ESAB Fabricator EM 401i, Fabricator EM 501i Instruction manual

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Fabricator EM 401i, Fabricator EM 501i

Instruction manual

0446 455 101  GB  20220303

Valid for: Serial number: from OP110YY-,

OP210YY-XXXXXX

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1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

2.1 Equipment

3 TECHNICAL DATA

4 INSTALLATION

4.1 Location

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4.2 Feeder mounting bracket instructions

4.3 Lifting instructions

4.4 Mains supply

5 OPERATION

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5.1 Connections and control devices

5.2 Welding control mode

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5.3 Connection of welding and return cable

5.4 Symbols and functions

5.5 Thermal protection

5.6 Fan control

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5.7 Usage of the cooling unit

5.8 Coolant connection

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5.9 Coolant pressure controller

6 MAINTENANCE

6.1 Maintenance

6.2 Routine maintenance

6.3 Power source

6.4 Cooling unit

6.5 Filling the coolant

7 TROUBLESHOOTING

8 ORDERING SPARE PARTS

ORDERING NUMBERS

BLOCK DIAGRAM

ACCESSORIES

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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

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

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1  SAFETY

• 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

• 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

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NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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1  SAFETY

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.

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2  INTRODUCTION

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 is available with and without built-in cooling unit.

EM 501i is available only with built-in cooling unit.

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.

2.1 Equipment

The power source is supplied with:

• 5m (16ft) return cable with earth clamp

• 5m (16ft) mains cable

• Instruction manual

• Quick start guide

• Safety instruction

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3  TECHNICAL DATA

3 TECHNICAL DATA

FabricatorEM 401i / EM 401i with cooling unit

Mains voltage 380-415V ±10%, 50/60Hz

Mains supply S

Primary current I

scmin

max

1.9MVA

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 S

Primary current I

scmin

max

6.2MVA

380V 400V 415V

MIG/MAG 39 A 37A 36A

MMA 41 A 38A 37A

Setting range (DC)

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3  TECHNICAL DATA

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 Q

Mains supply, S

sc min

max

66.7 PSI (4.6 bar)

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.

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3  TECHNICAL DATA

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.

4.2 Feeder mounting bracket instructions

WARNING!

Do not operate the equipment without the feeder mounting bracket.

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4  INSTALLATION

4.3 Lifting instructions

WARNING!

Secure the equipment - particularly if the ground is uneven or sloping.

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4  INSTALLATION

4.4 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 mm

4×6 mm

Maximal current rating I

1eff

max

29A 28A 26A

MIG/MAG 21A 20A 19A

MMA 22A 21A 20A

Input protection device (distribution box) Miniature circuit

Type Cand32A

breaker (MCB)

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mm

Maximal current rating I

1eff

max

41A 38A 38A

4×6mm

MIG/MAG 30A 28A 27A

MMA 31A 29A 28A

Input protection device (distribution box) Miniature circuit

TypeCand32A

breaker (MCB)

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.

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4  INSTALLATION

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 Connection (-): MIG/MAG: Return cable, MMA:

Return cable or welding cable 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

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.

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8 24 V AC power supply socket for gas regulator

9 Cooling unit mains switch ON/OFF

unit

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5  OPERATION

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 once.

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".

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5  OPERATION

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

SPd

speed

Slow wire feeding

F10

speed

(Creep start) m/min

F11 Pre-gas time

OFF 1.4–18

OFF

0–25s MIG/MAG: Gas delivery time before

MIG/MAG: The wire feed speed before the welding arc ignites or before the filler wire comes in contact with the workpiece

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

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5  OPERATION

Code Description Default Range Internal Menu Explanation

F25 Arc Start voltage OFF 12–38V(EM401i)

12–45V(EM501i)

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

F50 Arc Striking current OFF 30–400A (EM401i)

30–500A (EM501i)

F51 Hot Start current OFF 0–100A MMAW: Additional current during

FB0 Board software

and hardware version query

FB1 Fault record query Err – For service purpose

FB2 Machine model

query

–

C50 – For service purpose

010 – 104

110 – 102

210 – 103

300 – 201

MIG/MAG: Higher arc-start current and arc-start voltage to improve the arc-start fusion effect.

current and arc-start voltage.

MMAW: Current at the moment when electrode contacts base metal

arc start, based on the given welding current.

