ESAB fabricator 211i Service Manual

A-12922

ESAB Fabricator® 211i

3-IN-1 Multi Process
Welding Systems

Service
Manual

3163339

Révision : AA Issue Date: September 22, 2015 Manual No.: 0-5450

210

115V

208/230V

esab.com

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to
provide you with the best service and reliability in the industry. This product is backed by our extensive
warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on
the web at www.esab.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB
product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

ESAB is a Global Brand of manual and automation Plasma Cutting Products.

We distinguish ourselves from our competition through market-leading, dependable products that have stood
the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer working
environment within the welding industry.

WARNING

!

Read and understand this entire Manual and your employer’s safety practices before install­ing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply
ESAB Fabricator® 211i 3-in-1 Multi Process Welding Systems™
Service Manual Number 0-5450

Published by:

ESAB
2800 Airport Rd.
Denton, TX 76208

www.esab.com

Copyright 2015 by ESAB

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for
any loss or damage caused by any error or omission in this Manual, whether such
error results from negligence, accident, or any other cause.

Original Publication Date: September 22, 2015
Revision Date:

Record the following information for Warranty purposes:

Where Purchased:_______________________________ __________

Purchase Date:__________________________________ __________

Power Supply Serial #:___________________________ __________

Torch Serial #:___________________________________ __________

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar
with the principles of operation and safe practices for arc welding and cutting equip­ment, we urge you to read our booklet, “Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be
sure to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accom­panying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions
provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be
used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such re­pair or replacement become necessary, the manufacturer recommends that a telephone or written request for service
advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper use,
faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility

designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

PROTECT YOURSELF AND OTHERS!

!

OPERATING.

TABLE OF CONTENTS

SECTION 1: SAFETY .................................................................................................... 1-1

1.0 Safety Precautions....................................................................................................... 1-1

SECTION 2:

INTRODUCTION ................................................................................................. 2-1

2.02 Equipment Identification .............................................................................................. 2-1

2.03 Receipt Of Equipment .................................................................................................. 2-1

2.04 Description .................................................................................................................. 2-1

2.01 How To Use This Manual ............................................................................................. 2-1

2.05 Transportation Methods .............................................................................................. 2-2

2.06 User Responsibility ..................................................................................................... 2-2

2.07 Fabricator 211i Portable System Package (Part No. W1004201) ................................ 2-2

SECTION 3:

SAFETY AND INSTALLATION .................................................................................. 3-1

3.01 Duty Cycle ................................................................................................................... 3-1

3.02 Specifications .............................................................................................................. 3-2

3.03 Environment ................................................................................................................ 3-3

3.04 Location ...................................................................................................................... 3-3

3.05 Ventilation ................................................................................................................... 3-4

3.06 Electricity Supply ........................................................................................................ 3-4

3.07 Electromagnetic Compatibility ..................................................................................... 3-6

3.08 Victor Regulator .......................................................................................................... 3-7

3.09 Leak Testing The System ............................................................................................. 3-9

3.10 When You Finish Using The Regulator ........................................................................ 3-9

3.11 Storage Of The Regulator ............................................................................................ 3-9

3.12 Volt-Ampere Curves .................................................................................................. 3-10

SECTION 4:

Operation ......................................................................................................... 4-1

4.01 Fabricator 211i Power Source Controls, Indicators And Features ................................ 4-1

4.02 Attaching The TWECO Fusion 220A MIG Gun.............................................................. 4-7

4.03 Installing 33/44 lb Spool (12" diameter) ..................................................................... 4-8

4.04 Installing 12.5 lb Spool ( 8" diameter) ......................................................................... 4-9

4.05 Installing 1 lb Spool (4" diameter) ............................................................................. 4-10

4.06 Inserting Wire Into The Wire Feed Mechanism .......................................................... 4-11

4.07 Feed Roll Pressure Adjustment ................................................................................. 4-12

4.08 Changing the Feed Roll .............................................................................................. 4-12

4.09 Wire Reel Brake ......................................................................................................... 4-13

4.10 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire ................................. 4-13

4.11 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire ................................ 4-15

4.12 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire ............ 4-16

4.13 Setup For LIFT TIG (GTAW) Welding ......................................................................... 4-18

4.14 Setup For STICK (SMAW) Welding ........................................................................... 4-19

SECTION 5:

TROUBLESHOOTING ............................................................................................ 5-1

5.01 Basic Troubleshooting-Power Source Faults ............................................................... 5-1

5.02 Routine Service and Calibration Requirements ........................................................... 5-2

5.03 Check Unit before Applying Power .............................................................................. 5-4

5.04 Test Equipment and Tools Needed for Troubleshooting and Servicing ........................ 5-5

5.05 Visually Inspect ........................................................................................................... 5-5

5.06 Preliminary DC Bus Measurement of the Power PCB .................................................. 5-5

TABLE OF CONTENTS

5.07 Preliminary Check of the Control PCB ......................................................................... 5-6

5.08 Check Main Input Rectifier .......................................................................................... 5-7

5.09 DC Bus Voltage Measurement ..................................................................................... 5-8

5.10 PCB Connectors .......................................................................................................... 5-9

5.11 DIP Switch Settings, Control PCB ............................................................................. 5-16

5.12 Calibration ................................................................................................................. 5-17

5.13 Circuit Diagram ......................................................................................................... 5-19

5.14 Main Circuit Description ............................................................................................ 5-20

SECTION 6:

DISASSEMBLY PROCEDURE ................................................................................... 6-1

6.01 Safety Precautions for Disassembly ............................................................................ 6-1

6.02 Control PCB Removal .................................................................................................. 6-1

6.03 Front Panel Assembly Removal ................................................................................... 6-2

6.04 Display PCB Removal .................................................................................................. 6-3

6.05 Back Panel Removal .................................................................................................... 6-4

6.06 Power Switch S1 and Power Cord Removal ................................................................ 6-5

6.07 Base Panel Removal .................................................................................................... 6-6

SECTION 7:

ASSEMBLY PROCEDURES ..................................................................................... 7-1

7.01 Installing Base Panel ................................................................................................... 7-1

7.02 Installing Back Panel ................................................................................................... 7-2

7.03 Installing Front Panel ................................................................................................... 7-3

7.04 Installing Control PCB and Clear Cover Sheet.............................................................. 7-4

7.05 Installing Cover Panel and Door Panel......................................................................... 7-5

SECTION 8:

KEY SPARE PARTS .............................................................................................. 8-1

8.01 Tweco WeldSkill 220A MIG Gun (Used until January, 2013 ......................................... 8-1

8.02 Tweco Fusion 220A MIG Gun ..................................................................................... 8-2

8.03 Power Source Spare Parts ........................................................................................... 8-3

SECTION 9:

OptionAL Accessories .......................................................................................... 9-1

9.01 Optional Accessories ................................................................................................... 9-1

INTERNATIONAL CONTACT INFORMATION ............................................................. REAR COVER

ESAB FABRICATOR 211i

SECTION 1: SAFETY

1.0 Safety Precautions

Users of ESAB welding and plasma cutting 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 welding or plasma cutting 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 welding or plasma cutting
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 welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

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.

- 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.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/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 can provide you with all necessary cutting protection and accessories.

Manual 0-5450 1-1 SAFETY INSTRUCTIONS AND WARNINGS

ESAB FABRICATOR 211i

WARNING

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with appli-

cable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet cloth-

ing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

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 R AYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and

filter lens and wear protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable

materials nearby.

Arc welding and cutting can be injurious to yourself and others.
Take precautions when welding and cutting. Ask for your employer's
safety practices which should be based on manufacturers' hazard
data.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmuffs or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT-

ING.

PROTECT YOURSELF AND OTHERS!

Do not use the power source for thawing frozen pipes.

WARNING

CAUTION

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.

This product is solely intended for metal removal. Any other use
may result in personal injury and / or equipment damage.

CAUTION

SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5450

Read and understand the instruction manual before
installing or operating.

!

SECTION 2:

INTRODUCTION

ESAB FABRICATOR 211i

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part num­bers listed on page i.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION,
DANGER, and NOTE may appear. Pay particular attention to the
information provided under these headings. These special an­notations are easily recognized as follows:

NOTE!

An operation, procedure, or background
information which requires additional
emphasis or is helpful in efficient operation
of the system.

CAUTION

!

!

!

Additional copies of this manual may be purchased by contact­ing ESAB at the address and phone number in your area listed
on back cover of this manual. Include the Owner’s Manual
number and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no
charge in Acrobat PDF format by going to the ESAB web site
listed below

http://www.esab.com

A procedure which, if not properly followed,
may cause damage to the equipment.

WARNING

A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.

WARNING

Gives information regarding possible
electrical shock injury. Warnings will be
enclosed in a box such as this.

DANGER

Means immediate hazards which, if not
avoided, will result in immediate, serious
personal injury or loss of life.

2.02 Equipment Identification

The unit’s identification number (specification or part number),
model, and serial number usually appear on a data tag attached
to the rear panel. Equipment which does not have a data tag
such as torch and cable assemblies are identified only by the
specification or part number printed on loosely attached card or
the shipping container. Record these numbers on the bottom of
page i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice
to make sure it is complete and inspect the equipment for pos­sible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim. Furnish complete information
concerning damage claims or shipping errors to the location in
your area listed in the inside back cover of this manual.
Include all equipment identification numbers as described above
along with a full description of the parts in error.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when using
bars, hammers, etc., to un-crate the unit.

2.04 Description

The ESAB Fabricator 211i is a self contained single phase multi
process welding system that is capable of performing MIG
(GMAW/FCAW), STICK (SMAW) and LIFT TIG (GTAW) welding pro­cesses. The Power Source is equipped with an integrated wire
feed unit, digital voltage and amperage meters, and a host of
other features in order to fully satisfy the broad operating needs
of the modern welding professional. The Power Source is also
fully compliant to Standard CSA E60974-1-00 and UL 60974.1.
The ESAB Fabricator 211i provides excellent welding perfor­mance across a broad range of applications when used with
the correct welding consumables and procedures. The follow­ing instructions detail how to correctly and safely set up the
machine and give guidelines on gaining the best efficiency and
quality from the Power Source. Please read these instructions
thoroughly before using the unit.

Manual 0-5450 2-1 INTRODUCTION

ESAB FABRICATOR 211i

2.05 Transportation Methods

!

!

Lift Power Source with handles built into the top of the front and
rear molded panels.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure Power Source on a
proper skid before transporting.

WARNING

FALLING EQUIPMENT can cause serious
personal injury and equipment damage.

WARNING

FALLING EQUIPMENT can cause serious
personal injury and equipment damage.

2.06 User Responsibility

This equipment will perform as per the information contained
herein when installed, operated, maintained and repaired in
accordance with the instructions provided. This equipment must
be checked periodically. Defective equipment (including welding
leads) should not be used. Parts that are broken, missing, plainly
worn, distorted or contaminated, should be replaced immediate­ly. Should such repairs or replacements become necessary, it is
recommended that such repairs be carried out by appropriately
qualified persons approved by ESAB. Advice in this regard can be
obtained by contacting an Accredited ESAB Distributor.
This equipment or any of its parts should not be altered from
standard specification without prior written approval of ESAB.
The user of this equipment shall have the sole responsibil­ity for any malfunction which results from improper use or
unauthorized modification from standard specification, faulty
maintenance, damage or improper repair by anyone other than
appropriately qualified persons approved by ESAB.

2.07 Fabricator 211i Portable System
Package (Part No. W1004201)

• Fabricator 211i Power Source

• 12 ft. (3.6 m) Tweco Fusion 220 Amp MIG Gun

• Victor Argon Regulator / Flowmeter

• Drive Rolls:

.023"/.030" (0.6/0.8mm) "V" groove,

.023"/.035" (0.6/0.9mm)"V" groove (tted with .035" groove

lined up) ,

.030"/.035" (0.8/0.9mm) "V" knurled for Flux Cored Wire,

• Contact Tips (1 each)

.023"(0.6mm),.030"(0.8mm),

.035"(0.9mm) (tted)

.045"(1.1mm)

• Electrode Holder with 13 ft. (4m) lead

• Work Clamp with 10ft. (3.1m) lead

• Shielding Gas hose assembly

• 15A/20A Adapter Plug from 208/230V AC 50 Amps to 115V

Amps Circuits

• ESAB Cap

• Electrodes

• Large Spring

• Operating Manual

• DVD

INTRODUCTION 2-2 Manual 0-5450

A-12923

Figure 2-1: Fabricator 211i System Packaged W1004201

ESAB FABRICATOR 211i

Duty Cycle (PERCENTAGE)

SECTION 3:

SAFETY AND INSTALLATION

3.01 Duty Cycle

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output
without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the
following example is used. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 210 amperes at 24.5 volts.
This means that it has been designed and built to provide the rated amperage (210A) for 2 minutes, i.e. arc welding time, out of
every 10 minute period (20% of 10 minutes is 2 minutes). During the other 8 minutes of the 10 minute period the Welding Power
Source must idle and allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.

