ESAB EM 280C PRO MIG Welder Kit Instruction Manual

Instruction Manual for ESAB models including: EM 280C PRO, EM 350C PRO, EM 350C PRO SYNERGIC, EM 350C PRO MV SYNERGIC, EM 280C PRO MIG Welder Kit, EM 280C PRO, MIG Welder Kit, Welder Kit, Kit

Rustler EM

S051413, D, en-GB, Translated, usermanual-A4-portrait.print

Rustler EM - NET

20 gen 2024 — Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety ...

Rustler EM

[PDF] Rustler EM - NET

0448 350 883. Rustler EM 350C PRO MV Synergic. With Exeor Torch 315, Remote 4 m. 0448 280 890. Rustler EM 280C PRO. 0448 350 891. Rustler EM 350C PRO. 0448 350 ...

File Info : application/pdf, 46 Pages, 10.36MB

0463 930 101 GB

Rustler
EM 280C PRO, EM 350C PRO,
EM 350C PRO SYNERGIC,
EM 350C PRO MV SYNERGIC

Instruction manual
0463 930 101 GB 20240202

Valid for: OP250YY-, OP316YY-XX XXXX

TABLE OF CONTENTS

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 ............................................................................................................................... 16

5.1

Connections and control devices .............................................................................. 16

5.2

Recommended maximum current values for connection cables set ..................... 17

5.3

Connecting welding and return cables ..................................................................... 17

5.4

Polarity change............................................................................................................ 17

5.5

Turning the mains power on/off ................................................................................. 18

5.6

Bobbin brake................................................................................................................ 18

5.7

Changing and loading wire......................................................................................... 18

5.8

Changing feed rollers.................................................................................................. 19

5.9

Changing the wire guides........................................................................................... 19

5.9.1 Inlet wire guides ................................................................................................. 20

5.9.2 Middle wire guide ............................................................................................... 20

5.9.3 Outlet wire guide ................................................................................................ 21

5.10 Roller pressure ............................................................................................................ 21

6 CONTROL PANEL...................................................................................................................... 22

6.1

External control panel................................................................................................. 22

6.2

LED indicators description......................................................................................... 23

6.3

Internal control panel .................................................................................................. 27

6.4

Menu selection ............................................................................................................ 28

6.4.1 MIG/MAG and MIG/MAG SYN ........................................................................... 28

6.4.2 Hidden functions for MIG/MAG and MIG/MAG SYN .......................................... 28

6.4.3 MIG SPOT .......................................................................................................... 29

6.4.4 Hidden functions for MIG SPOT ......................................................................... 30

6.4.5 MMA ................................................................................................................... 30

6.4.6 Hidden functions for MMA .................................................................................. 31

7 MAINTENANCE .......................................................................................................................... 32

7.1

Routine maintenance .................................................................................................. 32

7.2

Power source ............................................................................................................... 33

7.3

Inspection, cleaning and replacement ...................................................................... 33

8 ERROR CODES.......................................................................................................................... 34

8.1

Error code descriptions .............................................................................................. 34

9 TROUBLESHOOTING ................................................................................................................ 36

10 CALIBRATION AND VALIDATION............................................................................................. 37

10.1 Measurement methods and tolerances ..................................................................... 37

10.2 Requirements specifications and standards ............................................................ 37

11 ORDERING SPARE PARTS ....................................................................................................... 38

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TABLE OF CONTENTS
WIRING DIAGRAM ................................................................................................................................ 39 ORDERING NUMBERS ......................................................................................................................... 41 WEAR PARTS........................................................................................................................................ 43 ACCESSORIES ..................................................................................................................................... 45

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1 SAFETY
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.
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.

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1 SAFETY
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.
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.

