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Summary of Contents for ESAB Rogue EM 180
- Page 1 Rogue EM 180 Instruction manual Valid for: HA324YY-XXXXXX 0447 979 001 GB 20231102...
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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 979 001 - 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 979 001 - 6 -...
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Page 7: Introduction
Feed roll, 0.6/0.8 mm V • Feed roll, 0.8/1.0 mm V • Feed roll, 1.0/1.2 mm VK • Electrode holder, 3 m, 16 mm , 35-50 OKC • Instruction manual • Safety instruction 0447 979 001 - 7 - © ESAB AB 2023... -
Page 8: Technical Data
3 TECHNICAL DATA TECHNICAL DATA Rogue EM 180 Outlet voltage 230 V 1~ 50/60 Hz Primary current GMAW - MIG 23 A SMAW - MMA 21 A GMAW - MIG 11.5 A SMAW - MMA 11.0 A No-load power demand when in energy saving mode 20 W... - Page 9 3 TECHNICAL DATA Rogue EM 180 Aluminum 16 ga. - 1.5-10 mm (3/8 in.) Dimensions l × w × h 590 × 220 × 385 mm (23.2 × 8.7 × 15.2 in.) Weight 16.9 kg (37.3 lbs) Enclosure class IP 23S...
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Page 10: 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 979 001 - 10 - © ESAB AB 2023... -
Page 11: Mains Supply
Connection/Disconnect should be carried out by competent persons. NOTE! Use the welding power source in accordance with the relevant local and national regulations. 1. Rating plate with supply connection data. 0447 979 001 - 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 7 kW, are recommended. 0447 979 001 - 12 - © ESAB AB 2023... -
Page 13: Operation
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. NOTE! When moving the equipment use intended handle. Never pull the cables. 0447 979 001 - 13 - © ESAB AB 2023... -
Page 14: Connections
Secure the work clamp to the work piece in a clean, debris free location. NOTE! Some wires it is recommended to use negative polarity such as self-shielded flux-core. See wire manufacturers recommendation. 0447 979 001 - 14 - © ESAB AB 2023... -
Page 15: Drive System Diagram
2) Insert the central plug into the mating socket on the power supply and tighten the adaptor nut firmly to secure it. 3) Ensure the central adapter and mating socket are connected properly by pulling on the torch coaxial cable. Movement should not be possible. 0447 979 001 - 15 - © ESAB AB 2023... - Page 16 5 OPERATION 1. Wire Feed Compartment Door 3. Remote Receptacle 2. Torch Receptacle WARNING! The mains supply must be disconnected. 1. Torch receptacle 0447 979 001 - 16 - © ESAB AB 2023...
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Page 17: Inserting And Replacing Wire
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 979 001 - 17 - © ESAB AB 2023... -
Page 18: Welding With Aluminium Wire
To weld with aluminum wire, use optional spool gun for the best result. Refer to the Spool Gun Instruction Manual for the correct set up. 0447 979 001 - 18 - © ESAB AB 2023... -
Page 19: 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 979 001 - 19 - © ESAB AB 2023... -
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 979 001 - 20 - © ESAB AB 2023... -
Page 21: Shielding Gas
(Ar) or (Ar + O Duty cycle The Rogue EM 180 has a welding current output of 180 A at 25% duty cycle (230 V). A self-resetting thermostat will protect the power source if the duty cycle is exceeded. If the power source operates at a 25% duty cycle, it will provide the rated amperage for a maximum of 2.5 minutes out of every 10-minute period. -
Page 22: User Interface
12. Left-hand display - Displays preset voltage and is selected various weld variables 6. Trigger mode LED - Illuminates when feature is 13. Push button 1 - Selects various weld variables selected 7. Over temperature indication 0447 979 001 - 22 - © ESAB AB 2023... -
Page 23: Weld Variables
Higher arc control settings give a more driving arc, which can increase weld penetration. The setting range is -9 to +9. 0447 979 001 - 23 - © ESAB AB 2023... -
Page 24: Synergic Control Panel
Gas purging occurs for 15 seconds when the gas purge button is pressed or until it is pressed again. Gas purge occurs without voltage or wire feeding. This function is active in Synergic MIG and MIG applications only. 0447 979 001 - 24 - © ESAB AB 2023... -
Page 25: Icon Reference Guide
6 USER INTERFACE Icon reference guide MIG Manual MIG Synergic Over Temperature Indicator 2T, Trigger On/Off 4T, Trigger Hold/Lock Spool Gun Wire Feed Speed Arc Dynamics Material Thickness Voltage Amps 0447 979 001 - 25 - © ESAB AB 2023... -
Page 26: Maintenance
Each use Visual check of regulator and Visual check of torch pressure consumable Weekly Visually inspect the torch body Visually inspect the cables and and consumables leads. Replace if necessary 0447 979 001 - 26 - © ESAB AB 2023... - Page 27 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 979 001 - 27 - © ESAB AB 2023...
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Page 28: Power Source And Wire Feeder Maintenance
See the "WEAR PARTS" appendix 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 979 001 - 28 - © ESAB AB 2023... -
Page 29: 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 979 001 - 29 - © ESAB AB 2023... -
Page 30: 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 31: Troubleshooting
Make sure that you are not exceeding the recommended duty cycle trips frequently for the weld current you are using. See section "Duty cycle" in the "OPERATION" chapter. Make sure that the air inlets or outlets are not clogged. 0447 979 001 - 31 - © ESAB AB 2023... -
Page 32: Ordering Spare Parts
Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. The Rogue EM 180 is designed and tested in accordance with the international standards IEC/EN 60974-1 and IEC/EN 60974-1 Class A. On completion of service or repair work, it is the responsibility of the person(s) performing the work to ensure that the product still complies with the requirements of the above standards. -
Page 33: Wiring Diagram
APPENDIX APPENDIX WIRING DIAGRAM 0447 979 001 - 33 - © ESAB AB 2023... - Page 34 APPENDIX 0447 979 001 - 34 - © ESAB AB 2023...
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Page 35: Ordering Numbers
* here. Make sure to use a manual with a serial number that corresponds with the product, see the front page of the manual. Technical documentation is available on the Internet at: www.esab.com 0447 979 001 - 35 - © ESAB AB 2023... -
Page 36: Wear Parts
Feedroll U groove 1.0/1.2 mm 0349 312 497 Drive Roll, Knurled VK Groove 0558 102 928 Guide, Inlet, Wire 0558 102 929 Guide, Outlet, Wire 0558 102 930 Key, Shaft, Motor, Drive 0447 979 001 - 36 - © ESAB AB 2023... -
Page 37: Accessories
, 35-50 OKC 0700 006 900 Electrode holder leadset, 3 m (10 ft), 16 mm , 35-50 OKC 0700 500 084 MMA 4, Remote control, 10 m (33 ft) W4014450 TIG foot control, 4.5 m (15 ft), 8-pin connector 0447 979 001 - 37 - © ESAB AB 2023... - Page 38 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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