100

90

80

70

60

50

40

30

20

Duty Cycle (PERCENTAGE)

10

0

SAFE OPERATING REGION

(MIG, TIG & STICK)

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

0

Figure 3-1: Fabricator 211i Duty Cycle on 208/230V AC

100

90

80

70

Welding Current (AMPS)

STICK

FABRICATOR 211i

MIG

STICK / TIG

Art # A-11265

FABRICATOR 211i

TIG

60

50

40

30

20

SAFE OPERATING REGION

(MIG, TIG & STICK)

10

0

0102030405060708090100 110 120 130140 150

Manual 0-5450 3-1 SAFETY/INSTALLATION

Welding Current (AMPS)

Figure 3-2: Fabricator 211i Duty Cycle on 115V AC

MIG

Art # A-11274

ESAB FABRICATOR 211i

3.02 Specifications

Description Fabricator 211i Multi Process 3 in 1 Welder

Power Source Part No. W1004200

Power Source Dimensions H17.12" x W10.47" x D 24.29" (435mm x 266mm x D617mm)

Power Source Mass 57.3lb (26kg)

Cooling Fan Cooled

Welder Type Multi Process Welding System

Applicable Standard CSA E60974-1-00 / UL60974-1 / IEC 60974-1

Number of Phases Single Phase

Nominal Supply Voltage 208/230 VAC ± 10% 115VAC± 10%

Nominal Supply Frequency 50/60Hz 50/60HZ

Welding Current Range
MIG Mode
STICK Mode
TIG Mode

Wirefeed Speed Range 100 - 600 IPM 100 - 400 IPM

MIG Welding Voltage Range 14.5 - 24.5V DC 14.5 - 19V DC

Nominal OCV 70V DC

Effective Input Current (I1eff)
for MIG (GMAW/FCAW)
for STICK (SMAW)
for LIFT TIG (GTAW)

Maximum Input Current (I1max)
for MIG (GMAW/FCAW)
for STICK (SMAW)
for LIFT TIG (GTAW)

Single Phase Generator Requirement 7.5 KW *3.7 KW

MIG (GMAW/FCAW) Welding Output, 104°F, 10 min. 210A @ 20%,24.5V

STICK (SMAW) Welding Output,1040°F, 10 min. 200A @ 25%,28.0V

TIG (GTAW) Welding Output, 104°F, 10 min. 200A @ 25%,18.0V

Open Circuit Voltage 70 V

Protection Class IP23S

Table 3-1: Fabricator 211i Specifications

10-210 Amps
10-200 Amps
10-200 Amps

14.4A/11.2A

16.8A/15.8A

11.7A/11.5A

32.2A/25.0A

33.6A/31.6A

23.3A/22.9A

122A @ 60%, 20.1V
95A @ 100%, 18.8V

130A @ 60%, 25.2V

101A @ 100%, 24.0V

130A @ 60%, 15.2V

101A @ 100%, 14.0V

10-140 Amps
10-110 Amps
10-150 Amps

15.5A

17.8A

17.4A

24.5A

30.1A

29.4A

110A @ 45%,19.5V

99A @ 60%, 19.0V

77A @ 100%, 17.9V

110A @ 35%,24.4V

90A @ 60%, 23.6V

70A @ 100%, 22.8V

150A @ 35%,16.0V
115A @ 60%, 14.6V
90A @ 100%, 13.6V

Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements.

Note 2: Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your
situation in this regard.

Note 3: Generator Requirements at the Maximum Output Duty Cycle.

* Some 115 VAC, 15 amp/20 amps electrical outlets fitted with GFCI (Ground Fault Circuit Interrupt) protection against nuisance
trip with this equipment due to worn or out of tolerance components in the GFCI. In such cases have the 115 VAC, 15 amp/20 amp
GFCI electrical outlet replaced by a qualified electrical trades person.

SAFETY/INSTALLATION 3-2 Manual 0-5450

ESAB FABRICATOR 211i

NOTE!

The recommended time delay fuse or circuit breaker size for 115V is 30 amp. An individual branch circuit
capable of carrying 30 amperes and protected by fuses or circuit breaker is recommended for this ap­plication. Fuse size is based on not more than 200 percent of the rated input amperage of the welding
Power Source (Based on Article 630, National Electrical Code)
ESAB continuously strives to produce the best product possible and therefore reserves the right to
change, improve or revise the specifications or design of this or any product without prior notice. Such
updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding
changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment
may differ from the above specifications due to in part, but not exclusively, to any one or more of the fol­lowing; variations or changes in manufactured components, installation and conditions and local power
grid supply conditions.

3.03 Environment

This Power Source is designed for use in environments with increased hazard of electric shock. Additional safety precautions may
be required when using unit in an environment with increased hazard of electric shock. Please refer to relevant local standards for
further information prior to using in such areas.
A. Examples of environments with increased hazard of electric shock are:

1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped
(kneeling, sitting or lying) position with physical contact with conductive parts.

2. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or
accidental contact by the operator.

3. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body
and the insulation properties of accessories.

B. Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near
vicinity of the operator, which can cause increased hazard, have been insulated.

3.04 Location

Be sure to locate the welder according to the following guidelines:

A. In areas, free from moisture and dust.

B. Ambient temperature between 14° F (0° C) to 104° F (40° C).

C. In areas, free from oil, steam and corrosive gases.

D. In areas, not subjected to abnormal vibration or shock.

E. In areas, not exposed to direct sunlight or rain.

F. Place at a distance of 12" (305mm) or more from walls or similar that could restrict natural air flow for cooling.

G. The enclosure design of this Power Source meets the requirements of IP23S as outlined in EN 60529. This provides adequate

protection against solid objects (greater than 1/2", 12mm) and direct protection from vertical drops. Under no circumstances
should the Power Source be operated or connected in a micro environment that will exceed the stated conditions. For further
information please refer to EN 60529.

H. Precautions must be taken against the power source toppling over. The power source must be located on a suitable horizontal

surface in the upright position when in use.

WARNING

This equipment should be electrically connected by a qualified electrician.

Manual 0-5450 3-3 SAFETY/INSTALLATION

ESAB FABRICATOR 211i

3.05 Ventilation

WARNING

!

3.06 Electricity Supply

CAUTION

!

The Electricity Supply voltage should be within 208/230V AC ± 10% or 115 V AC ± 10%. Too low a supply
voltage may cause poor welding performance in STICK mode such as the arc snuffing out during welding.
Too high a supply voltage will cause components to overheat and possibly fail. The Welding power Source
must be:

• Correctly installed, if necessary, by a qualied electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size power point and fuse as per the Specications on page 3-2.

WARNING

The Fabricator 211i must be electrically connected by a qualified electrical trades-person. Damage to the
PCA (Power Control Assembly) could occur if 265 VAC or higher is applied to the Primary Power Cable

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effec­tively ventilated.

WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO

SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging procedures

consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting OFF and red-tagging circuit
breaker or other disconnecting device.

Power Cords Included With Power Supply

Attached to the power supply is an input power cord with a 208/230Volt 50 Amp NEMA 6-50 P for plug. Supplied adapter allow for
connection of the power supply input cable plug to 115 V input power.

NOT TOUCH live electrical parts.

Art# A-11275

Electrical Input Requirements

Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the electri­cal input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type
of electrical service available, how proper connections should be made, and inspection required. The line disconnect switch provides
a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to
inspect or service the unit. The Welding Power Source must be:
Do not connect in input (WHITE or BLACK) conductor to the ground terminal.

SAFETY/INSTALLATION 3-4 Manual 0-5450

Figure 3-3: 115 VAC Adapter

ESAB FABRICATOR 211i

208/230V, 50A,1Ø

Do not connect the ground (GREEN) conductor to an input line terminal.

• Correctly installed, if necessary, by a qualied electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size power point, fuse and primary supply lead based on Table 3-2.

Refer to Figure 3-3 and Table 3-2.

WARNING

An electrical shock or fire hazard is probable if the following electrical service guide recommendations
are not followed. These recommendations are for a dedicated branch circuit sized for the rated output
and duty cycle of the welding Power Source.

50 / 60 Hz Single Phase Supply

Supply Voltage 208/230V AC 115V AC

Input Current at Maximum Output 32 Amps 30 Amps

Maximum Recommended Fuse* or Circuit Breaker Rating * Time
Delay Fuse, UL class RK5. Refer to UL248

Maximum Recommended Fuse^ or Circuit Breaker Rating ^Normal
Operating , UL class K5. Refer to UL248

Minimum Recommended Cord Size 12 AWG 12 AWG

Maximum Recommended Extension Cord Length 50 ft 25 ft

Minimum Recommended Grounding Conductor Size 12 AWG 12AWG

Table 3-2: Electrical Service Guide

50 Amps

50 Amps

30 Amps

30 Amps

!

CAUTION

The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when
welding with this product due to the amperage rating of the time-delay fuses or circuit breaker.

115

20A,1Ø

The Adapter enable
connection to all these
power outlets

115 VAC Adapter

115V,V,

15A,1Ø

Manual 0-5450 3-5 SAFETY/INSTALLATION

Primary Power Cable

Art# A-11240

Figure 3-4: Electrical Input Connections

ESAB FABRICATOR 211i

3.07 Electromagnetic Compatibility

WARNING

!

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromag­netic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with
the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit,
see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the
work, complete with associated input filters. In all cases, electromagnetic disturbances shall be reduced to the point where they are
no longer Troublesome.

NOTE!

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements
should only be authorized by a person who is competent to assess whether the changes will increase the
risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits
of other equipment.

B. Assessment of Area

Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding
area. The following shall be taken into account.

1. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment.

Extra precautions for Electromagnetic Compatibility may be required when this Welding Power
Source is used in a domestic situation.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

5. The health of people around, e.g. the use of pace-makers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to be carried out.

8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment
is compatible: this may require additional protection measures.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking
place. The surrounding area may extend beyond the boundaries of the premises.

C. Methods of Reducing Electromagnetic Emissions

1. Electricity Supply

Welding equipment should be connected to the Electricity Supply according to the manufacturer’s recommendations. If

interference occurs, it may be necessary to take additional precautions such as filtering of the Electricity Supply. Consideration
should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent.
Shielding should be electrically continuous throughout its length. The shielding should be connected to the Welding Power
Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and

service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding
equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s
instructions.

SAFETY/INSTALLATION 3-6 Manual 0-5450

ESAB FABRICATOR 211i

A-09414_AC

3. Welding Cables

The welding cables should be kept as short as possible and should be positioned close together but never coiled and running

at or close to the floor level.

4. Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic

components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic
components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

5. Earthing/grounding of the Work Piece

Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g.

ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all
instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage
to other electrical equipment. Where necessary, the connection of the work piece to earth should be made by direct con­nection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved
by suitable capacitance, selected according to national regulations.

6. Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference.

Screening the entire welding installation may be considered for special applications.

3.08 Victor Regulator

Pressure regulator (Figure 3-5) attached to the cylinder valve reduce high cylinder pressures to suitable low working pressures for
welding, cutting, and other applications.

Figure 3-5: Victor CS Regulator

WARNING

!

Use the regulator for the gas and pressure for which it is designed. NEVER alter a regulator for use with
any other gas.

NOTE!

Regulators purchased with open 1/8”, 1/4”, 3/8”, or 1/2” NPT ports must be assembled to their intended
system.

1. Note the maximum inlet pressure stamped on the regulator. DO NOT attach the regulator to a system that has a higher pres­sure than the maximum rated pressure stamped on the regulator.

2. The regulator body will be stamped “IN” or “HP” at the inlet port. Attach the inlet port to the system supply pressure connec­tion.

3. If gauges are to be attached to the regulator and the regu lator is stamped and listed by a third party (i.e. “UL” or “ETL”). The
following requirements must be met:
a) Inlet gauges over 1000 PSIG (6.87 mPa) shall conform with the requirements of UL 404, “Indicating Pressure Gauges for

Compressed Gas Service.”

b) Low pressure gauges must be UL recognized for the class of regulator they are being used on according to UL252A.

Manual 0-5450 3-7 SAFETY/INSTALLATION

ESAB FABRICATOR 211i

A-09845_AB

WARNING

!

4. Be sure that the regulator has the correct pressure rating and gas service for the cylinder used.

5. Carefully inspect the regulator for damaged threads, dirt, dust, grease, oil, or other flammable substances. Remove dust and

!

DO NOT use a regulator that delivers pressure exceeding the pressure rating of the downstream equip-

ment unless pro visions are made to prevent over-pressurization (i.e. system relief valve). Make sure the
pressure rating of the down stream equipment is compatible with the maximum delivery pressure of the
regulator.

dirt with a clean cloth. Be sure the inlet swivel filter is clean and in place. Attach the regulator (Figure 3-6) to the cylinder
valve. Tighten securely with a wrench.

