ESAB ES 150i, ES 180i User guide

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Rogue

ES 150i, ES 180i

Instruction manual

0463 732 201 GB 20220318

Valid for: HA017-, HA018-xxxx-xxxx

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TABLE OF CONTENTS

SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

INTRODUCTION

2.1 Equipment

TECHNICAL DATA

INSTALLATION

4.1 Location

4.2 Lifting instructions

4.3 Mains supply

OPERATION

5.1 Overview

5.2 Connections and control devices

5.3 Connecting welding and return cables

5.4 Turning the power on/off

5.5 Fan control

5.6 Thermal protection

5.7 Functions and symbols

5.8 Setting panel

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MAINTENANCE

6.1 Routine maintenance

6.2 Cleaning instruction

TROUBLESHOOTING

ORDERING SPARE PARTS

DIAGRAM

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ORDERING NUMBERS ACCESSORIES

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22 23 24 25

Rights reserved to alter specifications without notice.

0463 732 201 © ESAB AB 2022

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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

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1 SAFETY

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.

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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.

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1 SAFETY

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.

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1 SAFETY

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.

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2 INTRODUCTION

Overview Rogue ES 150i, ES 180i are 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 150i, ES 180i includes:

• Power Source

• Work Clamp Leadset

• Electrode Holder Leadset

• Safety Manual

• Quick Start Guide

• Shoulder Strap

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3 TECHNICAL DATA

Technical data

Rogue ES 180i Rogue ES 150i

Outlet voltage 230V±15%

1~ 50/60Hz

230V±15%

1~ 50/60Hz

Primary current

max

MMA

LiveTIG

36A 30A

24A 18.5A

No-loadpower demand when in energy saving mode 30W 30W

Setting range

MMA 20-180A 20-150A

Live TIG 10-180A 10-150A

Permissible load at MMA

20%dutycycle 170A/ 26.8V

25% duty cycle 150A/ 26V

60% duty cycle 97A/ 23.9V 97A/ 23.9V

100% duty cycle 75A/ 23V 75A/ 23V

Permissible load at Live TIG

25% duty cycle 180A/ 17.2V 150A/ 16V

60% duty cycle 116A/ 14.6V 97A/ 13.9V

100% duty cycle 90A/ 13.6V 75A/ 13V

Apparent power I2at maximum

current 8.7kVA 6.9kVA

Active

power I

at maximum current 5.5kW 4.35kW

Power factor at maximum current

Live TIG 0.63 0.63

MMA 0.63 0.63

Efficiency at maximum current

MMA 89% 89%

Live TIG 89% 89%

Open-circuit voltage U0max

VRD 35 V deactivated 63VDC 63VDC

VRD 35 V activated <30V <30V

Operating temperature -10to+40°C

-10to+40°C

(+14to 104°F)

Transportation temperature -20 to +55°C

(-4 to +131°F)

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(+14to 104°F)

-20 to +55°C

(-4 to +131°F)

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3 TECHNICAL DATA

Rogue ES 180i Rogue ES 150i

Continual sound pressure at

<70dB <70dB

no-load

Dimensions l×w×h 403×153×264mm

(15.8×6×10.4in.)

403×153×264mm (15.8×6×10.4in.)

Weight 6.8kg 6.8kg

Insulation class transformer H H

Enclosure class IP23S IP23S

Application class

Mains supply, S

sc 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.

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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.

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4 INSTALLATION

4.3 Mains supply

NOTE! Rogue ES 150i and ES 180i do not comply with IEC 61000-3-12. If it is connected to

a public low voltage 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 may be connected.

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.

Rating plate with supply connection

1. data.

Recommended fuse sizes and minimum cable area for the Rogue ES 150i, ES 180i

Rogue ES 150i ES 180i

Supply voltage 230VAC 230VAC

Electrical cable area 2.5mm

2.5mm

Maximal current rating

MMA/Stick (SMAW)

max

30A 36A

I1eff MMA/Stick (SMAW) 15A 16A

Fuse anti-surge type D MCB 20A 25A

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4 INSTALLATION

Recommended fuse sizes and minimum cable area for the Rogue ES 150i, ES 180i

Supply voltage 230VAC

Maximum recommended extension cord length 100m(328ft)

Minimum recommended extension cord size 4mm

NOTE!

Different variants of Rogue ES 150i, ES 180i 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 8 kW, are recommended.

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5 OPERATION

5.1 Overview

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!