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.

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5  OPERATION

2-stroke mode (welding without ending arc)

4-stroke mode (welding with ending arc)

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5  OPERATION

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 mm

100% 60% 35%

50 290 A 320 A 370 A 0.35V/100A

70 360 A 400 A 480 A 0.25V/100A

95 430 A 500 A 600 A 0.19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

100% 60% 35%

Duty cycle

Voltage drop/10m

Duty cycle

Voltage drop/10m

50 250 A 280 A 320 A 0.35V/100A

70 310 A 350 A 420 A 0.25V/100A

95 380 A 440 A 530 A 0.19V/100A

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5  OPERATION

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).

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5  OPERATION

5.7 Usage of the cooling unit

CAUTION! Important! Turn OFF the cooling unit when welding MMA or using air cooled MIG/TIG welding

torches to avoid excessive wear of the pump. Otherwise, the pump will work against a closed valve.

Turn ON the cooling unit when using a water cooled MIG welding torch to avoid damages on the cable set.

5.8 Coolant connection

For problem-free operation it is recommended that the height from the cooling unit to the water-cooled MIG/MAG torch is of 8.5m.

5.9 Coolant pressure controller

The pump has an enclosed pressure relief valve. The valve opens gradually when the pressure is too high. This can occur if a hose is folded, which causes the flow to fail or stop.

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6  MAINTENANCE

6 MAINTENANCE

6.1 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.

6.2 Routine maintenance

Maintenance schedule during normal conditions. Check equipment prior to every use.

Interval Area to maintain

Every 3 months

Clean weld terminals. Check or replace weld cables.

Every 6 months

Clean inside equipment. Use dry compressed air with 4bar pressure.

6.3 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:

• the welding process

• the arc time

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6  MAINTENANCE

• the working environment

• the surrounding environment, that is among others grinding.

Tools needed for the cleaning procedure:

• torx screwdriver, T25 and T30

• dry compressed air at a pressure of 4 bar

• protective equipment like ear plugs, safety glasses, masks, gloves and safety shoes

CAUTION!

Make sure that the cleaning procedure is done in a suitable prepared workspace.

Cleaning procedure

CAUTION!

The cleaning procedure should be carried out by authorised service technician.

1 Disconnect the mains supply.

WARNING!

Wait until the DC bus capacitors are discharged. The DC bus capacitor discharge time is at least 2 minutes!

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 (1). 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.

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6  MAINTENANCE

7 Install the plastic cover between the heat sink and the fan (1) and make sure it is

correctly fitted against the heat sink.

8 Reassemble the power source after cleaning and perform testing according to IEC

60974-4. Follow the procedure in section “After repair, inspection and test” in the Service manual.

6.4 Cooling unit

Dust, grinding, swarf

The air stream through the cooling unit carries particles that become trapped in the cooling element, particularly in dirty working environments. This results in reduced cooling capacity. For this reason, blow clean using compressed air at regular intervals.

The coolant system

The recommended coolant must be used in the system otherwise clumps can be created that block the pump, water connections or elements. Flushing can only be performed via red water connection. Then drain the tank manually, that is empty via the tank’s filling hole.

6.5 Filling the coolant

Only use ESAB’s ready mixed coolant, see the “ACCESSORIES” chapter.

• Fill with coolant. (The fluid level must not exceed the upper marking but must not be below lower marking.)

0446 455 101

CAUTION!

The coolant must be handled as chemical waste.

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6  MAINTENANCE

NOTE!

Coolant must be topped up if connecting a welding torch or coolant hosed that are 5 meters in length or longer. When adjusting the water level by topping up, the coolant hosed do not need to be disconnected.

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7  TROUBLESHOOTING

7 TROUBLESHOOTING

Perform these checks and inspections before sending for an authorised service technician.

The following table describes the welder error code, as well as the causes and solutions

Error Code

F00 F00 None Power-on self-test

E1 E1 None Welding torch fault When the equipment

E2 E2 None Output terminal

Displayed Content

Left

display

Right

display

Fault Cause Solution

over-temperature

is turned on, the welding torch trigger switch is on. the switch may be faulty.

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.

E3 E3 None Abnormal input

power

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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.

Verify that the input cables are connected properly. Verify that all the three input phases are present.

