ESAB Rogue EM 190 PRO User manual

Rogue EM 190 PRO
Instruction manual
0447 956 001  US  20230606
Valid for: Serial number:
HA303-xxxx-xxxx

TABLE OF CONTENTS
0447 956 001 -2- © ESAB AB 2023
1 SAFETY ...................................................................................................................................... 3
1.1 Meaning of symbols .................................................................................................... 3
1.2 Safety precautions ...................................................................................................... 3
1.3 User responsibility ...................................................................................................... 7
1.4 California proposition 65 warning ............................................................................. 9
2 INTRODUCTION ......................................................................................................................... 10
2.1 Equipment.................................................................................................................... 10
3 TECHNICAL DATA ..................................................................................................................... 11
4 INSTALLATION........................................................................................................................... 13
4.1 Location........................................................................................................................ 13
4.2 Lifting instructions ...................................................................................................... 13
4.3 Main supply.................................................................................................................. 14
4.4 Recommended fuse and cable sizes ......................................................................... 15
5 OPERATION ............................................................................................................................... 16
5.1 Connections................................................................................................................. 17
5.2 Cable connections - Weld, return and polarity change over................................... 17
5.3 Drive system diagram ................................................................................................. 18
5.4 Attaching fusion 180 GMAW gun ............................................................................... 18
5.5 Inserting and replacing wire....................................................................................... 19
5.5.1 Welding with aluminum wire............................................................................... 20
5.5.2 Installing 12.5 lb spool (8 in. diameter)............................................................... 21
5.5.3 Installing 2 lb spool (4 in. diameter).................................................................... 21
5.6 Setting the wire feed pressure ................................................................................... 22
5.7 Changing the feed/pressure rollers ........................................................................... 22
5.8 Shielding gas ............................................................................................................... 23
5.9 Duty cycle .................................................................................................................... 23
6 USER INTERFACE ..................................................................................................................... 24
6.1 Home screen................................................................................................................ 24
6.2 Navigation .................................................................................................................... 24
6.3 GMAW Synergic mode ................................................................................................ 25
6.4 GMAW Manual mode ................................................................................................... 25
6.5 Icon reference guide ................................................................................................... 28
7 MAINTENANCE.......................................................................................................................... 30
7.1 Routine maintenance .................................................................................................. 30
7.2 Power source and wire feeder maintenance ............................................................ 32
7.3 Torch and liner maintenance...................................................................................... 33
8 ERROR CODES.......................................................................................................................... 34
8.1 Error code descriptions .............................................................................................. 34
9 TROUBLESHOOTING ................................................................................................................ 35
10 ORDERING SPARE PARTS ....................................................................................................... 36
WIRING DIAGRAM ................................................................................................................................ 37
ORDERING NUMBERS ......................................................................................................................... 38
WEAR PARTS........................................................................................................................................ 39
ACCESSORIES ..................................................................................................................................... 40

1  SAFETY
0447 956 001 -3- © 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
WARNING!
These Safety Precautions are for your protection. They summarize precautionary information
from the references listed in the Additional Safety Information section. Before performing any
installation or operating procedures, be sure to read and follow the safety precautions listed
below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe
Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require ear
protection. The arc, like the sun, emits ultraviolet (UV) and other radiation
and can injure the skin and eyes. Hot metal can cause burns. Training in the
proper use of the processes and equipment is essential to prevent
accidents. Therefore:
1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when
welding or watching.
2. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields
and goggles are also required.
3. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck and
ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not
to look at the arc and not to expose themselves to the rays of the electric-arc or hot metal.
4. Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants, high-topped shoes,
and a welding helmet or cap for protection, to protect against arc rays and hot sparks or hot metal.
A flameproof apron may also be desirable as protection against radiated heat and sparks.
5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars
should be kept buttoned and open pockets eliminated from the front of the clothing.
6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or
curtains.
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.

1  SAFETY
0447 956 001 -4- © ESAB AB 2023
FIRES AND EXPLOSIONS
Heat from flames and arcs can start fires. Hot slag or sparks can also cause
fires and explosions. Therefore:
1. Protect yourself and others from flying sparks and hot metal.
2. Move all combustible materials well away from the work area or cover the materials with a
protective non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and
gas fuels, solvents, paints, and coating paper, etc.
3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a
hidden smoldering fire or fires on the floor below. Make certain that such openings are protected
from hot sparks and metal.
4. Do not weld, cut, or perform other hot work until the work piece has been completely cleaned so
that there are no substances on the work piece which might produce flammable or toxic vapors. Do
not perform hot work on closed containers, they may explode.
5. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand
bucket, or portable fire extinguisher. Be sure you are trained in its use.
6. Do not use equipment beyond its ratings. For example, an overloaded welding cable can overheat
and create a fire hazard.
7. After completing work, inspect the work area to make sure there are no hot sparks or hot metal that
could cause a fire later. Use fire watchers when necessary.
ELECTRICAL SHOCK
Contact with live electrical parts and ground can cause severe injury or
death. DO NOT use AC welding current in damp areas, if movement is
confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the earth system of the input power.
2. Connect the workpiece to a good electrical earth.
3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to
a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power source.
6. Make sure that all parts of your body are insulated from both the work piece and from the ground.
7. Do not stand directly on metal or the ground while working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power, before removing your gloves.
10.Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not mistake the
work lead for a earth cable.
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:

1  SAFETY
0447 956 001 -5- © ESAB AB 2023
1. Welders with pacemakers fitted should consult their doctor before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF:
a) Route the electrode and work cables together. Secure them with tape when possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on the same side of
your body.
d) Connect the work cable to the workpiece as close as possible to the area being welded.
e) Keep the welding power source and cables as far away from your body as possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in confined
spaces. Shielding gases can cause asphyxiation. Therefore:
1. Keep your head out of the fumes. Do not breathe the fumes and gases.
2. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld,
cut or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead beryllium or
cadmium unless positive mechanical ventilation is provided. Do not breathe in the fumes from these
materials.
3. Do not operate near degreasing and spraying operations. The heat or arc can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.
4. If you develop momentary eye, nose or throat irritation while operating, this is an indication that the
ventilation is not adequate. Stop work and take the necessary steps to improve ventilation in the
work area. Do not continue to operate if physical discomfort persists.
5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
6. WARNING: This product when used for welding or cutting, produces fumes or gases which contain
chemicals known to the State of California to cause birth defects and in some cases cancer
(California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A sudden
rupture of cylinder valve or relief device can injure or kill. Therefore:
1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
2. Use the proper gas for the process and use the proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not use adapters. Maintain hoses and fittings in good
condition. Follow the manufacturer's operating instructions for mounting a regulator to a
compressed gas cylinder.
3. Always secure cylinders in an upright position, by chain or strap, to suitable hand trucks,
undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or fixtures
where they may become part of an electrical circuit.
4. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not
connected. Secure and move cylinders by using suitable hand trucks.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause injury.
Therefore:
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

1  SAFETY
0447 956 001 -6- © ESAB AB 2023
4. To prevent accidental starting of equipment during service, disconnect negative (-) battery cable
from battery.
5. Keep hands, hair, loose clothing and tools away from moving parts.
6. Reinstall panels or covers and close doors when service is finished and before starting engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any other
accessories.
• Use equipment of adequate capacity to lift and support unit.
• If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side
of unit.
• Keep cables and cords away from moving vehicles when working from an aerial location.
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting and maintenance
work. Do not perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power
source from the incoming electrical power.
3. Maintain cables, earthing wire, connections, power cord and power supply in safe working
order. Do not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such
as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres
and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting equipment,
ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,
Cutting and Gouging,” Form 52-529.
The following publications are recommended:
• ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
• AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
• AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
• AWS SP - “Safe practices” - Reprint, Welding Handbook
• ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of Containers
That Have Held Hazardous Substances”
• OSHA 29 CFR 1910 - "Safety and health standards"
• CSA W117.2 - "Code for safety in welding and cutting"
• 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"

1  SAFETY
0447 956 001 -7- © ESAB AB 2023
1.3 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.
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 could result in injury to
the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
• its operation
• the location of emergency stops
• its function
• the relevant safety precautions
• welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
• no unauthorized person is 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
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 may cause injury to yourself and others. Take precautions when
welding and cutting.

1  SAFETY
0447 956 001 -8- © ESAB AB 2023
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 with pacemakers fitted should consult their doctor 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 the
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 ear defenders or other hearing protection.
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 a fire. Make sure 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!

1  SAFETY
0447 956 001 -9- © ESAB AB 2023
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
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.
1.4 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. (California Health &
Safety Code Section 25249.5 et seq.)
WARNING!
This product can expose you to chemicals including lead, which are known to the state of
California to cause cancer and birth defects or other reproductive harm. Wash hands after use.
For more information, go to www.P65Warnings.ca.gov.

2  INTRODUCTION
0447 956 001 - 10 - © ESAB AB 2023
2 INTRODUCTION
The RogueEM190PRO is a self-contained single phase welding system that is capable of
performing GMAW (MIG) welding.
The power source is equipped with an integrated wire feed unit, digital voltage, amperage meters, and
a host of other features.
2.1 Equipment
RogueEM190PRO is supplied with:
• Welding power source
• Tweco Fusion 180 MIG Torch 10ft (3m)
• Victor gas regulator/Flow gauge
• Gas hose 10ft (3m)
• Ground clamp lead set 10ft (3m), 16mm2, 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

