ESAB Rogue ES 201IP PRO Stick Welder User Manual

Introduction

The ESAB Rogue ES 201IP PRO is a robust and durable power source designed for professional welders. It utilizes the latest high-performance power electronics and digital control to ensure a precise and consistent arc. This machine provides smooth DC (Direct Current) welding power, suitable for welding various metals including alloyed and non-alloyed steel, stainless steel, and cast iron. This manual provides essential information for the safe and effective operation, setup, and maintenance of your ESAB Rogue ES 201IP PRO Stick Welder.

Safety Information

WARNING: Welding can be dangerous. Always follow safety precautions to prevent injury or death. Read and understand all safety warnings and instructions before operating this equipment.

• Always wear appropriate personal protective equipment (PPE), including welding helmet, gloves, protective clothing, and safety shoes.
• Ensure adequate ventilation to avoid inhaling welding fumes.
• Protect yourself and others from electric shock. Do not touch live electrical parts.
• Be aware of fire hazards. Keep flammable materials away from the welding area.
• Disconnect power before performing any maintenance or service.

Product Overview and Included Components

The ESAB Rogue ES 201IP PRO Stick Welder comes with the following components:

• Power source with 3 m (10 ft) mains cable and plug (N6-50P)
• Electrode holder with 3 m (10 ft) cable
• Return cable 3 m (10 ft)
• 230V to 120V Multi-Voltage Adapter Plug
• Shoulder strap

Figure 1: ESAB Rogue ES 201IP PRO Stick Welder and its standard accessories, including the power source, electrode holder, return cable, multi-voltage adapter, and shoulder strap.

Figure 2: Close-up view of the ESAB Rogue ES 201IP PRO front panel, showing the digital display, control knob, and connection points for welding cables.

Setup

1. Power Connection: The Rogue ES 201IP PRO features dual voltage input, allowing operation on either 120V or 230V outlets. Use the provided 230V to 120V Multi-Voltage Adapter Plug if connecting to a 120V supply. Ensure the power source is off before connecting to mains power.
2. Generator Compatibility: This unit is generator compliant. For optimal performance, a 7kW generator is recommended. Ensure the generator provides stable power.
3. Electrode Holder Connection: Connect the electrode holder cable to the positive (+) terminal on the front panel of the welder.
4. Return Cable Connection: Connect the return cable (ground clamp) to the negative (-) terminal on the front panel. Securely attach the ground clamp to the workpiece or welding table, ensuring good electrical contact.
5. Shoulder Strap: Attach the shoulder strap for easier portability and transport on the jobsite, garage, or in the shop.

Operating Instructions

Stick (SMAW) Welding

• Electrode Selection: The Rogue ES 201IP PRO can weld electrodes up to 4.0 mm (5/32 in.). Select the appropriate electrode for your material and application.
• Parameter Adjustment: Use the digital microprocessor controls to adjust welding parameters. The unit offers superior arc characteristics, providing smooth and stable performance, including a special mode for 6010 electrodes.
• Arc Force and Hot Start: Utilize the Arc Force and Hot Start settings for greater control over your arc, improving strike and preventing sticking.
• Pulse SMAW Functionality: This feature enhances performance by improving heat input control, minimizing distortion of thin materials, facilitating out-of-position welding with reduced undercuts, and decreasing spatter. This helps to effectively avoid common welding defects.
• Extension Cables: The Power Factor Correction (PFC) ensures a stable arc, resistant to power fluctuations, even when working with long extension cables up to 300 feet (12 AWG size).

Live TIG (GTAW) Welding (TIG torch sold separately)

The Rogue ES 201IP PRO supports TIG welding of mild steel or stainless steel via its "LIVE TIG" functionality. A TIG torch is required and sold separately for this operation. Refer to the TIG torch manual for specific setup and operating instructions.

Optional Remote Control

An optional analogue remote control (MMA 4) is available and sold separately for enhanced control over welding parameters from a distance.

Maintenance

Regular maintenance ensures the longevity and optimal performance of your welding machine.

• Cleaning: Periodically clean the exterior of the machine with a dry, soft cloth. Ensure ventilation openings are free from dust and debris to prevent overheating.
• Cable Inspection: Regularly inspect all cables (mains, electrode holder, return) for cuts, abrasions, or damaged insulation. Replace damaged cables immediately.
• Connection Points: Check and tighten all electrical connections to ensure good contact and prevent arcing.
• Storage: Store the welder in a clean, dry environment when not in use, protected from dust and moisture.

Troubleshooting

This section provides general guidance for common issues. For complex problems, contact qualified service personnel.

• No Power:
  • Check if the power cord is securely plugged into a live outlet.
  • Verify the circuit breaker or fuse has not tripped.
  • Ensure the power switch on the welder is in the "ON" position.
• Poor Arc Stability or No Arc:
  • Ensure the ground clamp has a clean, secure connection to the workpiece.
  • Check for proper electrode selection and polarity.
  • Verify welding parameters (current, Arc Force) are set correctly for the electrode and material.
  • Inspect welding cables for damage.
• Overheating Indication:
  • Allow the machine to cool down. The thermal overload protection will reset automatically.
  • Ensure adequate ventilation around the machine.
  • Check for blocked air vents.

Specifications

Warranty and Support

For warranty information and technical support, please contact ESAB customer service or visit the official ESAB website. Keep your purchase receipt as proof of purchase.

You can also visit the ESAB Store on Amazon for more product information and resources.