ESAB Rogue EMP 210 PRO - User Manual

Safety Information

WARNING! Arc welding and cutting can cause injury to yourself and others. Use caution and follow all safety precautions.

WARNING! Electric shock can be fatal! Ensure the welding machine is installed and grounded according to the user manual. Do not touch live electrical parts or electrodes with bare hands, wet gloves, or clothing. Isolate yourself from the workpiece and the ground. Ensure your working position is safe.

WARNING! Electric and magnetic fields may be hazardous to health. Welders using pacemakers should consult their doctor before welding. Exposure to electromagnetic fields may have other unknown effects on health. To reduce exposure to electromagnetic fields:

• Route the electrode and work cables on the same side of your body.
• If possible, secure them with tape. Do not position yourself between the torch and work cables. Do not wrap the torch or work cable around your body. Keep the welding machine power source and cables as far away from your body as possible.
• Connect the work cable as close as possible to the workpiece.

WARNING! Aerosols and gases can be hazardous to health. Keep your head away from aerosols. Use ventilation, extraction at the arc, or both, to direct aerosols and gases away from the breathing zone and immediate surroundings.

WARNING! Welding sparks can cause fires. Ensure that no flammable materials are nearby. Do not use in confined spaces.

WARNING! Hot surfaces can cause burns. Do not touch parts with bare hands. Wait for the machine to cool down before working on it. Use suitable tools and/or insulated welding gloves when handling hot parts to avoid burns.

WARNING! The product is intended for arc welding only.

WARNING! Do not use the welding power source to melt frozen pipes.

CAUTION! Class A equipment is not intended for use in residential areas where the public low-voltage power supply is connected. In these locations, difficulties may occur in ensuring electromagnetic compatibility of Class A equipment due to conducted and radiated disturbances.

ATTENTION! Dispose of electronic equipment at a recycling facility!

Follow European Directive 2012/19/EU on waste electrical and electronic equipment and its implementation in national law. Dispose of unusable electrical and/or electronic equipment at recycling facilities. As the party responsible for the equipment, it is your duty to obtain information about authorized collection points. For more information, contact your nearest ESAB dealer.

ESAB offers a wide range of welding accessories and protective equipment. For ordering information, contact your local ESAB dealer or visit our website.

Introduction

The Rogue EMP 210 PRO is an autonomous single-phase welding system capable of performing GMAW (MIG) welding, SMAW (STICK), and L-GTAW (LIVE GTAW) welding. The power source is equipped with an integrated wire feeder, digital voltage, amperage meters, and many other functions.

Equipment Included

• Welding power source
• MXL 201, Euro, 3 m welding gun
• Gas hose 4 m
• Work clamp lead kit, 3 m, 16 mm², 35–50 OKC
• Filler metal, OK AristoRod 12.50 0.8 mm, 1 kg
• Filler metal, Goldrox, 1 kg, 2.5×350 mm
• Drive roll, 0.6/0.8 mm V
• Drive roll, 0.8/1.0 mm V
• Drive roll, 1.0/1.2 mm U
• Electrode holder, 3 m, 16 mm², 35–50 OKC
• User manual

Technical Data

Duty Cycle: Duty cycle indicates the time in percent during a ten-minute period that you can weld or cut at a certain load without overloading. The duty cycle is valid at 40 °C / 104 °F.

Enclosure Rating: The IP code indicates the degree of protection of the enclosure against solid objects or water ingress. Equipment with the designation IP23S is intended for indoor and outdoor use, but should not be used in precipitation. The symbol S indicates that the power source is intended for areas with higher electrical risk.

Installation

Installation must be performed by a qualified person.

Location

Position the power source so that the cooling air inlets and outlets are not obstructed.

• A: Minimum 200 mm (8 inches)
• B: Minimum 200 mm (8 inches)

Lifting Instructions

Use the handles to lift the power source.

Power Supply

The supply voltage must be 230 V AC ±15% or 120 V ±15%. Too low a supply voltage can lead to poor welding results. Too high a supply voltage can cause overheating and potential failure of components. For information on the type of electrical service available, proper electrical connection procedures, and necessary inspections, consult your local power company.

The welding power source must be:

• Correctly installed, preferably by a trained electrician.
• Correctly grounded (electrically) in accordance with local regulations.
• Connected to the correct size socket and fuse, according to the table below.

ATTENTION! Use the welding power source in accordance with applicable local and national regulations.

CAUTION! Disconnect the input power and secure the locking/tagging procedures. Before removing input fuses, ensure that the input disconnect switch is locked (locked/tagged) in the open position. Connection/disconnection operations must be performed by qualified personnel.

Recommended Fuses and Cable Sizes

Power Supply from Generators

The power source can be powered by various types of generators. However, the power of some generators may not be sufficient for the correct operation of the welding power source. It is recommended to use a generator with an automatic voltage regulator (AVR) or equivalent or better regulator with a rated power of 9 kW.

Operation

ATTENTION! Read the safety instructions in the "SAFETY" chapter before using the equipment.

ATTENTION! Use the designated handle to move the equipment. Never pull the cords.

WARNING! Rotating parts can cause injury. Be careful.

