ESAB Fabricator EM 400i User manual

Instruction manual
0446 404 001 GB 20200806 Valid for: 008-xxx-xxxx
FabricatorEM400i,
FabricatorEM500i

TABLE OF CONTENTS
0446 404 001 © ESAB AB 2020
1SAFETY ....................................................................................................... 3
1.1 Meaning of symbols ............................................................................... 3
1.2 Safety precautions ................................................................................. 3
2INTRODUCTION.......................................................................................... 6
2.1 Overview ................................................................................................. 6
2.2 Equipment ............................................................................................... 6
3TECHNICAL DATA ...................................................................................... 7
4INSTALLATION ........................................................................................... 9
4.1 Location................................................................................................... 9
4.2 Lifting instructions ................................................................................. 10
4.3 Mains supply........................................................................................... 11
5OPERATION ............................................................................................... 13
5.1 Connections and control devices ......................................................... 13
5.1.1 Welding control mode........................................................................... 15
5.2 Connection of welding and return cable .............................................. 16
5.3 Symbols and functions .......................................................................... 17
5.4 Thermal protection ................................................................................. 17
5.5 Fan control .............................................................................................. 18
6MAINTENANCE .......................................................................................... 19
6.1 Routine maintenance ............................................................................. 19
6.2 Power source.......................................................................................... 19
7TROUBLESHOOTING ................................................................................. 21
8ORDERING SPARE PARTS ....................................................................... 24
BLOCK DIAGRAM............................................................................................... 25
ORDERING NUMBERS....................................................................................... 26
ACCESSORIES ................................................................................................... 27
Rights reserved to alter specifications without notice.

1 SAFETY
0446 404 001 -3- © ESAB AB 2020
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:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0446 404 001 -4- © ESAB AB 2020
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 extinguishing equipment must be clearly marked and close at
hand
○ 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.
Recommended ESAB coolant ordering number: 0465720002.
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.

1 SAFETY
0446 404 001 -5- © ESAB AB 2020
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.
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
0446 404 001 -6- © ESAB AB 2020
2 INTRODUCTION
2.1 Overview
The FabricatorEM400i and FabricatorEM500i are welding power sources intended for
MIG/MAG welding, welding with powder filled cored wire (FCAW-S) and welding with coated
electrodes (MMA). The power sources are intended for use with the following wire feed units:
• Feed 364
• Fabricator Feed 364
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.2 Equipment
The power source is supplied with:
• 5m return cable with earth clamp
• 4.5m mains cable
• instruction manual

3 TECHNICAL DATA
0446 404 001 -7- © ESAB AB 2020
3 TECHNICAL DATA
FabricatorEM400i
Mains voltage 380-440V ±10%, 3~50/60Hz
Primary current I max 380V 400V 415V 440V
MIG/MAG 24 A 23A 22A 21A
MMA 25 A 24A 23A 22A
Setting range (DC)
MIG/MAG 30A/12.0V-400A/34.0V
MMA 30A/21.2 V-400A/36.0V
Permissible load at MIG/MAG
60% duty cycle 400 A/34.0 V
100% duty cycle 310 A/29.5 V
Permissible load at MMA
60% duty cycle 400 A/36.0 V
100% duty cycle 310 A/32.4 V
Power factor at maximum current 0.93
Maximum input power at idle mode <50W
Efficiency at maximum current 87%
Open-circuit voltage 63.7V
Operating temperature -10 to +40°C
Transportation temperature -20 to +55°C
Dimensions l × w × h 712 × 325 × 470mm (28.1 × 12.8 × 18.5 in.)
Weight 59 kg (130 lb.)
Insulation class H
Enclosure class IP 23S
Application class
FabricatorEM500i
Mains voltage 380-440V ±10%, 3~50/60Hz
Primary current I max 380V 400V 415V 440V
MIG/MAG 34 A 33A 31A 30A
MMA 35 A 34A 32A 30A
Setting range (DC)
MIG/MAG 30A/15.5V-500A/39.0V
MMA 30A/21.2 V-500A/40.0V
Permissible load at MIG/MAG
60% duty cycle 500 A/39.0 V
100% duty cycle 390 A/33.5 V
Permissible load at MMA
60% duty cycle 500 A/40.0 V

3 TECHNICAL DATA
0446 404 001 -8- © ESAB AB 2020
FabricatorEM500i
100% duty cycle 390 A/35.6 V
Power factor at maximum current 0.93
Maximum input power at idle mode <50W
Efficiency at maximum current 87%
Open-circuit voltage 73.3V
Operating temperature -10 to +40°C
Transportation temperature -20 to +55°C
Dimensions l × w × h 712 × 325 × 470mm (28.1 × 12.8 × 18.5 in.)
Weight 62 kg (136.6 lb.)
Insulation class H
Enclosure class IP 23S
Application class
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, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23S is intended for indoor and outdoor use, but are not intended to be
used outside during precipitation unless sheltered.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION
0446 404 001 -9- © ESAB AB 2020
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 power source so that cooling air inlets and outlets are not obstructed.

