ESAB Rustler EM 350Cw PRO SYNERGIC Instruction Manual

Hide thumbs

Table Of Contents

Quick Links

Download this manual

Rustler

EM 280C PRO, EM 350C PRO,

EM 350C PRO SYNERGIC,

EM 350C PRO MV SYNERGIC

EM 350Cw PRO SYNERGIC

Instruction manual

Valid for: OP250-, OP316-, OP420YY-XX

XXXX

0463 930 201 GB 20241009

Table of Contents

Need help?

Do you have a question about the Rustler EM 350Cw PRO SYNERGIC and is the answer not in the manual?

Questions and answers

Summary of Contents for ESAB Rustler EM 350Cw PRO SYNERGIC

Page 1 Rustler EM 280C PRO, EM 350C PRO, EM 350C PRO SYNERGIC, EM 350C PRO MV SYNERGIC EM 350Cw PRO SYNERGIC Instruction manual Valid for: OP250-, OP316-, OP420YY-XX XXXX 0463 930 201 GB 20241009...
Page 4: Table Of Contents
..................Cleaning the power source ........................Cooling unit ......................Filling the coolant ..............Inspection, cleaning and replacement .......................... ERROR CODES ....................Error code descriptions ........................ TROUBLESHOOTING ..................... CALIBRATION AND VALIDATION 0463 930 201 - 4 - © ESAB AB 2024...
Page 5 TABLE OF CONTENTS ..............10.1 Measurement methods and tolerances ............10.2 Requirements specifications and standards ....................... ORDERING SPARE PARTS ..........................WIRING DIAGRAM ......................... ORDERING NUMBERS ............................WEAR PARTS ............................. ACCESSORIES 0463 930 201 - 5 - © ESAB AB 2024...
Page 6: 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 7 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 8 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. 0463 930 201 - 8 -...
Page 9: Introduction
Superb arc characteristic, optimized for most common based materials • MMA / SMAW / Stick welding mode ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual. Equipment The power source is supplied with: •...
Page 10: Technical Data
89 % No-load power demand < 30 W < 30 W < 30 W < 30 W when energy-saving mode Weight 54 kg 57.5 kg 61 kg 63 kg Recommended generator 12 kW 17 kW 17 kW 17 kW 0463 930 201 - 10 - © ESAB AB 2024...
Page 11 No-load power demand when energy-saving mode < 30 W Weight 78.5 kg Recommended generator 17 kW Operating temperature -10 to +40°C (+14 to 104°F) Transportation temperature -20 to +55°C (-4 to +131°F) 0463 930 201 - 11 - © ESAB AB 2024...
Page 12: Eco Design Information
The value of efficiency and consumption in idle state have been measured by method and conditions defined in the product standard EN 60974-1. Manufacturer’s name, product name, serial number and date of production can be read from rating plate. 0463 930 201 - 12 - © ESAB AB 2024...
Page 13 3B. Revision level (last digit of year and week number) 3C. Year & week produced (last two digits of year and week number) 3D. Sequential number system (each week starts with 0001) 0463 930 201 - 13 - © ESAB AB 2024...
Page 14: Installation
Electric shock! Do not touch the workpiece or the welding head during operation! NOTE! When moving the equipment use intended handle. Never pull the cables. Move instructions (No lifting) Mechanical lifting must be done with both outer handles. 0463 930 201 - 14 - © ESAB AB 2024...
Page 15: Mains Supply
4×4 mm Maximal current rating I (MIG/MAG) (230VAC input) 14 A 21 A 21 A (400VAC input) 25.3A (230VAC input) 9 A 13 A 13 A 1eff (400VAC input) Fuse 20 A 30 A 30 A (230VAC input) anti-surge type C 20 A 30 A 30 A (400VAC input) 0463 930 201 - 15 - © ESAB AB 2024...
Page 16 100 m/330 ft. 100 m/330 ft. extension cord length Minimum recommended 4×2.5 mm 4×2.5 mm 4×2.5 mm 4×4 mm extension cord size NOTE! EM 350C PRO MV Synergic power source can sense the main voltage 400 V or 230 V and adpot accordingly. 0463 930 201 - 16 - © ESAB AB 2024...
Page 17: Operation
