Warrior 500i

with Warrior Feed 304

Multi-Process - Warrior is designed for GMAW
(MIG), FCAW (Flux-Cored), SMAW (Stick), and GTAW
(TIG) welding, as well as ACAG (Arc Gouging), and
delivers up to 500 Amps @ 60% duty cycle
Welds .030-5/64 in. Flux-Cored and Solid wires
Great short arc performance with 500 Amps
Full range of stick capabilities with excellent 7018
and 6010 performance
Arc Gouges with electrodes up to 3/8 in. diameter
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 - reduces energy consumption and dirt intake
High-Duty cycle - for long runs across a variety of
applications
Automatic Hot Start / Variable Arc Control Optimize settings with total arc control - hot start,
arc force, and inductance settings. Allows the
welder to fine-tune the arc to get best possible
weld performance
Connection Cable set - power, gas and control
cables are in an all-in-one bundle with quick
disconnect plugs reduce set-up time. And they're
housed in a tough, protective cover so your cables
will last longer
Easy to use - simple and clear user interface so
you'll be in production quickly
All-in-one-panel - all of your controls, including
your power switch, are located on the 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 - IP23 rating for outdoor and
indoor use in rough environments

Simple functionality welders want at a

competitive price.
Introducing Warrior by ESAB - the breakthrough welding
machine you need to expand your skills. Warrior was
designed with input from real-world welders and built with
ESAB's leading-edge engineering to be a machine that's
as rugged and reliable as you are.

ESAB Welding and Cutting Products

esabna.com / 1.800.ESAB.123

Ordering Information
Ready to Weld Packages
Warrior 500i with Warrior 304, 5.5 ft........................ 0558101760
Warrior 500i with Warrior 304, 32 ft......................... 0558101761
Basic Packages
Warrior 500i with Warrior 304.................................. 0558101759
Warrior 500 with MobileFeed 300AVS.................... 0558101762
Power Source Only
Warrior 500i DC CC/CV inverter.............................. 0465350881
Warrior Power Source Rack
Includes 4 power sources, fused for 460 V, 3 ph.... 0588002000
Ready to Weld package includes: DC CC/CV inverter power
source, feeder, 15 ft. (4.5 m) 400 A torch, 5.5 ft. connection cable
set, work cable, reg. flowmeter Ar Co2
Basic package includes: DC CC/CV inverter power source,
feeder, 15 ft. (4.5 m) 400 A torch

Feeder Accessories
Wheel kit......................................................................0458707880
Strain relief for welding torch....................................0457341881
Feeder strain relief for connection cables...............0459234880
Lifting eye....................................................................0458706880
Quick connector MarathonPac adapter..................0558002354
Adapter for 11 lb spool...............................................0455410001
Steel spool cover, 12".................................................0459431880
Counter-balance Mini boom
For 12" spools........................................................... 0458705880
For 18" spools........................................................... 0458705882
Extension arm for 60 lb coil (18" spools)................. 0459233880
Coil adapter (requires 0459233880)....................................34323
Female gas hose quick-connector.......................... 0365803002
Gas flow checker..................................................................19043
PrecisionMaster gas saver kit.................................. 0558007079
Remote kit, warrior power source............................0465424880
Please see General Accessories section for additional options.

Connection Cable Sets

Air-Cooled Torch
5.6 ft. (1.7 m)............................................................. 0459836880
32.8 ft. (10.0 m)......................................................... 0459836882
49.2 ft. (15.0 m)......................................................... 0459836883
82.0 ft. (25.0 m)......................................................... 0459836884
Includes control cable, electrode cable, and gas hose
Instruction Manual
Warrior 500i............................................................ 0463 341 031
Warrior Feed 304................................................... 0463 343 031
Product Data Page ...................................................... ARC-23304

Warrior 500i
with Warrior Feed 304
Torches
HW-17V-2TL
12.5 ft. (3.6 m)..................................................................... 35857
25 ft. (7.6 m)........................................................................ 35856
HW-26V-2TL
12.5 ft. (3.6 m)..................................................................... 35858
HW-17, 18, 26 Accessory Kit............................................ 999126

GunMaster 400cc
25 ft. (7.6 m) Basic.................................................... 0558001674
12 ft. (3.6 m) x .035.045 in....................................... 0558001667
15 ft. (4.5 m) x .035.045 in. ..................................... 0558001669
15 ft. (4.5 m) x .0521/16 in...................................... 0558001670
See ARC-23095 for additional information.

Feeder Data
Power
Supply
42 VAC,
50/60 Hz

Wire Spool
Capacity
44 lb
(18 kg)

Max. Spool
Diameter
12 in.
(300 mm)
(enclosed)

Dimension
(L x W x H)

Wire Feed Speed

32-1000 in./min.
(0.8-25.0 m/min.)

