ESAB ES 150i PRO User manual

Instruction manual
0463 715 001 GB 20210113 Valid for: HA017-, HA020-xxxx-xxxx
ES 150iPRO, ES 200iPRO

TABLE OF CONTENTS
0463 715 001 © ESAB AB 2021
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols ............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 8
2.1 Equipment ............................................................................................... 8
3TECHNICAL DATA ...................................................................................... 9
4INSTALLATION............................................................................................ 11
4.1 Location................................................................................................... 11
4.2 Lifting instructions ................................................................................. 11
4.3 Mains supply........................................................................................... 12
5OPERATION ................................................................................................ 14
5.1 Overview ................................................................................................. 14
5.2 Connections and control devices ......................................................... 14
5.3 Connecting welding and return cables ................................................ 14
5.4 Turning the power on/off ....................................................................... 15
5.5 Fan control.............................................................................................. 15
5.6 Thermal protection ................................................................................. 15
5.7 Functions and symbols ......................................................................... 15
5.8 Setting panel........................................................................................... 17
5.9 Remote control ....................................................................................... 17
6MAINTENANCE........................................................................................... 18
6.1 Routine maintenance ............................................................................. 18
6.2 Cleaning instruction............................................................................... 18
7TROUBLESHOOTING ................................................................................ 20
8ORDERING SPARE PARTS ........................................................................ 21
KEY SPARE PARTS ............................................................................................ 22
DIAGRAM ............................................................................................................ 23
ORDERING NUMBERS....................................................................................... 24
ACCESSORIES ................................................................................................... 25
Rights reserved to alter specifications without notice.

1 SAFETY
0463 715 001 - 4 - © ESAB AB 2021
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
1.2 Safety precautions
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0463 715 001 - 5 - © ESAB AB 2021
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
If equipped with ESAB cooler
Use ESAB approved coolant only. Non-approved coolant might damage the equipment and
jeopardize product safety. In case of such damage, all warranty undertakings from ESAB
cease to apply.
Recommended ESAB coolant ordering number: 0465720002.
For ordering information, see the "ACCESSORIES" chapter in the instruction manual.
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.

1 SAFETY
0463 715 001 - 6 - © ESAB AB 2021
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
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.

1 SAFETY
0463 715 001 - 7 - © ESAB AB 2021
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0463 715 001 - 8 - © ESAB AB 2021
2 INTRODUCTION
Overview
ES 150i PRO, ES 200i PRO is an inverter-based power source intended for MMA (Manual
Metal Arc) and TIG (Tungsten Inert Gas) welding.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
ES 150i PRO, ES 200i PRO includes:
• Power Source
• Work Clamp Leadset
• Electrode Holder Leadset
• Operation Manual
• Shoulder Strap
• Carry Case

3 TECHNICAL DATA
0463 715 001 - 9 - © ESAB AB 2021
3 TECHNICAL DATA
Technical data
ES 150i PRO ES 200i PRO
Outlet voltage 240V±15%
1~ 50/60Hz
115V±15%
1~ 50/60Hz
240V±15%
1~ 50/60Hz
115V±15%
1~ 50/60Hz
Primary current
Imax MMA 20A 29A 29 A 29A
ImaxLiftTIG 12.5A 24A 19A 24A
No-load power demand
when in energy saving
mode
50W 50W 50W 50W
Setting range
MMA 20-150A 20-110A 20-200A 20-110A
Lift TIG 10-150A 10-140A 10-200A 10-140A
Permissible load at MMA
25% duty cycle 150A/ 26V 110A / 24.4V 200A/ 28V 110A/ 24.4V
60% duty cycle 97A/ 23.9V 70A/ 22.8V 129A/ 25.2V 70A/ 22.8V
100%dutycycle 75A/ 23V 55A / 22.2V 100A/ 24V 55A/ 22.2V
Permissible load at Lift TIG
25% duty cycle 150A/ 16V 140A / 15.6V 200A/ 18V 140A/ 15.6V
60% duty cycle 97A/ 13.9V 90A / 13.6V 129A/ 15.2V 90A/13.6 V
100% duty cycle 75A/ 13V 70A / 12.8V 100A/ 14V 70A/12.8 V
Apparent powerI2at
maximum current 4.8kVA 3.3kVA 6.9kVA 3.3kVA
Active powerI2
at maximum current 4.75kW 3.26kW 6.8kW 3.26kW
Power factor at maximum current
Lift TIG 0.99 0.99 0.99 0.99
MMA 0.99 0.99 0.99 0.99
Efficiency at maximum current
MMA 82% 82% 82% 82%
Lift TIG 82% 82% 82% 82%
Open-circuit voltage U0max
VRD deactivated 78VDC 78VDC 78VDC 78VDC
VRD <35 V activated <30V <30V <30V <30V
Operating temperature -10to +40°C
(+14to 104°F)
-10to +40°C
(+14to 104°F)
-10to +40°C
(+14to 104°F)
-10to +40°C
(+14to 104°F)
Transportation
temperature
-10to +40°C
(+14to 104°F)
-10to +40°C
(+14to 104°F)
-10to +40°C
(+14to 104°F)
-10to +40°C
(+14to 104°F)

3 TECHNICAL DATA
0463 715 001 - 10 - © ESAB AB 2021
ES 150i PRO ES 200i PRO
Continual sound
pressure at no-load <70dB <70dB <70dB <70dB
Dimensions l×w×h 403×153×264 mm
(15.8×6×10.4in.)
403×153×264 mm
(15.8×6×10.4in.)
Weight 8.4kg 9.85kg
Insulation class
transformer H H
Enclosure class IP23S IP23S
Application class
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23S is intended for indoor and outdoor use; however, should not be
operated in precipitation.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.