WARNING

DO NOT attach or use the regulator if oil, grease, flamma ble substances or damage is present! Have a
qualified repair technician clean the regulator or repair any damage.

Figure 3-6: Regulator to Cylinder Valve

6. Before opening the cylinder valve, turn the regulator adjusting screw counterclockwise until there is no pressure on the
adjusting spring and the screw turns freely.

7. Relief Valve (where provided): The relief valve is designed to protect the low pressure side of the regulator from high pres­sures. Relief valves are not intended to protect down stream equipment from high pressures.

WARNING

!

!

8. Slowly and carefully open the cylinder valve (Figure 3-7) until the maximum pressure shows on the high pressure gauge.

DO NOT tamper with the relief valve or remove it from the regulator.

WARNING

Stand to the side of the cylinder opposite the regulator when opening the cylinder valve. Keep the cylinder
valve between you and the regulator. For your safety, NEVER STAND IN FRONT OF OR BEHIND A REGULA­TOR WHEN OPENING THE CYLINDER VALVE!

SAFETY/INSTALLATION 3-8 Manual 0-5450

Art # A-09828

Figure 3-7: Open Cylinder Valve

ESAB FABRICATOR 211i

9. On all cylinders, except acetylene, open the valve completely to seal the valve packing. On gaugeless regulators, the indica­tor will register the cylinder contents open.

10. On acetylene cylinders, open the valve 3/4 of a turn and no more than 1-1/2.

WARNING

!

!

11. Attach the desired downstream equipment.

3.09 Leak Testing The System

Leak test the system before putting into operation.

1. Be sure that there is a valve in the downstream equipment to turn off the gas flow.

2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery pressure.

3. Close the cylinder valve.

4. Turn the adjusting screw/knob counterclockwise one turn.

5. Once leak testing has been performed and there are no leaks in the system, slowly open the cylinder valve and proceed.

!

Acetylene delivery pressure must not exceed 15 PSIG (103 kPa) or 30 PSIG (207 kPa). Acetylene can dis­sociate (decompose with explosive violence) above these pressure limits.

CAUTION

Keep the cylinder valve wrench, if one is required, on the cylinder valve to turn off the cylinder quickly, if
necessary.

a) If the high-pressure gauge reading drops, there is a leak in the cylinder valve, inlet fitting, or high-pressure gauge.
b) If the low-pressure gauge drops, there is a leak in the down stream equipment, hose, hose fitting, outlet fitting or low-

pressure gauge. Check for leaks using an approved leak detector solution.

c) If the high-pressure gauge drops and the low-pressure gauge increases at the same time, there is a leak in the regula-

tor seat.

d) If the regulator requires service or repair, take it to a qualified repair technician.

WARNING

If a leak has been detected anywhere in the system, dis continue use and have the system repaired. DO
NOT use leaking equipment. Do not attempt to repair a leaking system while the system is under pres­sure.

3.10 When You Finish Using The Regulator

1. Close the cylinder valve.

2. Open the valve on the downstream equipment. This drains all pressure from the system.

3. Close the valve on the downstream equipment.

4. Turn the adjusting screw counterclockwise to release the ten sion on the adjusting spring.

5. Check the gauges after a few minutes for verification that the cylinder valve is closed completely.

3.11 Storage Of The Regulator

When the regulator is not in use and has been removed from the cylinder, it should be stored in an area where it will be pro tected
from dust, oil, and grease. The inlet and outlet should be capped to protect against internal contamination and prevent insects from
nesting.

Manual 0-5450 3-9 SAFETY/INSTALLATION

ESAB FABRICATOR 211i

3.12 Volt-Ampere Curves

Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other set­tings fall between curves shown.

Figure 3-8: Fabricator 211i Volt-Ampere Curves

SAFETY/INSTALLATION 3-10 Manual 0-5450

Art # A-11297

ESAB FABRICATOR 211i

3

3A

4

5

6

7

9

8

10

11

12

13

14

2

1

16

15

21

A-12956

SECTION 4:

Operation

4.01 Fabricator 211i Power Source Controls, Indicators And Features

Figure 4-1: Front and Control Panel

Figure 4-2: Rear Panel Connections

17

Art # A-10938

Figure 4-3: Wire Feed Compartment Control

Manual 0-5450 4-1 INSTALLATION/SETUP

ESAB FABRICATOR 211i

1. Power Indicator

The power indicator is illuminated when the correct mains power is applied to the power source and when the ON/OFF switch
located on the rear panel is in the ON position.

2. Thermal Overload Indicator (Fault Indicator)

This welding power source is protected by a self resetting thermostat. The indicator will illuminate if the duty cycle of the power
source has been exceeded. Should the thermal overload indicator illuminate the output of the power source will be disabled. Once
the power source cools down this light will go OFF and the over temperature condition will automatically reset. Note that the mains
power switch should remain in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently. Do
not switch the unit off should a thermal overload condition be present.

3. Digital Wirespeed/Amperage Meter (Left Digital Display)

MIG Mode

This digital meter is used to display the pre-set (preview) Wirefeed Speed in IPM (Inches per minute) in MIG mode and actual weld­ing amperage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value
of Wirefeed Speed. This value can be adjusted by varying the Amperage Control Knob (4).

STICK and LIFT TIG Modes

The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and actual welding amperage of
the power source when welding. At times of non-welding, the amperage meter will display a pre-set (preview) value in both STICK
and LIFT TIG modes. This value can be adjusted by varying the Amperage Control Knob (4).

When welding, this digital meter will display actual welding amperage in all modes.

At the completion of welding, the digital meter will hold the last recorded amperage value for a period of approximately 10 seconds
in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit
will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period
of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.

NOTE!

The preview functionality provided on this power source is intended to act as a guide only. Some dif­ferences may be observed between preview values and actual welding values due to factors including
the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the
transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the
case of procedural work), it is recommended that alternate measurement methods be utilized to ensure
output values are accurate.

3A Wirespeed Indicator

The Wirespeed Indicator illuminates when MIG mode is selected to identify that the Digital Wirespeed/Amperage Meter is preview­ing Wirespeed in IPM (inches per minute).

The Wirespeed Indicator extinguishes when the user is MIG (GMAW/FCAW) welding or depressing the MIG gun trigger and the
Digital Wirespeed/Amperage Meter displays actual welding amperage of the power source.

4. Wirespeed/Amperage Control

In MIG mode, the Wirespeed/Amperage control knob adjusts the speed of the wire feed motor (which in turn adjusts the output
current by varying the amount of MIG wire delivered to the welding arc). The optimum wire speed depends upon the material type
and the welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the
required settings for a basic range of MIG (GMAW/FCAW) welding applications.

In STICK and LIFT TIG modes, the Wirespeed/Amperage control knob adjusts the amount of amperage (weld current) delivered to
the welding arc by the Power Source. It directly adjusts the Power Source to deliver the desired level of weld current.

INSTALLATION/SETUP 4-2 Manual 0-5450

ESAB FABRICATOR 211i

NOTE!

The preview functionality provided on this power source is intended to act as a guide only. Some dif­ferences may be observed between preview values and actual welding values due to factors including
the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the
transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the
case of procedural work), it is recommended that alternate measurement methods be utilized to ensure
output values are accurate.

5. MIG Gun Adapter (Tweco Style)

The MIG Gun adapter is the connection point for the Tweco Fusion MIG Gun. Connect the MIG Gun by pushing the MIG Gun connec­tor into the brass MIG Gun Adapter firmly and screw the locking screw in the MIG Gun Adapter within the Wire Feed Compartment
to secure the Tweco Fusion MIG Gun in position. Failure to properly lock the Tweco MIG Gun into the MIG Gun Adapter will result in
the Tweco Fusion MIG Gun being pushed out of the MIG Gun Adapter by the MIG welding wire or lack of shielding gas (porosity in
the weld) at the weld zone. To remove the MIG gun simply reverse these directions.

6. Positive Welding Output Terminal

The positive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory
such as the MIG gun (via the MIG polarity lead), electrode holder lead or work lead. Positive welding current flows from the power
source via this heavy duty bayonet type terminal. It is essential, however, that the male plug is inserted and turned securely to
achieve a sound electrical connection.

CAUTION

!

7. MIG Polarity Lead

The polarity lead is used to connect the MIG gun to the appropriate positive or negative output terminal (allowing polarity reversal
for different welding applications). In general, the polarity lead should be connected in to the positive welding terminal (+) when
using steel, stainless steel or aluminum electrode wire. When using gasless wire, the polarity lead is generally connected to the
negative welding terminal (-). If in doubt, consult the manufacturer of the electrode wire for the correct polarity. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

!

8. Negative Welding Output Terminal

The negative welding terminal is used to connect the welding output of the power source to the appropriate welding accessory
such as the MIG gun (via the MIG polarity lead), TIG torch or work lead. Negative welding current flows to the power source via this
heavy duty bayonet type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection.

!

Loose welding terminal connections can cause overheating and result in the male plug being
fused in the bayonet terminal

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being
fused in the bayonet terminal

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being
fused in the bayonet terminal

9. Remote Control Socket

The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source. To make connections,
align keyway, insert plug, and rotate threaded collar fully clockwise.

Manual 0-5450 4-3 INSTALLATION/SETUP

ESAB FABRICATOR 211i

2

1

5

4

8

7

Art # A-10421_AC

Socket Pin

1 Spool Gun Motor Negative

2

3

4

5

6

Trigger Switch Input

Trigger Switch Input

Spool Gun Motor (+24V DC)

5k ohm (maximum) connection to 5k ohm remote control potentiometer.

Zero ohm (minimum) connection to 5k ohm remote control potentiometer.

1

2

3
4

3

6

Figure 4-4: Remote Control Socket

5

6

7
8

Remote Wirespeed in MIG (GMAW/FCAW) mode

Remote Amps in LIFT TIG (GTAW) mode

Trigger Switch

WV

Remote Volts in
MIG (GMAW/FCAW)

Negative

Spool Gun Motor

Positive

Function

7

8

Note that the remote local switch (item 18) located in the wirefeed compartment should be set to remote for the amperage/voltage
controls to be operative.

10. Multifunction Control - Voltage, Down Slope & Arc Force

The multifunction control knob is used to adjust Voltage (MIG Mode), Down slope (LIFT TIG Mode) and Arc Force (STICK Mode)
depending on the welding mode selected.

Wiper arm connection to 5k ohm remote control Wirespeed MIG mode potentiometer. Wiper
arm connection to 5k ohm remote control Amps LIFT TIG mode potentiometer.

Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.

Table 4- 1

NOTE!

The preview functionality provided on this power source is intended to act as a guide only. Some differ­ences may be observed between preview values and actual welding values due to factors including the
mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer
mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of
procedural work), it is recommended that alternate measurement methods be utilized to ensure output
values are accurate.

When MIG Mode is Selected

In this mode the control knob is used to adjust the output voltage of the unit. The welding voltage is increased by turning the knob
clockwise or decreased by turning the knob anti-clockwise. The optimum voltage level required will dependent on the type of
welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required
output settings for a basic range of MIG welding applications.

INSTALLATION/SETUP 4-4 Manual 0-5450

ESAB FABRICATOR 211i

When STICK Mode is Selected

In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding
force (or “dig”) control. This feature can be particularly beneficial in providing the operator the ability to compensate for variability
in joint fit-up in certain situations with particular electrodes. In general increasing the arc force control toward ‘10’ (maximum arc
force) allows greater penetration control to be achieved. Arc force is increased by turning the control knob clockwise or decreased
by turning the knob anti-clockwise

When LIFT TIG Mode is Selected

In this mode the multifunction control knob is used to adjust down slope. Down slope allows the user to select the ramp down
time at the completion of the weld. The main function of down slope is to allow the welding current to be gradually reduced over
a pre-set time frame such that the welding pool is given time to cool sufficiently.

Note that when in 2T normal mode (refer item 12), the unit will enter down slope mode as soon as the trigger switch is released
(ie if the multifunction control knob is set to 5, the unit will ramp down from the present welding current to zero over 5 seconds).
If no down slope time is selected then the welding output will cease immediately. If the unit is set to 4T latch mode, to enter down
slope mode the trigger must be held in for the selected time period (ie press and release trigger to commence welding, then press
and hold trigger again to enter down slope mode). Should the trigger be released during the down slope phase (4T only), the output
will cease immediately.

11. Arc Control (Inductance)

The arc control operates in MIG mode only and is used to adjust the intensity of the welding arc. Lower arc control settings make
the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc which can increase weld penetration.
Soft means maximum inductance while Hard means minimum inductance.

12. Trigger Mode Control (MIG and LIFT TIG Mode only)

The trigger mode control is used to switch the functionality of the of the torch trigger between 2T (normal) and 4T (latch mode)

2T (Normal Mode)

In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch trigger to activate
the power source (weld). Release the torch trigger switch to cease welding.

4T (Latch Mode)

This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and
release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be de­pressed and released, thus eliminating the need for the operator to hold the torch trigger.

