ESAB EM 280C PRO Compact MIG Inverter Welder Package Instruction Manual

Instruction Manual for ESAB models including: EM 280C PRO Compact MIG Inverter Welder Package, EM 280C, PRO Compact MIG Inverter Welder Package, MIG Inverter Welder Package, Welder Package, Package

Rustler EM

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

Aleido CCMS

File Info : application/pdf, 52 Pages, 13.18MB

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

Instruction manual
0463 930 201 GB 20241009

Valid for: OP250-, OP316-, OP420YY-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 ............................................................................................. 12

4 INSTALLATION........................................................................................................................... 14

4.1

Location........................................................................................................................ 14

4.2

Move instructions (No lifting)..................................................................................... 14

4.3

Mains supply................................................................................................................ 15

5 OPERATION ............................................................................................................................... 17

5.1

Connections and control devices .............................................................................. 17

5.2

Recommended maximum current values for welding and return cables .............. 18

5.3

Connecting welding and return cables ..................................................................... 18

5.4

Polarity change............................................................................................................ 18

5.5

Turning the mains power on/off ................................................................................. 19

5.6

Usage of cooling unit .................................................................................................. 19

5.7

Bobbin brake................................................................................................................ 19

5.8

Changing and loading wire......................................................................................... 20

5.9

Changing feed rollers.................................................................................................. 20

5.10 Changing the wire guides........................................................................................... 21

5.10.1 Inlet wire guides ................................................................................................. 21

5.10.2 Middle wire guide ............................................................................................... 22

5.10.3 Outlet wire guide ................................................................................................ 22

5.11 Setting roller pressure ................................................................................................ 22

6 CONTROL PANEL...................................................................................................................... 24

6.1

External control panel................................................................................................. 24

6.2

LED indicators description......................................................................................... 25

6.3

Internal control panel .................................................................................................. 29

6.4

Menu selection ............................................................................................................ 30

6.4.1 MIG / MAG / GMAW and MIG / MAG / GMAW SYN .......................................... 30

6.4.2 Hidden functions for MIG / MAG / GMAW and MIG / MAG / GMAW SYN ......... 30

6.4.3 MIG SPOT .......................................................................................................... 31

6.4.4 Hidden functions for MIG SPOT ......................................................................... 32

6.4.5 MMA / SMAW / Stick .......................................................................................... 32

6.4.6 Hidden functions for MMA / SMAW / Stick ......................................................... 33

7 MAINTENANCE .......................................................................................................................... 34

7.1

Routine maintenance .................................................................................................. 34

7.2

Cleaning the power source ........................................................................................ 34

7.3

Cooling unit.................................................................................................................. 35

7.4

Filling the coolant........................................................................................................ 36

7.5

Inspection, cleaning and replacement ...................................................................... 37

8 ERROR CODES.......................................................................................................................... 38

8.1

Error code descriptions .............................................................................................. 38

9 TROUBLESHOOTING ................................................................................................................ 40

10 CALIBRATION AND VALIDATION............................................................................................. 41

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TABLE OF CONTENTS
10.1 Measurement methods and tolerances ..................................................................... 41 10.2 Requirements specifications and standards ............................................................ 41 11 ORDERING SPARE PARTS ....................................................................................................... 42 WIRING DIAGRAM ................................................................................................................................ 43 ORDERING NUMBERS ......................................................................................................................... 46 WEAR PARTS........................................................................................................................................ 47 ACCESSORIES ..................................................................................................................................... 49

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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 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

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1 SAFETY
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, EM 350 PRO MV Synergic and EM 350Cw PRO Synergic is a compact welding power source intended for welding with solid wires, flux cored wires and coated electrodes (MIG / MAG / GMAW, FCAW, and MMA / SMAW / Stick). The Rustler EM 350Cw PRO Synergic has an integrated cooling unit. 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 / SMAW / Stick 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

Mains voltage Mains supply Sscmin Primary current I max
MIG / MAG / GMAW

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

14 A

20.6 A

MMA / SMAW / Stick

13.5 A

20 A

Setting range

MIG / MAG / GMAW

40 A/16 V 280 A/28 V

MMA / SMAW / Stick

20 A/20.8 V 250 A/30 V

Wire feed speed

Permissible load at MIG / MAG / GMAW

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 / SMAW / Stick

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

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 17 kW

12.6 kW
0.9
89 % < 30 W
61 kg 17 kW

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

Operating temperature Transportation temperature Dimensions l × w × h Insulation class Enclosure class Application class

EM 280C PRO

EM 350C PRO EM 350 PRO SYN
-10 to +40°C (+14 to 104°F)

