ESAB Rogue EMP 210 PRO Instruction Manual
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ESAB Rogue EMP 210 PRO Instruction Manual

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Rogue EMP 210 PRO
Instruction manual
Valid for: Serial number:
HG325-xxxx-xxxx
0447 978 001   GB   20230622

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Summary of Contents for ESAB Rogue EMP 210 PRO

  • Page 1 Rogue EMP 210 PRO Instruction manual Valid for: Serial number: HG325-xxxx-xxxx 0447 978 001   GB   20230622...

  • Page 3: 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 978 001 - 3 - © ESAB AB 2023...

  • Page 4: Safety

    Sheets (SDSs). 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.
  • Page 5 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. For ordering information, see the "ACCESSORIES" chapter in the instruction manual.
  • Page 6 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. 0447 978 001 - 6 -...

  • Page 7: Introduction

    Filler metal, Goldrox, 1 kg, 2.5×350 mm • Feed roll, 0.6/0.8 mm V • Feed roll 0.8/1.0 mm V • Feed roll 1.0/1.2 mm U • Electrode holder, 3 m, 16 mm , 35–50 OKC • Safety Instruction 0447 978 001 - 7 - © ESAB AB 2023...

  • Page 8: Technical Data

    0.99 Efficiency at maximum current GMAW >80 % GTAW >80 % SMAW >80 % Open-circuit voltage U 78 V (VRD 35 V deactivated) Operating temperature -10 to +40°C (+14 to 104°F) 0447 978 001 - 8 - © ESAB AB 2023...
  • Page 9 The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding is not being carried out. The VRD function must be activated by a qualified service technician. 0447 978 001 - 9 - © ESAB AB 2023...

  • Page 10: Installation

    Position the power source so that cooling air inlets and outlets are not obstructed. A. Minimum 200 mm (8 in.) B. Minimum 200 mm (8 in.) Lifting instruction The power source can be lifted using any of the handles. 0447 978 001 - 10 - © ESAB AB 2023...

  • Page 11: Mains Supply

    Disconnect input power and secure employing ‘Lock-out’ / ‘Tagging’ procedures. Ensure input power line disconnect switch is locked (lock-out/Tagging) in the ‘Open’ position BEFORE removing input power fuses. Connection/Disconnect should be carried out by competent persons. 1. Rating plate 0447 978 001 - 11 - © ESAB AB 2023...

  • Page 12: Recommended Fuse And Cable Sizes

    Generators with Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power 9 kW, are recommended. 0447 978 001 - 12 - © ESAB AB 2023...

  • Page 13: Operation

    Electric shock! Do not touch the workpiece or the welding head during operation! WARNING! Assure that the side panels are closed during operation. WARNING! Tighten the bobbin locking nut in order to prevent it from sliding off the hub. 0447 978 001 - 13 - © ESAB AB 2023...

  • Page 14: Connections

    The power source has two output studs for connecting the weld and return cables: Electrode negative [-] terminal (5) and Electrode positive [+] terminal (8), see Section 5.1 "Connections", page 14. GMAW Synergic & Manual mode - solid wires GMAW Synergic & Manual mode - FCAW wires 0447 978 001 - 14 - © ESAB AB 2023...

  • Page 15: Drive System Diagram

    Some wires it is recommended to use negative polarity such as self-shielded flux-core. See wire manufacturers recommendation. Drive system diagram 1. Wire inching/purge 3. Wire spool 2. Wire feed mechanism 0447 978 001 - 15 - © ESAB AB 2023...

  • Page 16: Attaching Fusion 180 Mig Gun

    Do not place or point the torch near the face, hand or body as this may result in personal injury. WARNING! Make sure that the power is turned off, before replacing or installing any parts. 0447 978 001 - 16 - © ESAB AB 2023...
  • Page 17 6) With the GMAW torch lead reasonably straight feed the wire through the GMAW torch by depressing the wire inch button or trigger switch. 7) Close the spool side door. 0447 978 001 - 17 - © ESAB AB 2023...

  • Page 18: Welding With Aluminium Wire

    Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool. 3. Replace the plastic retaining nut until tight against wire spool. 0447 978 001 - 18 - © ESAB AB 2023...

  • Page 19: Installing 2 Lb Spool (4 In. Diameter)

    Correct adjustment will result in the wire reel circumference continuing no further than 1/8 in.-3/16 in. (3-5 mm) after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool. 0447 978 001 - 19 - © ESAB AB 2023...

  • Page 20: Changing The Feed/Pressure Rollers

    The choice of suitable shielding gas depends on the material. Typically mild steel is welded with mixed gas (Ar + CO ) or 100% carbon dioxide (CO ). Stainless Steel can be welded with mixed gas 0447 978 001 - 20 - © ESAB AB 2023...

