ESAB Rustler EM 201C User manual

Rustler
EM201C, EM203C, EM251C, EM253C
Instruction manual
0463 933 001  GB  20230710 Valid for: OP316-xxxx-xxxx

TABLE OF CONTENTS
0463 933 001 -4- © ESAB AB 2023
1 SAFETY ...................................................................................................................................... 6
1.1 Meaning of symbols .................................................................................................... 6
1.2 Safety precautions ...................................................................................................... 6
2 INTRODUCTION ......................................................................................................................... 9
2.1 Equipment.................................................................................................................... 9
3 TECHNICAL DATA ..................................................................................................................... 10
3.1 ECO design information ............................................................................................. 11
4 INSTALLATION........................................................................................................................... 13
4.1 Location........................................................................................................................ 13
4.2 Move instructions (No lifting)..................................................................................... 13
4.3 Mains supply................................................................................................................ 14
5 OPERATION ............................................................................................................................... 15
5.1 Connections and control devices .............................................................................. 15
5.2 Recommended maximum current values for connection cables set ..................... 16
5.3 Connecting welding and return cables ..................................................................... 16
5.4 Polarity change............................................................................................................ 16
5.5 Turning the mains power on/off ................................................................................. 17
5.6 Bobbin brake................................................................................................................ 17
5.7 Changing and loading wire......................................................................................... 17
5.8 Changing feed rollers.................................................................................................. 18
5.9 Roller pressure ............................................................................................................ 18
6 CONTROL PANEL...................................................................................................................... 20
6.1 External control panel................................................................................................. 20
6.2 LED indicators description......................................................................................... 21
6.3 Internal control panel .................................................................................................. 24
6.4 Menu selection ............................................................................................................ 25
6.4.1 MIG/MAG............................................................................................................ 25
6.4.2 Hidden functions for MIG/MAG .......................................................................... 26
6.4.3 MIG SPOT.......................................................................................................... 26
6.4.4 Hidden functions for MIG SPOT......................................................................... 27
6.4.5 MMA ................................................................................................................... 27
6.4.6 Hidden functions for MMA .................................................................................. 28
7 MAINTENANCE.......................................................................................................................... 29
7.1 Routine maintenance .................................................................................................. 29
7.2 Power source............................................................................................................... 30
7.3 Inspection, cleaning and replacement ...................................................................... 30
8 ERROR CODES.......................................................................................................................... 31
8.1 Error code descriptions .............................................................................................. 31
9 TROUBLESHOOTING ................................................................................................................ 33
10 CALIBRATION AND VALIDATION............................................................................................. 34
10.1 Measurement methods and tolerances ..................................................................... 34
10.2 Requirements specifications and standards ............................................................ 34
11 ORDERING SPARE PARTS ....................................................................................................... 35
BLOCK DIAGRAM................................................................................................................................. 36
ORDERING NUMBERS ......................................................................................................................... 40
WEAR PARTS........................................................................................................................................ 41

TABLE OF CONTENTS
0463 933 001 -5- © ESAB AB 2023
ACCESSORIES ..................................................................................................................................... 42

1  SAFETY
0463 933 001 -6- © 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
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

1  SAFETY
0463 933 001 -7- © ESAB AB 2023
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
• 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.
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 therefore that there are no inflammable
materials nearby
• Do not use on closed containers.

1  SAFETY
0463 933 001 -8- © ESAB AB 2023
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.
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
0463 933 001 -9- © ESAB AB 2023
2 INTRODUCTION
The RustlerEM201C, EM203C, EM 251C and EM253C is a compact welding power source
intended for welding with solid wires, flux cored wires and coated electrodes (MIG/MAG, FCAW, and
MMA).
The equipment has built in wheels and gas bottle bracket to move easily around the work place and
provide a better reach.
Main features of RustlerEMPRO:
• High output current and duty cycle
• Easy and intuitive set up
• Durable housing
• Superb arc characteristic, optimized for most common based materials
• MMA welding mode
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.
2.1 Equipment
The power source is supplied with:
• 4 m black rubber gas hose
• 3m return cable with crocodile type earth clamp
• Safety instruction
• Quick start guide

