ESAB Rogue EM 180 User manual

Rogue EM 180
Instruction manual
0447 979 001  GB  20231102 Valid for: HA324YY-XXXXXX

TABLE OF CONTENTS
0447 979 001 -3- © ESAB AB 2023
1 SAFETY ...................................................................................................................................... 4
1.1 Meaning of symbols .................................................................................................... 4
1.2 Safety precautions ..................................................................................................... 4
2 INTRODUCTION ......................................................................................................................... 7
2.1 Equipment.................................................................................................................... 7
3 TECHNICAL DATA ..................................................................................................................... 8
4 INSTALLATION........................................................................................................................... 10
4.1 Location........................................................................................................................ 10
4.2 Lifting instructions ...................................................................................................... 10
4.3 Mains supply................................................................................................................ 11
4.4 Recommended fuse and cable sizes ......................................................................... 12
5 OPERATION ............................................................................................................................... 13
5.1 Connections................................................................................................................. 14
5.2 Cable connection - Weld, return and polarity change over..................................... 14
5.3 Drive system diagram ................................................................................................. 15
5.4 Attaching MXL 201 with central adapter ................................................................... 15
5.5 Inserting and replacing wire....................................................................................... 17
5.5.1 Welding with aluminium wire .............................................................................. 18
5.5.2 Installing 12.5 lb spool (8 in. diameter)............................................................... 19
5.5.3 Installing 2 lb spool (4 in. diameter).................................................................... 19
5.6 Setting the wire feed pressure ................................................................................... 20
5.7 Changing the feed/pressure rollers ........................................................................... 20
5.8 Shielding gas ............................................................................................................... 21
5.9 Duty cycle .................................................................................................................... 21
6 USER INTERFACE ..................................................................................................................... 22
6.1 External control panel................................................................................................. 22
6.2 Weld Variables ............................................................................................................. 23
6.3 Arc Dynamics and Trigger Selection ......................................................................... 23
6.4 Synergic control panel................................................................................................ 24
6.5 Wire inching and gas purge button ........................................................................... 24
6.6 Icon reference guide ................................................................................................... 25
7 MAINTENANCE.......................................................................................................................... 26
7.1 Routine maintenance .................................................................................................. 26
7.2 Power source and wire feeder maintenance ............................................................ 28
7.3 Torch and liner maintenance...................................................................................... 29
8 ERROR CODES.......................................................................................................................... 30
8.1 Error code descriptions .............................................................................................. 30
9 TROUBLESHOOTING ................................................................................................................ 31
10 ORDERING SPARE PARTS ....................................................................................................... 32
WIRING DIAGRAM ................................................................................................................................ 33
ORDERING NUMBERS ......................................................................................................................... 35
WEAR PARTS........................................................................................................................................ 36
ACCESSORIES ..................................................................................................................................... 37

1  SAFETY
0447 979 001 -4- © ESAB AB 2023
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate, serious
personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual and
follow all labels, employer´s safety practices and Safety Data
Sheets (SDSs).
1.2 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.
All work must be carried out by trained personnel well-acquainted with the operation of the equipment.
Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the
operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
• no unauthorised person is stationed within the working area of the equipment when it is started
up
• no-one is unprotected when the arc is struck or work is started with the equipment
3. The workplace must:
• be suitable for the purpose
• be free from drafts

1  SAFETY
0447 979 001 -5- © ESAB AB 2023
4. Personal safety equipment:
• Always wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves
• Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns
5. General precautions:
• Make sure the return cable is connected securely
• Work on high voltage equipment may only be carried out by a qualified electrician
• Appropriate fire extinguishing equipment must be clearly marked and close at hand
• Lubrication and maintenance must not be carried out on the equipment during operation
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.
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions when
welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet
clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding. EMF
may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to EMF:
○ Route the electrode and work cables together on the same side of your body.
Secure them with tape when possible. Do not place your body between the torch
and work cables. Never coil the torch or work cable around your body. Keep
welding power source and cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the area being
welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases away from
your breathing zone and the general area.
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens and wear
protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1  SAFETY
0447 979 001 -6- © ESAB AB 2023
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only qualified
people remove covers for maintenance and troubleshooting as necessary. Reinstall
panels or covers and close doors when service is finished and before starting
engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable materials
nearby.
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• 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!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those
locations, due to conducted as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation in
accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be disposed of
at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
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.

