ESAB Rogue ET 180i Instruction Manual

Model: ET 180i

Brand: ESAB

1 Safety

1.1 Meaning of Symbols

As used throughout this manual:

• 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.
• NOTE! ℹ️: Important information.

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 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 unauthorized 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.

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.

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 the 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.

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.

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

Overview

The Rogue ET 180i is an inverter-based power source intended for MMA (Manual Metal Arc) and TIG (Tungsten Inert Gas) welding, HF TIG (High Frequency Tungsten Inert Gas) welding. ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.

2.1 Equipment

Rogue ET 180i includes:

• Power Source
• Work Clamp Leadset
• TIG Torch
• Gas Hose
• Safety Manual
• Quick Setup Guide

3 Technical Data

Technical Data

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 S indicates that the power source is designed for use in areas with increased electrical hazard.

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.

Diagram Description: Shows the power source with clearance requirements. 'A' indicates a minimum clearance of 200 mm (8 in.) from the air inlet. 'B' indicates a minimum clearance of 200 mm (8 in.) from the air outlet.

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 the handle on top of the case.

Diagram Description: Illustrates lifting the unit using the top handle with a hook. The hook should be attached to the handle, and the lifting angle should not exceed 30 degrees.

4.3 Mains Supply

NOTE! Rogue ET 180i does 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.

Diagram Description: Shows a rating plate (labeled '1') with supply connection data.

Recommended Fuse Sizes and Minimum Cable Area for the Rogue ET 180i

Extension Cord Recommendations

NOTE! Different variants of Rogue ET 180i, ET 200iP, ET 200iP 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 8 kW, are recommended.

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 the 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

Diagram Description: Shows the front and rear panels of the welding power source with numbered controls and connections:

Front Panel:

• 1. Setting panel
• 2. Positive welding terminal
• 3. Negative welding terminal
• 4. Power cable

Rear Panel:

• 5. Mains power supply switch, I/O
• 6. TIG Switch / Remote Socket
• 7. Gas supply output
• 8. Gas supply input

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.

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. 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 ET 180i is fitted with a fan-as-needed feature. The fan automatically switches off when not required. This minimizes power consumption and reduces the intake of contaminants like dust.

5.6 Thermal Protection

The power source includes thermal protection against overheating. When overheating occurs, welding stops, an overheating indicator on the panel lights up, and an error message is displayed. The protection automatically resets when the temperature has sufficiently reduced.

5.7 Functions and Symbols

MMA Welding

MMA welding, also known as welding with coated electrodes, involves striking an arc that melts the electrode, with its coating forming a protective slag.

For MMA welding, the power source requires:

• Welding cable with electrode holder
• Return cable with clamp

Arc Force

The Arc Force function adjusts the current in response to variations in arc length during welding. Use a low value for a calm arc with minimal spatter, and a high value for a hot, digging arc. Arc Force applies only to MMA welding.

Hot Start

The Hot Start function temporarily increases the current at the beginning of the weld to reduce the risk of insufficient fusion, electrode sticking, and scratching. Hot Start applies only to MMA welding.

TIG Welding

TIG welding melts the workpiece metal using an arc initiated from a non-consuming tungsten electrode, protected by shielding gas. This power source performs Live TIG start (TIG Live).

For TIG welding, the power source requires:

• A TIG torch with gas valve
• An argon gas cylinder
• An argon gas regulator
• Tungsten electrode

Diagram Description: Shows a TIG welding setup with the tungsten electrode placed against the workpiece. When lifted, the arc is struck at a limited current level.

HF Start

The HF (High Frequency) start function initiates the arc by a spark from the tungsten electrode to the workpiece as the electrode is brought close and the TIG torch trigger is pressed.

Voltage Reduction Device (VRD)

The VRD function ensures the open-circuit voltage does not exceed 35 V when welding is not active. A lit VRD indicator on the panel signifies this. Contact an authorized ESAB service technician to activate this function.

5.8 Setting Panel

Diagram Description: Illustrates the front panel of the ET 180i with numbered controls and indicators:

• 1. Overheating indicator
• 2. Display
• 3. VRD function (reduced open-circuit voltage) indicator
• 4. Trigger mode indicator
• 5. Options button
• 6. Welding current control knob and advanced feature control knob
• 7. Process selection button
• 8. MMA indicator
• 9. TIG Live indicator
• 10. TIG HF indicator

Process Selection Button (7): Allows selection of TIG HF (10), TIG Live (9), MMA (8), Navigation, and Parameter selection.

To access the advanced feature menu, press the Process selection button (7) for 3 seconds, then press it again to select values. Use the Welding current control knob (6) to adjust values.

In TIG HF or TIG Live mode, parameters include: Gas pre flow time (PREG 0-5 s), Start current (IGNA 10-100%), Up slope time (SLPU 0-10 s), Down slope time (SLPD 0-10 s), End current (FINA 10-100%), Gas post flow time (POSG 0.5-15 s), Background current (BKGA 10-100%).

In MMA mode, parameters include: Hot start (HOTS -10 to +10), Arc force (ARCF -10 to +10), Cellulose electrode (CELL On / Off).

Press the Options button (5) to set:

• Trigger mode (4): 2 stroke / 4 stroke

5.9 Remote Control

Connect the remote control to the front of the power source. It activates automatically. The maximum setting is determined by the front panel control, regardless of the remote control setting.

6 Maintenance

WARNING! The mains supply must be disconnected during cleaning and maintenance.

CAUTION! Only persons with the appropriate electrical knowledge (authorized personnel) may remove the safety plates.

CAUTION! The product is covered by manufacturer's warranty. Any attempt to carry out repair work by non-authorized 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, ensure:

• 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.

6.2 Cleaning Instruction

To maintain performance and increase the lifetime of the power source, regular cleaning is mandatory. The frequency depends on the welding process, arc time, and 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 welder's output welding current.

7 Troubleshooting

Perform these checks and inspections before sending for an authorized service technician.

Check: The mains voltage is disconnected before starting any type of repair action.

8 Ordering Spare Parts

CAUTION! Repair and electrical work should be performed by an authorized ESAB service technician. Use only ESAB original spare and wear parts.

The Rogue ET 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.

Diagram

Electrical Schematic: A detailed electrical schematic diagram is provided for the Rogue ET 180i, applicable from serial number HA026-xxxx-xxxx.

Ordering Numbers

Technical documentation is available on the Internet at: www.esab.com

Accessories

TIG Torches

• 0700 025 588: TIG Torch, SR-B 26, 4 m
• 0700 025 581: TIG Torch, SR-B 26, 8 m
• 0700 025 589: TIG Torch, SR-B 26FX-R, 4 m Remote
• 0700 025 590: TIG Torch, SR-B 26FX-R, 8 m Remote

Return Cable Kits

• 0700 006 901: Return cable kit, OKC 50, 3 m
• 0700 006 885: Return cable kit, OKC 50, 5 m

Other Accessories

• 0700 006 900: Electrode holder Handy, 200 A with 25 mm², 3 m, OKC 50
• 0700 500 084: Remote control, MMA 4
• W4014450: Foot pedal, with 4.5 m (15 ft) cable, 8 PIN
• 0700 500 086: Shoulder strap