3  TECHNICAL DATA
0463 933 001 - 10 - © ESAB AB 2023
3 TECHNICAL DATA
EM201C EM203C EM251C EM 253C
Mains voltage 230 V ±15%,
1~ 50/60 Hz
400 V ±15%,
3~ 50/60 Hz
230 V ±15%,
1~ 50/60 Hz
400 V ±15%,
3~ 50/60 Hz
Primary current I max
MIG/MAG 25.5 A 8.6 A 35A 12 A
MMA 26 A 10 A 33.5A 11.5 A
Setting range
MIG/MAG
30A/15.5V -
200A/24V
40A/15.6V -
200A/24V
30A/15.5V -
250A/26.5V
40A/16V -
250A/26.5V
MMA
20A/20.8V -
180A/27.2V
20A/20.8V -
200A/28V
20A/20.8V -
200A/28V
20A/20.8V -
220A/28.8V
Wire feed speed 1.5 - 18m/min 1.5 - 18m/min
Permissible load at MIG/MAG
35 % duty cycle 200A/24V 200A/24V 250A/26.5V 250A/26.5V
60 % duty cycle 152 A/21.6 V 152 A/21.6 V 152 A/21.6 V 191A/23.6V
100% duty cycle 118 A/19.9 V 118 A/19.9 V 118A/19.9V 148A/21.4V
Open-circuit voltage 56V 56V 56V 56V
Permissible load at MMA
25 % duty cycle 180A/27.2V - - -
35 % duty cycle - 200A/28V 220A/28.8V 220A/28.8V
60 % duty cycle 116A/24.6 V 152 A/26.1 V 168A/26.7V 168A/26.7V
100% duty cycle 90 A/23.6 V 118 A/24.7 V 130A/25.2V 130A/25.2V
Open-circuit voltage 56V 57.5V 56V 63V
Apparent power at maximum
current 6kVA 6.9kVA 8.05kVA 8.3kVA
Active power I2at maximum
current 5.94kW 6.2kW 7.97kW 7.5kW
Power factor at maximum
current 0.99 0.9 0.99 0.9
Efficiency at maximum output
power 87 % 86 % 84 % 89 %
No-load power demand when
energy-saving mode
36W 20W 43W 20W
Weight 46kg 46kg 48kg 52kg
Recommended generator 7kW 8kW 10 kW 10 kW
Operating temperature -10 to +40°C (+14 to 104°F)
Transportation temperature -20 to +55°C (-4 to +131°F)
Dimensions l × w × h 959 × 482 × 717 mm
Insulation class F

3  TECHNICAL DATA
0463 933 001 - 11 - © ESAB AB 2023
EM201C EM203C EM251C EM 253C
Enclosure class IP 23
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 IP23 is intended for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased electrical
hazard.
3.1 ECO design information
The equipment has been designed in order to be compliant with the Directive 2009/125/EC and the
Regulation 2019/1784/EU.
Efficiency and idle power consumption:
Name Idle power Efficency when max power
consumption
EM201C 36W 87%
EM203C 20W 86%
EM251C 43W 84%
EM523C 20W 89%
The value of efficiency and consumption in idle state have been measured by method and conditions
defined in the product standard EN 60974-1.

3  TECHNICAL DATA
0463 933 001 - 12 - © ESAB AB 2023
Manufacturer’s name, product name, serial number and date of production can be read from rating
plate.
1. Product name
2. Manufacturer's name and address
3. Serial number
3A. Manufacturing location code
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)

4  INSTALLATION
0463 933 001 - 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.
4.1 Location
Position the power source so that cooling air inlets and outlets are not obstructed.
WARNING!
Electric shock! Do not touch the workpiece or the
welding head during operation!
WARNING!
The wheels may freely slide on slopes greater than 10 degrees. Take precautions while
working on the slopes.
4.2 Move instructions (No lifting)
Mechanical lifting must be done with both outer handles.

4  INSTALLATION
0463 933 001 - 14 - © ESAB AB 2023
4.3 Mains supply
NOTE!
Mains supply requirements
This equipment complies 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.
1. Rating plate with supply connection data.
Recommended fuse sizes and minimum cable area
EM201C EM203C EM251C EM253C
Mains voltage 230V±15%,
1~50/60Hz
400V±15%,
3~50/60Hz
230V±15%,
1~50/60Hz
400V±15%,
3~50/60Hz
Mains cable area 3G×2.5mm24×2.5mm23G×4mm24×2.5mm2
Maximal current
rating Imax 26A 20A 35A 12A
I1eff 15A 5.9A 21A 7A
Fuse
Anti-surge
Type C MCB
16A
16A
16A
16A
32A
32A
16A
16A
Maximum
recommended
extension cord length
100m/330ft. 100m/330ft. 100m/330ft. 100m/330ft.
Minimum
recommended
extension cord size
3G×2.5mm24×2.5mm23G×4mm24×2.5mm2

5  OPERATION
0463 933 001 - 15 - © 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 intended handle. Never pull the cables.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
5.1 Connections and control devices
1. External control panel 7. Mains power supply switch, O/I
2. Connector for welding torch 8. Mains cable
3. Cable for change the polarity 9. Heater socket (optional)
4. Negative welding terminal: Return 10. Wire feeding mechanism
5. Positive welding terminal: Welding cable 11. Internal control panel
6. Connection for shielding gas
CAUTION!
The heater socket may only be installed by ESAB After-Sales personnel.

