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).
1.2Safety 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
○ 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.
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.
0446 404 001
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.
•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.
The FabricatorEM400i and FabricatorEM500i 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.
Dimensions l × w × h712 × 325 × 470mm (28.1 × 12.8 × 18.5 in.)
Weight62 kg (136.6 lb.)
Insulation classH
Enclosure classIP 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 symbolindicates that the power source is designed for use in areas with increased
electrical hazard.
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.
4.1Location
Position the power source so that cooling air inlets and outlets are not obstructed.
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
FabricatorEM400i
Mains
380 V 3~ 50/60Hz 400 V 3~ 50/60Hz 415 V 3~ 50/60Hz 440 V 3~ 50/60Hz
voltage
Mains
4 × 6 mm²4 × 6 mm²4 × 6 mm²4 × 6 mm²
cable area
Maximal
28 A27 A25 A21A
current
rating I
I
1eff
max
MIG/MAG20 A19 A18 A17A
MMA21 A20 A19 A18A
Input circuit
breakerMCB
Type C & 40 A or greater
(distribution
box)
FabricatorEM500i
Mains
380 V 3~ 50/60Hz 400 V 3~ 50/60Hz 415 V 3~ 50/60Hz 440 V 3~ 50/60Hz
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 ≥40kW, 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.
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!
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.
4-stroke repeat mode (Welding with repeated ending arc)
5.2Connection 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 mm
2
Duty cycle
100%60%35%
Voltage
drop/10m
50285 A320 A370 A0.352V/100A
70355 A400 A480 A0.254V/100A
95430 A500 A600 A0.189V/100A
Recommended maximum welding current values for the welding/return cable(copper)
at an ambient temperature of +40°C and normal 10minutes cycle
Cable size mm
2
Duty cycle
100%60%35%
Voltage
drop/10m
50250 A280 A320 A0.352V/100A
70310 A350 A420 A0.254V/100A
95375 A440 A530 A0.189V/100A
5.3Symbols and functions
Mains power supply
switch
Overheating (3)
Protective earthPositioning of lifting eye
Arc forceInductance
Gas detectionMMA welding
Ending arc current /
Crater fill current
Ending arc voltage / Crater fill
voltage
5.4Thermal 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.
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 FabricatorEM400i 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 FabricatorEM500i 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).
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.
6.1Routine maintenance
Maintenance schedule during normal conditions. Check equipment prior to every use.
IntervalArea to maintain
Every 3 months
Clean or replace
unreadable labels.
Every 6 months
Clean inside
equipment. Use dry
compressed air with
reduced pressure.
Clean weld terminals. Check or replace weld
cables.
6.2Power source
To maintain the performance and increase the lifetime of the power source it is mandatory to
clean it regularly. How often depends on:
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
Perform these checks and inspections before sending for an authorised service technician.
Welder Error Codes and Solutions
Shows the screens
The following table describes the welder error code, as well as the causes and solutions
Error
Code
Left
display
Right
display
FaultCauseSolution
F00F00NonePower-on self-test
E1E1NoneWelding torch fault When the
equipment is
turned on, the
welding torch
trigger switch is on.
the switch may be
faulty.
Displayed Content
E2E2NoneOutput terminal
over-temperature
The OKC terminal
and welding cable
is not connected
properly. The
copper
cross-sectional
area of the output
power cable is too
small. The output
cable OKC fails to
meet the
specification
requirement. The
fan does not work
or slows down.
Turn off the switch.
Replace the
welding torch.
Verify the OKC
terminal and
welding cable is
connected properly.
Use cables with
correct
cross-sectional
areas. Select
suitable cable
OKC. Verify that
the fan blades are
not stuck with any
foreign objects.
The input power
cable is not
connected properly.
Input power
overvoltage occurs.
Input power under
voltage occurs.
Input power phase
imbalance occurs.
The input power
frequency exceeds
the range.
The rated duty
cycle is exceeded.
The air vent of the
housing is blocked.
The fan does not
work or slows
down.
Verify that the input
cables are
connected properly.
Verify that all the
three input phases
are present.
Ensure that the
user does not
exceeds the rated
duty cycle range.
Verify that the air
vent is not blocked.
Verify that the fan
blades are not
stuck with any
foreign objects that
the fan blades are
not stuck with any
foreign objects.
E5E51 - 8Button errorButton is not
working. Button
does not rebound
after being
pressed.
E6E6NoneOutput overcurrent The output is
short-circuited, or
the current is too
high.
E7E7NoneInput power faultThe input power
cable is not
connected properly.
Input power phase
loss or phase
imbalance occurs.
E8E8NoneOutput overvoltage The input voltage is
too high. The
output cables are
not connected
correctly.
Check the button
and make sure it
does not stick
Verify that the
output is not
short-circuited.
Verify that the input
cables are
connected properly.
Verify that the input
power is normal.
Verify that the input
voltage is normal.
Verify that the
output cables are
connected
correctly.
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
The FabricatorEM400i / FabricatorEM500i is designed and tested in accordance with
international standard GB/T 15579.1 & IEC 60974-1. On completion of service or repair
work, it is the responsibility of the person(s) performing the work to ensure that the product
still complies with the requirements of the above standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. When ordering, please state product type, serial number, designation and spare
part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.