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2 INTRODUCTION
2 INTRODUCTION
The Rustler EM 280PRO, EM 350 PRO, EM 350 PRO Synergic and EM 350 PRO MV Synergic 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

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3 TECHNICAL DATA
3 TECHNICAL DATA

Mains voltage Primary current I max MIG/MAG

EM 280C PRO EM 350C PRO EM 350 PRO SYN
400 V ±15%, 3~ 50/60 Hz

14 A

20.6 A

MMA

13.5 A

20 A

Setting range

MIG/MAG

40 A/16 V 280 A/28 V

MMA

20 A/20.8 V 250 A/30 V

Wire feed speed

Permissible load at MIG/MAG

40 % duty cycle

280 A/28 V

60 % duty cycle

229 A/25.5 V

100% duty cycle

177 A/22.9 V

Open-circuit voltage

65 V

Permissible load at MMA

40 % duty cycle

250 A/30 V

60 % duty cycle

204 A/28.2 V

100% duty cycle

158 A/26.3 V

Open-circuit voltage

63 V

Apparent power at maximum current

9.7 kVA

Active power I2 at maximum current

8.7 kW

Power factor at maximum

current

0.9

Efficiency at maximum output power

90 %

No-load power demand when energy-saving mode

< 30 W

Weight

54 kg

Recommended generator

12 kW

Operating temperature

30 A/15.5 V 350 A/31.5 V

20 A/20.8 V 320 A/32.8 V

1.5 - 22 m/min

350 A/31.5 V 286 A/28.3 V 222 A/25.1 V
71 V

320 A/32.8 V 262 A/30.5 V 203 A/28.1 V
66.6 V

14 kVA

12.6 kW

0.9

89 % < 30 W

57.5 kg

61 kg

17 kW

-10 to +40°C (+14 to 104°F)

EM 350C PRO MV SYN
400/230V±15%, 3~50/60 Hz
40 A (230VAC input)
20 A (400VAC input)
33 A (230VAC input)
19 A (400VAC input)
30 A/15.5 V 350 A/31.5 V 20 A/20.8 V 320 A/32.8 V
350 A/31.5 V 286 A/28.3 V 222 A/25.1 V
74 V
320 A/32.8 V 262 A/30.5 V 203 A/28.1 V
74 V 14 kVA
12.6 kW
0.9
89 %
< 30 W 63 kg 17 kW

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3 TECHNICAL DATA
Transportation temperature Dimensions l × w × h Insulation class Enclosure class Application class

EM 280C PRO EM 350C PRO EM 350 PRO EM 350C PRO

SYN

MV SYN

-20 to +55°C (-4 to +131°F)

977 × 487 × 800 mm F
IP 23

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 hazard.

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

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

EM 280C PRO EM 350C PRO EM 350C PRO SYNERGIC EM 350C PRO MV SYNERGIC

<30 W <30 W <30 W <30 W

Efficency when max power consumption 89% 89% 89% 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.
Manufacturer's name, product name, serial number and date of production can be read from rating plate.

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3 TECHNICAL DATA
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)

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4 INSTALLATION
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!
4.2 Move instructions (No lifting)
Mechanical lifting must be done with both outer handles.

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4 INSTALLATION
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 280C PRO EM 350C PRO

EM 350C PRO SYN

Mains voltage

400 V ±15%, 3~50/60 Hz

Mains cable area
Maximal current rating Imax (MIG/MAG)

4×2.5 mm2 14 A

4×2.5 mm2 21 A

I1eff
Fuse anti-surge type C MCB

9 A
20 A 20 A

13 A
30 A 30 A

EM 350C PRO MV SYN
400/230V±15%, 3~50/60Hz
4×4 mm2
40A (230VAC input)
20A (400VAC input)
25.3A (230VAC input)
13A (400VAC input)
40A (230VAC input)
30A (400VAC input)

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4 INSTALLATION

Recommended fuse sizes and minimum cable area

Maximum recommended extension cord length

100 m/330 ft.

Minimum recommended extension cord size

4×2.5 mm2

100 m/330 ft. 4×4 mm2

NOTE! EM 350C PRO MV Synergic power source can sense the main voltage 400 V or 230 V and
adpot accordingly.

