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Summary of Contents for ESAB Rogue EM 125
- Page 1 Rogue EM 125 Instruction manual Valid for: Serial number: HA301-xxxx-xxxx 0447 954 001 US 20230719...
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Page 2: Table Of Contents
Power source and wire feeder maintenance ..................Torch and liner maintenance .......................... ERROR CODES ....................Error code descriptions ........................ TROUBLESHOOTING ....................... ORDERING SPARE PARTS ..........................WIRING DIAGRAM ......................... ORDERING NUMBERS ............................WEAR PARTS ............................. ACCESSORIES 0447 954 001 - 2 - © ESAB AB 2023... -
Page 3: Safety
7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly for long distances. Bystanders should also wear goggles over safety glasses. 0447 954 001 - 3 - © ESAB AB 2023... - Page 4 ELECTRIC AND MAGNETIC FIELDS May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: 0447 954 001 - 4 - © ESAB AB 2023...
- Page 5 1. Keep all doors, panels, guards, and covers closed and securely in place. 2. Stop the engine or drive systems before installing or connecting a unit. 3. Have only qualified people remove covers for maintenance and troubleshooting as necessary 0447 954 001 - 5 - © ESAB AB 2023...
- Page 6 NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other Hot Work" • CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders” • ANSI Z87.1, "Occupational and Educational Personal Eye and Face Protection Devices" 0447 954 001 - 6 - © ESAB AB 2023...
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Page 7: User Responsibility
1 SAFETY User responsibility 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. - Page 8 • 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! 0447 954 001 - 8 - © ESAB AB 2023...
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Page 9: California Proposition 65 Warning
This product is solely intended for arc welding. 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. California proposition 65 warning WARNING! Welding or cutting equipment produces fumes or gases which contain chemicals known in the State of California to cause birth defects and, in some cases, cancer. -
Page 10: Introduction
2 INTRODUCTION INTRODUCTION The Rogue EM 125 is a self-contained single phase welding system that is capable of performing GMAW (MIG) welding. ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual. Equipment Rogue EMP 125 is supplied with: •... -
Page 11: Technical Data
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, it should not be operated in precipitation. 0447 954 001 - 11 - © ESAB AB 2023... - Page 12 3 TECHNICAL DATA Application class The symbol indicates that the power source is designed for use in areas with increased electrical hazard. 0447 954 001 - 12 - © ESAB AB 2023...
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Page 13: Installation
Position the power source so that cooling air inlets and outlets are not obstructed. A. Minimum 8 in. (200 mm) B. Minimum 8 in. (200 mm) Lifting instructions The power source can be lifted using any of the handles. 0447 954 001 - 13 - © ESAB AB 2023... -
Page 14: Recommended Fuse And Cable Sizes
• Connected to the correct size power point and fuse as indicated in table below. NOTE! Use the welding power source in accordance with the relevant local and national regulations. 0447 954 001 - 14 - © ESAB AB 2023... - Page 15 (Lock-out/Tagging) in the 'Open' position BEFORE removing input power fuses. Connection/Disconnect should be carried out by competent persons. 1. Rating plate with supply connection data. 0447 954 001 - 15 - © ESAB AB 2023...
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Page 16: Operation
WARNING! Make sure the side panels are closed during operation. WARNING! Tighten the spool locking nut in order to prevent it from sliding off the hub. 4 in. (100 mm) 8 in. (200 mm) 0447 954 001 - 16 - © ESAB AB 2023... -
Page 17: Connections
The power source is delivered with the polarity changeover cable free hanging and not connected to the positive or negative weld terminals. Some wires, e.g. self-shielded cored wires, are recommended to be welded with negative polarity. 0447 954 001 - 17 - © ESAB AB 2023... -
Page 18: Drive System Diagram
1) Open the spool side door. 2) Remove wire retention nut. 3) Release the pressure roller arm by levering the tension screw (1). 4) Lift the pressure roller arm (2). 0447 954 001 - 18 - © ESAB AB 2023... - Page 19 The wire liner fitted in the torch is recommended for welding with Fe and SS wires. This unit is not recommended for welding aluminum. 0447 954 001 - 19 - © ESAB AB 2023...
