Related Manuals for ESAB Rogue EM 190 PRO
Summary of Contents for ESAB Rogue EM 190 PRO
- Page 1 Rogue EM 190 PRO Instruction manual Valid for: Serial number: HA303-xxxx-xxxx 0447 956 001 US 20230606...
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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 956 001 - 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 956 001 - 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 956 001 - 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 956 001 - 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 956 001 - 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 956 001 - 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
, 35–50 OKC • OK AristoRod 12.50, 0.030 in. (0.8 mm), 2.4 lb (1.1 kg) • Feed roll 0.023/0.030 in. (0.6/0.8 mm) V (Fitted) • Feed roll 0.030/0.035 in. (0.8/0.9 mm) V (Spare) • Feed roll 0.030/0.035 in. (0.8/0.9 mm) VK (Spare) • Instruction manual 0447 956 001 - 10 - © ESAB AB 2023... -
Page 11: Technical Data
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 104 °F (40 °C) or below. 0447 956 001 - 11 - © ESAB AB 2023... - Page 12 Equipment marked IP23S is intended for indoor and outdoor use; however, it 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. 0447 956 001 - 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 956 001 - 13 - © ESAB AB 2023... -
Page 14: Main 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 956 001 - 14 - © ESAB AB 2023... -
Page 15: 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 956 001 - 15 - © ESAB AB 2023... -
Page 16: Operation
Electric shock! Do not touch the workpiece or the welding head during 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. 0447 956 001 - 16 - © ESAB AB 2023... -
Page 17: Connections
The polarity changeover cable is used to select the correct polarity for the weld output. The correct polarity is determined by the wire that has been selected to complete the weld. To configure the 0447 956 001 - 17 - © ESAB AB 2023... -
Page 18: Drive System Diagram
The mains supply must be disconnected during installation. 1) Open wire feed compartment door and loosen retaining thumb screw. 2) Fit the MIG gun power pin into torch receptacle, insert fully. 3) Tighten retaining thumb screw. 0447 956 001 - 18 - © ESAB AB 2023... -
Page 19: Inserting And Replacing Wire
(3), between the rollers, through the outlet guide and into the GMAW torch. Ensure that the wire is aligned with the correct groove in the drive roll. 0447 956 001 - 19 - © ESAB AB 2023... -
Page 20: Welding With Aluminum Wire
Fe and SS wires. To weld with aluminum wire, use optional spool gun for the best result. Refer to Spool Gun Instruction Manual for the correct set up. 0447 956 001 - 20 - © ESAB AB 2023... -
Page 21: Installing 12.5 Lb Spool (8 In. Diameter)
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 956 001 - 21 - © ESAB AB 2023... -
Page 22: Setting The Wire Feed Pressure
4) Remove the feed roll retaining screw by turning it counterclockwise. 5) Change the feed roll. 6) Tighten the feed roll retaining screw by turning it clockwise. 7) Secure the pressure roller arm and wire drive tension screw. 0447 956 001 - 22 - © ESAB AB 2023... -
Page 23: 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 956 001 - 23 - © ESAB AB 2023... -
Page 24: User Interface
NOTE! After welding, the display hold the last actual welding parameters and the duration of the weld for 10 seconds. 0447 956 001 - 24 - © ESAB AB 2023... -
Page 25: 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 956 001 - 25 - © ESAB AB 2023... - Page 26 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 956 001 - 26 - © ESAB AB 2023...
- Page 27 Higher arc control settings give a more driving arc which can increase weld penetration. Setting range -9 to 0447 956 001 - 27 - © ESAB AB 2023...
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Page 28: Icon Reference Guide
These times will repeat as long the torch trigger is depressed. Setting range: Stitch time 0.0-10.0 s, dwell time 0.0-10.0 s Icon reference guide GMAW Manual GMAW Synergic 2T, Trigger On/Off 4T, Trigger Hold/Lock Arc dynamics Information 0447 956 001 - 28 - © ESAB AB 2023... - Page 29 6 USER INTERFACE Jobs Remote Settings Spot weld Synergic setting Weld variables Amps Voltage Wire feed speed 0447 956 001 - 29 - © ESAB AB 2023...
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Page 30: 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 31 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 956 001 - 31 - © ESAB AB 2023...
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Page 32: 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 956 001 - 32 - © ESAB AB 2023... -
Page 33: 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) Reinstall contact tip and nozzle. 0447 956 001 - 33 - © ESAB AB 2023... -
Page 34: Error Codes
Error codes indicate that a fault has occurred in the equipment. Errors are indicated by the text "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 authorized ESAB service technician. Error codes Title Display... -
Page 35: Troubleshooting
Make sure that you are not exceeding the recommended duty cycle trips frequently for the weld current you are using. See Section 5.9 "Duty cycle", page 23. Make sure that the air inlets or outlets are not clogged. 0447 956 001 - 35 - © ESAB AB 2023... -
Page 36: 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 37: Wiring Diagram
APPENDIX APPENDIX WIRING DIAGRAM 0447 956 001 - 37 - © ESAB AB 2023... -
Page 38: Ordering Numbers
APPENDIX ORDERING NUMBERS Ordering number Denomination Type Notes 0700 301 083 Power source with wire feeder Rogue EM 190 PRO Technical documentation is available on the Internet at: www.esab.com 0447 956 001 - 38 - © ESAB AB 2023... -
Page 39: Wear Parts
160 A 1210-1120 Standard nozzle (5/8 in. id) tweco spool gun 160 A 2031-2107 Conduit / Liner (compatible with TWECO spool gun 160 A) 1510-1101 Gas diffuser (tweco spool gun 160 A) 0447 956 001 - 39 - © ESAB AB 2023... -
Page 40: Accessories
TWECO Fusion 180 GMAW torch, 3 m (10 ft.) 0781-9411 Victor Regulator/Flow Gauge 0700 400 858 Gas hose, 3 m (10 ft.) 0700 006 901 Work clamp lead set, with 50 mm OKC connector, 3 m (10 ft) 0447 956 001 - 40 - © ESAB AB 2023... - Page 41 APPENDIX 0447 956 001 - 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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