5  OPERATION
0463 933 001 - 16 - © ESAB AB 2023
5.2 Recommended maximum current values for
connection cables set
Recommended maximum welding current values for the welding/return cable(copper) at an
ambient temperature of +25°C and normal 10minutes cycle
Cable size mm2Duty cycle Voltage
drop/10m
100% 60% 35%
50 285A 320A 370A 0.352V/100A
70 355A 400A 480A 0.254V/100A
95 430A 500A 600A 0.189V/100A
Recommended maximum welding current values for the welding/return cable(copper) at an
ambient temperature of +40°C and normal 10minutes cycle
Cable size mm2Duty cycle Voltage
drop/10m
100% 60% 35%
50 250A 280A 320A 0.352V/100A
70 310A 350A 420A 0.254V/100A
95 375A 440A 530A 0.189V/100A
5.3 Connecting welding and return cables
The power source has two outputs, a positive welding terminal (+) and a negative welding terminal (-),
for connecting welding and return cables. The output to which the welding cable is connected depends
on the welding method or type of electrode used.
Connect the return cable to the other output on the power source. Secure the return cable's contact
clamp to the work piece and ensure that there is good contact between the work piece and the output
for the return cable on the power source.
• For MIG/MAG and MMA welding, the welding cable can be connected to the positive welding
terminal (+) or negative welding terminal (-) depending on the type of electrode used. The
connecting polarity is stated on the electrode packaging.
5.4 Polarity change
The power source is delivered with the polarity changeover cable connected to the positive terminal.
Some wires, e.g. self-shielded cored wires, are recommended to be welded with negative polarity.
Negative polarity means that the polarity changeover cable is connected to the negative terminal and
the return cable to the positive terminal. Check the recommended polarity for the welding wire you
want to use.
The polarity can be changed by moving the polarity changeover cable to suit the applicable welding
process.

5  OPERATION
0463 933 001 - 17 - © ESAB AB 2023
5.5 Turning the mains power on/off
Turn on the mains power by turning switch to the ”I” position.
Turn the unit off by turning the switch to the ”O” position.
Whether the mains power supply is interrupted or the power source is switched off in the normal
manner, weld programs will be stored so that it is available next time the unit is started.
CAUTION!
Do not turn off the power source during welding (with load).
5.6 Bobbin brake
The bobbin brake force should be increased just enough to prevent wire feed overrun. The actual
brake force needed, is dependent of the wire feed speed and the size and weight of the bobbin spool.
Do not overload the bobbin brake! A too high brake force may overload the motor and reduce the
welding result.
The bobbin brake force is adjusted using the 6 mm hexagon Allen screw in the middle of the brake
hub nut.
5.7 Changing and loading wire
1) Open the left door of the power source
2) Untighten and remove the brake hub nut and remove the old wire spool.

5  OPERATION
0463 933 001 - 18 - © ESAB AB 2023
3) Insert a new wire spool into the unit and straighten out the new welding wire 10–20cm. File away
burrs and sharp edges from the end of the wire before inserting it into the feeder mechanism.
4) Lock the wire spool onto the brake hub, by tightening the brake hub nut.
5) Thread the wire through the feeder mechanism.
NOTE!
Replace the brake hub nut and the brake hub sleeve if they are worn out and do not lock
properly.
6) Close and lock the left door of the wire feeder.
5.8 Changing feed rollers
When changing to a different type of wire, the feed rollers should be changed to match the new type of
wire. For information about correct feed roller depending on wire diameter and type, see the WEAR
PARTS appendix.
1) Open the side panel.
2) Disconnect the pressure sensor (1) by folding it backwards.
3) Disconnect and remove the Allen screw (2) and the washer.
4) Pull out the feed roller (3).
During installation, repeat the steps above in reverse order.
Choice of track in the feed roller.
Turn the feed roller with the dimensioning mark for the required track towards you.
5.9 Roller pressure
The roller pressure should be adjusted separately on each tensioner unit, depending on used wire
material and diameter.
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.

5  OPERATION
0463 933 001 - 19 - © ESAB AB 2023
Figure A. Figure B.
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 approx. 5mm from the piece of wood (figure A) the feed rollers
should slip.
If you hold the welding torch approx. 50mm from the piece of wood, the wire should be fed out and
bend (figure B).

6  CONTROL PANEL
0463 933 001 - 20 - © ESAB AB 2023
6 CONTROL PANEL
6.1 External control panel
1. Process selection button 3. Left potentiometer knob
2. Parameter selection button 4. Right potentiometer knob
Process selection button (1)
The various welding processes such as MIG, MIG SPOT and MMA can be selected through this
button. When the machine is turned ON, it will be in MIG mode by default. Press this button to
change to MIG SPOT/MMA and repeat.
Parameter selection button (2)
Parameter selection button is used to switch the functionality of the torch trigger from trigger mode,
Inductance and Menu.
Trigger mode
To access the functions, press the parameter selection button and let the
trigger mode symbol ON. The left display shows the letter TRG and the
right display shows 2T or 4T. Select the function by turning the knob (4).
Inductance
To access the functions, press the parameter selection button and let the
inductance symbol ON. The left display shows the letter IND and the right
display shows the value. The knob (4) is used to change the value of the
selected function.