(optional) (EM 350Cw only) 5. Polarity changeover cable 12. Wire inlet adapter for Marathon Pac™ (optional) 6. Negative welding terminal 13. Wire feeding mechanism 7. Positive welding terminal 14. Internal control panel 0463 930 201 - 17 - © ESAB AB 2024...
Page 18: Recommended Maximum Current Values For Welding And Return Cables
(+). Some wires, e.g. self-shielded cored wires, are recommended to be welded with negative polarity. In this case, connect the polarity changeover cable to the negative welding terminal (-) and the return cable to the positive welding terminal (+). See wire/electrode manufacturers recommendation. 0463 930 201 - 18 - © ESAB AB 2024...
Page 19: Turning The Mains Power On/Off
ELP (ESAB Logic Pump) The EM 350Cw PRO SYNERGIC is fitted with a water recirculator and detection system called ELP (ESAB Logic Pump), which checks that the coolant hoses are connected. The coolant from the cooler automatically starts flowing when welding starts. NOTE! The cooling unit will be applicable only for MIG / MAG / GMAW welding.
Page 20: Changing And Loading Wire
For information about correct feed rolls, see the WEAR PARTS appendix. 1) Open the left door of the wire feeder. 2) Unlock the feed rollers, by rotating the quick lock 1/3 turn (A) for each feed roll. 0463 930 201 - 20 - © ESAB AB 2024...
Page 21: Changing The Wire Guides
2) Remove the inlet wire guide (B). 3) Install the correct inlet wire guide (according to the WEAR PARTS appendix). 4) Lock the new inlet wire guide using the wire guide quick lock (A). 0463 930 201 - 21 - © ESAB AB 2024...
Page 22: 5.10.2 Middle Wire Guide
The feed roll pressures should be adjusted independently, determined by the wire type and diameter. The front feed roll pressure should be slightly higher than the rear feed roll pressure. 0463 930 201 - 22 - © ESAB AB 2024...
Page 23 Correct adjustment will result in the wire reel circumference continuing no further than 3-5 mm after release of the trigger. The electrode wire should be slack without becoming dislodged from wirespool. 0463 930 201 - 23 - © ESAB AB 2024...
Page 24: Control Panel
The left display will show IND and right display will show a value. Turn the right potentiometer knob to increase or decrease the arc dynamics value. 0463 930 201 - 24 - © ESAB AB 2024...
Page 25: Led Indicators Description
A process with synergic voltage and inductance, in relation to wire feed speed using predetermined synergic line programs providing stable arc performance. The process operates through short circuit, globular and spray transfer mode. 0463 930 201 - 25 - © ESAB AB 2024...
Page 26 This function is applicable only in MIG/MAG Synergic. Time Selected time in the display for the spot and rest time in seconds. This function is applicable only in MIG/MAG Spot. 0463 930 201 - 26 - © ESAB AB 2024...
Page 27 The overheating protection resets automatically when the temperature has fallen with in its normal working temperature. 2-stroke mode (welding without ending arc) 0463 930 201 - 27 - © ESAB AB 2024...
Page 29: Internal Control Panel
This function is active in MIG / MAG / GMAW applications only. Gas selection button This is used to select the proper gas type that is currently connected to the equipment in the internal control panel. 0463 930 201 - 29 - © ESAB AB 2024...
Page 30: Menu Selection
Left diplay letter Function Default Right display settings Display value druing WFS/AMP welding Workpoint in synergic WFS/THI Unit (metric or imperial) MPM/IPM Trigger job select ON/OFF 0463 930 201 - 30 - © ESAB AB 2024...
Page 31: Mig Spot
Spot time is a time when the arc will be enabled after pressing the trigger. Dwell time (DWE) Dwell time is used to define time without arc between spot welds. 0463 930 201 - 31 - © ESAB AB 2024...
Page 32: Hidden Functions For Mig Spot
The arc force function determines how the current changes in response to variations in arc length during welding. Use a low value of arc force to get a calm arc with little spatter and use a high value to get a hot and digging arc. 0463 930 201 - 32 - © ESAB AB 2024...