Note that when operating in LIFT TIG mode, the power source will remain activated until the selected downslope time has elapsed
(refer Item 10).

13. Process Selection Control

The process selection control is used to select the desired welding mode. Three modes are available, MIG (GMAW/FCAW), LIFT TIG
(GTAW) and STICK (SMAW) modes. Refer to section 4.09 or 4.10 for MIG (GMAW/FCAW) set up details, section 4.12 for LIFT TIG
(GTAW) set-up details or section 4.13 for STICK (SMAW) set-up details.

Note that when the unit is powered off the mode selection control will automatically default to MIG mode. This is necessary so
as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work
piece during power up.

14. Digital Voltage Meter (Right Digital Display)

MIG Mode

This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the power source when
welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Voltage. This value can be adjusted by
varying the Multifunction Control Knob (10).

Manual 0-5450 4-5 INSTALLATION/SETUP

ESAB FABRICATOR 211i

STICK and LIFT TIG Modes

This digital meter is used to display the Welding Output Terminal Voltage in STICK / LIFT TIG modes during non-welding or welding.
This value cannot be adjusted by varying the Multifunction Control Knob (10).

When welding, this digital meter will display actual welding voltage in all modes.

At the completion of welding, the digital meter will hold the last recorded voltage value for a period of approximately 10 seconds
in all modes. The voltage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will
revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of
10 seconds elapses following the completion of welding in which case the unit will return to preview mode.

NOTE!

The preview functionality provided on this power source is intended to act as a guide only. Some dif­ferences may be observed between preview values and actual welding values due to factors including
the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the
transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the
case of procedural work), it is recommended that alternate measurement methods be utilized to ensure
output values are accurate.

15. Gas Inlet (MIG mode only for MIG Gun or Spool Gun operation)

The Gas Inlet connection,5/8-18 UNF female thread is used to supply the appropriate MIG welding gas to the Power Source. Refer
to section 4.09 or 4.10 for MIG (GMAW/FCAW) set up details

WARNING

!

16. On / Off Switch

This Single Phase circuit breaker performs a dual function.

It is used to turn the unit on/off and it will also trip in the event of a fault.

Only Inert Shielding Gases specifically designed for welding applications should be used.

WARNING

When the front digital displays are lit, the machine is connected to the Electricity Supply and the

17. Wiredrive Motor Circuit Breaker

The 4A Circuit Breaker protects the unit from electrical faults and will operate in the event of a motor overload.

internal electrical components are at Mains voltage potential.

NOTE!

If a circuit breaker trips, a short cooling period must be allowed before an attempt is made to reset the
unit by pressing the circuit breaker reset button.

18. Local / Remote Switch (located in wirefeed compartment)

The local/remote switch is used only when a remote control device (such as a TIG torch with remote current control) is fitted to the
unit via the remote control socket (item 9). When the local/remote switch is in the remote position, the unit will detect a remote
device and work accordingly. When in the local mode, the unit will not detect the remote device and will operate from the power
source controls only. Note that the trigger will operate at all times on the remote control socket irrespective of the position of the
local/remote switch (ie in both local and remote modes).

Should a remote device be connected and the remote/local switch set to remote, the maximum setting of the power source will
be determined by the respective front panel control, irrespective of the remote control device setting. As an example, if the output
current on the power source front panel is set to 50% and the remote control device is set to 100%, the maximum achievable output
from the unit will be 50%. Should 100% output be required, the respective front panel control must be set to 100%, in which case
the remote device will then be able to control between 0-100% output.

INSTALLATION/SETUP 4-6 Manual 0-5450

ESAB FABRICATOR 211i

Wire Drive Tension Knob

Pressure Arm

Outlet Guide

Inlet Guide

Art # A-11242_AB

MIG Gun Connector

Locking Screw

8 pin plug

MIG Gun Adapter

MIG Gun Connector

8 pin socket

19. Burnback Control (located in wirefeed compartment)

The burnback control is used to adjust the amount of MIG wire that protrudes from the MIG gun after the completion of MIG welding
(commonly referred to as stick out). To decrease the burnback time (or lengthen the amount of wire protruding from the MIG gun at
the completing of welding), turn the burnback control knob anti clockwise. To increase the burnback time (or shorten the amount
of wire protruding from the torch at the completing of welding), turn the Burnback Control knob clockwise.

20. MIG Gun & Spool Gun Switch

The MIG Gun / Spool Gun switch is used to switch welding mode between MIG Gun functionality and Spool Gun functionality

21. Cooling Fan

When the Fabricator 211i is powered up, the fan turns on for approximately 3 seconds and turns off. At the time of welding, the
fan turns on when welding is started, and will stay on for 10 minutes after you stop welding. After the 10 minutes has elapsed,
the fan will turn off.

In STICK mode, the fan is on all the time.

The Fabricator 211i is designed with an intelligent fan control. It automatically switches the cooling fan off when it is not required.
This has two main advantages; (1) to minimize power consumption, and (2) to minimize the amount of contaminants such as dust
that are drawn into the power source.

Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required.

4.02 Attaching The TWECO Fusion 220A MIG Gun

Fit the Fusion MIG gun to the power source by pushing the MIG gun connector into the MIG gun adapter and screwing the locking
screw clockwise to secure the MIG gun to the MIG gun adapter.
Connect the 8 pin plug by aligning the keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded collar fully
clockwise to lock the plug into position.

Manual 0-5450 4-7 INSTALLATION/SETUP

Figure 4-5: Attaching MIG Gun

ESAB FABRICATOR 211i

4.03 Installing 33/44 lb Spool (12" diameter)

As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Spool of 33/44 lb. or 12" diameter.
Installation of wire spool, Refer to Figure 4-6.

1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.

2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool rotates counter
clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool.

3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.

NOTE!

The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to Section

4.09..

CAUTION

!

Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp
the end of the wire firmly and don’t let go of it.

Wire Spool
Hub Nut

Flat Washer
Large Hole

Flat Washer
Small Hole

33/44 lb (12")
Wire Spool

Spring

Retaining Clip
Use inner holes on
Spool Hub

Keyed Washer

Fiber Washer

Pin

Spool Hub

Art # A-11266

Figure 4-6: 33/44 lb (12") Spool Installation

INSTALLATION/SETUP 4-8 Manual 0-5450

ESAB FABRICATOR 211i

4.04 Installing 12.5 lb Spool ( 8" diameter)

In order to fit a 12.5 lb spool (8" diameter) assemble parts in the sequence shown in Figure 4-7.
Installation of wire spool:

1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.

2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool rotates counter
clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool.

3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.

NOTE!

The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section

4.09.

CAUTION

!

Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp
the end of the wire firmly and don’t let go of it.

Fiber Washer

Retaining Clip

12.5 lb (8")
Wire Spool

Use inner holes on
Spool Hub

Pin

Wire Spool
Hub Nut

Flat Washer
Large Hole

Flat Washer
Small Hole

Spring

Keyed Washer

Spool Hub

Art # A-11267

Figure 4-7: 12.5lb (8") Spool Installation

Manual 0-5450 4-9 INSTALLATION/SETUP

ESAB FABRICATOR 211i

4.05 Installing 1 lb Spool (4" diameter)

In order to fit a 1 lb spool (4" diameter) assemble parts in the sequence shown in Figure 4-8.
Installation of wire spool:

1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.

2. Place Fiber Washer and Large Spring onto the Shaft, then load the Wire Spool on the Shaft so that the wire will feed off the
bottom of the spool as spool rotates counter clockwise.

3. Then place Flat Washer Large Hole, Keyed Washer, Spring, Flat Washer Small Hole as shown in Figure 4-8. Finally secure
with Wire Spool Hub Nut.

NOTE!

The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section

4.09.

CAUTION

!

Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp
the end of the wire firmly and don’t let go of it.

Fiber

1lb (4") Diameter
Wire Spool

Washer

Wire Spool
Hub Nut

Flat Washer
Large Hole

Flat Washer
Small Hole

Large
Spring

Keyed Washer

Spring

Art # A-11298_AB

Figure 4-8: 1lb (4") Spool Installation

INSTALLATION/SETUP 4-10 Manual 0-5450

ESAB FABRICATOR 211i

4.06 Inserting Wire Into The Wire Feed Mechanism

Release the tension from the pressure arm by turning the adjustable wire drive tension knob in an anti-clockwise direction. Then
push the tension knob toward the back of the machine to releases the pressue arm (Figure 4-9). With the MIG welding wire feeding
from the bottom of the spool (Figure 4-10) pass the electrode wire through the inlet guide, between the rolls, through the outlet guide
and into the MIG gun. Re-secure the pressue arm and wire drive tension knob and adjust the pressure accordingly (refer to Section

4.07). Remove the contact tip from the MIG gun. With the MIG gun lead reasonably straight, feed the wire through the MIG gun by
depressing the trigger switch. Fit the appropriate contact tip.

WARNING

Before connecting the work clamp to the work make sure the Electricity Supply is switched off.
The electrode wire will be at welding voltage potential while it is being feed through the system.
Keep MIG gun away from eyes and face.

Wire Drive Tension Knob

Pressure Arm

Art # A-10426_AB

Inlet Guide

Art # A-10427_AB

Outlet Guide

Figure 4-9: Wire Drive Assembly Components

MIG Welding Wire

Figure 4-10: MIG Welding Wire - Installation

Manual 0-5450 4-11 INSTALLATION/SETUP

ESAB FABRICATOR 211i

GROOVE “B”GROOVE “A”

4.07 Feed Roll Pressure Adjustment

The pressure (top) roll applies pressure to the grooved feed roll via an adjustable pressure knob. These devices should be adjusted to
a minimum pressure that will provide satisfactory WIREFEED without slippage. If slipping occurs, and inspection of the wire contact
tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and
swarf. If it is not the cause of slipping, the feed roll pressure can be increased by rotating the pressure knob clockwise.

WARNING

!

4.08 Changing the Feed Roll

To change feed roll remove the feed roll retaining screw by turning in an anticlockwise direction. Once the feed roll is removed then
to replace feed roll simply reverse these directions.

Before changing the feed roll ensure that the Electricity Supply to the power source is switched off.

CAUTION

The use of excessive pressure may cause rapid wear of the feed rolls, shafts and bearing.

NOTE!

Be sure not to lose key that is located on Drive Motor Shaft. This key must align with drive roll groove for
proper operation.

A dual groove feed roll is supplied as standard. It can accommodate 0.6/0.8mm diameter hard wires. Select the roll required with the
chosen wire size marking facing outward.

GROOVE “B” SIZE

Figure 4-11: Dual Groove Feed Roll

GROOVE “A” SIZE

A-09583

Feed Roll Retaining Screw

Art # A-10428

INSTALLATION/SETUP 4-12 Manual 0-5450

Figure 4-12: Changing the Feed Roll

ESAB FABRICATOR 211i

4.09 Wire Reel Brake

The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking.
If it is considered necessary, adjustment can be made by turning the Thumb Screw inside the open end of the hub clockwise to
tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 3 - 4mm (0.1"-0.15") after
release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool.

CAUTION

!

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical com­ponentry and possibly an increased incidence of electrode wire Burnback into contact tip.

Spool Hub Tension
Thumb Screw

Art # A-10429

Figure 4-13: Wire Reel Brake

4.10 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire

A. Select MIG mode with the process selection control. (refer to Section 4.01.13 for further information)

B. Connect the MIG polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.

Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male
plug is inserted and turned securely to achieve a sound electrical connection.

C. Fit the MIG gun to the power source. (Refer to section 4.02 Attaching the TWECO Fusion 220A MIG gun).

D. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. Welding

current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is
inserted and turned securely to achieve a sound electrical connection.

E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 3.08) then connect

the shielding gas hose from the rear of the power source to the regulator/flowmeter outlet.

F. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.

G. Switch the LOCAL/REMOTE switch inside the

wire feed compartment to LOCAL to use the
Power Sources Wirespeed and Voltage controls.

H. Switch the MIG GUN/SPOOL GUN switch inside

the wire feed compartment to MIG GUN.

Manual 0-5450 4-13 INSTALLATION/SETUP

ESAB FABRICATOR 211i

!

Shielding Gas Hose Fitted with Quick Connect

MIG Gun

WARNING

Before connecting the work clamp to the work make sure the Electricity Supply is switched off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suit­able stationary support to prevent falling or tipping.

CAUTION

!

Loose welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding
Power Source.

Positive Welding
Terminal (+)

MIG Polarity Lead

Figure 4-14: Setup for MIG Welding with Gas Shielded MIG Wire

8 pin plug

Negative Welding
Terminal (-)

Work Lead

Art # A-11244

INSTALLATION/SETUP 4-14 Manual 0-5450

ESAB FABRICATOR 211i

!

4.11 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire

A. Select MIG mode with the process selection control (refer to Section 4.01.13 for further information).

B. Connect the MIG polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.

Welding current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male
plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the work lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer. Welding

current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is
inserted and turned securely to achieve a sound electrical connection.

D. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.

E. Switch the LOCAL/REMOTE switch inside the

wire feed compartment to LOCAL to use the
Power Sources Wirespeed and Voltage controls.

F. Switch the MIG GUN/SPOOL GUN switch inside

the wire feed compartment to MIG GUN.

WARNING

Before connecting the work clamp to the work make sure the Electricity Supply is switched off.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused
in the terminal.
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.

MIG Gun

MIG Polarity Lead

Art # A-11245

Negative Welding
Terminal (-)

8 pin plug

Positive Welding
Terminal (+)

Work Lead

Manual 0-5450 4-15 INSTALLATION/SETUP

Figure 4-15: Setup for MIG Welding with Gasless MIG Wire

ESAB FABRICATOR 211i

Thumb screw

Art #

A-11629

4.12 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire

Select MIG mode with the Process Selection Control.

For setup and operation of the spool gun, please refer to the spool gun operations manual.
Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to SPOOL GUN.
Connect the shielding gas for the to the Shielding Gas Inlet on the rear panel of the Power Source.

1. Make sure the welding
power source is turned
OFF before connecting
the welding gun.

2. Open side panel and
loosen thumb screw.

3. Insert the back end of the
Spool gun into the gun
receiving bushing.

4. Tighten thumb screw and
replace side panel.

5. Connect gas supply fitting
and tighten with a wrench.

6. Align Control Plug to
panel fitting and tighten
securely.

INSTALLATION/SETUP 4-16 Manual 0-5450

!

!

Shielding Gas Hose Fitted with Quick Connect

ESAB FABRICATOR 211i

WARNING

Before connecting the work clamp to the work make sure the main power supply is switched
off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suit­able stationary support to prevent falling or tipping.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.
Remove any packing material prior to use. Do not block the air vents at the front or rear of the Welding
Power Source.

Spool Gun Switch

MIG polarity lead

Spool Gun

Figure 4-16: Setup for Spool Gun Welding with Gas Shielded MIG Wire

Positive Welding
Terminal (+)

Work Lead

Remote Control

Socket

Negative Welding
Te rminal (-)

Art # A-10576

Manual 0-5450 4-17 INSTALLATION/SETUP

ESAB FABRICATOR 211i

!

4.13 Setup For LIFT TIG (GTAW) Welding

A. Select LIFT TIG mode with the process selection control (refer to Section 4.01.13 for further information).

B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source via heavy duty

bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound elec­trical connection.

C. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source via heavy duty

bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound elec­trical connection.

D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below. The TIG

torch will require a trigger switch to operate in LIFT TIG Mode.

NOTE!

A ESAB 26V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch
trigger switch to TIG weld OR a ESAB Foot Control with an 8 pin plug must be used to turn the weld cur­rent on/off as well as providing remote control of the weld current.

E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 3.08) then connect

the shielding gas hose from the TIG torch to the regulator/flowmeter outlet. Note that the TIG torch shielding gas hose is
connected directly to the regulator/flowmeter. The power source is not fitted with a shielding gas solenoid to control the
gas flow in LIFT TIG mode therefore the TIG torch will require a gas valve.

WARNING

Before connecting the work clamp to the work and inserting the electrode in the TIG Torch
make sure the Electricity Supply is switched off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a sta­tionary support to prevent falling or tipping.

CAUTION

!

F. Switch the LOCAL/REMOTE switch inside the

wire feed compartment to LOCAL to use the
Power Sources Amperage control or REMOTE
for remote amperage using a Foot Control.

Remove any packaging material prior to use. Do not block the air vents at the front or rear of
the Welding Power Source.
Loose welding terminal connections can cause overheating and result in the male plug being
fused in the terminal.

INSTALLATION/SETUP 4-18 Manual 0-5450

Art # A-11246_AB

!

Positive Welding
Terminal (+)

Work Lead

TIG Remote Control

Negative Welding
Terminal (-)

TIG Torch

Figure 4-17: Setup for TIG Welding

ESAB FABRICATOR 211i

Connect to shielding gas
regulator/ow gauge.
Secure the gas cylinder
in an upright position by
chaining it to a stationary
support to prevent falling
or tipping.

Note: A Tweco 26V TIG torch with
an 8 pin plug must be used to turn the
weld current on/o via the TIG torch trigger
switch to TIG weld OR a Tweco Foot
Control with an 8 pin plug must be used to
turn the weld current on/o as well as
providing remote control of the weld current.

4.14 Setup For STICK (SMAW) Welding

A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer.

Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male
plug is inserted and turned securely to achieve a sound electrical connection.

B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer. Welding current

flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted
and turned securely to achieve a sound electrical connection.

C. Select STICK mode with the process selection control (refer to Section 4.01.13 for further information).

WARNING

Before connecting the work clamp to the work and inserting the electrode in the electrode holder

C. Switch the LOCAL/REMOTE switch inside the wire

feed compartment to LOCAL to use the Power Sources
Amperage control or REMOTE for remote amperage
control using a Hand Pendant Control.

make sure the Electricity Supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.

Manual 0-5450 4-19 INSTALLATION/SETUP

ESAB FABRICATOR 211i

Positive Welding
Terminal (+)

Negative Welding
Terminal (-)

Work Lead

Electrode Holder

Art # A-11247

INSTALLATION/SETUP 4-20 Manual 0-5450

Figure 4-18: Setup for Manual Arc Welding.

SECTION 5:

TROUBLESHOOTING

5.01 Basic Troubleshooting-Power Source Faults

NOTE!

In the table below, words "Faulty Power PCB, Control PCB or Display PCB" will appear, refer to relative sec­tions to detect and confirm the fault.
Refer to Section 5.06, 5.08, 5.09 and 5.10/Item 1/Power PCB to detect whether the Power PCB is defective.
Refer to Section 5.07, 5.10/Item 4/Control PCB and 5.11 to detect whether the Control PCB is defective.
Refer to Section 5.10/Item 3/ Display PCB to detect whether the Display PCB is defective..
If Power PCB, Control PCB or Display PCB is broken, replace accordingly.

Fault Possible Cause Remedy

1 There is no weld output and

all front panel displays are offA B

The main Power Switch is set to OFF
Line fuse is blown

C

The main Power Switch is faulty

D

Loose connection

E

Faulty Power PCB
Faulty Control PCB

F

Faulty Display PCB

G

ESAB FABRICATOR 211i

A

Set main Power Switch to ON

B

Replace Line fuse

C

Replace main Power Switch

D

Tighten connections

E

Replace Power PCB

F

Replace Control PCB

G

Replace Display PCB

2 There is no weld output and

all front panel displays are off
or flickering on & off

3 There is no weld output and

the yellow over temperature
light is on

4 Mode switch does not change

welding mode

5 The wirefeed motor and the

weld output do not operate
when the torch trigger switch
is depressed

A The internal protection circuit to shut the

unit down if the mains supply voltage is
too high has operated

A

Unit has overheated

B

Airflow inlet or outlet ducts are blocked
Fan does not operate

C

A Faulty Display PCB A Replace Display PCB

A

Internal wiring fault

B

Over temperature light is on

C

Power Source set to REMOTE

D

Trigger wires shorted to weld voltage
inside torch

E

Trigger wires or torch switch faulty

F

Faulty Power PCB

G

Faulty Control PCB

H

Faulty Display PCB

A Check to see if mains supply voltage

is <274VAC. A generator with poor
voltage regulation may cause a
supply voltage in excess of 274VAC.
Connect Power Source to a supply
voltage <274VAC.

A

Allow unit to cool with fan running
until over temperature light
extinguishes

B

Remove blockages from airflow
ducts

C

Replace fan. Check fan wiring header
is plugged securely into Control PCB.
Check fan wiring for damage.

A

Check continuity of internal wiring
from Torch adaptor through to boards
Allow unit to cool

B

Set switch to LOCAL

C

Repair trigger wires in torch

D

Check & Repair

E

Replace Power PCB

F

Replace Control PCB

G

Replace Display PCB

H

Manual 0-5450 5-1 TROUBLESHOOTING

ESAB FABRICATOR 211i

6 The wirefeed motor does

not operate when the torch
trigger switch is depressed

7 The wirefeed motor operates

at maximum speed and
cannot be adjusted.

8 Wirefeed motor operates

when the torch trigger switch
is depressed but the gas
valve does not operate.

9 A welding arc can be

established but the weld is
erratic or inconsistent

A

Power Source set to TIG or STICK mode
Wirefeeder motor wiring has become loose

B

Trigger wires or torch switch faulty

Faulty Power PCB
C
D

A BFaulty Power PCB

Faulty Display PCB

A

Internal wiring fault

B

Faulty Solenoid
C

Debris in gas system causing solenoid to

stay open or closed

D

Faulty Power PCB
E

Faulty Control PCB

A

Work Lead cable too small
B

Loose welding connections
C

Loose work clamp
D

Incorrect weld polarity selected

E

No shielding gas
F

Wind blows shielding gas away

G

Incorrect TIG tungsten electrode
H

Poorly prepared or worn TIG tungsten

Table 5-1 Power Source Faults

A

Set power Source to MIG mode
Check motor wiring

B

Check & Repair

C

Replace trigger switch/wire

D

Replace Power PCB

A BReplace Power PCB

Replace Display PCB

A

Check solenoid wiring header
is plugged securely into Control
PCB. Check solenoid wiring is not
damaged

B

Replace Solenoid

C

Clean out gas system. Disassemble
solenoid & clean out debris

D

Replace Power PCB

E

Replace Control PCB

A

Use correct weld cable size

B

Tighten welding connections

C

Tighten work clamp

D

Correct weld polarity. Refer to
weld consumable manufacturers
recommended polarity

E

Connect shielding gas

F

Shield welding area from drafts

G
H

Use correct tungsten type
Regrind tungsten to correct shape

5.02 Routine Service and Calibration Requirements

WARNING

There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do
not attempt to open or repair unless you are an accredited ESAB Service Provider. Disconnect the Welding
Power Source from the Mains Supply Voltage before disassembling.

Routine Inspection, Testing & Maintenance

The inspection and testing of the power source and associated accessories shall be carried out by a licensed electrician. This includes
an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with ESAB's original specifications.

A. Testing Schedule

1. For transportable equipment, at least once every 3 months; and

2. For fixed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the
most recent inspection.

A transportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which
it is operated.

TROUBLESHOOTING 5-2 Manual 0-5450

ESAB FABRICATOR 211i

NOTE!

Please refer to local guidelines for further information

B. Insulation Resistance

Minimum insulation resistance for in-service ESAB Inverter Power Sources shall be measured at a voltage of 500V between the
parts referred to in Table 5-2 below. Power sources that do not meet the insulation resistance requirements set out below shall be
withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.

Components to be Tested

Input circuit (including any connected control circuits) to welding circuit
(including any connected control circuits)

All circuits to exposed conductive parts

Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage exceeding extra low voltage

Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage not exceeding extra low voltage

Separate welding circuit to separate welding circuit

Table 5-2 Minimum Insulation Resistance Requirements: ESAB Inverter Power Sources

C. Earthing

The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be earthed, and -

1. The earth terminal of a fixed power source; or

2. The earth terminal of the associated plug of a transportable power source

Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying ESAB welding
power sources should be inspected by a licensed electrical worker in accordance with the requirements below -

1. For outlets/wiring and associated accessories supplying transportable equipment - at least once every 3 months; and

2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12 months.

D. General Maintenance Checks

Minimum Insulation

Resistance (MΩ)

5

2.5

10

1

1

Welding equipment should be regularly checked by an accredited ESAB Service Provider to ensure that:

1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in
good condition.

2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit.

3. The Welding System is clean internally, especially from metal filing, slag, and loose material.

E. Accessories

Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be inspected at least monthly
by a competent person to ensure that the equipment is in a safe and serviceable condition. All unsafe accessories shall not be used.

F. Repairs

If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited ESAB Service Provider.

Manual 0-5450 5-3 TROUBLESHOOTING

ESAB FABRICATOR 211i

Power Source Calibration

A. Schedule

Output testing of all ESAB Inverter Power Sources and applicable accessories shall be conducted at regular intervals to ensure they
fall within specified levels. Calibration intervals shall be as outlined below -

1. For transportable equipment, at least once every 3 months; and

2. For fixed equipment, at least once every 12 months.

If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in EN 60974-1, then
the above tests should be carried out prior to entering this location.

B. Calibration Requirements

Where applicable, the tests outlined in Table 5-3 below shall be conducted by an accredited ESAB service agent.

Testing Requirements

Output current (A) to be checked to ensure it falls within applicable ESAB power source specifications

Output Voltage (V) to be checked to ensure it falls within applicable ESAB power source specifications

Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required ESAB power
source / wire feeder specifications

Accuracy of digital meters to be checked to ensure it falls within applicable ESAB power source specifications

Table 5-3 Calibration Parameters

Periodic calibration of other parameters such as timing functions are not required unless a specific fault has been identified.