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7  TROUBLESHOOTING

Error Code

Left

display

Right

display

E4 E4 None IGBT or diode

over-temperature

Fault Cause Solution

The rated duty cycle is exceeded. The air vent of the housing is blocked. The fan does not work or slows down.

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.

Displayed Content

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.

Check the button and make sure it does not stick.

Verify that the output is not short-circuited.

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.

E9 E9 None Primary side

overcurrent

E10 E10 None Primary side

overvoltage

E11 E11 None Current sensor

disconnection

The output is short-circuited.

The input voltage is too high.

The connector on the current sensor is disconnected or damaged.

E12 E12 None PCB not registered The PCB is not

certified.

E13 E13 None Overcurrent of wire

feeder motor

The welding wire is blocked or jammed

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.

Verify that the output is not short-circuited.

Verify that the input voltage is normal.

Refer note below the table

Check whether the welding wire is blocked or jammed

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7  TROUBLESHOOTING

Error Code

Left

display

Right

display

E14 E14 1/2 Gas solenoid valve

on Wire feeder

Fault Cause Solution

Gas solenoid valve short Circuit or damage;/ Gas solenoid valve open circuit or cable disconnect

Check whether the valve is short-circuited or damaged;/ Check whether the valve is open or whether the cable is disconnected;

Displayed Content

E17 E17 None The encoder of the

wire feeder motor has an open circuit problem

Loose control cable or wire

Check whether the control cable is loose, or the wire feeder is stuck

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.

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.

Poor cooling effect. • Clean the cooling element using compressed air

• Check the coolant level

• Check the on/off switch on the cooling unit is set to ON

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.

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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 401i/EM 401i with cooling unit / EM 501i with cooling unit is designed and tested in accordance with international standards ENIEC60974-1, ENIEC60974-2 and ENIEC60974-10. 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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APPENDIX

ORDERING NUMBERS

Ordering number Denomination Type Notes

0446 400 884 Power source Fabricator EM 401i CE

0446 400 883 Power source Fabricator EM 401i with cooling unit CE

0446 400 882 Power source Fabricator EM 501i with cooling unit CE

0446 455 * Instruction manual

0463 802 001 Service manual

0463 810 001 Spare parts list

The three last digits in the document number of the manual show the version of the manual. Therefore they are replaced with * here. Make sure to use a manual with a serial number or software version that corresponds with the product, see the front page of the manual.

Technical documentation is available on the Internet at: www.esab.com

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APPENDIX

BLOCK DIAGRAM

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APPENDIX

ACCESSORIES

0446 401 881 Fabricator Feed 304

0446 401 882 Fabricator Feed 304w

Connection set, 70mm2, 19 poles

0459 836 880 2 m

0459 836 881 5 m

0459 836 882 10 m

0459 836 884 25 m

Connection set water, 70mm2, 19 poles

0459 836 890 2 m

0459 836 891 5 m

0459 836 892 10 m

0459 836 894 25 m

Connection set water, 95mm2, 19 poles

0459 836 990 2 m

0459 836 991 5 m

0459 836 992 10 m

0459 836 994 25 m

0465 720 002 ESAB ready mixed coolant (10l/2.64gal)

Use of any other cooling liquid than the prescribed one might damage the equipment. In case of such damage, all warranty undertakings from ESAB cease to apply.

0447 014 001 Converter plug for gas heater supply

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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 http://esab.com

ESAB Fabricator EM 401i, Fabricator EM 501i Instruction manual

TABLE OF CONTENTS

1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

2.1 Equipment

3 TECHNICAL DATA

4 INSTALLATION

4.1 Location

4.2 Feeder mounting bracket instructions

4.3 Lifting instructions

4.4 Mains supply

5 OPERATION

5.1 Connections and control devices

5.2 Welding control mode

5.3 Connection of welding and return cable

5.4 Symbols and functions

5.5 Thermal protection

5.6 Fan control

5.7 Usage of the cooling unit

5.8 Coolant connection

5.9 Coolant pressure controller

6 MAINTENANCE

6.1 Maintenance

6.2 Routine maintenance

6.3 Power source

6.4 Cooling unit

6.5 Filling the coolant

7 TROUBLESHOOTING

8 ORDERING SPARE PARTS

ORDERING NUMBERS

BLOCK DIAGRAM

ACCESSORIES