EM 350C PRO MV SYN

-20 to +55°C (-4 to +131°F)

977 × 487 × 800 mm F
IP 23

Mains voltage Mains supply Sscmin Primary current I max MIG / MAG / GMAW MMA / SMAW / Stick I1eff Setting range MIG/MAG MMA Wire feed speed Permissible load at MIG / MAG / GMAW 40 % duty cycle 60 % duty cycle 100% duty cycle Open-circuit voltage Permissible load at MMA / SMAW / Stick 40 % duty cycle 60 % duty cycle 100% duty cycle Open-circuit voltage Apparent power at maximum current Active power I2 at maximum current Power factor at maximum current Efficiency at maximum output power No-load power demand when energy-saving mode Weight Recommended generator Operating temperature Transportation temperature

EM 350Cw PRO SYN 400 V±15%, 3~50/60 Hz
0.5 MVA
20.6 A 20 A 13 A
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
0.8 85.3 % < 30 W 78.5 kg 17 kW -10 to +40°C (+14 to 104°F) -20 to +55°C (-4 to +131°F)

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3 TECHNICAL DATA
Cooling power Cooling volume Maximum flow Maximum pressure Dimensions l × w × h Insulation class Enclosure class Application class

EM 350Cw PRO SYN 1 kW 4.5 l
1.9 lpm 4.5 bar 977 × 470 × 1005 mm
F IP 23

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

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 EM 350Cw PRO SYNERGIC

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

Efficency when max power consumption 89% 89% 89% 89% 85.3%

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!
NOTE! When moving the equipment use intended handle. Never pull the cables.
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/350Cw 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!
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. Euro central connector 3. Coolant connection, BLUE, to the torch
(EM 350Cw only) 4. Coolant connection, RED, from the torch
(EM 350Cw only) 5. Polarity changeover cable
6. Negative welding terminal 7. Positive welding terminal

8. Gas inlet connection 9. Mains supply switch, O/I 10. Mains cable
11. Receptable for CO2 heater (optional)
12. Wire inlet adapter for Marathon PacTM (optional)
13. Wire feeding mechanism 14. Internal control panel

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5 OPERATION

5.2 Recommended maximum current values for welding and return cables

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 polarity changeover cable is used to select the correct polarity for the weld output. The correct polarity is determined by the wire that has been selected to complete the weld. To configure the machine to operate with positive electrode, insert and secure the polarity changeover cable into the positive [+] terminal and the return lead into the negative [-] terminal. Be sure that the connections are tight.
Secure the work clamp to the work piece in a clean, debris free location.
· For MIG / MAG / GMAW and MMA / SAMW / Stick welding, the welding cable can be connected to the positive welding terminal (+) or negative welding terminal (-) depending on the type of electrode used. See the wire/electrode manufacturers recommendation.
5.4 Polarity change
The power source is delivered with the polarity changeover cable connected to the positive welding terminal (+). Some wires, e.g. self-shielded cored wires, are recommended to be welded with negative polarity.
In this case, connect the polarity changeover cable to the negative welding terminal (-) and the return cable to the positive welding terminal (+). See wire/electrode manufacturers recommendation.

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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 Usage of cooling unit
ELP (ESAB Logic Pump) The EM 350Cw PRO SYNERGIC is fitted with a water recirculator and detection system called ELP (ESAB Logic Pump), which checks that the coolant hoses are connected. The coolant from the cooler automatically starts flowing when welding starts.
NOTE! The cooling unit will be applicable only for MIG / MAG / GMAW welding.
5.7 Bobbin brake
The bobbin brake force should be adjusted to prevent wire overrun. The actual brake force needed, is dependent of the wire feed speed and the size and weight of the wire spool. Do not overload the bobbin brake! A high brake force may overload the motor and reduce motor life and result in poor weld quality. The bobbin brake force can be adjusted by rotating the 6 mm hexagon Allen screw in the middle of the brake hub nut.

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5 OPERATION
5.8 Changing and loading wire
1) Open the left door of the power source 2) Remove the brake hub nut and remove the wire spool.

3) Insert a new wire spool into the unit by placing the spool of wire on the spool hub. 4) Secure the spool of wire on the spool hub, by tightening the spool hub nut. 5) Straighten out the new welding wire 1020 cm and thread the wire through the wire feeder
mechanism. 6) Close and latch the door.
5.9 Changing feed rollers
When changing to a different type or size of wire, the feed rollers should be changed to match the new type or size of wire. For information about correct feed rolls, see the WEAR PARTS appendix. 1) Open the left door of the wire feeder. 2) Unlock the feed rollers, by rotating the quick lock 1/3 turn (A) for each feed roll.