2  INTRODUCTION
0447 979 001 -7- © ESAB AB 2023
2 INTRODUCTION
The RogueEM180PRO is a self-contained single phase welding system that is capable of
performing GMAW (MIG) welding.
2.1 Equipment
RogueEM180PRO is supplied with:
• Welding power source
• MXL 201, Euro, 3 m
• Gas hose, 4 m
• Work clamp lead set, 3 m, 16 mm2, 35-50OKC
• OK Aristo Rod 12.50 0.8mm, 1kg
• 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 VK
• Electrode holder, 3 m, 16mm2, 35-50OKC
• Instruction manual
• Safety instruction

3  TECHNICAL DATA
0447 979 001 -8- © ESAB AB 2023
3 TECHNICAL DATA
Rogue EM 180
Outlet voltage 230 V 1~ 50/60 Hz
Primary current
Imax GMAW - MIG 23A
Imax SMAW - MMA 21A
Ieff GMAW - MIG 11.5A
Ieff SMAW - MMA 11.0A
No-load power demand when in energy saving mode 20W
Setting range
GMAW 30 A/15.5V–180 A/23V
SMAW 10 A/20.4V–150 A/26V
Permissible load at GMAW
25% duty cycle 180 A / 23 V
60% duty cycle 116 A / 19.8 V
100% duty cycle 90 A / 18.5 V
Permissible load at SMAW
25% duty cycle 150 A / 26 V
60% duty cycle 97 A / 23.9 V
100% duty cycle 75 A / 23 V
Power factor at maximum current
GMAW 0.8
SMAW 0.8
Efficiency at maximum current
GMAW 82.7%
SMAW 82.7%
Open-circuit voltage U0max 78V
Operating temperature -10 to +40°C (+14 to 104°F)
Transportation temperature -20 to +55°C (-4 to +161°F)
Constant sound pressure when idling <66 db
Wire feed speed range 2-16.5 m/min (75~650 in/min)
Bobbin size 100mm (4in.)
200mm (8in.)
Wire diameter
GMAW 0.6 – 0.8 mm (.023–.030 in.)
FCAW 0.8 – 0.9 mm (.030–.035 in.)
Maximum material thickness
Mild Steel 24 ga - 0.5-10 mm (3/8 in.)

3  TECHNICAL DATA
0447 979 001 -9- © ESAB AB 2023
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
Application class
Duty cycle
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 40°C/104°F, or below.
Enclosure class
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, 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.

4  INSTALLATION
0447 979 001 - 10 - © ESAB AB 2023
4 INSTALLATION
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product may cause
radio interference. It is the user's responsibility to take adequate precautions.
CAUTION!
Remove any packaging material prior to use. Do not block the air vents at the front or rear of
the welding power source.
4.1 Location
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)
4.2 Lifting instructions
The power source can be lifted using any of the handles.

4  INSTALLATION
0447 979 001 - 11 - © ESAB AB 2023
WARNING!
Secure the equipment - particularly if the
ground is uneven or sloping.
4.3 Mains supply
The supply voltage should be 120V ±15%. Too low supply voltage may cause poor welding
performance. Too high welding supply voltage will cause components to overheat and possibly fail.
Contact the local electric utility for information about the type of electrical service available, how proper
connections should be made, and inspection required.
The welding power source must be:
• Correctly installed, if necessary, by a qualified electrician.
• Correctly earthed (electrically) in accordance with local regulations.
• Connected to the correct size power point and fuse as table below.
CAUTION!
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.
NOTE!
Use the welding power source in accordance with the relevant local and national regulations.
1. Rating plate with supply connection data.

4  INSTALLATION
0447 979 001 - 12 - © ESAB AB 2023
4.4 Recommended fuse and cable sizes
WARNING!
An electrical shock or fire hazard is probable if the following electrical service guide
recommendations are not followed. These recommendations are for a dedicated branch circuit
sized for the rated output and duty cycle of the welding power source
230 V, 1 ~ 50/60 Hz
Supply voltage 230 V AC
Input current at maximum output 23A
Maximum recommended fuse* or circuit breaker rating
* Time delay fuse 25A
Maximum recommended fuse ofcircuit breaker rating 32.0A
Minimum recommended cord size 2.5 mm2(14 AWG)
Maximum recommended extension cord length 100 m (325 ft)
Minimum recommended grounding conductor size 2.5 mm2(14 AWG)
Supply from power generators
The power source can be supplied from different types of generators. However, some generators may
not provide sufficient power for the welding power source to operate correctly. Generators with
Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power
7kW, are recommended.

5  OPERATION
0447 979 001 - 13 - © ESAB AB 2023
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY" chapter
of this manual. Read it through before you start using the equipment!
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
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.
NOTE!
When moving the equipment use intended handle. Never pull the cables.

