.4 ft. (5 m)... 0561000156
Includes: power source, 5.5 ft. (1.7 m),16 ft. (5 m), or 32 ft. (9.7 m) cable
connection set, Warrior Feed 304 4-roll wire feeder, .035/.045 in.
(0.9/1.2 mm) V-groove drive rolls/guide tube, Gunmaster 400cc
torch with .035-.045 in. (0.9-1.2 mm) accessories, R-33-FM-580
gas regulator/flowmeter, 49 ft. (15 m) work cable/ground clamp.
Input power cable is not included.
Canada package also includes trolley with wheels & 1-cylinder rack.
MobileFeed 300AVS Wire Feeder Package
Warrior 500i/MobileFeed, 380/460/575V, 3ph... 0558101762
Includes: .052/1/16 in. (1.4/1.6 mm) K-groove drive rolls,
GunMaster 400cc torch with .052-1/16 in. (1.4-1.6 mm)
accessories. Regulator/flowmeter and cylinder cart not included.
Basic Packages
Warrior 500i, 380/460/575V, 3ph, 5.5 ft. (1.7 m).. 0558101759
Includes: power source, feeder, 15 ft. (4.5 m) 400A torch.
Power Source Only
Warrior 500i, 380/460/575V, 3ph...................... 0465350881
Warrior Power Source Pack (includes 4 power sources)
Warrior 500i power source 4-pack .................. 0588002000
Specify input voltage when ordering.
ESAB Welding and Cutting Products
USA: www.esabna.com / 1.800.ESAB.123 | Canada: www.esab.ca / 1.877.935.3226 | Mexico: www.esab.com.mx / (81) 8305-3700
ARC-23304a 02/14
1
1
Warrior 500i
with Warrior Feed 304
™
Options & Accessories
Feeder Accessories
Wheel kit.......................................................... 0458707880
Strain relief for welding torch........................... 0457341881
Feeder strain relief for connection cables........ 0459234880
Lifting eye........................................................ 0458706880
Quick connector Marathon Pac adaptor.......... 0558002354
Adaptor for 11-lb (5-kg) spool.......................... 0455410001
Steel spool cover, 12 in. (305 mm).................... 0459431880
Remote adaptor kit, Miggytrac/Railtrac........... 0465451880
M1 remote....................................................... 0459491895
Remote cable.................................................. 0459553880
Counterbalance MiniBoom
For 12 in. (305 mm) spools............................... 0458705880
For 18 in. (457 mm) spools............................... 0458705882
Power Source Accessories
Auto transformer, 208/230/460V, 3ph.............. 0588002040
Electrode Holder Assemblies
175A, 15 ft. (4.5 m)........................................... 0558001791
300A, 15 ft. (4.5 m)..................................................... 21226
Trolley, 1 cylinder............................................. 0465510880
Wheel kit.......................................................... 0465416880
Water cooler.................................................... 0465427880
Remote Controls, power source
Remote kit (required)........................................ 0465424880
FS003-B remote foot control, 25 ft. (7.6 m)...... 0558008905
RCA-2B remote torch control, 25 ft. (7.6 m)..... 0558008904
Remote control AT1 analog ............................. 0459491896
Remote control AT1 course-fine analog .......... 0459491897
Cable interconnect analog 12P, 16.4 ft. (5 m)... 0459552880
Cable interconnect analog 12P, 33 ft. (10 m).... 0459552881
Cable interconnect analog 12P, 50 ft. (15 m).... 0459552882
Cable interconnect analog 12P, 82 ft. (25 m).... 0459552883
Warrior 500i spool gun option.......................... 0588002061
1
1
Extension arm for 60-lb coil (18 in. spools)....... 0459233880
Coil adaptor for 60-lb (27.2-kg) coils ......................... 34323
Female gas hose quick-connector................... 0365803002
Gas flow checker....................................................... 19043
PrecisionMaster gas saver kit.......................... 0558007079
1
Requires extension arm #0459233880.