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5 OPERATION 3) Relieve the pressure on the feed rollers, by folding the tensioner units (B) down to release
the swing arms (C).
4) Remove the feed rollers and install the correct ones (according to the WEAR PARTS appendix).
5) Reapply the pressure to the feed rollers, by pushing the swing arms (C) down and secure them using the tensioner arms (B).
6) Secure the feed rollers by rotating the quick lock 1/3 turn (A). 7) Close and latch the door.
5.10 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.
5.10.1 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).

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5 OPERATION
5.10.2 Middle wire guide

1) Pinch the center wire guide and pull out to remove the guide (A). 2) To install the center wire guide, pinch the guide and push it into place. The clips will lockthe
guide into place.
5.10.3 Outlet wire guide

1) Release the pressure on the front feed roll pressure arm by rotating the front tensioning arm outwards.
2) Remove the lower front feed roll. 3) Remove the center wire guide. 4) Unlock the wire outlet guide quick lock (A) by folding it out. 5) Remove the wire outlet guide (B). 6) Install the new wire outlet guide. 7) Lock the new wire outlet guide into place using the wire guide quick lock (A). 8) Reinstall the lower front feed roll.
5.11 Setting roller pressure
The feed roll pressures should be adjusted independently, determined by the wire type and diameter. The front feed roll pressure should be slightly higher than the rear feed roll pressure.

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5 OPERATION
1) Make sure that the wire moves freely through the wire guides and set the feed roll pressure. Donot over tighten.

Figure A.

Figure B.

2) To check that the feed pressure is set correctly, you can feed the wire against a non-conductive surface, e.g. a piece of wood.
When you hold the welding torch approximately 5 mm from the piece of wood (figure A) the feed rolls should slip.
If you hold the welding torch approximately 50 mm from the piece of wood, the wire should feed out and bend (figure B).
The table below serves as a guideline showing approximate feed roll pressure settings for standard conditions with correct spool brake force. If the torch cables are long, dirty or worn, the pressure setting may need to be increased. Always check the feed roll pressure setting on a case-by-case basis by feeding out the wire against an insulated object as described above.

Wire material

Wire diameter (mm) 0.6 0.8 1.0 1.2 1.4 1.6 (in.) .023 .030 .040 .045 .052 1/16

Pressure setting

Fe, Ss Tensioner unit 1

2.5

Tensioner unit 2

33.5

Cored Tensioner unit 1

Tensioner unit 2

2.53

1. Tensioner unit 1

2. Tensioner unit 2

3) The wire spool hub incorporates a friction brake. If it is necessary, adjustment can be made by turning the spool locking nut inside the open end of the hub clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 3-5 mm after release of the trigger. The electrode wire should be slack without becoming dislodged from wirespool.

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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 with 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 until the trigger mode symbol is illuminated. The left display will show TRG and right display will show 2T or 4T. Select 2T or 4T by turning the right potentiometer knob (4).
Arc dynamics
To access the functions, press the parameter selection button until the arc dynamics symbol is illuminated. The left display will show IND and right display will show a value. Turn the right potentiometer knob to increase or decrease the arc dynamics value.

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6 CONTROL PANEL

MENU
Under the menu there are number of weld variables to be accessed. To access the weld variables press the parameter selection button until the Menu ICON is illuminated. Press this button again to enter the weld variable menu. The left display will show the variable to adjust and the right display will show the value.
Use the left potentiometer to select the desired weld variable and use the right potentiometer to increase or decrease the values.
NOTE! The list of MENU functions will vary depending on the application selected.
Left potentiometer knob (3)
In MIG / MAG / GMAW / FCAW mode, the knob is used to adjust weld voltage, the parameter chart is located in the wire feeder compartment.
In MIG SYN mode (EM 350C PRO SYNERGIC) turning the knob will select the TRIM setting of voltage. In TRIM function, the knob clockwise increases the voltage by 0.1V increments and the maximum value is +5V.
Right potentiometer knob (4)
In MIG / MAG / GMAW / FCAW mode, the right knob adjusts the wire feed speed. The optimum wire feed speed will be dependent on the type of welding application, material type and thickness. Wire feed speed can be set by using the parameter chart is located in the wire feeder compartment.
In MIG SYN mode 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.
In MMA modes, the knob adjusts the welding output current.
Jobs (5)
There are 5 job buttons that can be used to store current weld data for later recall. These 5 buttons are reserved to any wire process.
When the desired weld parameters have been established the user can press and hold the button 1-5 to store the current weld data.
To recall any stored weld data, the user can select any of the 5 stored jobs by pressing the desired button.