WARNING! Risk of electric shock! Do not touch the workpiece or welding head during operation!

WARNING! Ensure that the side panels are closed during operation.

WARNING! Secure the spool retaining nut to prevent the spool from sliding off the drum.

Connections

1. Pushbutton (menu access)
2. Pushbutton (return to previous menu)
3. Pushbutton encoder (parameter adjustment and display navigation)
4. Encoder (parameter adjustment)
5. Polarity changeover cable
6. Torch trigger and spool gun control
7. Electrode output terminal (positive +)
8. GMAW torch and spool gun connection
9. Input power cable
10. Input power switch
11. Gas inlet

Cable Connection – Welding, Return, and Polarity Changeover

The power source has two outputs for connecting welding and return cables: negative terminal [–] (5) and positive terminal [+] (8), see "Connections", page 14.

GMAW Synergic and GMAW Manual Modes – Solid Wire

GMAW Synergic and GMAW Manual Modes – FCAW Wire

The polarity changeover cable is used to select the correct polarity of the welding output. The correct polarity is determined by the wire selected to complete the weld. Set the machine to operate with positive electrode input and connect the polarity changeover cable to the positive terminal [+] and the return lead to the negative terminal [-]. Ensure all electrical connections are securely fastened. Fasten the work clamp to the workpiece in a clean, debris-free location.

Stick (SMAW)

Live GTAW

ATTENTION! Some wires require negative polarity, such as self-shielded flux-cored wire. Refer to the wire manufacturer's recommendation.

Drive System Diagram

1. Wire inching/ejection
2. Wire feed mechanism
3. Wire spool

Attaching the MXL 201 Central Adapter

1. Ensure the wire guide is correctly installed.
2. Insert the central adapter into the power source connection socket and tighten the adapter nut firmly to secure it.
3. Ensure the central adapter and connection socket are properly connected by pulling the torch coaxial cable. Movement should not be possible.

WARNING! Disconnect the mains power.

Wire Insertion and Replacement

The Rogue EMP 210 PRO can be used with 100 mm (4 inches) and 200 mm (8 inches) spools. Refer to "Technical Data", page 8 for suitable wire sizes for each wire type.

WARNING! Do not place or point the torch near your face, hands, or body, as this may cause injury.

WARNING! Before replacing or installing parts, ensure that the power is turned off.

WARNING! Risk of crushing when changing wire spools! Do not use protective gloves when inserting welding wire between the drive rolls.

1. Open the spool side cover.
2. Release the pressure roller lever by tilting the tension screw (1).
3. Lift the pressure roller lever (2) up.
4. Remove the drive roll retaining screw by turning it counterclockwise.
5. Replace the drive roll.
6. Secure the drive roll retaining screw by turning it clockwise.
7. Secure the pressure roller lever and the wire tension screw.
8. Close the spool side cover.

Welding with Aluminum Wire

ATTENTION! Ensure you use the correct drive/pressure rolls. For more information, see "CONSUMABLES", page 40.

ATTENTION! Do not forget to use the correct contact tip for the wire diameter in the welding torch. The torch is equipped with a contact tip suitable for 0.030-inch (0.8 mm) wire. If using a different diameter, the contact tip and drive roll must be changed. It is recommended to use the wire guide in the torch when welding with Fe and SS wires.

For best results when welding aluminum with the MXL 210, use a Teflon guide and a U-groove drive roll, and keep the torch lead as straight as possible.

Installing a 5 kg (200 mm spool)

To install a 5 kg (200 mm spool), assemble the parts in the sequence shown in the figure below. Follow the steps below to install the wire spool.

1. Remove the plastic retaining nut.
2. Place the wire spool onto the hub, loading it so that the wire exits from the bottom of the spool as the spool rotates counterclockwise. Ensure that the spool hub's alignment pin is aligned with the corresponding hole in the wire spool.
3. Replace the plastic retaining nut until it is snug against the wire spool.

Installing a 1 kg (100 mm spool)

To install a 1 kg (100 mm spool), assemble the parts in the sequence shown in the figure below. Follow the steps below to install the wire spool.

1. Remove the plastic retaining nut.
2. Place the wire spool onto the hub, loading it so that the wire exits from the bottom of the spool as the spool rotates counterclockwise. Ensure that the spool hub's alignment pin is aligned with the corresponding hole in the wire spool.
3. Replace the plastic retaining nut until it is snug against the wire spool.

Wire Feed Pressure Adjustment

First, check if the wire moves freely in the wire guide. Then, adjust the drive roll pressure. Do not set the pressure too high.

To check if the pressure is set correctly, you can direct the wire against an insulated object, such as a piece of wood.

If you hold the welding torch approximately 5 mm (0.2 inches) from the wood (Illustration A), the drive rolls should slip. If you hold the torch approximately 50 mm from the wood, the wire should feed and bend (Illustration B).

The wire spool on the hub has a friction brake, which is adjusted during manufacturing to provide optimal braking. If necessary, this can be adjusted by turning the thumb screw on the open end of the hub clockwise to tighten the brake. Proper adjustment will result in the wire spool continuing to turn for no more than 1/8–3/16 inches (3–5 mm) after the trigger is released. The electrode wire should be slack, without coming out of the wire spool.