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5 OPERATION
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 2. Connector for welding torch 3. Cable for change the polarity 4. Negative welding terminal: Return
5. Positive welding terminal: Welding cable 6. Connection for shielding gas

7. Mains power supply switch, O/I 8. Mains cable 9. Heater socket (optional) 10. Wire inlet adapter to use with Marathon PacTM
(optional) 11. Wire feeding mechanism 12. Internal control panel

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5 OPERATION

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 mm2

100%

Duty cycle 60%

35%

Voltage drop/10 m

285 A

320 A

370 A

0.352 V/100 A

355 A

400 A

480 A

0.254 V/100 A

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 mm2

100%

Duty cycle 60%

35%

Voltage drop/10 m

250 A

280 A

320 A

0.352 V/100 A

310 A

350 A

420 A

0.254 V/100 A

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.

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5 OPERATION

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.

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5 OPERATION
3) Insert a new wire spool into the unit and straighten out the new welding wire 1020 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 left door of the wire feeder.
2) Unlock the feed rollers to be exchanged, by rotating the roller quick lock (A) for each roller.
3) Relieve the pressure on the feed rollers, by folding the tensioner units (B) down and thereby releasing the swing arms (C).

4) Remove the feed rollers and install the correct ones (according to the WEAR PARTS appendix). 5) Reapply the pressure on the feed rollers, by pushing the swing arms (C) down and secure them
using the tensioner units (B). 6) Lock the rollers by rotating the roller quick locks (A). 7) Close and lock the left door of the wire feeder.
5.9 Changing the wire guides
When changing to a different type of wire, the wire guides may have to be changed to match the new type of wire. For information about the correct wire guides depending on wire diameter and type, see the WEAR PARTS appendix.

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5 OPERATION
5.9.1 Inlet wire guides
1) Unlock the inlet wire guide quick lock (A) by folding it out. 2) Remove the inlet wire guide (B). 3) Install the correct inlet wire guide (according to the WEAR PARTS appendix). 4) Lock the new inlet wire guide using the wire guide quick lock (A).
5.9.2 Middle wire guide
1) Apply a little pressure on the middle wire guide clip and pull out the middle wire guide (A). 2) Push in the correct type of wire guide (according to the WEAR PARTS appendix). The clip
automatically locks the wire guide when in the correct position.

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5 OPERATION
5.9.3 Outlet wire guide

1) Remove the lower right feed roller (see Section 5.8 "Changing feed rollers", page 19). 2) Remove the middle wire guide (see Section 5.9.2 "Middle wire guide", page 20). 3) Unlock the outlet wire guide quick lock (A) by folding it out. 4) Remove the outlet wire guide (B). 5) Install the correct outlet wire guide (according to the WEAR PARTS appendix). 6) Lock the new outlet wire guide using the wire guide quick lock (A). 7) Reattach the second pair of feed rollers and reapply the roller pressure (see Section 5.8 "Changing
feed rollers", page 19).
5.10 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.

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).

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6 CONTROL PANEL
6 CONTROL PANEL
6.1 External control panel

1. Process selection button 2. Parameter selection button 3. Left potentiometer knob

4. Right potentiometer knob 5. Jobs

Process selection button (1)
The various welding processes such as MIG, MIG SYN, 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 SYN/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.

