ESAB Fabricator EM 400i Bedienungsanleitung

Instruction manual

0446 404 001 GB 20200806 Valid for: 008-xxx-xxxx

FabricatorEM400i,

FabricatorEM500i

TABLE OF CONTENTS

0446 404 001 © ESAB AB 2020

1SAFETY ....................................................................................................... 3

1.1 Meaning of symbols ............................................................................... 3

1.2 Safety precautions ................................................................................. 3

2INTRODUCTION.......................................................................................... 6

2.1 Overview ................................................................................................. 6

2.2 Equipment ............................................................................................... 6

3TECHNICAL DATA ...................................................................................... 7

4INSTALLATION ........................................................................................... 9

4.1 Location................................................................................................... 9

4.2 Lifting instructions ................................................................................. 10

4.3 Mains supply........................................................................................... 11

5OPERATION ............................................................................................... 13

5.1 Connections and control devices ......................................................... 13

5.1.1 Welding control mode........................................................................... 15

5.2 Connection of welding and return cable .............................................. 16

5.3 Symbols and functions .......................................................................... 17

5.4 Thermal protection ................................................................................. 17

5.5 Fan control .............................................................................................. 18

6MAINTENANCE .......................................................................................... 19

6.1 Routine maintenance ............................................................................. 19

6.2 Power source.......................................................................................... 19

7TROUBLESHOOTING ................................................................................. 21

8ORDERING SPARE PARTS ....................................................................... 24

BLOCK DIAGRAM............................................................................................... 25

ORDERING NUMBERS....................................................................................... 26

ACCESSORIES ................................................................................................... 27

Rights reserved to alter specifications without notice.

1 SAFETY

0446 404 001 -3- © ESAB AB 2020

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

1 SAFETY

0446 404 001 -4- © ESAB AB 2020

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.

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.

1 SAFETY

0446 404 001 -5- © ESAB AB 2020

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.

2 INTRODUCTION

0446 404 001 -6- © ESAB AB 2020

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

3 TECHNICAL DATA

0446 404 001 -7- © ESAB AB 2020

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

3 TECHNICAL DATA

0446 404 001 -8- © ESAB AB 2020

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.

4 INSTALLATION

0446 404 001 -9- © ESAB AB 2020

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 INSTALLATION

0446 404 001 - 10 - © ESAB AB 2020

4.2 Lifting instructions

WARNING!

Secure the equipment - particularly

if the ground is uneven or sloping.

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