ESAB Rogue ES 180i Pro User manual

Rogue
Instruction manual
0463 710 001 GB 20200323 Valid for: A01-xxx-xxxx
ES 180iPro, ES 200iPro

TABLE OF CONTENTS
0463 710 001 © ESAB AB 2020
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols ............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 8
2.1 Equipment ............................................................................................... 8
3TECHNICAL DATA ...................................................................................... 9
4INSTALLATION............................................................................................ 11
4.1 Location................................................................................................... 11
4.2 Lifting instructions ................................................................................. 11
4.3 Mains supply........................................................................................... 12
5MAINTENANCE........................................................................................... 14
5.1 Routine maintenance ............................................................................. 14
5.2 Cleaning instruction............................................................................... 14
6TROUBLESHOOTING ................................................................................ 16
7ORDERING SPARE PARTS ........................................................................ 17
DIAGRAM ............................................................................................................ 18
ORDERING NUMBERS....................................................................................... 19
ACCESSORIES ................................................................................................... 20
Rights reserved to alter specifications without notice.

1 SAFETY
0463 710 001 -4- © ESAB AB 2020
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
0463 710 001 -5- © ESAB AB 2020
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.
Recommended ESAB coolant ordering number: 0465720002.
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.

1 SAFETY
0463 710 001 -6- © ESAB AB 2020
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.
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.

1 SAFETY
0463 710 001 -7- © ESAB AB 2020
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
0463 710 001 -8- © ESAB AB 2020
2 INTRODUCTION
Overview
Rogue ES 180i Pro, ES 200i Pro is an inverter-based power source intended for MMA
(Manual Metal Arc) and TIG (Tungsten Inert Gas) welding.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
Rogue ES 180i Pro, ES 200i Pro includes:
• Power Source
• Work Clamp Leadset
• Electrode Holder Leadset
• Safety Manual
• Quick Start Guide
• Shoulder Strap

3 TECHNICAL DATA
0463 710 001 -9- © ESAB AB 2020
3 TECHNICAL DATA
Technical data
Rogue ES 200i Pro Rogue ES 180i Pro
Outlet voltage 230V±15%
1~ 50/60Hz
115V±15%
1~ 50/60Hz
230V±15%
1~ 50/60Hz
115V±15%
1~ 50/60Hz
Primary current
Imax MMA 30 A 29A 26A 29A
ImaxLiveTIG 19.5A 24A 16.5A 24A
No-loadpower
demand when in
energy saving mode 50W 50W 50W 50W
Setting range
MMA 20-200A 20-110A 20-180A 20-110A
Live TIG 10-200A 10-140A 10-180A 10-140A
Permissible load at MMA
25% duty cycle 200A/ 28V 110A/ 24.4V 180A/ 27.2V 110A / 24.4V
60% duty cycle 129A/ 25.2V 70A/ 22.8V 116A/ 24.6V 70A/ 22.8V
100% duty cycle 100A/ 24V 55A/ 22.2V 90A/ 23.6V 55A / 22.2V
Permissible load at Live TIG
25% duty cycle 200A/ 18V 140A/ 15.6V 180A/ 17.2V 140A / 15.6V
60% duty cycle 129A/ 15.2V
90A/
13.6 V 116A/ 14.6V 90A / 13.6V
100% duty cycle 100A/ 14V
70A/
12.8 V 90A/ 13.6V 70A / 12.8V
Apparent power I2
at maximum current 6.9kVA 3.3kVA 6kVA 3.3kVA
Active
power I2
at maximum current 6.8kW 3.26kW 5.94kW 3.26kW
Power factor at maximum current
Live TIG 0.99 0.99 0.99 0.99
MMA 0.99 0.99 0.99 0.99
Efficiency at maximum current
MMA 82% 82% 82% 82%
Live TIG 82% 82% 82% 82%
Open-circuit voltage U0max
VRD 35 V
deactivated 78VDC 78VDC 78VDC 78VDC
VRD 35 V activated <30V <30V <30V <30V

