ESAB Warrior YardFeed 200 Bedienungsanleitung

Instruction manual

0463 387 131 US 20150918 Valid for: serial no. 528-xxx-xxxx

Warrior™ YardFeed 200

Warrior™YardFeed200w

TABLE OF CONTENTS

0463 387 131 © ESAB AB 2015

1 SAFETY PRECAUTIONS ..................................................................................... 3

2 INTRODUCTION................................................................................................... 9

3 TECHNICAL DATA ............................................................................................. 10

4 INSTALLATION................................................................................................... 12

4.1 Lifting instructions.............................................................................................12

5 OPERATION ....................................................................................................... 13

5.1 Connections and control devices.....................................................................14

5.2 Function .............................................................................................................. 15

5.3 Wire feed pressure.............................................................................................16

5.4 Replacing and inserting wire ............................................................................17

5.5 Changing feed rollers ........................................................................................17

6 MAINTENANCE.................................................................................................. 18

6.1 Inspection and cleaning ....................................................................................18

7 ORDERING SPARE PARTS ............................................................................... 19

DIAGRAM ..................................................................................................................20

ORDERING NUMBERS.............................................................................................22

WEAR PARTS............................................................................................................23

ACCESSORIES .........................................................................................................27

Rights reserved to alter specifications without notice.

1 SAFETY PRECAUTIONS

0463 387 131 -3- © ESAB AB 2015

1 SAFETY PRECAUTIONS

WARNING!

These Safety Precautions are for your protection. They summarise precautionary

information from the references listed in the Additional Safety Information section.

Before performing any installation or operating procedures, be sure to read and

follow the safety precautions listed below as well as all other manuals, material

safety data sheets, labels, etc. Failure to observe the Safety Precautions could

result in injury or death.

PROTECT YOURSELF AND OTHERS

Some welding, cutting and gouging processes are noisy and require

hearing protection. The arc, like the sun, emits ultraviolet (UV) and

other radiation and can injure the skin and eyes. Hot metal can cause

burns. Training in the proper use of the processes and equipment is

essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets,

face shields and goggles are also required.

2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face,

neck and ears from sparks and rays of the arc when operating or observing operations.

Warn bystanders not to look at the arc and not to expose themselves to the rays of the

electric-arc or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers,

high-topped shoes and a welding helmet or cap for protection, to protect against arc rays

and hot sparks or hot metal. A flameproof apron may also be desirable as protection

against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and

collars should be kept buttoned and open pockets eliminated from the front of the

clothing.

5. Protect other personnel from arc rays and hot sparks using a suitable nonflammable

partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be

hot and can fly for long distances. Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS

The heat from flames and arcs can start fires. Hot slag or sparks can

also cause fires and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials

with a protective nonflammable covering. Combustible materials include wood, cloth,

sawdust, liquid and gas fuels, solvents, paints and coating paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and

cause a hidden smoldering fire or fires on the floor below. Make certain that such

openings are protected from hot sparks and metal.

3. Do not weld, cut or perform other hot work until the workpiece has been completely

cleaned, to ensure there are no substances on the workpiece which might produce

flammable or toxic vapors. Do not perform hot work on closed containers. They may

explode.

1 SAFETY PRECAUTIONS

0463 387 131 -4- © ESAB AB 2015

4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water

pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can

overheat and create a fire hazard.

6. After completing work, inspect the work area to make sure there are no hot sparks or hot

metal that could cause a fire later. Use fire watchers when necessary.

7. For additional information refer to NFPA Standard 51B, "“Fire Prevention in Use of

Cutting and Welding Processes", available from the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK

Contact between live electrical parts and earth can cause severe injury

or death. DO NOT use AC welding current in damp areas, if movement

is confined, or if there is danger of falling. Therefore:

1. Be sure the power source frame (chassis) is connected to the earth system of the input

power.

2. Connect the workpiece to a good electrical earth.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you

or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and

power source.

6. Make sure that all parts of your body are insulated from the workpiece and from earth.

7. Do not stand directly on metal or the ground while working in tight quarters or a damp

area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power, before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific earthing

recommendations. Do not mistake the work lead for a earth cable.

ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current flowing through any conductor

causes localised Electric and Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables and welding

machines. Therefore:

1. Welders with pacemakers fitted should consult their doctor before welding. EMF may

interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimise exposure to EMF:

a) Route the electrode and work cables together. Secure them with tape when possible.

b) Never coil the torch or work cable around your body.

c) Do not place your body between the torch and work cables. Route cables on the

same side of your body.

d) Connect the work cable to the workpiece as close as possible to the area being

welded.

e) Keep the welding power source and cables as far away from your body as possible.