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6 CONTROL PANEL

MENU
There are basic functions in the menu feature. To access the functions, press the parameter selection button until the MENU symbol is ON. The left display shows a letter and the right display shows a value. Select the function by pressing the same button. The knob (4) is used to change the value of the selected function. The knob (3) is used to change the different functions.
NOTE! The list of MENU functions will vary depending on the application selected.
Left potentiometer knob (3)
In MIG (GMAW/FCAW) mode, the knob is used to adjust the output voltage of the unit. In Manual MIG Mode, the setup chart is attached to the Wirefeeder compartment door.
In MIG SYN mode (EM 350C PRO SYNERGIC) turning the knob will select the TRIM function. In TRIM function, the knob clockwise increases the voltage by 0.1V increments and the maximum value is +5V.
In the Parameter selection state, adjusting the left knob (3) will select the different feature and the name will shows on the left LED.
Right potentiometer knob (4)
The right knob (4) adjusts the amount of welding current delivered by the power source. In MMA modes, the knob directly adjusts the power inverter to deliver the desired level of output current.
In MIG (GMAW/FCAW) mode, the right knob adjusts the speed of the wire feed motor. The optimum Wire feed speed required will be dependent on the type of welding application. the setup chart is attached to the Wirefeeder compartment door.
In MIG SYN mode (EM 350C PRO SYNERGIC) turning the right Knob will select wire feed speed or thickness. The default value will be wire feed speed and thickness can be selected in the hidden functions.
Jobs (5)
These buttons have five sets of welding dates for the user to load and save. It can be applied for MIG/ MAG welding.

6.2 LED indicators description

Indicator

Description
MIG/MAG
Constant voltage control process is where the set voltage and the wire feed speed are set independent of each other.

MIG/MAG SYN
A process with synergic voltage and inductance, in relation to wire feed speed using predetermined synergic line programs providing stable arc performance. The process operates through short circuit, globular and spray droplet transfer mode.

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6 CONTROL PANEL Indicator

Description MIG/MAG SPOT Spot welding is used when you want to spot weld thin plates together.
NOTE! It is not possible to shorten the welding time by releasing the trigger switch.
MMA MMA welding may also be referred to as welding with coated electrodes. Striking the arc melts the electrode, and its coating forms protective slag.
Measured voltage Measured value in the display for welding voltage V is an average numerical value which is calculated during the welding excluding the weld termination.
Trim Trim is the process of adjusting the parameter within an acceptable range. This function is applicable only in MIG/MAG Synergic.
Measured amperage Measured value in the display for welding current A is an average numerical value which is calculated during the weld excluding the weld termination.
Wire feed speed Measured value in the display for wire feed speed is an average numerical value which is calculated during the weld excluding the weld termination.
Thickness Selected thickness in the display for the welding workpiece. This function is applicable only in MIG/MAG Synergic.
Time Selected time in the display for the spot and rest time in seconds. This function is applicable only in MIG/MAG Spot.

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6 CONTROL PANEL

Indicator

Description
2-stroke
This indicator blinks in green and displays 2T.
With 2-stroke, gas pre-flow starts when the welding torch trigger switch is pressed. The welding process then starts. Releasing the trigger switch stops welding entirely and starts gas post-flow.
4-stroke
This indicator lit in static green and displays 4T.
With 4 stroke, the gas pre-flow starts when the welding torch trigger switch is pressed in and the wire feed starts when it is released. The welding process continues until the switch is pressed in again, the wire feed then stops and when the switch is released the gas post-flow starts.
Inductance
The arc control is used to adjust the intensity of the welding arc. Lower arc control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc which can increase weld penetration. Soft means maximum inductance while Hard means minimum inductance.
Thermal protection
The welding power source has overheating protection that operates if the temperature becomes too high. When this occurs, the welding current is interrupted, and an overheating indication lamp is lit. The overheating protection resets automatically when the temperature has fallen with in its normal working temperature.

2-stroke mode (welding without ending arc)

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6 CONTROL PANEL 4-stroke mode (welding without ending arc)

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6 CONTROL PANEL
6.3 Internal control panel

1. Material selection button 2. Wire diameter selection button

3. Wire inch and gas purge button 4. Gas selection button (Synergic variant only)

Material selection button
This is used to select welded base material for optimal characteristics in the internal control panel.
Wire diameter selection button
This is used to select the diameter of the installed wire in the internal control panel.
Wire inching and gas purge button
Wire inching is used to feed wire without welding voltage being applied. The wire is fed as long as the button is pressed. This function is active in MIG applications only.
Gas purging is used while measuring the gas flow or for flushing any air or moisture from the gas hoses before welding starts. Gas purging occurs for 15 seconds when the gas purge button or torch trigger is pressed or until it is pressed again. Gas purge occurs without voltage or wire feed start. This function is active in MIG applications only.
Gas selection button
This is used to select the proper gas type that is currently connected to the equipment in the internal control panel.