5  OPERATION
0447 979 001 - 14 - © ESAB AB 2023
5.1 Connections
1. Push button - Arc dynamics, trigger control 7. Torch trigger and spool gun control receptacle
2. Encoder – Adjusts Wire feed speed and
selects weld variables
8. Polarity changeover cable
3. Encoder – Adjusts Voltage control and selects
weld variables
9. Electrode negative terminal [-]
4. Push button selector - weld variables 10. Mains supply switch, ON/OFF
5. GMAW torch and spool gun connection 11. Gas inlet
6. Electrode positive terminal (+)
5.2 Cable connection - Weld, return and polarity
change over
The power source has two output studs for connecting the weld and return cables: Electrode negative
[-] terminal (9) and Electrode positive [+] terminal (6).
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
machine to operate with electrode positive insert and secure the polarity changeover cable into the
positive [+] terminal and the return lead into the negative [-] terminal. Be sure that the connections are
tight. 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.

5  OPERATION
0447 979 001 - 15 - © ESAB AB 2023
5.3 Drive system diagram
1. Wire inching / Gas Purge 3. Wire spool
2. Wire feed mechanism
5.4 Attaching MXL 201 with central adapter
1) Check that the wire guide liner is fitted correctly.
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.

5  OPERATION
0447 979 001 - 16 - © ESAB AB 2023
1. Wire Feed Compartment Door 3. Remote Receptacle
2. Torch Receptacle
WARNING!
The mains supply must be disconnected.
1. Torch receptacle

5  OPERATION
0447 979 001 - 17 - © ESAB AB 2023
5.5 Inserting and replacing wire
RogueEM180 can be used with bobbin sizes of 100mm (4in.) and 200mm (8in.). See the
TECHNICAL DATA" chapter for suitable wire dimensions for each wire type.
WARNING!
Do not place or point the torch near the face, hand or body as this may result in personal
injury.
WARNING!
Risk of crushing when replacing the wire bobbin! Do not use safety gloves when inserting the
welding wire between the feed rollers.
1) Open the spool side door.
2) Release the pressure roller arm by levering the tension screw toward you (1).
3) Lift the pressure roller arm up (2).
4) With the GMAW welding wire feeding from the bottom of the spool, pass the electrode wire through
the inlet guide (3), between the rollers, through the outlet guide and into the GMAW torch. Ensure
the wire is aligned with the correct groove in the drive roll.
5) Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure if
necessary.
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.

5  OPERATION
0447 979 001 - 18 - © ESAB AB 2023
5.5.1 Welding with aluminium wire
NOTE!
Make sure the correct feed/pressure rollers are used. For more information see "WEAR
PARTS" chapter.
NOTE!
Make sure to use the correct contact tip in the welding torch for the wire diameter used. The
torch is fitted with a contact tip for 0.8mm (0.030in.) wire. If you use another diameter, make
sure to change the contact tip and drive roll. The wire liner fitted in the torch is recommended
for welding with Fe and SS wires.
To ensure the best results welding aluminum with the MXL 210, use a Teflon liner and U groove drive
roll and keep the torch conduit as straight as possible.
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.

5  OPERATION
0447 979 001 - 19 - © ESAB AB 2023
5.5.2 Installing 12.5 lb spool (8 in. diameter)
In order to fit a 12.5lb spool (8in. diameter) assemble parts in the sequence shown in the figure
below. To install wire spool, follow the steps below.
1. Remove plastic retaining nut.
2. Place wire spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the
spool rotates counterclockwise. 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.
5.5.3 Installing 2 lb spool (4 in. diameter)
In order to fit a 2lb spool (4in. diameter) assemble parts in the sequence shown in the figure below.
To install wire spool, follow the steps below.
1. Remove plastic retaining nut.
2. Place wire spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the
spool rotates counterclockwise. 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.

5  OPERATION
0447 979 001 - 20 - © ESAB AB 2023
5.6 Setting the wire feed pressure
Illustration A Illustration B
Start by making sure that the wire moves smoothly through the wire guide. Then set the pressure of
the wire feeder's pressure rollers. It is important that the pressure is not too high.
To check that the feed pressure is set correctly, you can feed out the wire against an insulated
object, e.g. a piece of wood.
When you hold the welding torch approximately 5mm (0.2in.) from the piece of wood (illustration
A), the feed rollers should slip.
If you hold the welding torch approximately 50 mm (2in.) from the piece of wood, the wire should
be fed out and bend (Illustration B).
The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum
braking. If it is considered necessary, adjustment can be made by turning the thumb screw inside the
open end of the hub clockwise to tighten the brake. 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.
CAUTION!
Overtension of the brake will cause rapid wear of mechanical wire feeder parts, overheating of
electrical components and possibly more incidences of contact tip burnback.
5.7 Changing the feed/pressure rollers
One dual groove feed roller is supplied as standard. Change the feed roller to match the filler metal
wire diameter.
1) Open the spool side door.
2) Release the pressure roller arm by levering the tension screw.
3) Lift the pressure roller arm.
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.
8) Close the spool side door.
NOTE!
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.