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 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 and arc then stop and when the switch is released the gas post-flow starts.
Arc dynamics
The arc dynamics is used to adjust the intensity of the welding arc. Lower settings make the arc softer with less weld spatter. Higher 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 arc characteristics.
Wire diameter selection button
This is used to select the diameter of the installed wire.
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 / MAG / GMAW 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 / MAG / GMAW 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 / GMAW and MIG / MAG / GMAW SYN

In MIG / MAG / GMAW 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 output.
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 / GMAW and MIG / MAG / GMAW SYN

Long press the parameter selection button to navigate the hidden MENU option (No welding). Select the desired function 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 the display to show the wire feed speed (WFS) or amperage (AMP) values during welding.
Synergic (SYN)
This function enables to set the 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 or imperial values.
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 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 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 Dwell 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 the display to show 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 or imperial values.
Version No. (VEN)
This function enables viewing the software versions of the 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 / SMAW / Stick

In MMA mode, press the parameter selection button once the MENU option will appear. Select the desired function (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 / SMAW / Stick

Long press the parameter selection button to navigate the hidden MENU option (No welding). Select the desired function (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 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.

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.
7.2 Cleaning the 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

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7 MAINTENANCE
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.
CAUTION! Repair, cleaning, and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.
1) Disconnect the power source from the mains supply. WARNING! The mains supply must be disconnected during cleaning and maintenance.
2) Remove the screws and panels.

3) Clean both sides of the power source, using dry compressed air with pressure of below 4 bar (58 psi).
4) Make sure that there is no dust left on any part of the power source.
5) Reassemble the power source after cleaning and perform testing according to IEC 60974-4. Follow the procedure in section "After repair, inspection and test" in the service manual.

7.3 Cooling unit
Dust, grinding, swarf, etc... The airstream through the cooling unit carries particles that become trapped in the cooling element, particularly in dirty working environments.
This results in reduced cooling capacity.
The coolant system The recommended coolant must be used in the system, otherwise blockage can be created that will block the pump, water connections, water lines, or heat exchanger. Use of any other cooling liquid besides ESAB premixed coolant might damage the equipment and will void product warranty.

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7 MAINTENANCE
7.4 Filling the coolant
Use only ESAB'sready mixed coolant. See chapter "ACCESSORIES". · Fill with coolant (The fluid level must not exceed the upper marking and must not be below lower
marking).
CAUTION! The coolant must be handled as chemical waste.
NOTE! Coolant must be topped up if connecting a welding torch or coolant hoses that are 5 m in length or longer. When adjusting the coolant level by topping up, the coolant hoses do not need to be disconnected.

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7 MAINTENANCE
7.5 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
Err 215

Description Torch trigger-related error The torch trigger is pressed all the time or the torch trigger signal is shorted and the ARC will not be 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 shorted.
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.
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.
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.

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8 ERROR CODES

Error code Err 216
Err 311

Description Over output current The output current 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.
Over output current for wire feeder The wire feeder motor current is 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 with limited 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.

Poor cooling effect

Clean the cooling element using compressed air.

Check the coolant level.

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

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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 60974-2, 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
Rustler EM 280 PRO

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APPENDIX Rustler EM 350 PRO

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APPENDIX Rustler EM 350Cw PRO Synergic

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APPENDIX
ORDERING NUMBERS

Ordering number 0448 280 880 0448 350 881 0448 350 882 0448 350 883 0448 350 884 0448 280 990 0448 350 991 0448 350 992 0448 350 993 0448 350 994 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 350Cw PRO Synergic Rustler EM 280C PRO Rustler EM 350C PRO Rustler EM 350C PRO Synergic Rustler EM 350C PRO MV Synergic Rustler EM 350Cw PRO 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 With Exeor Torch 420w, Remote 4 m
Rustler EM PRO Rustler EM PRO

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

MIG Torch Exeor 315

0700 026 114

MIG Torch Exeor 315 R4, Remote, 4 m

Exeor PSF 420w R4

0700 026 186

Exeor PSF 420w R4, Remote 3 m

0700 026 187

Exeor PSF 420w R4, Remote 4 m

0700 026 188

Exeor PSF 420w R4 Remote 5 m

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

0448 479 880

Extension hose kit

F102 440 880

Quick connector Marathon PacTM

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

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

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APPENDIX
0700 006 888 0465 720 002

Electrode holder kit, Handy 300, OKC 50, 5 m
ESAB ready mixed coolant (10 l/2.64 gal).
Use of any other cooling liquid than the prescribed one might damage the equipment. In case of such damage, all warranty undertakings from ESAB cease to apply.

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APPENDIX

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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