1 SAFETY PRECAUTIONS

0463 387 131 -5- © ESAB AB 2015

FUMES AND GASES

Fumes and gases, can cause discomfort or harm, particularly in

confined spaces. Do not breathe fumes and gases. Shielding gases

can cause asphyxiation. Therefore:

1. Always provide adequate ventilation in the work area by natural or mechanical means.

Do not weld, cut or gouge on materials such as galvanised steel, stainless steel, copper,

zinc, lead beryllium or cadmium unless positive mechanical ventilation is provided. Do

not breathe in the fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc can react with

chlorinated hydrocarbon vapours to form phosgene, a highly toxic gas and other irritant

gases.

3. If you develop momentary eye, nose or throat irritation while operating, this is an

indication that the ventilation is not adequate. Stop work and take the necessary steps to

improve ventilation in the work area. Do not continue to operate if physical discomfort

persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation

recommendations.

5. WARNING: This product when used for welding or cutting, produces fumes or gases that

contain chemicals known to the State of California to cause birth defects and in some

cases cancer (California Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING

Cylinders, if mishandled, can rupture and violently release gas.

Sudden rupture of cylinder valve or relief device can injure or kill.

Therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator

designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain

hoses and fittings in good condition. Follow the manufacturer's operating instructions for

mounting a regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position, by chain or strap, to suitable hand trucks,

undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or

fixtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if

regulator is not connected. Secure and move cylinders by using suitable hand trucks.

4. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of

Compressed Gases in Cylinders", which is available from Compressed Gas Association,

1235 Jefferson Davis Highway, Arlington, VA 22202.

1 SAFETY PRECAUTIONS

0463 387 131 -6- © ESAB AB 2015

WARNING!

EQUIPMENT MAINTENANCE

Faulty or improperly maintained equipment can cause injury or death.

Therefore:

1. Always have qualified personnel perform the installation, troubleshooting and

maintenance work. Do not perform any electrical work unless you are

qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect

the power source from the incoming electrical power.

3. Maintain cables, earthing wire, connections, power cord and power supply in

safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from

heat sources such as furnaces, wet conditions such as water puddles, oil or

grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

CAUTION!

ADDITIONAL SAFETY INFORMATION

For more information on safe practices for electric arc welding and cutting

equipment, ask your supplier for a copy of "Precautions and Safe Practices

for Arc Welding, Cutting and Gouging", Form 52-529.

The following publications, which are available from the American Welding

Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 . "Recommended Practices for Plasma Arc Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon, Arc Gouging and

Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding"

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc welding"

7. AWS SP - "Safe practices" - Reprint, Welding Handbook

8. ANSI/AWS F4.1 - "Recommended Safe Practices for Welding and Cutting of

Containers That Have Held Hazardous Substances"

MEANING OF SYMBOLS

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

1 SAFETY PRECAUTIONS

0463 387 131 -7- © ESAB AB 2015

DANGER!

Means immediate hazards that, 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.

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

could result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ the location of emergency stops

○ its function

○ the relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is within the working area of the equipment when it is started

○ no-one is unprotected when the arc is struck or work is started with the equpment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could

become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified electrician

○ Appropriate fire extinquishing equipment must be clearly marked and close at hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

1 SAFETY PRECAUTIONS

0463 387 131 -8- © ESAB AB 2015

CAUTION!

Read and understand the instruction manual before

installing or operating.

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 such locations, due to conducted as

well as radiated disturbances.

CAUTION!

This product is solely intended for arc welding.

NOTE!

Dispose of electronic equipment at a recycling

facility!

To conform with the 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.

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

0463 387 131 -9- © ESAB AB 2015

2 INTRODUCTION

The Warrior™ YardFeed 200 and Warrior™ YardFeed 200w wire feed units are intended for

MIG/MAG (GMAW) welding together with welding power sources:

• Warrior 400i CC/CV

• Warrior 500i CC/CV

They are available in different versions, see chapter "ORDERING NUMBERS".

The wire feed units are sealed and contain a four-wheel drive wire feed mechanism as well

as control electronics.

They can be used together with wire from ESAB, standard S200 Ø 200 mm / Ø 8 inch —

7.5kg/15lbs.

ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of

this manual.

3 TECHNICAL DATA

0463 387 131 - 10 - © ESAB AB 2015

3 TECHNICAL DATA

Warrior™ YardFeed 200

Power voltage 42 V, 50–60 Hz

Power requirement 252 VA

Rated supply current I16 A

Settings data

Wire feed speed 1.9-25.0 m/min (75-985 inch/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 inch), 7.5kg / 15lbs

Wire dimension

Fe 0.6–1.2 mm (0.023–0.047 inch)

Ss 0.6–1.2 mm (0.023–0.047 inch)

Al 1.0–1.2 mm (0.039–0.047 inch)

Cored wire 0.8–1.6 mm (0.031–0.063 inch)

Weight

WYF 200 12 kg (26.5 lbs)

WYF 200w 12.2 kg (26.9 lbs)

Dimensions (l × w × h) 593 × 210 × 312 mm

(23.3×8.3×12.28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 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

Factory standard settings

The standard factory settings for the Warrior™ YardFeed 200 are inch/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).

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