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6 CONTROL PANEL

6.4 Menu selection

6.4.1 MIG/MAG and MIG/MAG SYN

In MIG mode, press the parameter selection button three times to navigate to MENU option. Select the desired welding function one after other by turning the left potentiometer knob and adjust the desired value by turning the right potentiometer knob.

Left diplay letter B-B CRA PRG POG RIN

Function Burnback Crater fill time Pre-flow Post-flow Creep start (Run in)

Default 0.1 0 0.1 0.5 ON

Right display settings 0.01-0.35 0.0-9.9 0.5-9.9 0.5-9.9 ON/OFF

Burnback (B-B)
Burnback time is a delay between the time when the wire starts to brake until the time when the power source switches off the welding voltage.
Too short burnback time results in a long wire stick out after completion of welding, with a risk of the wire being caught in the solidifying weld pool.
Too long a burnback time results in a shorter stick out, with increased risk of the arc striking back to the contact tip.
Crater fill (CRA)
Crater filling makes a controlled reduction in the heat and size of the weld pool possible when completing the weld. This makes it easier to avoid pores, thermal cracking and crater formation in the weld joint.
Pre/flow (PRG)
Pre-flow controls the time during which shielding gas flows before the arc is struck.
Post/flow (POG)
This controls the time during which shielding gas flows after the arc is extinguished.
Creep start (RIN)
Creep start feeds out the wire at a low wire feed speed until it makes electrical contact with the workpiece.

6.4.2 Hidden functions for MIG/MAG and MIG/MAG SYN

Long press the parameter selection button to navigate the hidden MENU option (No welding). Select the desired function one after the other by turning the left potentiometer knob and adjust the value by turning the right potentiometer knob.

Left diplay letter DIS
SYN UNT TJS

Function Display value druing welding Workpoint in synergic Unit (metric or imperial) Trigger job select

Default WFS
WFS MPM OFF

Right display settings WFS/AMP
WFS/THI MPM/IPM ON/OFF

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6 CONTROL PANEL

Left diplay letter VEN RES

Function Version no. Default settings

Default V4.0 No

Right display settings No/Yes

Display (DIS)
This function enables to display of the wire feed speed (WFS) or amperage (AMP) values during welding.
Synergic (SYN)
This function enables to set up a machine work point based on wire feed speed (WFS) or material thickness (THI).
Unit (UNT)
This function enables switching the units of measure for wire feed speed and thickness between the metric (MPM) or imperial (IPM).
Trigger job (TJS)
This function permits changing between different welding data memories by pressing the trigger of the welding torch. Pressing the trigger once will activate Job 1 and pressing the trigger twice will activate Job 2. The same procedure should be followed for all the Jobs.
Version No. (VEN)
This function enables viewing the software versions of the connected system.
Reset (RES)
This function resets to the factory default settings. All saved jobs will be deleted as a result of the reset.

6.4.3 MIG SPOT

In MIG SPOT mode, press the parameter selection button three times to navigate to the MENU option. Select the desired welding function one after the other by turning the left potentiometer knob and adjusting the value by turning the right potentiometer knob.

Left diplay letter B-B S/T DWE POG

Function Burnback Spot time Rest time Post-flow

Default 0.1 0.1 0.1 0.5

Right display settings 0.01-0.35 0.1-5.0 OFF/0.1-5.0 0.5-9.9

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6 CONTROL PANEL

Post-flow (POG) This controls the time during which shielding gas flows after the arc is extinguished.