1
Connection Cable Sets, Air-Cooled Torch
5.6 ft. (1.7 m).................................................... 0459836880
32.8 ft. (10 m)................................................... 0459836882
49.2 ft. (15 m)................................................... 0459836883
82 ft. (25 m)...................................................... 0459836884
Order cable separately.
1
Work Cable Extensions
16.4 ft. (5 m) - 2/0 AWG.................................... 0558101878
33 ft. (10 m) - 2/0 AWG..................................... 0558101879
50 ft. (15 m) - 2/0 AWG..................................... 0558101880
82 ft. (25 m) - 2/0 AWG..................................... 0558101881
82 ft. (25 m) - 4/0 AWG..................................... 0558101882
115 ft. (35 m) - 4/0 AWG.................................... 0558101883
Control Panel
Power On/Off
Digital Volt / Amp Meter
Wire Feeder
Connector
Resettable
Circuit Breaker
Output Power
Connectors
VRD LED
Over Temperature LED
Output Voltage/Current Control
Stick Mode Selector
Automatic Hot Start/
Variable Arc Control
ESAB Welding and Cutting Products
United States / esabna.com / 1.800.ESAB.123 Canada / esab.ca / 1.877.935.3226 Mexico / esab.com.mx / (81) 8305.3700
ARC-23304a 02/14
Process Selector
Warrior 500i
with Warrior Feed 304
™
Options & Accessories continued
Warrior Feed 304 Wire Feeder
Warrior Feed 304............................................. 0465250880
Warrior Feed 304w .......................................... 0465250881
Warrior Feed 304 for ST-21 & ST-16................. 0588002048
Warrior Feed 304 NAS ..................................... 0558002068
1
2
Warrior Feed 304 has 4-roll drive system and 19 pole amphenol
cable connection. Includes digital meters, .035/.045 in. (0.9/1.2 mm)
V-groove drive rolls/guide tube and spool enclosure.
Includes water solenoid connections.
Special order upon request.
1
2
Feed Roll Kits
V-Groove .023-.030 in. (0.6-0.8 mm)................ 0558003134
V-Groove .035-.045 in. (0.9-1.14 mm).............. 0558003135
V-Groove .052-.1/16 in. (1.3-1.6 mm)............... 0558003136
K-Groove 035-.045 in. (0.9-1.14 mm).............. 0558003137
K-Groove 045-.052 in. (1.14-1.3 mm).............. 0558003138
K-Groove 1/16-5/64 in. (1.6-2.0 mm)............... 0558003139
GMAW Torches
GunMaster 400cc, 25 ft. (7.6 m) basic.............. 0558001674
GunMaster 400cc,12 ft. (3.6 m) x .035-.045 in..0558001667
GunMaster 400cc,15 ft. (4.5 m) x .035-.045 in. .0558001669
GunMaster 400cc,15 ft. (4.5 m) x .052-1/16 in..0558001670
GTAW Torches
HW-17V-2TL, 12.5 ft. (3.6 m)...................................... 35857
HW-17V-2TL, 25 ft. (7.6 m)......................................... 35856
HW-26V-2TL, 12.5 ft. (3.6 m)...................................... 35858
HW-17, 18, 26 accessory kit.................................... 999126
V = Gas Valve.
Gouging Torch
Q4000 gouging torch package, 10 ft. (3 m).....Q61-082-009
Mobilefeed 300 AVS 4-Roll Suitcase Wire Feeder
Mobilefeed 300 AVS LC-40.............................. 0558005729
Warrior 500i can be paralleled to utilize larger gouging rods.
This optional wire feeder includes digital meter, gas solenoid valve,
contactor, LC-40 male connector and .045-1/16 in. (1.2-1.6 m)
serrated drive rolls.