4 INSTALLATION
0446 404 001 - 10 - © ESAB AB 2020
4.2 Lifting instructions
WARNING!
Secure the equipment - particularly
if the ground is uneven or sloping.

4 INSTALLATION
0446 404 001 - 11 - © ESAB AB 2020
4.3 Mains supply
NOTE!
This equipment does not comply with IEC 61000-3-12. If it is connected to a public
low voltage system, it is the responsibility of installer or the user of the equipment to
ensure, by consultation with the distribution network if necessary, that the equipment
may be connected.
Make sure that the welding power source is connected to the correct supply voltage and that
it is protected by the correct fuse rating. A protective earth connection must be made in
accordance with regulations.
The power source will automatically adjust to the supplied input voltage.
Recommended MCB sizes and minimum cable area
FabricatorEM400i
Mains
voltage
380 V 3~ 50/60Hz 400 V 3~ 50/60Hz 415 V 3~ 50/60Hz 440 V 3~ 50/60Hz
Mains
cable area
4 × 6 mm² 4 × 6 mm² 4 × 6 mm² 4 × 6 mm²
Maximal
current
rating Imax
28 A 27 A 25 A 21A
I1eff
MIG/MAG 20 A 19 A 18 A 17A
MMA 21 A 20 A 19 A 18A
Input circuit
breaker-
MCB
(distribution
box)
Type C & 40 A or greater
FabricatorEM500i
Mains
voltage
380 V 3~ 50/60Hz 400 V 3~ 50/60Hz 415 V 3~ 50/60Hz 440 V 3~ 50/60Hz
Mains
cable area
4 × 6 mm² 4 × 6 mm² 4 × 6 mm² 4 × 6 mm²
Maximal
current
rating Imax
38 A 36 A 35 A 31A
I1eff
MIG/MAG 28 A 27 A 26 A 24A
MMA 29 A 28 A 26 A 24A
Input circuit
breaker-
MCB
(distribution
box)
Type C & 63A or greater

4 INSTALLATION
0446 404 001 - 12 - © ESAB AB 2020
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!
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.

5 OPERATION
0446 404 001 - 13 - © ESAB AB 2020
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
1. Connection (+): MIG/MAG: Welding
cable, MMA: Welding cable or return
cable
6. Fuse for the gas heater input supply
2. 2. Connection (-): MIG/MAG: Return
cable, MMA: Return cable or welding
cable
7. Mains power supply switch, ON/OFF
3. 3. Indicating LED, Overheating 8. Mains cable inlet
4. Connection of wire feed unit 9. 110V AC power supply socket for gas
heater
5. Circuit breaker 10A (wirefeeder motor) 10. CAN communication connector (Factory
use)
The following figure shows the front control panel and the buttons on the control panel of the
welder.

5 OPERATION
0446 404 001 - 14 - © ESAB AB 2020
S.no. Name Function
1 Ending arc current
/ Crater fill current
Adjusts the crater fill / Ending arc current in 4T and 4T repeat
mode
2 Ending arc voltage
/ Crater fill voltage
Adjusts the crater fill / Ending arc voltage in 4T and 4T repeat
mode
3 Arc force The arc force is important in determining how the current
changes in response to a change in the arc length. A lower value
gives a calmer arc with less spatter. It only applies to MMA
welding.
4 Inductance Sets the dynamic of arc. The lower inductance will give softest
arc and higher inductance will give hardest arc.
5 Wire diameter Selects the diameter of the welding wire. Only applicable for MIG
welding
6 Welding process /
Wire type and gas
Selects the welding process
• Solid wire-CO2, (MIG/MAG)
• Solid-Mix gas, (MIG/MAG)
• Cored wire (MIG/MAG)
• MMA welding
If MMA mode to be selected, press and hold for 2 seconds. To
come out from MMA mode again press and hold for 2 seconds.
7 Welding control Selects the welding control mode.
8 Gas detection Detects gas flow.
9 Value adjusting
knob
Manually adjusts
• the current for MMA process
• the ending arc voltage, ending arc current, Inductance for
MIG/MAG process and
• the current and voltage within specified ranges.