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Page 20: Setting The Wire Feed Pressure
Visual indication on the face of the drive roll indicates the diameter of the groove on the outside of the drive roll and the groove that is in use for the selected wire diameter. 0447 954 001 - 20 - © ESAB AB 2023... -
Page 21: Shielding Gas
3 minutes out of every 10-minute period. For the remaining time, 7 minutes, the power source must be allowed to cool down. 3 minutes 7 minutes A different combination of duty cycle and welding current can be selected. 0447 954 001 - 21 - © ESAB AB 2023... -
Page 22: User Interface
6. Over temperature indication arc dynamics value) 3. Push button (select arc dynamics) 7. Left-hand display (displays preset voltage) 4. Right-hand display (display preset wire feed speed and arc dynamics value) 0447 954 001 - 22 - © ESAB AB 2023... -
Page 23: Led Indicators Description
Pre-flow is the time during which shielding gas flows before the arc is struck. This is manually controlled by the trigger. Post-flow Post-flow is the time during which shielding gas flows after the arc is extinguished. This is manually controlled by the trigger. 0447 954 001 - 23 - © ESAB AB 2023... -
Page 24: Maintenance
NOTE! Regular maintenance is important for safe and reliable operation. CAUTION! Repair and electrical work should be performed by an authorized ESAB service technician. Use only ESAB original spare and wear parts. CAUTION! All warranty undertakings from the supplier cease to apply if the customer attempts any work to rectify any faults in the product during the warranty period. - Page 25 Bring the unit to an authorized service provider to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions. 0447 954 001 - 25 - © ESAB AB 2023...
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Page 26: Power Source And Wire Feeder Maintenance
6) Remove and clean the feed roller (2) with a soft brush. Clean the pressure roller attached to the wire feeder mechanism with a soft brush. Torch and liner maintenance 1) Disconnect the power source from the input power. 0447 954 001 - 26 - © ESAB AB 2023... - Page 27 4) Remove the contact tip and nozzle. 5) Clean the liner by blowing low-pressure dry compressed air through the end of the liner that is closest to the contact tip. 6) Reinstall contact tip and nozzle. 0447 954 001 - 27 - © ESAB AB 2023...
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Page 28: Error Codes
Error codes indicate that a fault has occurred in the equipment. Errors are indicated by the text "Err" followed by the error code number shown in the display. Error code descriptions Error codes that the user can handle are listed below. If any other error code appears, contact an authorized ESAB service technician. Error codes Title Display... -
Page 29: Troubleshooting
Make sure that you are not exceeding the recommended duty cycle trips frequently for the weld current you are using. See Section 5.8 "Duty cycle", page 21. Make sure that the air inlets or outlets are not clogged. 0447 954 001 - 29 - © ESAB AB 2023... -
Page 30: Ordering Spare Parts
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back cover of this document. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list. -
Page 31: Wiring Diagram
APPENDIX APPENDIX WIRING DIAGRAM 0447 954 001 - 31 - © ESAB AB 2023... -
Page 32: Ordering Numbers
APPENDIX ORDERING NUMBERS Ordering number Denomination Type Notes 0700 301 081 Power source with wire feeder Rogue EM 125 Technical documentation is available on the Internet at: www.esab.com 0447 954 001 - 32 - © ESAB AB 2023... -
Page 33: Wear Parts
0.023/0.030 in. (0.6/0.8 mm) 1444-1181 VK groove 0.030/0.030 in. (0.8/0.8 mm) 1444-1182 Nozzle, ½ in. orifice 1444-1183 Contact tip M6×25, 0.035 in. (0.9 mm) 1444-1184 Contact tip M6×25, 0.030 in. (0.8 mm) 1444-1185 Contact tip M6×25, 0.023 in. (0.6 mm) 0447 954 001 - 33 - © ESAB AB 2023... -
Page 34: Accessories
0460 330 880 Trolley 2-wheel with cylinder support 1444-1178 Integrated GMAW torch, 3 m (10 ft.) 1444-1186 Work clamp lead set with 25mm OKC connector, 3 m (10 ft.) 0700 400 858 Gas hose, 3 m (10 ft.) 0447 954 001 - 34 - © ESAB AB 2023... - Page 35 APPENDIX 0447 954 001 - 35 - © ESAB AB 2023...
- Page 36 For contact information visit http://esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 manuals.esab.com...
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