C. Calibration Equipment

All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement
in question. Only test equipment with valid calibration certificates (NATA certified laboratories) shall be utilized.

5.03 Check Unit before Applying Power

If the problem cannot be solved by the basic (external) troubleshooting guide, the Power Source cover will have to be removed to allow
the technician to analyse failures with a few common tools.

WARNING

!

Checking Unit Before Applying Power

!

Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two
minutes for capacitors to discharge after disconnection from mains supply voltage.

WARNING

Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit.
Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off
before removing case.
Check DC bus voltage according to Section 5.06 after removing case.
Before troubleshooting or applying power to unit, complete the following checks to avoid causing further
damage.

TROUBLESHOOTING 5-4 Manual 0-5450

ESAB FABRICATOR 211i

Art # A-10750

5.04 Test Equipment and Tools Needed for Troubleshooting and Servicing

• DigitalMultimeter

• DCclip-onammeter

• Screwdriverandspanner

• Oscilloscope&isolatingtransformer

Art # A-09849

5.05 Visually Inspect

Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or arcing of PCB, trans­formers, switches, or rectifier when a failure occurs. Carefully inspect all components within these units.
Look in particular for the following:

a) Loose or broken wires or connectors.

b) Burned or scorched parts or wires or evidence of arcing.

c) Any accumulation of metal dust or filings that may have caused shorting or arcing.
If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of components used in the Power
Source.
Locate the faulty component(s) then replace where necessary.

5.06 Preliminary DC Bus Measurement of the Power PCB

WARNING

!

Check DC bus voltage has discharged to less than 5VDC before servicing. Ensure the mains supply plug is
disconnected from receptacle.

Manual 0-5450 5-5 TROUBLESHOOTING

ESAB FABRICATOR 211i

DC Bus Testing Multimeter Lead Placement

Upper capacitor bank

Lower capacitor bank

Table 5-4 DC BUS, Multimeter set to measure DC volts

Positive meter lead to testpoint 1

Negative meter lead to testpoint 2

Positive meter lead to testpoint 2

Negative meter lead to testpoint 3

5.07 Preliminary Check of the Control PCB

WARNING

!

Read and follow safety information in Section 5.03 before proceeding.

Voltage with Supply

Voltage OFF

0 VDC

0 VDC

Art # A-10751

IGBT Testing Multimeter Lead Placement Diode Voltage

IGBT V8 & V8-1

IGBT T1 & T2

IGBT T4 & T5

Table 5-5 IGBT’s, Multimeter set to measure Diode Voltage

TROUBLESHOOTING 5-6 Manual 0-5450

Positive meter lead to testpoint 3

Negative meter lead to testpoint 4

Positive meter lead to testpoint 6

Negative meter lead to testpoint 5

Positive meter lead to testpoint 3

Negative meter lead to testpoint 7

0.2 – 0.8 VDC

0.2 – 0.8 VDC

0.2 – 0.8 VDC

ESAB FABRICATOR 211i

IGBT Testing Multimeter Lead Placement Ohms

IGBT V8 & V8-1 Positive meter lead to testpoint 4

Negative meter lead to testpoint 3

IGBT T1 & T2 Positive meter lead to testpoint 5

Negative meter lead to testpoint 6

IGBT T4 & T5 Positive meter lead to testpoint 7

Negative meter lead to testpoint 3

Table 5-6 IGBT’s, Multimeter set to measure ohms (Ω)

Inrush Resistor Multimeter Lead Placement Ohms

Resistor

Positive meter lead to testpoint 8

Negative meter lead to testpoint 9

Table 5-7 Inrush PTC, Multimeter set to measure ohms (Ω)

DIODE Testing Multimeter Lead Placement Diode Voltage

DIODE V7 & V7-1

DIODE T18, T19, T20, T21

DIODE T14, T15, T16, T17

Positive meter lead to testpoint 10

Negative meter lead to testpoint 11

Positive meter lead to testpoint 12

Negative meter lead to testpoint 13

Positive meter lead to testpoint 14

Negative meter lead to testpoint 15

Table 5-8 Diodes, Multimeter set to measure Diode Voltage

>150 Ω

>150 Ω

>150 Ω

3 Ω

0.2 – 0.8 VDC

0.2 – 0.8 VDC

0.2 – 0.8 VDC

5.08 Check Main Input Rectifier

Art # A-10752

Manual 0-5450 5-7 TROUBLESHOOTING

ESAB FABRICATOR 211i

Input Rectifier Testing Multimeter Lead Placement Diode Voltage

AC1 to DC+

AC2 to DC+

AC1 to DC-

AC2 to DC-

Table 5-9 Input Rectifier, Multimeter set to measure Diode Voltage

Measurements may be made directly onto the main input rectifier. AC1 and AC2 may be measured from the pins on the mains supply
plug with the main power switch set to the ON position.

5.09 DC Bus Voltage Measurement

Apply voltage to the Power Source.

WARNING

There are extremely dangerous voltage and power levels present inside these Power Sources. Do not attempt
to diagnose or repair unless you have had training in power electronics measurement and troubleshooting tech­niques.
Once power is applied to the Power Source, there are extremely hazardous voltage and power levels present.
Do not touch any live parts

Positive meter lead to 16

Negative meter lead to testpoint 18

Positive meter lead to 17

Negative meter lead to testpoint 18

Positive meter lead to testpoint 19

Negative meter lead to testpoint 16

Positive meter lead to testpoint 19

Negative meter lead to testpoint 17

0.2 – 0.8 VDC

0.2 – 0.8 VDC

0.2 – 0.8 VDC

0.2 – 0.8 VDC

Art # A-10750

TROUBLESHOOTING 5-8 Manual 0-5450

DC Bus Testing Multimeter Lead Placement Voltage with Supply Voltage ON

Upper capacitor bank

Lower capacitor bank

Overall capacitor bank

Positive meter lead to testpoint 1

Negative meter lead to testpoint 2

Positive meter lead to testpoint 2

Negative meter lead to testpoint 3

Positive meter lead to testpoint 1

Negative meter lead to testpoint 3

Table 5-10 DC BUS, Multimeter set to measure DC volts

Note: These DC voltages are at nominal mains supply voltage of 240VAC/110VAC.

5.10 PCB Connectors

1. Power PCB

ESAB FABRICATOR 211i

190 VDC +/-10%

190 VDC +/-10%

385 VDC +/-10%

IN Header Pin Pin function Signal

1 +15V 15 VDC
2 IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk
3 IGBT 2 pwm drive signal, 15V p-p square wave 15 VDC pk
4 IGBT 2 pwm drive signal, 15V p-p square wave 15 VDC pk
5 IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk

6 Rectified secondary of current transformer TR8 15 VDC pk
7 0V 0 VDC

Table 5-11 IN Header pin function (connects to DRIVE header on control PCB)

Manual 0-5450 5-9 TROUBLESHOOTING

Art # A-10753

ESAB FABRICATOR 211i

PWM Header Pin Pin function Signal

1 0VDC 0 VDC
2 Motor pwm drive signal 5 VDC pk

Table 5-12 PWM Header pin function (connects to PWM header on control PCB)

MD Header Pin Pin function Signal

1 Motor positive 24 VDC
2 Motor negative 0 VDC

Table 5-13 MD Header pin function (connects to MT-IN header on motor PCB)

DY2 Header Pin Pin function Signal

1 +24V 24 VDC
2 0V 0 VDC
3 -24V -24 VDC

Table 5-14 DY2 Header pin function (connects to SOURCE header on control PCB)

DY1 Header Pin Pin function Signal

1 +24V (solenoid positive) 24 VDC
2 0V 0V
3 No connection n/c
4 +24V (solenoid positive) 24 VDC
5 Solenoid negative 0 VDC

Table 5-15 DY1 Header pin function

QF/FJ Header Pin Pin function Signal

1 +24V (VRD positive) 24 VDC
2 Solenoid negative 0 VDC
3 +24V (solenoid positive) 24 VDC
4 0V 0 VDC

Table 5-16 QF/FJ Header pin function (Connects to QF/DY header on control PCB)

RX Header Pin Pin function Signal

1 Inrush Resistor

2 Inrush Resistor

Table 5-17 RX Header pin function (connects to Inrush Resistor)

JC Header Pin Pin function Signal

1 +5V +5 VDC

2 PFC OK signal, 5V = PFC OK

Table 5-18 JC Header pin function (connects to PFC header on control PCB)

FJ Header Pin Pin function Signal

1 Fan positive +24 VDC

2 Fan negative 0 VDC

Table 5-19 FJ Header pin function (connects to FAN)

CON3 Header Pin Pin function Signal

1 24VDC +24 VDC

2

3 Fan control signal, 0V = Fan ON 0VDC

Table 5-20 CON3 Header pin function (connects to FUNs on control PCB)

TROUBLESHOOTING 5-10 Manual 0-5450

2. Spoolgun PCB

MT-IN Header Pin Pin function Signal

1 Motor positive from Power PCB 24 VDC
2 Motor negative from Power PCB 0 VDC
3 Motor negative 0 VDC
4 Motor positive 24 VDC

Table 5-21 MT-IN Header pin function (Connects to MD header on Power PCB & to Motor)

ESAB FABRICATOR 211i

Art # A-10754

SGM Header Pin Pin function Signal

1 Spool Gun Motor negative 0 VDC
2 Spool Gun Motor positive 24 VDC

Table 5-22 SG-M Header pin function (connects to SGM header on display PCB)

PP Header Pin Pin function Signal

1 Spool Gun Switch
2 Spool Gun Switch

Table 5-23 PP Header pin function (connects to Spool Gun Switch)

15V Header Pin Pin function Signal

1 0VDC 0 VDC
2 15VDC 15 VDC

Table 5-24 15V Header pin function (connects to 15V header on display PCB)

FUSE Header Pin Pin function Signal

1 Circuit Breaker
2 Circuit Breaker

Table 5-25 FUSE Header pin function (connects to Motor Circuit Breaker)

Manual 0-5450 5-11 TROUBLESHOOTING

ESAB FABRICATOR 211i

3. Display PCB

Art # A-10755

GUN Header Pin Pin function Signal

1 +24V trigger positive (0V when trigger closed) 24 VDC
2 0VDC 0 VDC

Table 5-26 GUN Header pin function (connects to GUN header on control PCB)

GUN1 Header Pin Pin function Signal

1 +24V trigger positive (0V when trigger closed) 24 VDC
2 0VDC 0 VDC

Table 5-27 GUN Header pin function (connects to front panel torch trigger terminals)

REMOTE Header Pin Pin function Signal

1 Remote switch
2 Remote switch

Table 5-28 REMOTE Header pin function (connects to remote switch)

J12 Header Pin Pin function Signal

1 Serial display data & eprom (D-IN) 5 VDC digital
2 Serial display data (LOAD) 5 VDC digital
3 Serial display data (CLK) 5 VDC digital
4 2T/4T pushbutton (0V when button pushed) 0VDC
5 Serial display eprom (D-OUT) 5 VDC digital
6 Stick mode (used for remote / local)
7 Chip select 5 VDC digital
8 MODE pushbutton (0V when button pushed) 0VDC

9 15VDC 15 VDC
10 Remote / Local switch
11 Inductance pot terminal 2
12 Volts setpoint 0 – 5 VDC
13 Inductance pot terminal 1
14 Amps setpoint 0 – 5 VDC
15 5VDC 5 VDC
16 0V 0 VDC

Table 5-29 J12 Header pin function (connects to MB header on control PCB)

TROUBLESHOOTING 5-12 Manual 0-5450

ESAB FABRICATOR 211i

Art # A-10756

R-G Header Pin Pin function Signal

1 Spool gun motor negative 24 VDC

2 +24V trigger positive (0V when trigger closed) 24 VDC
3 0VDC 0 VDC
4 Spool gun motor 0 VDC
5 -12VDC -12 VDC
6 +12VDC +12 VDC
7 Remote amps -12 to +12 VDC
8 Remote volts -12 to +12 VDC

Table 5-30 R-G Header pin function (connects to front panel 8 pin remote socket)

SGM Header Pin Pin function Signal

1 Motor negative 0 VDC
2 Motor positive 24 VDC

Table 5-31 SGM Header pin function (connects to SGM header on spoolgun PCB)

15V Header Pin Pin function Signal

1 0VDC 0VDC
2 15VDC 15 VDC

Table 5-32 15V Header pin function (connects to 15V header on spoolgun PCB)

4. Control PCB

GUN Header Pin Pin function Signal

1 +24V trigger positive (0V when trigger closed) 24 VDC
2 0VDC 0 VDC

Table 5-33 GUN Header pin function (connects to GUN header on display PCB)

PWM Header Pin Pin function Signal

1 0VDC 0 VDC
2 Motor pwm drive signal 5 VDC pk

Table 5-34 PWM Header pin function (connects to PWM header on power PCB)