Warrior Feed 304 Front Panel
Warrior Feed 304 Wire Feeder Data
42 VAC,
50/60 Hz
Wire Spool
Capacity,
lbs. (kg)
Max. Spool
Diameter,
in. (mm)
Wire Feed Speed,
ipm (m/min)
Dimensions
(LxWxH), in. (mm)
44 (18)
12 (300)
32-1000 (0.8-25)
27 x11x16
(690 x 275 x 420)
1
Weight
Enclosed,
lbs. (kg)
33 (15)
Wire Dimensions, in. (mm)
Steel
Stainless steel
Aluminum
Cored wire
.023–1/16 (0.6–1.6)
.023–1/16 (0.6–1.6)
.040–1/16 (0.8–1.6)
.030–1/16 (0.9–1.6)
Enclosed.
1
ESAB Welding and Cutting Products
USA: www.esabna.com / 1.800.ESAB.123 | Canada: www.esab.ca / 1.877.935.3226 | Mexico: www.esab.com.mx / (81) 8305-3700
ARC-23304a 02/14
Power
Supply
Warrior 500i
with Warrior Feed 304
™
Warrior Feed 304 Wire Feeder Wear Parts
Wire Type
1
Feeder Roller
(4 required)
2
Inlet
Nozzle
3
Intermediate
Nozzle
4
Outlet
Nozzle
Groove
Type
Marking
023/.030 (0.6-0.8)
Fe, Ss, C
0459052001
0455049001
0455072002
0469837880
V
0.6 S2 / 0.8 S2
.030/.035-.040
(0.8/0.9-1.0)
Fe, Ss, C
0459052002
0455049001
0455072002
0469837880
V
0.8 S2 / 1.0 S2
.035-.040/.045
(0.9-1.0/1.1)
Fe, Ss, C
0459052003
0455049001
0455072002
0469837880
V
1.0 S2 / 1.2 S2
.052/1/16 (1.3/1.6)
Wire Diameter,
in. (mm)
1
Fe, Ss, C
0459052013
0455049001
0455072002
0469837880
V
1.4 S2 / 1.6 S2
.035-.040/.045
(0.9-1.0/1.1)
C
0458825001
0455049001
0455072002
0469837880
V-K
1.0 R2 / 1.2 R2
.045/.045 (1.1/1.1)
C
0458825010
0455049001
0455072002
0469837880
V-K
1.2 R2 / 1.2 R2
.045/.052 (1.1/1.3)
C
37319
0455049001
0455072002
0469837880
V-K
1.2 R2 / 1.4 R2
1/16-5/64 (1.6-2.0)
C
37320
0455049001
0455072002
0469837880
V-K
1.6 R2
.035-3/64 (0.8-0.9)
Al
36860
0455049001
0456615001
0469837881
U
0.8 A2 / 1.0 A2
3/64-1/16 (0.9-1.6)
Al
36861
0455049001
0456615001
0469837881
U
1.2 A2 / 1.6 A2
C = cored wire, K = knurled groove.
As delivered.
1
Specifications
Input voltage
380/460/575V, 3ph, 50/60Hz
Permitted load at:
60% duty cycle
100% duty cycle
500A/40 V
400A/36 V
Setting range:
GMAW/FCAW (MIG)/GTAW (TIG)
SMAW (STICK)
16-500A
4-500A
Open circuit voltage
54V
Open circuit power
500W
Power factor at maximum current
0.92
Efficiency at maximum current
88%
Dimensions, LxWxH, in. (mm)
28.1x12.8 x18.5 (712x325x470)
Weight, lbs. (kg)
115 (52)
Operating temperature, °F (°C)
14 to 104 (-10 to 40)
Enclosure class
IP 23
ESAB Welding and Cutting Products
United States / esabna.com / 1.800.ESAB.123 Canada / esab.ca / 1.877.935.3226 Mexico / esab.com.mx / (81) 8305.3700
ARC-23304 07/13
Warrior 500i
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