3 TECHNICAL DATA
0463 710 001 - 10 - © ESAB AB 2020
Rogue ES 200i Pro Rogue ES 180i Pro
Operating
temperature
-10to
+40°C
(+14to
104°F)
-10to
+40°C
(+14to
104°F)
-10to
+40°C
(+14to
104°F)
-10to
+40°C
(+14to
104°F)
Transportation
temperature
-20 to +55°C
(-4 to +131°F)
-20 to +55°C
(-4 to +131°F)
-20 to +55°C
(-4 to +131°F)
-20 to +55°C
(-4 to +131°F)
Continual sound
pressure at
no-load
<70dB <70dB <70dB <70dB
Dimensions
l×w×h
403×153×264
mm
(15.8×6×10.4
in.)
403×153×264
mm
(15.8×6×10.4
in.)
403×153×264m
m
(15.8×6×10.4i
n.)
403×153×264m
m
(15.8×6×10.4i
n.)
Weight 8.4kg 8.4kg 8.4kg 8.4kg
Insulation class
transformer
H H H H
Enclosure class IP23S IP23S IP23S IP23S
Application class
Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
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
0463 710 001 - 11 - © ESAB AB 2020
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.
4.1 Location
Position the power source so that cooling air inlets and outlets are not obstructed.
A. Minimum 200 mm (8 in.)
B. Minimum 200 mm (8 in.)
WARNING!
Secure the equipment - particularly if the ground is uneven or sloping.
4.2 Lifting instructions
These units are equipped with a handle for carrying purposes.
WARNING!
Electric shock can kill. Do not touch live electrical parts. Disconnect input power
conductors from de-energized supply line before moving the welding power source.
WARNING!
Falling equipment can cause serious personal injury and equipment damage.
Lift the unit with handle on top of case.

4 INSTALLATION
0463 710 001 - 12 - © ESAB AB 2020
4.3 Mains supply
NOTE!
Rogue ES 180i Pro and ES 200i Pro comply with IEC 61000-3-12 provided that the
short-circuit power is greater than or equal to Sscmin at the interface point between the
user's supply and the public system. It is the responsibility of the installer or user of
the equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment is connected only to a supply with a short-circuit power
greater than or equal to Sscmin. Refer to the technical data in the TECHNICAL DATA
chapter.
The power source will automatically adjust to the supplied input voltage. Make sure that it is
protected by the correct fuse rating. A protective ground connection must be made, in
accordance with regulations.
1. Rating plate with supply connection
data.
Recommended fuse sizes and minimum cable area for the ES 180i Pro, ES 200i Pro
Supply voltage 230VAC 115VAC
Electrical cable area 2.5mm22.5mm2
Maximal current rating
Imax MMA/Stick (SMAW) 30A 29A

4 INSTALLATION
0463 710 001 - 13 - © ESAB AB 2020
Recommended fuse sizes and minimum cable area for the ES 180i Pro, ES 200i Pro
I1eff MMA/Stick (SMAW) 15A 14.5A
Fuse anti-surge type D MCB 20A 20A
Recommended fuse sizes and minimum cable area for the ES 180i Pro, ES 200i Pro
Supply voltage 230VAC 115VAC
Maximum recommended
extension cord length 100m(328ft) 100m(328ft)
Minimum recommended
extension cord size 4mm24mm2
NOTE!
Different variants of ES 180i Pro, ES 200i Pro are certified for different outlet
voltages. Always refer to the rating plate for the specification of the power source in
use.
NOTE!
Use the power source in accordance with the relevant national regulations.
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 MAINTENANCE
0463 710 001 - 14 - © ESAB AB 2020
5 MAINTENANCE
WARNING!
The mains supply must be disconnected during cleaning and maintenance.
CAUTION!
Only persons with the appropriate electrical knowledge (authorised personnel) may
remove the safety plates.
NOTE!
Regular maintenance is important for safe and reliable operation.
NOTE!
Perform maintenance more often during severe dusty conditions.
Before each use - make sure that:
• Product and cables are not damaged,
• The torch is clean and not damaged.
5.1 Routine maintenance
Maintenance schedule during normal conditions. Check equipment prior to every use.
Interval Area to maintain
Every 3 months
Clean or replace
unreadable labels.
Clean weld terminals. Check or replace weld
cables.
Every 6 months
Clean inside
equipment. Use dry
compressed air with
reduced pressure.
5.2 Cleaning instruction
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
CAUTION!
Make sure that the cleaning procedure is done in a suitable prepared workspace.

