ESAB Fabricator EM400i, Fabricator EM500i Instruction manual

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

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

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
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1 SAFETY
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.
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.
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1 SAFETY
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.
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2 INTRODUCTION

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
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3 TECHNICAL DATA

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
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3 TECHNICAL DATA
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.
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4 INSTALLATION

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.
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4 INSTALLATION

4.2 Lifting instructions

WARNING!
Secure the equipment - particularly if the ground is uneven or sloping.
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4 INSTALLATION

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
380 V 3~ 50/60Hz 400 V 3~ 50/60Hz 415 V 3~ 50/60Hz 440 V 3~ 50/60Hz
voltage
Mains
4 × 6 mm² 4 × 6 mm² 4 × 6 mm² 4 × 6 mm²
cable area
Maximal
28 A 27 A 25 A 21A
current rating I
I
1eff
max
MIG/MAG 20 A 19 A 18 A 17A
MMA 21 A 20 A 19 A 18A
Input circuit breaker­MCB
Type C & 40 A or greater (distribution box)
FabricatorEM500i
Mains
380 V 3~ 50/60Hz 400 V 3~ 50/60Hz 415 V 3~ 50/60Hz 440 V 3~ 50/60Hz
voltage
Mains
4 × 6 mm² 4 × 6 mm² 4 × 6 mm² 4 × 6 mm²
cable area
Maximal
38 A 36 A 35 A 31A
current rating I
I
1eff
max
MIG/MAG 28 A 27 A 26 A 24A
MMA 29 A 28 A 26 A 24A
Input circuit breaker­MCB
Type C & 63A or greater (distribution box)
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4 INSTALLATION
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.
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5 OPERATION

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
2. 2. Connection (-): MIG/MAG: Return
cable, MMA: Return cable or welding cable
3. 3. Indicating LED, Overheating 8. Mains cable inlet
4. Connection of wire feed unit 9. 110V AC power supply socket for gas
5. Circuit breaker 10A (wirefeeder motor) 10. CAN communication connector (Factory
The following figure shows the front control panel and the buttons on the control panel of the welder.
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6. Fuse for the gas heater input supply
7. Mains power supply switch, ON/OFF
heater
use)
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5 OPERATION
S.no. Name Function
1 Ending arc current
/ Crater fill current
2 Ending arc voltage
/ Crater fill voltage
Adjusts the crater fill / Ending arc current in 4T and 4T repeat mode
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.
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5 OPERATION

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)
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5 OPERATION
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.
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5 OPERATION
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
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 mm
2
Duty cycle
100% 60% 35%
Voltage
drop/10m
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.
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5 OPERATION

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).
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6 MAINTENANCE

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.
Every 6 months
Clean inside
equipment. Use dry
compressed air with
reduced pressure.
Clean weld terminals. Check or replace weld
cables.

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:
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6 MAINTENANCE
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.
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7 TROUBLESHOOTING

7 TROUBLESHOOTING
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
Fault Cause Solution
F00 F00 None Power-on self-test
E1 E1 None Welding torch fault When the
equipment is turned on, the welding torch trigger switch is on. the switch may be faulty.
Displayed Content
E2 E2 None Output 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.
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7 TROUBLESHOOTING
Error Code
Left
display
Right
display
Fault Cause Solution
E3 E3 None Abnormal input
power
E4 E4 None IGBT or diode
over-temperature
Displayed Content
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.
E5 E5 1 - 8 Button error Button is not
working. Button does not rebound after being pressed.
E6 E6 None Output overcurrent The output is
short-circuited, or the current is too high.
E7 E7 None Input power fault The input power
cable is not connected properly. Input power phase loss or phase imbalance occurs.
E8 E8 None Output 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.
E9 E9 None Primary side
overcurrent
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The output is short-circuited.
Verify that the output is not short-circuited.
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7 TROUBLESHOOTING
Error Code
Left
display
Right
display
E10 E10 None Primary side
overvoltage
E11 E11 None Current Hall
connector disconnection
E12 E12 None PCB not registered The PCB is not
Fault Cause Solution
The input voltage is too high.
The current Hall connector is
Verify that the input voltage is normal.
Refer note below the table*
disconnected.
Refer note below
certified.
the table*
NOTE!
Call ESAB authorised service personnel.
Perform these checks and inspections before sending for an authorised service technician.
Type of fault Corrective action
No arc. Check that the mains power supply switch is turned
on.
Check that the mains, welding and return cables are correctly connected.
Check that the correct current value is set.
Check the mains power supply fuses.
Displayed Content
The welding current is interrupted during welding.
The thermal protection trips frequently
Check whether the thermal protection trip has operated (indicated by the orange LED on the front).
Make sure that you are not exceeding the rated data for the power source (i.e. that the unit is not being overloaded).
Check that the ambient temperature is not above the one for the rated duty cycle 40°C/104°F.
Poor welding performance Check that the welding current supply and return
cables are correctly connected.
Check that the correct current value is set.
Check that the correct welding wires are being used.
Check the main power supply fuses.
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8 ORDERING SPARE PARTS

8 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.
The FabricatorEM400i / FabricatorEM500i 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.
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BLOCK DIAGRAM

BLOCK DIAGRAM
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ORDERING NUMBERS

ORDERING NUMBERS
Ordering number Denomination Type Notes
0700 020 001 Power source FabricatorEM400i CCC
0700 020 002 Power source FabricatorEM500i CCC
0446 575 001 Spare parts list
Technical documentation is available on the Internet at: www.esab.com
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ACCESSORIES

ACCESSORIES
0700 020 003 Feed 364
0700 020 004 Fabricator Feed 364
0349 490 624 5m 70mm2 inter connection cable
0349 490 608 10m 70mm2 inter connection cable
0349 490 607 15m 70mm2 inter connection cable
0349 490 606 25m 70mm2 inter connection cable
0349 305 138 5m 50mm2 inter connection cable
0349 305 357 10m 50mm2 inter connection cable
0349 305 355 15m 50mm2 inter connection cable
0349 305 356 25m 50mm2 inter connection cable
0465 416 880 Wheel Kit
0349 313 450 Trolley, compatible with Fabricator Feed
364
0446 404 001
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© ESAB AB 2020
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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
For contact information visit esab.com
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