Manual 0-5450 5-13 TROUBLESHOOTING

ESAB FABRICATOR 211i

PFC Header Pin Pin function Signal

1 5V +5 VDC

2 PFC OK signal, 1= PFC OK

Table 5-35 PFC Header pin function (connects to JC header on Power PCB)

QF/DY Header Pin Pin function Signal

1 +24V (VRD positive) 24 VDC

2 Solenoid negative 0 VDC

3 +24V (solenoid positive) 24 VDC

4 0V 0 VDC

Table 5-36 QF/FJ Header pin function (Connects to QF/FJ header on Power PCB)

FUNs Header Pin Pin function Signal

1 24VDC +24 VDC

2

3 Fan control signal, 0V = Fan ON

DRIVE Header Pin Pin function Signal

1 +15V 15 VDC

2 IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk

3 IGBT 2 pwm drive signal, 15V p-p square wave 15 VDC pk

4 IGBT 2 pwm drive signal, 15V p-p square wave 15 VDC pk

5 IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk

6 Rectified secondary of current transformer TR8 15 VDC pk

7 0V 0 VDC

Table 5-38 DRIVE Header pin function (connects to IN header on Power PCB)

Table 5-37 FUNs Header pin function (not used)

WVIN Header Pin Pin function Signal

1 Positive welding terminal positive VDC

2 No connection n/c

3 Negative welding terminal 0 VDC

Table 5-39 WVIN Header pin function

IFB Header Pin Pin function Signal

1 +15V 15 VDC

2 -15V -15 VDC

3 Current sensor signal

4 0V 0 VDC

Table 5-40 IFB Header pin function (Connects to welding output current sensor)

SOURCE Header Pin Pin function Signal

1 +24V 24 VDC

2 0V 0 VDC

3 -24V -24 VDC

Table 5-41 SOURCE Header pin function (connects to DY2 header on control PCB)

TROUBLESHOOTING 5-14 Manual 0-5450

ESAB FABRICATOR 211i

CR Header Pin Pin function Signal

1 +5V 5 VDC
2 Wiper 10k Burnback potentiometer 0 – 5 VDC
3 0V 0 VDC

Table 5-42 CR Header pin function (connects to 10k Burnback potentiometer)

OT1 Header Pin Pin function Signal

1 Diode thermostat
2 Diode thermostat

Table 5-43 OT1 Header pin function (connects to igbt thermostat)

OT2 Header Pin Pin function Signal

1 Igbt thermostat (0VDC when thermostat closed)
2 0V 0 VDC

Table 5-44 OT2 Header pin function (connects to NTCS header on Power PCB)

MB Header Pin Pin function Signal

1 Serial display data & eprom (D-IN) 5 VDC digital
2 Serial display data (LOAD) 5 VDC digital
3 Serial display data (CLK) 5 VDC digital
4 2T/4T pushbutton (0V when button pushed) 0VDC
5 Serial display eprom (D-OUT) 5 VDC digital
6 Stick mode (used for remote / local)
7 Chip select 5 VDC digital
8 MODE pushbutton (0V when button pushed) 0VDC

9 15VDC 15 VDC
10 Remote / Local switch
11 Inductance pot terminal 2
12 Volts setpoint 0 – 5 VDC
13 Inductance pot terminal 1
14 Amps setpoint 0 – 5 VDC
15 5VDC 5 VDC
16 0V 0 VDC

Table 5-45 MB Header pin function (connects to J12 header on display PCB)

Manual 0-5450 5-15 TROUBLESHOOTING

ESAB FABRICATOR 211i

5.11 DIP Switch Settings, Control PCB

1. DIP Switch SW0, control PCB

ON

12

SW0 No. SW0 Position

1 Set to OFF for Fabricator 211i
2 Set to OFF for Fabricator 211i

Table 5-46 SW0 Dip Switch Position

Art # A-12073

TROUBLESHOOTING 5-16 Manual 0-5450

5.12 Calibration

1. Calibration

ESAB FABRICATOR 211i

ON

12

Art # A-12073

Set SW0 position 1 to ON while the power source is turned off, to allow calibration of output volts & amps.

2. Output Current Calibration

Select STICK mode on the front panel.

Measure no load output welding voltage and adjust WVF potentiometer so Volts display reads within 0.2V of the measured value.
Connect a load to the output terminals. The load should be of a resistance to give 25V at 250A.

Set front panel AMPS potentiometer to minimum.

Adjust Imin trimpot until output amps is 10A +/- 0.2A

Set front panel AMPS potentiometer to maximum.

Adjust Imax trimpot until output amps is 200A +/- 1A

Recheck settings

Set front panel AMPS potentiometer to maximum.

Adjust A potentiometer so Amps display reads within 0.5A of the measured value.

3. Output Voltage Calibration

Select MIG mode on the front panel.
Remove the load from the output terminals.
Set front panel VOLTS potentiometer to minimum.
Adjust Vmin trimpot until output volts is 14.0V +/- 0.2V
Set front panel VOLTS potentiometer to maximum.
Adjust W2 trimpot until output volts is 26V +/- 0.2V
Recheck settings

4. Wire Speed Calibration

NOTE!

These adjustments are on the wiring side of the main Power module circuit board.

Manual 0-5450 5-17 TROUBLESHOOTING

ESAB FABRICATOR 211i

Art # A-10758

Select MIG mode on the front panel.
Remove the load from the output terminals.
Set MIG output voltage to maximum.

Set front panel WIRESPEED (AMPS) potentiometer to minimum. AMPS display should read “30”
Adjust W02 trimpot until motor volts are 4.2V +/- 0.2V or motor feedroll shaft speed is 27rpm
Set front panel WIRESPEED (AMPS) potentiometer to maximum. AMPS display should read “218”
Adjust W05 trimpot until motor volts are 24.7V +/- 0.2V or motor feedroll shaft speed is 191rpm
Recheck settings

Turn Mains power off & allow power supplies to discharge
Set SW0 position 1 to OFF while the power source is turned off, to resume normal power source operation.

TROUBLESHOOTING 5-18 Manual 0-5450

5.13 Circuit Diagram

ACOUT

DC -

DC +

RED

BLACK

+15V 1

IGBT Driver A 2

IGBT Driver B 3

GND 7

Over Current Signal 6

OT2

Funs

RED

Main Power PCB1

Control PCB2

4 GND

1 +15V

2 -15V

3 Current Feedback

Current Sensor

CONNECTOR LAYOUT DIAGRAM

MWPBFI

FunsDRIVE

ON

1

FAN

PFC CIRCUIT

GUN

MB

BLACK

POS

NEG

+

-

BLACK

WVIN

OT1

DRIVE

IFB

RED

YELLOW

GRAY

WHITE

IN

1

IGBT Driver B 4

IGBT Driver A 5

1 +15V

2 IGBT Driver A

3 IGBT Driver B

7 GND

6 Over Current Signal

4 IGBT Driver B

5 IGBT Driver A

1

1

1

+24VDC 1

-24VDC 3

GND 2

1 +24VDC

2 GND

3 -24VDC

DY2

SOURCE

1

+

1

1

MOTOR PWM CONTROL

CIRCUIT

PWM

PWM

1 PWM RETURN

2 PWM (MOTOR DRIVER 5VDC PEAK)

1

1

1

1

1

ACOUT

SHEETMETAL COVER

VR

BR1

BR2

+++

+

1

1

1

GAS

SOLENOID

1

1

1

1

1

Wirefeeder

Power

Fault

MIG

LIFT TIG

STICK

2T Normal

4T Latch

Process

Trigger

Wirefeed / Amps

Volts

Down Slope / Arc Force(%)

Arc Control

Amps / Wirefeed Display

Volts Display

12

3456

78

Front View

8A/250V

Fuse

MIG GUN

SPOOL GUN

1

1

K1

L1

L2

GND

OT1

OT2

CR

SOURCE

QF / DY

WVIN

JC

1

2

MB

1

POT1

1

CR

JC

QF / DY

GND

+24VDC

3 POT MAX (+5VDC)

2 WIPER

1 POT MIN

RED

BLK

YEL

1 +24VDC

1

1 - OUTPUT

3 + OUTPUT

8 Pin Remote Control

Spool Gun

1

SPOOL GUN (0V) 1

TORCH SWITCH (+24V) 2

TORCH SWITCH RIN (0VDC) 3

SPOOL GUN (+24VDC) 4

5

REMOTE CONTROL IN (+15V ) 6

(REMOVE VOLTAGE) POT WIPER 8

(REMOVE AMPS/WIRESPEED) POT WIPER 7

1

LOCAL

REMOTE

-15VDC

1

1

GUN

+24VDC 1

GND

1

1 +15VDC

1 +15VDC

GND

DISPLAY DATA &EPROM (D-IN) 1

SEIAL DISPLAY DATA (LOAD) 2

SEIAL DISPLAY DATA (CLK) 3

2T/4T PUSHBUTTON 4

SERIAL DISPLAY DATA (EPROM) 5

STICK 6

+15VDC 9

PROCESS PUSHBUTTON 8

POT3 B 11

POT2 WIPER 12

POT3 A (PANEL DEMAND) 13

POT1 WIPER 14

+15VDC 15

GND

1

1

RED

WHITE

YELLOW

RED

BLACK

1 +24CDC

GND

+24CDC 1

N/A 2

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

RED

JC

2 +5VDC

1

INPUT 230V/115V

OUTPUT CONTROL SIGNAL

1

SPOOL GUN PCB3

PP

15V

FUSE

SGM

Display PCB4

DY1

QF/FJ

GUN

MT

75

ć

75

ć

RED

RED

BLACK

BLACK

RED

BLACK

CON3

FJ

BURN BACK PCB 5

RED

YELLOW

RED

BLACK

INPUT 115/208/230VAC

50/60Hz50/60Hz50/60Hz

MD

RED

YELLOW

1

R-G

remote15V

SGM

1

1

Art#A-11249_AC

ESAB FABRICATOR 211i

Manual 0-5450 5-19 TROUBLESHOOTING

ESAB FABRICATOR 211i

5.14 Main Circuit Description

WARNING

!

The mains supply voltage is connected via a double pole switch to the input rectifier Q1 through an EMC filter. Overvoltage protec­tion is provided by varistor CY1.

The rectifier output charges the main capacitor bank (C16, C17, C18, C19, C22 and C23) to high voltage. Inrush current limiting is
provided by a PTC which is then bypassed by relay J1 after a few seconds.

The primary igbt transistors (T1, T2, T4, and T5) switch the transformer primary at high frequency and varying duty cycle. The
transformer return wire is taken from the junction of the capacitors C20 and C21 (the voltage at this point is approximately half
the DC bus voltage).

Secondary output voltage from the transformer is rectified by the output diodes (T13, T14, T15, T16, T17, T18, T19, and T20) to
DC. This DC is controlled by the PWM of the primary side igbt transistors, and is filtered by an inductor before connecting to the
welding output terminals.

Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes
for capacitors to discharge after disconnection from mains supply voltage.

A thermal overload device (thermistor) is fixed to the rectifier heatsink. When an over temperature occurs, the control circuit
inhibits the trigger, gas solenoid, wire drive system and the welding output. The thermal overload indicator LED on the front panel
is illuminated.

The current transformer TR8 provides a signal to the control circuit to indicate both transformer primary current, and also detect
transformer saturation. The Hall effect current sensor is powered from regulated + & - 15VDC supplies and provides a voltage
signal proportional to the output DC welding current to allow the control circuit to regulate welding current.

TROUBLESHOOTING 5-20 Manual 0-5450

1

2

3

45

6

7

111213

14

8

9

10

Art # A-10760_AB

1

SECTION 6:

DISASSEMBLY PROCEDURE

6.01 Safety Precautions for Disassembly

WARNING

Gives information regarding possible electrical shock injury. Warnings will be enclosed in a box such as this.
Unplug unit before beginning Disassembly procedure.

6.02 Control PCB Removal

WARNING

Read and follow safety information in Section 5.03 before proceeding with disassembly.

Remove cover panel before remove the control PCB.

1. M4 Screw. Remove 4 screws from Control PCB.

2. Disconnect DRIVE harness from DRIVE connector.

3. Disconnect SOURCE harness from SOURCE connector.

4. Disconnect CR harness from CR connector.

5. Disconnect FUNs harness from FUNs connector.

6. Disconnect IGBT OT2 harness from IGBT OT2 connector.

7. Disconnect IGBT OT1 harness from IGBT OT1 connector.

8. Disconnect GUN harness from GUN connector.

9. Disconnect QF/DY harness from QF/DY connector.

10. Disconnect WVIN harness from WVIN connector.

11. Disconnect MB harness from MB connector.

12. Disconnect JC harness from JC connector.

13. Disconnect PWM harness from PWM connector.

14. Disconnect IFB harness from IFB connector.

ESAB FABRICATOR 211i

Manual 0-5450 6-1 DISASSEMBLY PROCEDURES

ESAB FABRICATOR 211i

6.03 Front Panel Assembly Removal

WARNING

Read and follow safety information in Section 5.03 before proceeding with disassembly.