5 MAINTENANCE
0463 710 001 - 15 - © ESAB AB 2020
CAUTION!
During cleaning, always wear recommended personal safety equipment, such as
ear plugs, safety glasses, masks, gloves and safety shoes.
1. Disconnect the power source from the mains supply.
2. Open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal
filings, slag and loose material. Keep the shunt and lead screw surfaces clean as
accumulated foreign material may reduce the welders output welding current.

6 TROUBLESHOOTING
0463 710 001 - 16 - © ESAB AB 2020
6 TROUBLESHOOTING
Perform these checks and inspections before sending for an authorised service technician.
• Check that the mains voltage is disconnected before starting any type of repair action.
Type of fault Corrective action
MMA welding problems Check the welding process is set for MMA.
Check that the welding and return cables are correctly
connected to the power source.
Make sure that the return clamp has good contact with the
workpiece.
Check that the correct electrodes and polarity are being used.
For polarity, check electrode packaging.
Check that the correct Welding current (A) is set.
Adjust Arc Force and Hot start.
TIG welding problems Check the welding process is set for Live TIG as necessary.
Check that the TIG torch and return cables are correctly
connected to the power source.
Make sure that the return clamp has good contact with the
workpiece.
Make sure that the TIG torch lead is connected to the negative
welding terminal.
Make sure that the correct shielding gas, gas flow, welding
current, filler rod placement, electrode diameter and welding
mode on power source is used.
Make sure that the gas valve on the TIG torch is ON.
No arc Check that the electrical power supply switch is turned on.
Check that the display is on to verify that the power source has
power.
Check that the setting panel is displaying correct values.
Check that the welding and return cables are correctly
connected.
Check the electrical power supply fuses.
Welding current is
interrupted during welding
Check whether the Over Temperature LED (Thermal Protection)
on the setting panel is on.
Continue with Troubleshooting “No Arc”.
The thermal protection
trips frequently
Make sure that the recommended duty cycle for the weld
current has not been exceeded.
Refer to power source “Duty cycle” section in "TECHNICAL
DATA", page9.
Make sure that the air inlets or outlets are not clogged.
Clean the inside of the machine using routine maintenance
methods.

7 ORDERING SPARE PARTS
0463 710 001 - 17 - © ESAB AB 2020
7 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
The Rogue ES 180i Pro, ES 200i Pro is designed and tested in accordance with the
international and European standards EN60974-1 and EN60974-10. 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.
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. This facilitates dispatch and ensures
correct delivery.

DIAGRAM
0463 710 001 - 18 - © ESAB AB 2020
DIAGRAM
From serial number A01-xxx-xxxx

ORDERING NUMBERS
0463 710 001 - 19 - © ESAB AB 2020
ORDERING NUMBERS
Ordering number Denomination Type Notes
0700 500 078 Power source ES 180i Pro Europe
0700 500 079 Power source ES 200i Pro Europe
0700 500 082 Power source ES 200i Pro Middle
East
0700 500 074 Power source ES 200i Pro India
0463 710 001 Instruction manual
Technical documentation is available on the Internet at: www.esab.com
The three last digits in the document number of the manual show the version of the manual.
Therefore they are replaced with * here. Make sure to use a manual with a serial number or
software version that corresponds with the product, see the front page of the manual.

ACCESSORIES
0463 710 001 - 20 - © ESAB AB 2020
ACCESSORIES
TIG torches
0700 025 514
0700 025 522
SR-B 17V, OKC 50, 4m
SR-B 26V, OKC 50, 4m
Return cable kits
0700 006 889
0700 006 903
Return cable kit, OKC 50, 5m
Return cable kit, OKC 50, 3m
0160 360 881 OKC 50 male cable connector, 1/0-4/0
cable (50mm²) EU
0700 006 900 Electrode holder Handy 200A with25mm²,
3m, OKC 50
0700 500 084 Remote control, Handheld remote, MMA4
W4014450 Remote control, Foot pedal, with 4,5 m
(15ft) cable, 8PIN
0700 500 085 Rogue plastic case (Toolbox)
0700 500 086 Shoulder strap