Page 33: Hidden Functions For Mma / Smaw / Stick
This function enables viewing the software versions of the system. Reset (RES) This function resets to the factory default settings. All saved jobs will be deleted as a result of the reset. 0463 930 201 - 33 - © ESAB AB 2024...
Page 34: Maintenance
To maintain the performance and increase the lifetime of the power source it is mandatory to clean it regularly. How often depends on: • the welding process • the arc time • the working environment 0463 930 201 - 34 - © ESAB AB 2024...
Page 35: Cooling Unit
During cleaning, always wear recommended personal safety equipment, such as ear plugs, safety glasses, masks, gloves and safety shoes. CAUTION! Repair, cleaning, and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. 1) Disconnect the power source from the mains supply.
Page 36: Filling The Coolant
7 MAINTENANCE Filling the coolant Use only ESAB'sready mixed coolant. See chapter "ACCESSORIES". • Fill with coolant (The fluid level must not exceed the upper marking and must not be below lower marking). CAUTION! The coolant must be handled as chemical waste.
Page 37: Inspection, Cleaning And Replacement
Blow the wire guide clean regularly and clean the contact tip. After cleaning and perform testing according to IEC 60974-4. Follow the procedure in section “After repair, inspection and test” in the Service manual. 0463 930 201 - 37 - © ESAB AB 2024...
Page 38: Error Codes
"Err" followed by the error code number shown in the display. Screens 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 code Description Err 002...
Page 39 2. Check the wire pressure setting and adjust if needed. 3. Check the drive rolls for wear and replace if needed. 4. Make sure the filler metal spool can rotate with limited resistance. Adjust the brake hub if needed. 0463 930 201 - 39 - © ESAB AB 2024...
Page 40: Troubleshooting
Poor cooling effect Clean the cooling element using compressed air. Check the coolant level. Check that the ambient temperature is not above the one for the rated duty cycle 40°C/104°F. 0463 930 201 - 40 - © ESAB AB 2024...
Page 41: Calibration And Validation
(TRMS, RMS or rectified arithmetic mean), significantly larger deviations are to be expected! The ESAB Rustler EM PRO welding power source presents the measured value in rectified arithmetic mean and should therefore not show any significant differences compared to other ESAB welding equipment, due to the measurement method.
Page 42: 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 46: Ordering Numbers
With Exeor Torch 315, Remote 4 m 0448 350 883 Rustler EM 350C PRO MV Synergic With Exeor Torch 315, Remote 4 m 0448 350 884 Rustler EM 350Cw PRO Synergic With Exeor Torch 420w, Remote 4 m 0448 280 990 Rustler EM 280C PRO 0448 350 991 Rustler EM 350C PRO 0448 350 992 Rustler EM 350C PRO Synergic...
Page 47: Wear Parts
0446 080 882 0.9–1.6 mm (2 mm) 0445 830 881 (Euro) 0445 830 884 (Tweco) Wire diameter 0.070–3/32 in. 0445 822 002 0446 080 883 1.8–2.4 mm (3 mm) 0445 830 882 (Euro) 0463 930 201 - 47 - © ESAB AB 2024...
Page 48 0445 850 051 0445 850 052 Inlet wire guide Middle wire guide Outlet wire guide 0445 830 886 (Tweco) 0445 822 001 0446 080 881 (2 mm) 0445 830 885 (Euro) 0463 930 201 - 48 - © ESAB AB 2024...
Page 49: Accessories
0448 156 880 Top storage toolbox 0448 157 880 User Interface protective cover 0700 401 024 heater kit 0700 006 902 Electrode holder kit, Handy 300, OKC 50, 3 m 0463 930 201 - 49 - © ESAB AB 2024...
Page 50 ESAB ready mixed coolant (10 l/2.64 gal). Use of any other cooling liquid than the prescribed one might damage the equipment. In case of such damage, all warranty undertakings from ESAB cease to apply. 0463 930 201 - 50 - © ESAB AB 2024...
Page 52 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...

This manual is also suitable for:

Rustler em 350c proRustler em 350c pro synergicRustler em 350c pro mv synergicRustler em 280c pro