5.2 Connections and control devices

1. Setting Panel 4. Power Cable

2. Positive welding terminal 5. Mains power supply switch, I/O

3. Negative welding terminal

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 workpiece, and make sure that there is a good contact between the workpiece and the output for the return cable on the power source.

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5 OPERATION

• For TIG welding, the negative welding terminal (-) is used for the welding torch and the positive welding terminal (+) is used for the return cable.

• For 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 connection polarity is stated on the electrode packaging.

5.4 Turning the power on/off

Turn on the power by turning the switch to the “ON” (I) position.

Turn the unit off by turning the switch to the “O” position.

Whether the power supply is interrupted or the power source is switched off in the normal manner, weld programs are stored so that they are available the next time the unit is started.

CAUTION!

Do not turn off the power source during welding (with load).

5.5 Fan control

The Rogue ES 150i, ES 180i is fitted with a fan as needed feature. Fan as needed automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimize the amount of contaminants such as dust that are drawn into the power source.

Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required.

5.6 Thermal protection

The power source includes thermal protection against overheating. When overheating occurs the welding is stopped and overheating indicator on the panel will be lit and an error message shows in the display. The protection is automatically reset when the temperature has been sufficiently reduced.

5.7 Functions and symbols

MMA welding

MMA welding may also be referred to as welding with coated electrodes. Striking the arc melts the electrode, and its coating forms protective slag.

For MMA welding the power source shall be supplemented with:

• welding cable with electrode holder

• return cable with clamp

Arc force

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The arc force function determines how the current changes in response to variations in arc length during welding. Use a low value of arc force to get a calm arc with little spatter and use a high value to get a hot and digging arc.

Arc force only applies to MMA welding.

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5 OPERATION

Hot start

The hot start function temporarily increases the current in the beginning of the weld. Use this function to reduce risk of insufficient fusion and electrode sticking and scratching. Hold process selection button and the display switches to "HS" (Hot Start). Turn the current control knob, the display shows 0 or -1 to -10 or 1 to 10 (-10 to +10).

Press the process selection button again the display switches to AF (Arc Force).

Hot start only applies to MMA welding.

TIG welding

TIG welding melts the metal of the workpiece, using an arc struck from a tungsten electrode that does not melt. The weld pool and electrode are protected by shielding gas.

For TIG welding, the welding power source shall be supplemented with:

• a TIG torch with gas valve

• an argon gas cylinder

• an argon gas regulator

• tungsten electrode

This power source performs Live TIG start.

The tungsten electrode is placed against the workpiece. When lifted away from workpiece the arc is struck at a limited current level.

Voltage Reduction Device (VRD)

The VRD function ensures that the open-circuit voltage does not exceed 35V when welding is not being carried out. This is indicated by a lit VRD indicator on the panel. Contact an authorised ESAB service technician to activate this function.

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5 OPERATION

5.8 Setting panel

1. VRD function (reduced open-circuit

4. Select welding method, indicated by (3).

voltage) indicator.

2. Overheating indication. 5. Welding current control knob / HS (Hot

Start) / AF (Arc Force) control.

3. Indication of welding method: MMA or

6. Display, shows set or measured value.

Live TIG.

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6 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.

CAUTION!

The product is covered by manufacturer's warranty. Any attempt to carry out repair work by non-authorised service centers or personnel will invalidate the warranty.

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.

6.1 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.

Every 6 months

Clean inside

equipment. Use dry

compressed air with

reduced pressure.

Clean weld terminals. Check or replace weld

cables.

6.2 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:

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6 MAINTENANCE

• the welding process

• the arc time

• the working environment

CAUTION!

Make sure that the cleaning procedure is done in a suitable prepared workspace.

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.

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7 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.

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Refer to power source “Duty cycle” section in "TECHNICAL DATA", page10.

Make sure that the air inlets or outlets are not clogged.

Clean the inside of the machine using routine maintenance methods.

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8 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 150i, ES 180i 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.

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DIAGRAM

For serial number HA017-xxxx-xxxx, HA18-xxxx-xxxx

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ORDERING NUMBERS

Ordering number Denomination Type Notes

0700 500 076 Power source ES 150i

0700 500 077 Power source ES 180i

0463 732 101 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.

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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 500 085 Rogue plastic case (Toolbox)

0700 500 086 Shoulder strap

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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00

http://manuals.esab.com

For contact information visit esab.com