6.4.4 Hidden functions for MIG SPOT

Left diplay letter DIS
UNT VEN RES

Function Display value druing welding Unit (metric or imperial) Version no. Default settings

Default WFS
MPM V4.0 No

Right display settings WFS/AMP
MPM/IPM No/Yes

Display (DIS)
This function enables to display of the wire feed speed (WFS) or amperage (AMP) values during welding.
Unit (UNT)
This function enables switching the units of measure for wire feed speed and thickness between the metric (MPM) or imperial (IPM).
Version No. (VEN)
This function enables viewing the software versions of the connected system.
Reset (RES)
This function resets to the factory default settings. All saved jobs will be deleted as a result of the reset.

6.4.5 MMA

In MMA mode, press the parameter selection button once the MENU option will appear. Select the desired function one by one (HOT, ARC) by turning the left potentiometer knob and adjust the value by turning the right potentiometer knob.

Left diplay letter HOT ARC

Function Hot start Arc force

Default AUT AUT

Right display settings 0-10 0-10

Hot start
The hot start function temporarily increases the current in the beginning of the weld, thus reducing the risk of lack of fusion in the starting point.
Arc force
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.

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6 CONTROL PANEL

6.4.6 Hidden functions for MMA

Long press the parameter selection button to navigate the hidden MENU option (No welding). Select the desired function one by one (RES, VER) by turning the left potentiometer knob and adjust the value by turning the right potentiometer knob.

Left diplay letter VEN RES

Function Version no. Default settings

Default V4.0 No

Right display settings No/Yes

Version No. (VEN) This function enables viewing the software versions of the connected system.
Reset (RES) This function resets to the factory default settings. All saved jobs will be deleted as a result of the reset.

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7 MAINTENANCE
7 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.

7.1 Routine maintenance

Maintenance schedule during normal conditions. Check equipment prior to every use.

Interval Every 3 months

Area to maintain

Every 6 months

Clean or replace unreadable labels.

Clean weld terminals. Check or replace weld cables.

Clean inside equipment. Use dry compressed air with reduced pressure.

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7 MAINTENANCE
7.2 Power source
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
7.3 Inspection, cleaning and replacement
CAUTION! Make sure that the cleaning procedure is done in a suitable prepared workspace.
CAUTION! The cleaning procedure should be carried out by authorised service technician.
Wire feed mechanism Check regularly that the wire feed unit is not clogged with dirt. · Cleaning and replacement of the wire feed unit mechanism's worn parts should take place at
regular intervals in order to achieve trouble-free wire feed. Note that if pre-tensioning is set too hard, this can result in abnormal wear on the pressure roller, feed roller and wire guide. · Clean the liners and other mechanical parts of the wire feed mechanism, using compressed air, at regular intervals or if the wire feed seems slow. · Changing nozzles. · Checking driving-wheel. · Changing the cog-wheel package.
Bobbin holder Inspect at regular intervals that the brake hub sleeve and the brake hub nut are not worn out and that they lock properly, replace if necessary.
Welding torch The wear parts of the welding torch should be cleaned and replaced at regular intervals in order to achieve trouble-free wire feed. Blow the wire guide clean regularly and clean the contact tip. After cleaning and perform testing according to IEC 60974-4. Follow the procedure in section "After repair, inspection and test" in the Service manual.

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8 ERROR CODES
8 ERROR CODES
The error code is used to indicate that a fault has occurred in the equipment. Errors are indicated by the text "Err" followed by the error code number shown in the display. Screens

8.1 Error code descriptions

Error codes that the user can handle are listed below. If any other error code appears, contact an authorised ESAB service technician.

Error code Err 002
Err 205
Err 206

Description
Torch trigger-related error The torch trigger be pressed all the time or the torch trigger signal be short circuit and the ARC is also not established.
Action:
1. Check that the Torch Trigger Switch is not depressed when the Power Source is switched ON.
2. When releasing the trigger, check if the torch switch is short circuit. 3. If the error code persist, retrieve the service log.
Lack-phase protection The input socket loses the phase when connecting the input wires to the socket.
Action:
1. Check the condition of the mains supply and make sure they are all good connection.
2. Make sure that the power source connects to the rated input mains supply voltage and turn the mains power supply switch ON. If the error code persist, retrieve the service log.
Over temperature The power source run more than the duty cycle.
Action:
1. Wait until the power source cools down for ten minutes. 2. Make sure that you are not exceeding the rated data for the power source. 3. Make sure that the power source connects to the rated input mains supply
voltage and turn the mains power supply switch ON. If the error code persist, retrieve the service log.