3  TECHNICAL DATA
0447 956 001 - 11 - © ESAB AB 2023
3 TECHNICAL DATA
RogueEM190PRO
Outlet voltage 230 V 1~ 50/60 Hz
Primary current 16A
Ieff 8.8A
No-load power demand when in energy saving mode <20W
Permissible load
30% duty cycle 145A/21.25V
60% duty cycle 102 A/19.1 V
100% duty cycle 79 A/17.95 V
Power factor at maximum current 0.99
Efficiency at maximum current >82%
Open-circuit voltage U0max
(VRD 35 V deactivated)
78V
Operating temperature +14 to 104°F (-10 to +40°C)
Transportation temperature -4 to +161°F (-20 to +55°C)
Constant sound pressure when idling <66 db
Wire feed speed range 75-650ipm (2-16.5mpm)
Amperage range 30-190A
Voltage range 12.0-26.0V
Bobbin size 4in. (100mm)
8in. (200mm)
Wire diameter
GMAW: 0.023, 0.030, 0.035in. (0.6, 0.8,
0.9mm)
FCAW: 0.030, 0.035, 0.040, 0.045in. (0.8,
0.9, 1.0, 1.2mm)
Maximum material thickness
GMAW/Flux-cored:
Mild Steel: 24ga.-3/8in. (0.6-10.0mm)
Aluminum: 18ga.-3/8in. (1.2-10.0mm)
Stainless: 20ga.-1/4in. (1.0-6.0mm)
Dimensions l × w × h 23.2 × 8.7 × 15.2in. (590 × 220 × 385 mm)
Weight 37.3lbs (16.9 kg)
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 104°F (40°C) or below.

3  TECHNICAL DATA
0447 956 001 - 12 - © ESAB AB 2023
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, 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.

4  INSTALLATION
0447 956 001 - 13 - © 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 956 001 - 14 - © ESAB AB 2023
WARNING!
Secure the equipment - particularly if the
ground is uneven or sloping.
4.3 Main supply
The supply voltage should be 230VAC ±15%. Too low of supply voltage may cause poor welding
performance. Too high of 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 grounded (electrically) in accordance with local regulations.
• Connected to the correct size power point and fuse as indicated in table below.
NOTE!
Use the welding power source in accordance with the relevant local and national regulations.
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.
1. Rating plate

4  INSTALLATION
0447 956 001 - 15 - © 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
Supply voltage 230VAC, 1~50/60Hz
Input current at maximum output 16A
Maximum recommended fuse* or circuit breaker rating
* Time delay fuse 25A
Maximum recommended fuse of circuit breaker rating 32.0A
Minimum recommended cord size 14AWG (2.08mm2)
Maximum recommended extension cord length 325ft. (100m)
Minimum recommended grounding conductor size 14AWG (2.08mm2)
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
9kW, are recommended.

5  OPERATION
0447 956 001 - 16 - © 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!
NOTE!
When moving the equipment, use the handle. Never pull the cables.
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
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.

5  OPERATION
0447 956 001 - 17 - © ESAB AB 2023
5.1 Connections
1. Push button (menu access) 7. Torch trigger and spool gun control receptacle
2. Push button (return to previous menu) 8. Electrode positive terminal (+)
3. Push button encoder (parameter adjust and
display navigation)
9. GMAW torch and spool gun connection
4. Encoder (parameter adjust) 10. Mains supply cable
5. Electrode negative terminal (-) 11. Mains supply switch, ON/OFF
6. Polarity changeover cable 12. Gas inlet
5.2 Cable connections - Weld, return and polarity
change over
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17.
GMAWSynergic & Manual mode - solid wires GMAWSynergic & Manual mode - FCAW wires
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

5  OPERATION
0447 956 001 - 18 - © ESAB AB 2023
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.
Secure the work clamp to the work piece in a clean, debris free location.
NOTE!
For some wires it is recommended to use negative polarity such as self-shielded flux-core.
See wire manufacturer's recommendation.
5.3 Drive system diagram
1. Wire inching/purge 3. Wire spool
2. Wire feed mechanism
5.4 Attaching fusion 180 GMAW gun
Direct plug GMAW guns install by inserting the power pin of the torch into the torch receptacle located
on the front of the unit and tightening the power pin retaining thumb screw. GMAW guns require a
control wire assembly to connect the trigger leads to the unit. The control wire assembly is located
near the power pin and plugs into the remote control socket.
WARNING!
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.

5  OPERATION
0447 956 001 - 19 - © ESAB AB 2023
4) Locate the control wire assembly, align keyway with the key on the remote control socket, insert
plug, and rotate threaded collar fully clockwise.
1. Thumb screw 2. Torch receptacle
5.5 Inserting and replacing wire
RogueEM190 can be used with bobbin sizes of 4in. (100mm) and 8in. (200mm). See Section 3
"Technical data", page11, 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!
Make sure that the power is turned off, before replacing or installing any parts.
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 (1).
3) Lift the pressure roller arm (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
that the wire is aligned with the correct groove in the drive roll.

5  OPERATION
0447 956 001 - 20 - © ESAB AB 2023
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.
5.5.1 Welding with aluminum wire
NOTE!
Make sure the correct feed/pressure rollers are used. For more information see Section 11.3
"WEAR PARTS", page39.
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 0.030in. (0.8mm) 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 weld with aluminum wire, use optional spool gun for the best result. Refer to Spool Gun Instruction
Manual for the correct set up.