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.