  • Page 21: Duty Cycle

    2.5 minutes out of every 10-minute period. The remaining time, 7.5 minutes, the power source must be allowed to cool down. 2.5 minutes 7.5 minutes A different combination of duty cycle and welding current can be selected. 0447 978 001 - 21 - © ESAB AB 2023...

  • Page 22: User Interface

    NOTE! After welding, the display hold the last actual welding parameters and the duration of the weld for 10 seconds. 0447 978 001 - 22 - © ESAB AB 2023...

  • Page 23: Gmaw Synergic Mode

    To select and enter any of the tiles rotate right-hand push button encoder to the desired tile and press the encoder. After the user enters there will be various options to select from. 0447 978 001 - 23 - © ESAB AB 2023...
  • Page 24 This optimizes the welding parameters from the minimum to maximum material thicknesses that the machine or process is capable of welding. NOTE! Mild Steel (Fe) is used in the example below. Other combinations are available. 0447 978 001 - 24 - © ESAB AB 2023...
  • Page 25 Higher arc control settings give a more driving arc which can increase weld penetration. Setting range -9 to 0447 978 001 - 25 - © ESAB AB 2023...

  • Page 26: Smaw (Mma) Mode

    GMAW Manual mode is a constant voltage weld process where the voltage and wire feed speed are set independent of each other. 1. Process selection 2. Settings 3. Information 4. Electrode type 5. Remote 6. Jobs 7. Hot start 8. Arc force 0447 978 001 - 26 - © ESAB AB 2023...

  • Page 27: Live Gtaw Mode

    4. Remote - when paired with the TWECO TIG Foot Control, current/amperage can be increased or decreased at the weld site. 5. Jobs – See Section 6.4 "GMAW Manual mode", page 23. Icon reference guide GMAW Manual GMAW Synergic Stick LIVE GTAW 0447 978 001 - 27 - © ESAB AB 2023...
  • Page 28 Hot start The increase of amps when striking the Information electrode to reduce sticking. Jobs Remote Settings Spot weld Synergic setting Weld variables Electrode type Voltage Amps Wire feed speed 0447 978 001 - 28 - © ESAB AB 2023...

  • Page 29: Maintenance

    NOTE! Regular maintenance is important for safe and reliable operation. CAUTION! Repair and electrical work should be performed by an authorised 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 30 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 978 001 - 30 - © ESAB AB 2023...

  • Page 31: Power Source And Wire Feeder Maintenance

    See Section 11.3 "WEAR PARTS", page 39 for ordering replacement items. 6) Remove and clean the feed roller (3) with a soft brush. Clean the pressure roller attached to the wire feeder mechanism with a soft brush. 0447 978 001 - 31 - © ESAB AB 2023...

  • Page 32: Torch And Liner Maintenance

    4) Remove the torch from the power source and remove the contact tip and nozzle. 5) Clean the liner by blowing low-pressure dry compressed through the end of the liner that was mounted closest to the power source. 6) Re-install contact tip and nozzle. 0447 978 001 - 32 - © ESAB AB 2023...

  • Page 33: Error Codes

    "Error" 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 authorised ESAB service technician. Error codes Title...

  • Page 34: Troubleshooting

    Make sure the work clamp has proper contact with the work piece. Make sure the power source is turned on and GTAW welding process is selected. Make sure all connections are tight and leak-free. 0447 978 001 - 34 - © ESAB AB 2023...
  • Page 35 Make sure that you are not exceeding the recommended duty cycle trips frequently for the weld current you are using. See Section . Make sure the air inlets or outlets are not clogged. 0447 978 001 - 35 - © ESAB AB 2023...

  • Page 36: Ordering Spare Parts

    Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list.

  • Page 37: Wiring Diagram

    APPENDIX APPENDIX WIRING DIAGRAM 0447 978 001 - 37 - © ESAB AB 2023...

  • Page 38: Ordering Numbers

    APPENDIX ORDERING NUMBERS Ordering number Denomination Type Notes 0700 301 092 Power source with wire feeder Rogue EMP 210 PRO Technical documentation is available on the Internet at: www.esab.com 0447 978 001 - 38 - © ESAB AB 2023...

  • Page 39: Wear Parts

    Feed roller V groove 1.0 and 1.2 mm 0367556004 Feedroll U groove 1.0/1.2 mm 0349312497 Drive roll, Knurled V-groove 0.9/1.2 mm 0558102928 Wire guide, inlet 0558102929 Wire guide, outlet 0558102930 Motor drive key shaft 0447 978 001 - 39 - © ESAB AB 2023...

  • Page 40: Accessories

    Work clamp leadset, 3 m, 16 mm , 35-50 OKC 0700 006 900 Electrode holder leadset, 3 m, 16 mm , 35-50 OKC 0700 500 084 MMA 4, Remote control, 10 m W4014450 TIG foot control, 4.5 m, 8-pin connector 0447 978 001 - 40 - © ESAB AB 2023...
  • Page 41 APPENDIX 0447 978 001 - 41 - © ESAB AB 2023...
  • Page 42 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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