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8 ERROR CODES

Error code Err 215
Err 216
Err 311

Description Output Short Circuit Short circuit is detected during output activation fault trigger.
Action:
1. Make sure that the welding cables are properly installed of the weld terminals. 2. Turn OFF the power source and wait a few minutes. If the error code persist,
retrieve the service log.
Over output current The output amps over design limitation.
Action:
1. Make sure that you are not exceeding the rated data for the power source. 2. Turn OFF the power source and wait a few minutes. 3. Set the power source to the rated output voltage & current, If the error code
persist, retrieve the service log.
Over output current for wire feeder The wire feeder motor amps over design limitation.
Action:
1. Check the liner, clean using pressurized air. Replace the liner if damaged or worn out.
2. Check the wire pressure setting and adjust if needed. 3. Check the drive rolls for wear and replace if needed. 4. Make sure the filler metal spool can rotate without much resistance.
Adjust the brake hub if needed.

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9 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

No arc

Check that the mains power supply switch is turned on.

Check that the mains, welding and return cables are correctly connected

Check that the correct current value is set.

Check the mains power supply fuses.

The thermal protection trips frequently

Make sure that you are not exceeding the rated data for the power source (i.e. that the unit is not being overloaded).

Check that the ambient temperature is not above the one for the rated duty cycle 40°C/104°F.

Poor welding performance Check that the welding current supply and return cables are correctly connected.

Check that the correct current value is set.

Check that the correct welding wires are being used.

Check the main power supply fuses.

The wire feed is slow/stiff through the wire feed mechanism

Clean the liners and other mechanical parts of the wire feed mechanism, using pressurized air.
Clean and adjust the roller pressure as per the table on the decal on the left side door.

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10 CALIBRATION AND VALIDATION
10 CALIBRATION AND VALIDATION

WARNING! Calibration and validation should be performed by a trained service technician, possessing sufficient training in welding and measurement technology. The technician should have knowledge of hazards that may occur during welding and measurement and should take necessary protective actions!

10.1 Measurement methods and tolerances
When calibrating and validating, the reference measuring instrument must use the same measuring method in the DC range (averaging and rectification of the measured values). A number of measurement methods are used for reference instruments, e.g. TRMS (True Root Mean Square), RMS (Root-Mean-Square) and rectified arithmetic mean. Rustler EM PRO uses the rectified arithmetic mean value and should therefore be calibrated against a reference instrument using the rectified arithmetic mean value.
In the field application it will occur that a measuring device and a Rustler EM PRO may display different values even though both systems are validated and calibrated. This is due to the measurement tolerances and the method of measurement of the two measurement systems. This can result in a total deviation up to the sum of both measurement tolerances. If the measurement method differ (TRMS, RMS or rectified arithmetic mean), significantly larger deviations are to be expected!
The ESAB Rustler EM PRO welding power source presents the measured value in rectified arithmetic mean and should therefore not show any significant differences compared to other ESAB welding equipment, due to the measurement method.

10.2 Requirements specifications and standards

Rustler EM PRO is designed to meet the accuracy for indication and meters required by IEC/EN 60974-14, by definition Standard grade.

Calibration accuracies of displayed value

Arc voltage

±1.5 V (UminU2) under load, resolution 0.25 V (Theoretical measuring range in a Rustler EM PRO system is 0.25-199 V.)

Welding current

±2.5% of I2 max according to rating plate of the unit under test, resolution 1 A. The measuring range is specified by the rating plate on
the used Rustler EM PRO welding power source.

Recommended method and applicable standard ESAB recommend calibration and validation to be executed according to IEC/EN 60974-14(:2018) or
EN 50504:2008 (unless another way of execution is communicated from ESAB).

