ESAB has launched the new Fabricator Pro EM series of heavy-duty, inverter-based systems for MIG/MAG and stick welding. Offering energy savings, reliability and affordability in a modern inverter-based and microprocessor controlled package, these systems are ideal for meeting Africa’s rugged fabrication, onsite construction and shutdown needs.
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For fabrication and construction firms that need reliable and efficient welding systems that can withstand rugged industrial environments, ESAB South Africa has introduced the Fabricator Pro EM 400i and EM 500i inverter-based welding power sources and associated wire feeders. Optimised for welding carbon or stainless steel with 1.0, 1.2 or 1.6 mm diameter solid and flux-cored wires, Fabricator Pro inverters also offer an advanced MMA/Stick/SMAW welding option.
The units use inverter-based technology to offer increased welding performance, improved portability and energy efficiency and more advanced controls to boost weld quality and productivity — all at highly affordable prices. The Fabricator Pro EM 400i has an output rating of 400 A at 60% duty cycle, while the Pro EM 500i is rated at 500 A at 60% duty cycle. Both power sources measure 1020x500x865 mm and weigh 75 kg, which is up to 65% lighter than conventional technology units. They are driven off three-phase primary power voltages of between 380 and 415 V with a variation tolerance of ±10%, and input frequencies of 50 and 60 Hz are accommodated.
Housed in a weather-protected IP23-rated case, the Fabricator Pro has an air tunnel cooling design that isolates electronics from dust, oil, metal shavings and other airborne contaminants. Thick metal side panels provide impact protection, yet the design enables easy access for service and maintenance. Large feet provide ground clearance and extra protection for the chassis, while its two ergonomic handles are crane rated. Because of this rugged design, ESAB offers a 3-year warranty on these power sources.
Inverter-based advantages
The new Fabricator Pro units feature inverter-based power transformation technology. They operate at 87% electrical efficiency, which is a 30% improvement over step-regulated power sources, so they lower primary power consumption and are more environmentally friendly. An energy saving mode reduces power consumption to less than 50 W when the machine is idle. The welding power sources also have a power factor of 0.93, lowering primary amperage requirements, which can allow more machines to be used on the same circuit breaker or reducing the incidence of nuisance trips.
Inverter technology also provides a faster response to changing arc conditions. Coupled with microprocessor controls, the technology enables ESAB to incorporate additional functions to enhance welding performance while simplifying operation.
Using highly visible LED displays and controls with easily understood terminology and symbols, operators start welding by selecting from one of three options: solid wire, cored wire or MMA. If a wire welding process is selected, operators then select the correct wire diameter (1.0, 1.2 or 1.6 mm) and gas type (100% CO2 or mixed gas) and the Fabricator Pro will then automatically choose the best parameters for that combination. Users can also adjust welding wire feed speed (amperage) and voltage independently if desired.
Additional controls allow operators to adjust inductance, which can reduce spatter, enhance bead-wetting action and create a flatter bead profile when MIG/MAG welding in short circuit transfer mode. Users can also set crater fill voltage and amperage at the end of the weld to prevent crater cracking, with the crater fill function activated by setting the welding machine torch control to four touch (4T) or 4T repeat mode.
For MMA welding, adjustable Arc Force provides additional amperage in low voltage situations to prevent the electrode from sticking to the work piece, which can deliver increased penetration.
Easy connectivity
Quick connectors at the back of the Fabricator Pro make it easy to connect to the wire feeder, with power being supplied via a 24 V socket. Water-cooled versions feature a water cooler integrated into the power source and a quick connection for the torch. The optional trolley features a low, easy loading platform to hold a single gas cylinder, while a wheel kit for the power source is also available.
Key power source advantages include:
- The Fabricator EM Pro is a rugged and reliable welding system for heavy applications: delivering 400 A or 500 A at 60% duty cycle.
- There are three variants: a 500 A unit with integrated torch cooling, and two 400 A units, one with and one without the torch cooler.
- Energy savings advantages accrue from the high power factor, high efficiency and low idle power.
- The machines offer a lower cost of operation and deliver all the added benefits of an inverter technology at a similar price to a conventional transformer machine.
- The machines are built with integrated, wide and large wheels and a gas cylinder support to facilitate moving the whole system around the workshop. Two side cable handling supports are also included.
- A wide voltage tolerance gives more stable welding output.
- Variable inductance control offers better arc performance and control.
- IP23S ingress protection enables their use anywhere, for field and workshop applications.
Two feeder options
ESAB offers two wire feeder choices specifically for use with the Fabricator Pro. The Feed 364 features a four-wheel drive stand protected by a steel case and plastic cover to shield the wire spool, which accepts 200 and 300 mm spools weighing up to 18 kg.
The Pro Feed 364 is an open, sled-type feeder that can accommodate larger spools; it also features a powerful 4-wheel drive stand. Both feeders offer voltage and amperage control at the feeder. When ordered as part of a package, the Fabricator Pro comes with the ESAB PSF torches, specified as either air- or water-cooled in a variety of duty cycle ratings.
Key wire feeder advantages include:
- The feeders are protected with cover for the feed-wire coil.
- They have simple, clear and easy to operate panels, with functions on the front for faster and easier adjustments.
- 2T, 4T/4T repeat functions offer greater welder comfort on long weld beads. The 4T and 4T repeat functions allow welders to work with two different parameters, switching between them using the torch trigger.
- They are robust: The EM Pro 364 is constructed in thick and resistant steel that guarantee durability in the most aggressive environments.
- A robust wire feeding mechanism with four drive wheels guarantees durability and efficient wire feed traction.
- Steel handles make for easy lifting and transportation.
“At ESAB, we exist to shape the future of welding and cutting. We connect fabricators with the widest range of products under our industry-leading brand portfolio with the latest technologies to solve virtually any industrial challenge,” says Jannie Bronkhorst of ESAB South Africa. “Then we back this up with our knowledge, experience and passion to help fabricators to be more productive than ever before.
“The new ESAB Fabricator Pro EM welding machines offer a simple, very versatile and dependable option for welding contractors that regularly have to set up at remote and rugged construction facilities. They really are an ideal solution for African fabricators,” concludes Bronkhorst.