5 OPERATION
0446 404 001 - 15 - © ESAB AB 2020
5.1.1 Welding control mode
2-stroke
With 2-stroke, gas pre-flow starts when the welding torch trigger switch is
pressed. The welding process then starts. Releasing the trigger switch stops
welding entirely and starts gas post-flow.
4-stroke
With 4 stroke, the gas pre-flow starts when the welding torch trigger switch is
pressed in and the wire feed starts when it is released. The welding process
continues until the switch is pressed in again, then the ending arc is generated
using the ending arc voltage and current. Releasing the trigger switch stops the
welding and gas post-flow starts.
4-stroke repeat
When the torch trigger switch is pressed in, the gas flow starts and an arc is
generated. When the trigger switch is released the arc generation is locked.
When the trigger switch is pressed in again, the ending arc is generated using
the ending arc voltage and current. When the switch is released again, the
welding stops. When the trigger switch is pressed in again within two seconds
and holding it, welding with repeated ending arc starts. When the switch is
released the repeated ending arc stops. If the switch is not pressed in again
within 2seconds, the welding with repeated ending arc stops.
2-stroke mode (welding without ending arc)

5 OPERATION
0446 404 001 - 16 - © ESAB AB 2020
4-stroke mode (welding with ending arc)
4-stroke repeat mode (Welding with repeated ending arc)
5.2 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.

5 OPERATION
0446 404 001 - 17 - © ESAB AB 2020
Recommended maximum welding current values for the welding/return cable(copper)
at an ambient temperature of +25°C and normal 10minutes cycle
Cable size mm2Duty cycle Voltage
drop/10m
100% 60% 35%
50 285 A 320 A 370 A 0.352V/100A
70 355 A 400 A 480 A 0.254V/100A
95 430 A 500 A 600 A 0.189V/100A
Recommended maximum welding current values for the welding/return cable(copper)
at an ambient temperature of +40°C and normal 10minutes cycle
Cable size mm2Duty cycle Voltage
drop/10m
100% 60% 35%
50 250 A 280 A 320 A 0.352V/100A
70 310 A 350 A 420 A 0.254V/100A
95 375 A 440 A 530 A 0.189V/100A
5.3 Symbols and functions
Mains power supply
switch
Overheating (3)
Protective earth Positioning of lifting eye
Arc force Inductance
Gas detection MMA welding
Ending arc current /
Crater fill current
Ending arc voltage / Crater fill
voltage
5.4 Thermal protection
The welding power source has overheating protection that operates if the temperature
becomes too high. When this occurs, the welding current is interrupted, and an overheating
indication lamp is lit. The overheating protection resets automatically when the temperature
has fallen with in its normal working temperature.

5 OPERATION
0446 404 001 - 18 - © ESAB AB 2020
5.5 Fan control
The fan will run during the startup of the machine and will continue to run only for 10 minutes
if there is no operation.
In FabricatorEM400i when the welding current is less than 200A, the fan will run at low
speed, if the welding current goes above 200A, the fan will run at high speed.
In FabricatorEM500i when the welding current is less than 300A, the fan will run at low
speed, if the welding current goes above 300A, the fan will run at high speed.
After the welding stops, the fan will continue to run for 10 minutes and the power source
switches to idle mode (energy-saving mode).

6 MAINTENANCE
0446 404 001 - 19 - © ESAB AB 2020
6 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.
6.1 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 6 months
Clean inside
equipment. Use dry
compressed air with
reduced pressure.
6.2 Power source
To maintain the performance and increase the lifetime of the power source it is mandatory to
clean it regularly. How often depends on:

6 MAINTENANCE
0446 404 001 - 20 - © ESAB AB 2020
• the welding process
• the arc time
• the working environment
CAUTION!
Make sure that the cleaning procedure is done in a suitable prepared workspace.
Cleaning procedure
1. Disconnect the power source from the mains supply.
WARNING!
Wait for 4 minutes for the capacitors to discharge before continuing.
2. Remove the side panels on the power source.
3. Remove the top panel on the power source.
4. Remove the plastic cover between the heat sink and fan (b).
5. Clean the power source with dry compressed air (4 bar) as follows:
○ The upper rear part.
○ From the rear panel through the secondary heat sink.
○ The inductor, transformer and current sensor.
○ The power components side, from the rear side behind PCB15AP1.
○ The PCBs at both sides.
6. Make sure that there is no dust left on any part of the power source.
7. Install the plastic cover between the heat sink and the fan (b) and make sure it is
correctly fitted against the heat sink.
8. After having finished cleaning the power source, reattach the power source panels in
the reverse order.