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11 ORDERING SPARE PARTS
11 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 Rustler EM 280 PRO, EM 350 PRO, EM 350 PRO SYNERGIC and EM 350 MV PRO SYNERGIC are designed and tested in accordance with the international and European standards EN IEC 60974-1, EN IEC 60974-5 and EN IEC 60974-10 Class A. 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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APPENDIX
APPENDIX
WIRING DIAGRAM
EM 280 PRO

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APPENDIX EM 350 PRO

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APPENDIX
ORDERING NUMBERS

Ordering number 0448 280 880 0448 350 881 0448 350 882 0448 350 883 0448 280 890 0448 350 891 0448 350 892 0448 350 893 0463 930 * 0448 320 001

Denomination Rustler EM 280C PRO Rustler EM 350C PRO Rustler EM 350C PRO Synergic Rustler EM 350C PRO MV Synergic Rustler EM 280C PRO Rustler EM 350C PRO Rustler EM 350C PRO Synergic Rustler EM 350C PRO MV Synergic Instruction manual Spare parts list

Notes With Exeor Torch 315, Remote 4 m With Exeor Torch 315, Remote 4 m With Exeor Torch 315, Remote 4 m With Exeor Torch 315, Remote 4 m
Rustler EM PRO Rustler EM PRO

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

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APPENDIX

WEAR PARTS

Fe, Ss and cored wire
Wire diameter (in.) .023 .030 .040 (mm) 0.6 0.8 0.9/1. 0

.045 .052 1/16 .070 5/64 1.2 1.4 1.6 1.8 2.0

V-groove

Feed roller 0445 850 001 0445 850 002 0445 850 003 0445 850 004 0445 850 005 0445 850 006 0445 850 007

Inlet wire guide

Middle wire guide

Outlet wire guide

0445 822 001 (2 mm)

0446 080 882

0445 830 883 (Tweco) 0445 830 881 (Euro)

Cored wire Different wire guides dependent on wire diameter!

Wire diameter (in.) .040 .045 .052 1/16 .070 5/64

(mm) 0.9/1. 1.2

1.4

1.6

1.8

2.0

V-K-knurled

Inlet wire guide Middle wire guide

3/32 2.4
Feed roller 0445 850 030 0445 850 031 0445 850 032 0445 850 033 0445 850 034 0445 850 035 X 0445 850 036
Outlet wire guide

Wire diameter 0.0401/16 in. 0445 822 001

0.91.6 mm

(2 mm)

Wire diameter 0.0703/32 in. 0445 822 002

1.82.4 mm

(3 mm)

0446 080 882 0446 080 883

0445 830 883 (Tweco) 0445 830 881 (Euro) 0445 830 884 (Tweco) 0445 830 882 (Euro)

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APPENDIX

Al wire
Wire diameter (in.) .023 .030 .040 (mm) 0.6 0.8 0.9/1. 0

.045 .052 1/16 .070 1.2 1.4 1.6 1.8

U-groove

Inlet wire guide

Middle wire guide

Feed roller 0445 850 050 0445 850 051 0445 850 052
Outlet wire guide

0445 822 001 (2 mm)

0446 080 881

0445 830 886 (Tweco) 0445 830 885 (Euro)

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APPENDIX
ACCESSORIES

0700 026 114

MIG Torch Exeor 315 R4, Remote, 4 m

MIG Torch PSF 315 0700 0250 030 3 m 0700 0250 031 4 m 0700 0250 032 5 m

F102 440 880

Quick connector Marathon PacTM

0448 156 880 0448 157 880 0700 401 024 0700 006 902 0700 006 888

Top storage toolbox User Interface protective cover CO2 heater kit Electrode holder kit, Handy 300, OKC 50, 3 m Electrode holder kit, Handy 300, OKC 50, 5 m

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For contact information visit http://esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
manuals.esab.com

References

Ibex PDF Creator 6.5.1.9 [.NET 6.0/64]P/R