ESAB Fabricator EM 401i User manual

Fabricator EM 401i,
Fabricator EM 501i
Instruction manual
0446 455 001  GB  20210630
Valid for: Serial number:
OP110YY-XXXXXX

TABLE OF CONTENTS
0446 455 001 -3- © ESAB AB 2021
1 SAFETY ...................................................................................................................................... 4
1.1 Meaning of symbols .................................................................................................... 4
1.2 Safety precautions ...................................................................................................... 4
2 INTRODUCTION ......................................................................................................................... 7
2.1 Equipment.................................................................................................................... 7
3 TECHNICAL DATA ..................................................................................................................... 8
4 INSTALLATION........................................................................................................................... 11
4.1 Location........................................................................................................................ 11
4.2 Lifting instructions ...................................................................................................... 11
4.3 Mains supply................................................................................................................ 12
5 OPERATION ............................................................................................................................... 14
5.1 Connections and control devices .............................................................................. 14
5.2 Welding control mode................................................................................................. 17
5.3 Connection of welding and return cable ................................................................... 19
5.4 Symbols and functions ............................................................................................... 20
5.5 Thermal protection ...................................................................................................... 20
5.6 Fan control ................................................................................................................... 20
5.7 Usage of the cooling unit............................................................................................ 21
5.8 Coolant connection .................................................................................................... 21
5.9 Coolant pressure controller ...................................................................................... 21
6 MAINTENANCE.......................................................................................................................... 22
6.1 Maintenance................................................................................................................. 22
6.2 Routine maintenance .................................................................................................. 22
6.3 Power source ............................................................................................................... 22
6.4 Cooling unit.................................................................................................................. 24
6.5 Filling the coolant........................................................................................................ 24
7 TROUBLESHOOTING ................................................................................................................ 25
8 ORDERING SPARE PARTS ....................................................................................................... 28
ORDERING NUMBERS ......................................................................................................................... 29
BLOCK DIAGRAM................................................................................................................................. 30
ACCESSORIES ..................................................................................................................................... 31

1  SAFETY
0446 455 001 -4- © ESAB AB 2021
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
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

1  SAFETY
0446 455 001 -5- © ESAB AB 2021
• 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
WARNING!
Wire feeders are intended to be used with power sources in MIG/MAG mode only.
If used in any other welding mode, such as MMA, the welding cable between wire feeder and
power source must be disconnected, or else the wire feeder becomes live or energized.
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
• 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
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.

1  SAFETY
0446 455 001 -6- © ESAB AB 2021
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 therefore 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.
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 those
locations, due to conducted as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling facility!
In observance of 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 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 455 001 -7- © ESAB AB 2021
2 INTRODUCTION
The Fabricator EM 401i and Fabricator EM 501i 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:
• Fabricator Feed 304
• Fabricator Feed 304w
EM 401i and EM 501i are available with a built-in cooling unit to support liquid cooled torches.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.
2.1 Equipment
The power source is supplied with:
• 5m return cable with earth clamp
• Instruction manual

3  TECHNICAL DATA
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3 TECHNICAL DATA
FabricatorEM 401i / EM 401i with cooling unit
Mains voltage 380-415V ±10%, 50/60Hz
Mains supply Sscmin 1.9MVA
Primary current I max 380V 400V 415V
MIG/MAG 28 A 27A 25A
MMA 29 A 28A 26A
Setting range (DC)
MIG/MAG 30A/15.5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 0.91
Maximum input power at idle mode <35 W
Efficiency at maximum current 86%
Open-circuit voltage 65.0V
Recommended wire 0.8 -1.2 mm
Operating temperature -10 to +40°C (14 to 104 °F)
Transportation temperature -40 to +70 °C (-40 to 158 °F)
Dimensions l × w × h 1035×500×1015mm (40.7×19.6×39.9in.)
Weight
Weight without cooling unit 102.0 kg (225 lbs)
Weight with cooling unit without coolant 107.5 kg (237 lbs)
Weight with cooling unit with coolant 111.5 kg (246 lbs)
Insulation class H
Enclosure class IP 23
Application class
FabricatorEM 501i with cooling unit
Mains voltage 380-415V ±10%, 50/60Hz
Mains supply Sscmin 6.2MVA
Primary current I max 380V 400V 415V
MIG/MAG 39 A 37A 36A
MMA 41 A 38A 37A
Setting range (DC)

3  TECHNICAL DATA
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FabricatorEM 501i with cooling unit
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
100% duty cycle 390 A/35.6 V
Power factor at maximum current 0.91
Maximum input power at idle mode <35W
Efficiency at maximum current 87%
Open-circuit voltage 78.0V
Recommended wire 1.0-1.6 mm
Operating temperature -10 to +40°C (14 to 104 °F)
Transportation temperature -40 to +70 °C (-40 to 158 °F)
Dimensions l × w × h 1035×500×1015mm (40.7×19.6×39.9in.)
Weight
Weight with cooling unit without coolant 111.5 kg (246 lbs)
Weight with cooling unit with coolant 115.5 kg (255 lbs)
Insulation class H
Enclosure class IP 23
Application class
Cooling unit (500A - 60% duty cycle) Only for power sources with cooling units
Cooling power 1 kW at 25°C ambient temperature
Coolant ESABs ready mixed coolant
Coolant quantity 4.5 l
Maximum water flow 1.8 l/min
Maximum pressure lift for torch Qmax 66.7 PSI (4.6 bar)
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
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 IP23 is intended for indoor and outdoor use.

3  TECHNICAL DATA
0446 455 001 - 10 - © ESAB AB 2021
Application class
The symbol indicates that the power source is designed for use in areas with increased electrical
hazard.