BT Weld FAB 500HD Air Cooled 500A Multi-Process MIG Welder 415V

The BT Weld FAB 500HD is a heavy-duty 500A multi-process welder package for fabrication shops that weld all day. It runs on 415V three phase power and delivers a 100% duty cycle at the full 500A output, with synergic or manual MIG, DC TIG, stick (MMA) and arc air gouging from the one machine.

The package pairs the FAB 500 power source with a separate 4-roll FAB Feed wire feeder on a trolley, and comes in two configurations: Air Cooled, with a BZ36 HD MIG torch, or Water Cooled, with the FAB Cool 7 L water cooler and a BZ501 water-cooled MIG torch. The full contents of each package are itemised in the Specifications tab. Backed by a 5 year limited warranty.

Where this product is used

• Heavy steel fabrication
• Structural and plate welding, up to 30 mm plate
• Mining and earthmoving maintenance and repair
• Manufacturing and production lines
• General engineering workshops that weld all day
• Arc air gouging for weld preparation and repair (with a gouging torch, sold separately)

Features

• 100% duty cycle at the full 500A, so it keeps welding through long production shifts
• Synergic MIG for fast setup, or manual MIG for full control of the arc
• One machine covers MIG (gas and gasless), DC TIG, stick (MMA) and arc air gouging
• Separate 4-roll FAB Feed wire feeder, so the feeder can sit close to the job
• Suits D200 and D300 wire spools, 0.6-2.4 mm wire
• Spool gun compatible (SPX36, sold separately)
• Weld parameter storage to save and recall settings for repeat work
• VRD (voltage reduction device) and thermal overload protection
• 5 year limited warranty

Key specifications

Choosing the right option

Both packages use the same FAB 500 power source and FAB Feed wire feeder, so welding output, duty cycle and processes are identical. The difference is torch cooling. The Air Cooled package suits most fabrication work and has fewer parts to maintain. The Water Cooled package adds the FAB Cool 7 L cooler and a BZ501 water-cooled torch, which keeps the torch cooler and lighter in the hand on long, high-current runs. An Air Cooled package can be converted later with the FAB Cool water cooler, coolant and a BZ501 torch. For arc air gouging you will need a gouging torch such as the Bossweld K4 Arc Air Gouging Torch 1000 Amp. Not sure which suits your workshop? Give us a call and we will help you choose.

See also: Bossweld MST 500X Air Cooled Welder Package 415 V, Bossweld MST 350X Water Cooled Welder Package 415 V, Bossweld K4 Arc Air Gouging Torch 1000 Amp, Bossweld Argon Dual Stage Twin Gauge Regulator (Side Entry).

Using it

The package comes trolley-mounted with the primary lead and 32A three phase plug fitted, so it connects to a 415V 32A three phase outlet. If you are running it from a generator, BT Weld specifies 32 kVA.

The FAB Feed wire feeder connects to the power source with the 2 m interconnection cable supplied. If you need to work further from the machine, 5 m, 10 m and 15 m interconnecting cables are available. The feeder comes with 0.9/1.2 mm V-groove rollers fitted for solid wire, and 1.2/1.6 mm knurled rollers as spares for flux-cored wire.

Synergic MIG sets the welding parameters for you from the job, and the weld parameter storage lets you save settings and recall them for repeat work.

Storage and handling

The package weighs 153 kg (Air Cooled) or 156 kg (Water Cooled) and ships palletised. Use mechanical handling to move it on and off the pallet, and move it on its trolley once on site. The machine is rated IP21S, so protect it from rain and wet conditions and store it in a dry place.

Limits and safety

This is a 415V three phase machine drawing up to 32.3A. The supply outlet should be installed by a licensed electrician. The VRD reduces open-circuit voltage in stick mode, and thermal overload protection shuts the output down if the machine overheats. The spec sheet lists compliance with EN 60974-1:2021 and EN 60974-10:2021. Aluminium can be welded in MIG mode only. Always wear appropriate welding PPE and read the operating manual before use.