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
0446 455 001 -8- © ESAB AB 2021
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
0446 455 001 -9- © ESAB AB 2021
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.

4  INSTALLATION
0446 455 001 - 11 - © ESAB AB 2021
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.
4.2 Lifting instructions

4  INSTALLATION
0446 455 001 - 12 - © ESAB AB 2021
WARNING!
Secure the equipment - particularly if the
ground is uneven or sloping.
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 401i / EM 401i with cooling unit
Mains voltage 380V 3~50/60Hz 400V3~ 50/60Hz 415V3~ 50/60Hz
Mains cable area 4×6 mm24×6 mm24×6 mm2
Maximal current rating Imax 29A 28A 26A
I1eff
MIG/MAG 21A 20A 19A
MMA 22A 21A 20A
Input protection device
(distribution box) Miniature circuit
breaker (MCB)
Type Cand32A
Fabricator EM 501i with cooling unit
Mains voltage 380V3~ 50/60Hz 400V3~ 50/60Hz 415V3~ 50/60Hz
Mains cable area 4×6mm24×6mm24×6mm2
Maximal current rating Imax 41A 38A 38A
I1eff
MIG/MAG 30A 28A 27A
MMA 31A 29A 28A
Input protection device
(distribution box) Miniature circuit
breaker (MCB)
TypeCand32A

4  INSTALLATION
0446 455 001 - 13 - © ESAB AB 2021
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.
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 455 001 - 14 - © ESAB AB 2021
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
8 24 V AC power supply socket for gas regulator
2 Connection (-): MIG/MAG: Return cable, MMA:
Return cable or welding cable
9 Cooling unit mains switch ON/OFF
3 Indicating LED, Overheating 10 Coolant filling
4 Connection of wire feed unit 11 Min/Max of coolant
5 Fuse for the gas regulator input supply 12 Connection RED for coolant (return) to cooling
unit
6 Mains power supply switch, ON/OFF 13 Connection BLUE for coolant from cooling unit
7 Mains cable inlet
WARNING!
Do not use DC- in MIG mode, if DC- needed, please contact authorised ESAB local service.

5  OPERATION
0446 455 001 - 15 - © ESAB AB 2021
The following figure shows the front control panel and the buttons on the control panel of the welder.
S.no. Name Function
1 Ending arc current Adjusts the Ending arc current in 4T and 4T repeat mode
2 Ending arc voltage Adjusts the 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. Lower inductance will give hard arc and higher
inductance will give soft 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.
NOTE!
Gas options are only for solid wires and not for cored wires.
7 Welding control Selects the welding control mode (2T, 4T, 4T repeat).
See chapter "5.3 Welding control mode".

5  OPERATION
0446 455 001 - 16 - © ESAB AB 2021
S.no. Name Function
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.
Internal menu feature
1. Press the arc current and arc voltage buttons (see items 1 and 2 in the "Connections
and control devices" chapter) at the same time for 3 seconds to enter the internal
menu and press the arc current and arc voltage buttons at the same time to exit the
internal menu settings.
2. In the internal menu setting, use the knob on the panel to switch between menu
options at the same level and adjust parameter values.
3. In the internal menu setting, the inductance button on the panel is used as the
parameter selection confirmation button.
4. When setting each parameter in the internal menu, when the digital display shows
"OFF", the current parameter is the default parameter of the welding power source,
and when the digital display shows other values, it is the user setting parameter.
Code Description Default Range Internal Menu Explanation
F01 Restore factory
settings
F02 Given wire feeding
speed
SPd
F10
Slow wire feeding
speed OFF 1.4–18
MIG/MAG: The wire feed speed
before the welding arc ignites or
before the filler wire comes in
contact with the workpiece
(Creep start) m/min
F11 Pre-gas time OFF 0–25s MIG/MAG: Gas delivery time before
arc starts
F14 Post-gas time OFF 0–25s MIG/MAG: Gas delivery time after
arc ends
F20 DC burn back
voltage
OFF 12–45V MIG/MAG: The voltage at the end
of welding, to melt a part of wire at
the tip to prevent the wire from
sticking to the workpiece
F21 DC burn back time OFF 0 – 1.00 s MIG/MAG: Time for DC burn back
voltage. Longer time will lead to
melt the contact tip
F22 DC chopping time OFF 0–1.00s MIG/MAG: The function is to
prevent obvious small balls at the
end of the wire after welding and
improve the success rate of arc
starting next time. This parameter is
used in conjunction with burn-back
voltage and burn-back time

5  OPERATION
0446 455 001 - 17 - © ESAB AB 2021
Code Description Default Range Internal Menu Explanation
F25 Arc Start voltage OFF 12–38V(EM401i)
12–45V(EM501i)
MIG/MAG: Higher arc-start current
and arc-start voltage to improve the
arc-start fusion effect.
F26 Arc Start current OFF 30–400A (EM401i)
30–500A (EM501i)
F27 Arc Start time OFF 0–10.0s MIG/MAG: The duration of arc-start
current and arc-start voltage.
F50 Arc Striking current OFF 30–400A (EM401i)
30–500A (EM501i)
MMAW: Current at the moment
when electrode contacts base metal
F51 Hot Start current OFF 0–100A MMAW: Additional current during
arc start, based on the given
welding current.
FB0 Board software
and hardware
version query –
010 – 104
For service purpose
110 – 102
210 – 103
300 – 201
FB1 Fault record query Err – For service purpose
FB2 Machine model
query
C50 – For service purpose
5.2 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, the wire feed then stops and when the switch is released the
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 2 seconds, the welding with repeated ending arc stops.

5  OPERATION
0446 455 001 - 18 - © ESAB AB 2021
2-stroke mode (welding without ending arc)
4-stroke mode (welding with ending arc)

5  OPERATION
0446 455 001 - 19 - © ESAB AB 2021
4-stroke repeat mode (Welding with repeated ending arc)
5.3 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.
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  OPERATION
0446 455 001 - 20 - © ESAB AB 2021
5.4 Symbols and functions
Mains power supply switch Overheating (3)
Protective earth Positioning of lifting eye
Arc force Inductance
Gas detection MMA welding
Arc-closing current / Ending
arc current
Arc-closing voltage / Ending arc
voltage
5.5 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.
5.6 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 401i 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 501i 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).