26.6 x 10.4 x 16.5 in.

(675 x 265 x 418 mm)

Weight

Wire Dimensions

32 lb (14.5 kg)

Steel
.023.062 in. (0.61.6 mm)
Stainless steel
.023.062 in. (0.61.6 mm)
Aluminum
.030.062 in. (0.81.6 mm)
Cored wire
.035.062 in. (0.91.6 mm)

Panel (MMC) functions

Wire feed speed (WFS)
Digital V/A meters
Gas purge/wire inching

Wear Parts
Wire Type

1
Feeder Roller
(4 required)

2
Inlet Nozzle

3
Intermediate
Nozzle

4
Outlet Nozzle

Groove
Type

023 / .030

Fe, Ss, C

0459052001

0455049001

0455072002

0469837880

0.6 S2 / 0.8 S2

.030 / .035 -.040

Fe, Ss, C

0459052002

0455049001

0455072002

0469837880

0.8 S2 / 1.0 S2

.035 - .040 / .045*

Fe, Ss, C

0459052003

0455049001

0455072002

0469837880

1.0 S2 / 1.2 S2

.052 / .063

Wire Diameter (in.)

Marking

Fe, Ss, C

0459052013

0455049001

0455072002

0469837880

1.4 S2 / 1.6 S2

.035 -.040 / .045

0458825001

0455049001

0455072002

0469837880

V-K

1.0 R2 / 1.2 R2

.045 / .045

0458825010

0455049001

0455072002

0469837880

V-K

1.2 R2 / 1.2 R2

.045 / .052

0458825002

0455049001

0455072002

0469837880

V-K

1.2 R2 / 1.4 R2

1/16 - 5/64

0458825003

0455049001

0455072002

0469837880

V-K

1.6 R2

.035 - 3/64

Al

0458824001

0455049001

0456615001

0469837881

0.8 A2 / 1.0 A2

3/64 - 1/16

Al

0458824003

0455049001

0456615001

0469837881

1.2 A2 / 1.6 A2

C = cored wire

ESAB Welding and Cutting Products

esabna.com / 1.800.ESAB.123

* as delivered

K = knurled groove

Warrior 500i
with Warrior Feed 304
Power Source Features
Multi-voltage ready to work
anywhere
Inverter technology - increased
energy efficiency and more
power from a lighter, smaller,
and more portable unit
Provides superior starts and an
extremely smooth and stable
arc transfer with excellent weld
finishes

Control Panel

Power On/Off

Digital Volt / Amp Meter

VRD LED
Over Temperature LED
Wire Feeder Connector

Output Voltage /
Current Control

Resettable Circuit Breaker

Stick Mode Selector

Output Power Connectors

Automatic Hot Start /

Variable Arc Control

Process Selector

ESAB Welding and Cutting Products

esabna.com / 1.800.ESAB.123

Warrior 500i
with Warrior Feed 304
Power Source Accessories
Electrode holder assembly
15 ft. (300 Amps)............................................................... 21226
15 ft. (175 Amps).....................................................0558001791
Trolley, 1-cylinder........................................................0465510880
Wheel kit......................................................................0465416880
Water cooler................................................................0465427880
Work cable assembly
15 ft. w/clamp 50 mm OKC................................................ 36253
32 ft. w/clamp 50 mm OKC......................................0558001906

Remote controls
FS003-B Foot control - 25 ft. cable.........................0558008905
RCA-2B torch control - 25 ft. cable..........................0558008904
See Remote Controls section for additional options
Q4000 gouging torch, 10 ft. pkg.............................. Q61-082-009
Please see General Accessories section for additional options.

Specifications
Warrior 500i
Input voltage

380/460 V 3 ph 50/60 Hz
380/575 V 3 ph 50/60 Hz

Permitted load
60% duty cycle 500 A / 40 V
100% duty cycle 400 A / 36 V
Setting range
GMAW/FCAW (MIG/MAG)

16 - 500 A

SMAW (STICK)

16 - 500 A

GTAW (TIG) 4 - 500 A

Open circuit voltage

54 V

Open circuit power

500 W

Power factor at maximum current

0.92

Efficiency at maximum current

88%

Dimensions L x W x H

28.1 x 12.8 x 18.5 in.

(712 x 325 x 470 mm)

Weight

115 lb (52 kg)

Operating temperature

14 to 104F (-10 to 40C)

Enclosure class

IP 23

ESAB Welding and Cutting Products

esabna.com / 1.800.ESAB.123