1. Screws on front panel.

2. Positive output terminal bolts. Unscrew output terminal bolts.

3. Negative output terminal bolts. Unscrew Negative output terminal bolts.

1

2

3

A-12943

DISASSEMBLY PROCEDURES 6-2 Manual 0-5450

6.04 Display PCB Removal

1

WARNING

Read and follow safety information in Section 5.03 before proceeding with disassembly.

1. Remove Control Panel screw (4).

2. Display PCB.

3. Disconnect the harnesses from the connectors.

ESAB FABRICATOR 211i

2

A-12944

3

Manual 0-5450 6-3 DISASSEMBLY PROCEDURES

ESAB FABRICATOR 211i

1

6.05 Back Panel Removal

WARNING

Read and follow safety information in Section 5.03 before proceeding with disassembly.

1. Remove the screws on the back .

2. Remove Rear Panel screws .

3. Remove The Ground Wire.

4. Wire from Power PCB.

Disconnect the two wires from switch.

5. Remove The Screw and Disconnect the pipe from gas inlet.

2

3

5

A-12945

DISASSEMBLY PROCEDURES 6-4 Manual 0-5450

4

6.06 Power Switch S1 and Power Cord Removal

3

5

WARNING

Read and follow safety information in Section 5.03 before proceeding with disassembly.

1. Gas inlet. Remove gas inlet from rear panel.

2. Remove The Ground Wire.

3. Remove the screws which control the supply cord.

4. Remove the two screws and push SW1 out from the rear panel.

5. Remove the two supply wires from the switch.

6. Remove the supply wires which connect to power PCB.

7. Input Power Cord ground wire filter.

Cut the tie-wrap and remove the Ferrite core from the ground wire.

8. Remove The Screw and Disconnect the pipe from gas inlet.

9. Disconnect harness from power PCB.

10. Remove Fan.

ESAB FABRICATOR 211i

4

1

7

8

2

6

A-12946

10

Manual 0-5450 6-5 DISASSEMBLY PROCEDURES

9

ESAB FABRICATOR 211i

2

6.07 Base Panel Removal

WARNING

Read and follow safety information in Section 5.03 before proceeding with disassembly.

1. Remove Wire Feeder Screws.

2. Remove inductor assembly Screws.

3. Remove Power PCB assembly Screws.

4. Remove Center Panel Screws.

3

Art # A-10765

1

4

DISASSEMBLY PROCEDURES 6-6 Manual 0-5450

7.01 Installing Base Panel

1. Power PCB assembly.

2. Install Power PCB assembly screws.

3. Install inductor assembly Screws.

4. Install Wire Feeder Screws.

5. Install Center Panel Screws.

ESAB FABRICATOR 211i

SECTION 7:

ASSEMBLY PROCEDURES

32

4

5

1

Art # A-10766

Manual 0-5450 7-1 ASSEMBLY PROCEDURES

ESAB FABRICATOR 211i

2

5

7.02 Installing Back Panel

1. Install gas inlet.

2. Install the power supply cord and the screws.

3. Install fan.

4. Reconnect the pipe to gas inlet and the screw.

5. Reconnect the supply wires.

6. Reconnect the supply wires which connect to power PCB.

7. Install the two screws

8. Reinstall magnetic core onto Ground Wire.

9. Reconnect Ground Wire to the terminal.

10. Reconnect Rear Panel screws.

11. Reconnect the harness to FAN connector.

2

1

7

9

A-12949

1

3

7

4

6

11

ASSEMBLY PROCEDURES 7-2 Manual 0-5450

ESAB FABRICATOR 211i

7.03 Installing Front Panel

1. Reinstall output Dinse on front panel with 27mm wrench.

Reconnect positive output terminal bolts and tighten with 17mm wrench. ( Note: reconnect wires, pay attention to the wire

colour.)

Reconnect negative output terminal bolts and tighten with 17mm wrench. (note: reconnect wires and pay attention to the wire

colour.)

2. Place display PCB and control panel assembly into front panel. Install screws.

3. Reconnect Front Panel screws.

A-12947

1

2

3

Manual 0-5450 7-3 ASSEMBLY PROCEDURES

ESAB FABRICATOR 211i

1

2

3

45

6

7

111213

14

8

9

10

Art # A-10760_AB

1

15

Art # A-10769

7.04 Installing Control PCB and Clear Cover Sheet

Refer to diagram on page 7-5.

1. Install 4 screws.

2. Plug harness into DRIVE connector.

3. Plug harness into SOURCE connector.

4. Plug harness into CR connector.

5. Plug harness into FUNs connector.

6. Plug harness into m IGBT OT2 connector.

7. Plug harness into IGBT OT1 connector.

8. Plug harness into GUN connector.

9. Plug harness into QF/DY connector.

10. Plug harness into WVIN connector.

11. Plug harness into MB connector.

12. Plug harness into JC connector.

13. Plug harness into PWM connector.

14. Plug harness into IFB connector.
Verify harness connections with the system schematic to insure all connections are correct.

15. Install clear protective sheet.

ASSEMBLY PROCEDURES 7-4 Manual 0-5450

7.05 Installing Cover Panel and Door Panel

1

Install Screws

Tighten Screws Front & Rear

2

A-12948

1. Install Ground Screw, which connects the ground wire to the cover.

2. Install cover panel and door panel. Install Screws. Tighten screws.

ESAB FABRICATOR 211i

Art # A-11363_AC

Manual 0-5450 7-5 ASSEMBLY PROCEDURES

ESAB FABRICATOR 211i

This Page Intentionally Blank

ASSEMBLY PROCEDURES 7-6 Manual 0-5450

ESAB FABRICATOR 211i

SECTION 8:

KEY SPARE PARTS

8.01 Tweco WeldSkill 220A MIG Gun (Used until January, 2013

MIG Gun Part No: WS220TA-15-3035

9

Figure 8-1: Tweco WeldSkill 220 MIG Gun

TWECO WELDSKILL 220A MIG GUN PARTS

ITEM PART NO. DESCRIPTION

1 1210-1112 Nozzle 1/2" - 12.7 mm Flush

2 1110-1102 Contact Tip .035" - 0.9mm

3 1510-1140 Gas Diffuser

4 2042-2053 Microswitch

5 2042-2054 Trigger Lever

6 2042-2055 Trigger Lever Spring

7 2035-12110 Tweco Rear Connector Plug

8 1420-1140 Conduit Assembly .030" to .035" - 0.8mm to 0.9mm

9 WS-354-TA-LC 8- Pin Control Wire

Table 8-1: Tweco WeldSkill 220 MIG Gun Parts

Art # A-11248_AB

Manual 0-5450 8-1 KEY SPARE PARTS

ESAB FABRICATOR 211i

8.02 Tweco Fusion 220A MIG Gun

Torch Part No: F220TA-12-3035

Art# A-11672_AB

Item

No.

1 Velocity Nozzle**

2 Velocity Contact Tip**

3 Handle / Trigger Repair Kit F80

4 Conduit Assembly* WS42-3035-15

5A Tweco Rear Connector 350-174H

5

5B Tweco Control Wire 35K-350-1

5C Tweco Control Wire & Plug WS-354-TA-LC

Description Part No.

VNS-75FAS

Table 8-2: Tweco Fusion 220A MIG Gun Parts

** Patent Pending
* Refer to ESAB Catalog No. 64-2103 for additional
options.

VNS-50

VNS-50F

VNS-62

VNS-62F

VNS-37

VNS-37F

VTS-23

VTS-30

VTS-35

VTS-40

VTS-45

VTSA-364

VTS-52

VTS-116

VTSA-116

VTS-564

Figure 8-2

KEY SPARE PARTS 8-2 Manual 0-5450

8.03 Power Source Spare Parts

ESAB FABRICATOR 211i

810

11

15

26

4

3

29

9

2

1

Art # A-11250

16

25

24

23

12

32

33

19

17

18

30

31

34

Figure 8-3

20

14

22

35

13

36

5

7

6

Manual 0-5450 8-3 KEY SPARE PARTS

ESAB FABRICATOR 211i

Item Part Number Description

1 W7005621 PCB Power, Fab 211i
2 W7005638 PCB Control, Fab 211i
3 W7005602 PCB Display, Fab 211i
4 W7005607 PCB Spool Gun, Fab 211i
5 W7005603 Wiredrive Assembly, Fab 211i
6 W7004906 Thumbscrew,Feedroll Positioner
7 W4014800 DRIVE RL2 Roll, .023/.035 “V”
8 W7005622 Fan Assembly, Fab 211i UL/CSA

9 W7003010 Rectifier Bridge,1000V,50A
10 W7003033 Gas Solenoid Valve Assy
11 W7003215 Gas Inlet Fitting
12 W7004909 Connector Socket,50 Dinse
13 W7004955 Connector Plug,50 Dinse
14 W7003242 Socket,8 Pin,w/ Harness
15 W7005623 Switch CB,Main On-Off
16 W7004911 CT, Output
17 W7005617 Spool Hub Assembly
18 W7005608 Washer,Friction,Spool Hub
19 W7005609 Spool Hub
20 W7004966 Adapter,ESAB 4,141i-211i
21 W7005619 Guide,Inlet,.023-.045 (not shown)
22 W7004967 Guide,Outlet,.023-.045
23 W7005557 Front, Panel, Fab 211i UL/CSA
24 W7005610 Panel, Base, Fab 211i
25 W7005625 Center Panel, Fab 211i
26 W7005556 Rear, Panel, Fab 211i UL/CSA
27 W7005560 Panel, Cover, Fab 211i (not shown)
28 W7005559 Panel, Door, Fab 211i (not shown)
29 W7005558 Panel,Control,Fab 211i
30 W7004972 Knob,1/4” IDx1” ODx0.9” H
31 W7005630 Knob,1/4” IDx1.25” ODx.9” H
32 W7005629 Circuit Breaker,4A
33 W7004943 Switch,250V/2A
34 870734 Knob,1/4” IDx.72” ODx.9” H
35 W7004940 PCB, Burnback Potentiometer
36 W7005632 Shroud, WF Motor, 211i
37 W7005561 Label, Identification, Fab 211i (not shown)
38 W7005562 Setup Chart English Version (not shown)
39

40

7978044PKD

W7005635

Large Spring, for One Pound Spool (not shown)

Latch, door, slide (not shown)

Table 8-3: Fabricator 211i Parts

KEY SPARE PARTS 8-4 Manual 0-5450

9.01 Optional Accessories

26V TIG Torch & Accessories (required for TIG welding) Part No. W4014603

12.5 ft cable length; 12.5 ft gas hose length; 8 pin control plug;
1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32", 1/8" col­lets; 1/16", 3/32",1/8:" collet bodies; No. 5, 6, 7 Alumina nozzle;
short back cap; long back cap

ESAB Spool Gun (required for aluminum MIG welding) Part No. 1027-1390
160A, 12ft (3.6M) Length, suits 4" (100mm) spools

Professional 4 Wheel Cart, Dual Cylinder ................... Part No. W4015002

Professional 4 Wheel Cart, Single Cylinder ................ Part No. W4015001

Small Cart, Single Cylinder .......................................... Part No. W4014700

Roll Cage ...................................................................... Part No. W4015104

ESAB FABRICATOR 211i

SECTION 9:

OptionAL Accessories

Foot Control ................................................................. Part No. 600285

For remote amperage control when TIG welding

ESAB Helmet (USA Only) ............................ Part No. 4100-1004

WeldSkill Auto-Darkening Helmet Skull & Fire (USA Only)

Drive Roll .023" - .030" (0.6/0.8mm ) V groove, (fitted) Part No. 7977036

Drive Roll .023" - .035" (0.6/0.9 mm) V groove . Part No. W4014800

Drive Roll .035"/.045" (0.9/1.2 mm) V groove .. Part No. 7977660

Drive Roll .030" - .035" (0.8/0.9 mm) U groove .. Part No. 7977731

Drive Roll .040" - 3/64" (1.0/1.2 mm) U groove . Part No. 7977264

Drive Roll .030" - .035" (0.8/0.9 mm) V knurled Part No. 7977732

Drive Roll .045"(1.2 mm) V knurled ............. Part No. 704277

Stick Lead, 200A, 13ft, 50mm Dinse ............. Part No. WS200E13

Ground Lead, 200A, 10Ft, 50mm Dinse .......... Part No. WS200G10

Victor Argon Regulator/ Flowgauge .................... Part No. 130781-4169

Accessory Kit for TIG Torch ................................... Part No. P062900010

1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32",
1/8" collets; 1/16", 3/32",1/8:" collet bodies; No. 5, 6, 7
Alumina nozzle; short back cap; long back cap

Manual 0-5450 9-1 OPTIONS/ACCESSORIES

ESAB FABRICATOR 211i

This Page Intentionally Blank

OPTIONS/ACCESSORIES 9-2 Manual 0-5450

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Printed in China