CAUTION! Overtightening the brake will cause rapid wear of the mechanical wire feed parts, overheating of electrical components, and potentially more contact tip burn-through incidents.

Drive Roll and Pressure Roller Replacement

The standard equipment includes one double-groove drive roll. Replace the drive roll as needed to match the filler metal. Refer to the wire manufacturer's recommendations.

ATTENTION! Carefully observe that the key on the drive motor shaft is not lost. For correct operation, this key must be aligned with the groove in the drive roll.

1. Open the spool side cover.
2. Release the pressure roller lever by tilting the tension screw.
3. Lift the pressure roller lever (2) up.
4. Remove the drive roll retaining screw by turning it counterclockwise.
5. Replace the drive roll.
6. Secure the drive roll retaining screw by turning it clockwise.
7. Secure the pressure roller lever and the wire tension screw.
8. Close the spool side cover.

ATTENTION! The visual marking on the front of the drive roll indicates the groove on the outside of the drive roll and the groove to be used for the selected wire diameter.

Shielding Gas

The choice of shielding gas depends on the material. Typically, mild steel is welded with a gas mixture (Ar + CO₂) or 100% carbon dioxide (CO₂). Stainless steel can be welded with a gas mixture (Ar + CO₂). Aluminum can be welded with argon (Ar), and bronze can be welded with pure argon (Ar) or a mixture of argon and oxygen (Ar + O₂).

Duty Cycle

The duty cycle for the Rogue EMP 210 PRO welding current output is 100 A (120 V) and 210 A (230 V) at a 25% duty cycle. If the duty cycle is exceeded, the power source is protected by a self-resetting thermostat.

Example: If the power source operates at a 25% duty cycle, it provides the rated current for a maximum of 2.5 minutes out of every 10-minute period. The remaining 7.5 minutes must be allowed for the power source to cool down.

• 25%
• 7.5 minutes

Other duty cycle and current combinations can be selected.

User Interface

Read the general safety instructions regarding equipment handling in the "SAFETY" chapter. Read the general operating information in the "OPERATION" chapter of this user manual before putting the equipment into service!

When the startup sequence is completed, the user interface will display the main menu.

Home Screen

1. Voltage adjustment (encoder)
2. Wire feed speed adjustment, menu navigation, and selection (pushbutton encoder)
3. Menu button – press to open the menu
4. Back button – press to return
5. Display – home screen

a) Voltage display

b) Wire feed speed display

c) Overview of machine settings

d) Synergic configuration display

Menu Navigation

1. The left encoder is used to limit the voltage in GMAW Synergic mode or adjust the voltage in GMAW Manual mode.
2. The right pushbutton encoder is used to adjust the material thickness in GMAW Synergic mode or wire feed speed in GMAW Manual mode.
3. The Menu button allows access to the system menu for custom configuration.

See "GMAW Synergic Mode", page 23 and "GMAW Manual Mode", page 23.

1. The Back button takes the user back to the previous screen in GMAW Synergic or GWAM Manual mode.
2. The User Display divides the screen into four sections:

a) The left side displays the preset voltage in GMAW Synergic mode and the actual voltage during welding.

b) The right side displays the preset material thickness in GMAW Synergic mode and the preset wire feed speed in GMAW Manual mode. The welding current is also displayed during welding.

c) The status bar provides the user with a brief overview of the machine's status.

d) The header bar provides the user with an overview of the selected material, wire diameter, and gas type selected in Synergic mode.

ATTENTION! After welding, the screen will display the last actual welding parameters and the welding duration for 10 seconds.

GMAW Synergic Mode

GMAW Synergic mode is a constant voltage welding process where the voltage and wire feed are linked using preset synergistic data, providing stable arc performance across the range of wire and gas combinations.

Synergic mode operates in short-circuit, globular, and spray transfer modes.

1. Process Selection
2. Settings
3. Information
4. Weld Variables
5. Synergic Mode Settings
6. Jobs
7. Trigger Selection

GMAW Manual Mode

GMAW Manual mode is a constant voltage welding process where voltage and wire feed speed are set independently of each other.

1. Process Selection
2. Settings
3. Information
4. Weld Variables
5. Arc Dynamics
6. Jobs
7. Trigger Selection

To select and insert any plate, turn the right pushbutton encoder to the desired plate and press the encoder. After the user has inserted, there are various options to choose from.

1. Process Selection – Allows selection of Synergic GMAW, Manual GMAW, SMW (MMA), or Live GTAW modes.

Settings

• Language selection
• Unit of measure (inch/mm)
• Display brightness
• Job switching activation (multiple jobs are available for the operator)
• Factory reset
• Information (software version)

ATTENTION! Factory reset will erase all custom configurations and reset the machine to the factory default configuration. The total arc time will not be erased or reset to the factory configuration.

Information

Allows the operator to configure various settings at the system level.

• Consumables and spare parts
• Accessories
• Filler metals
• General maintenance
• User manual

Weld Variables

Allows setting specific welding variables that can improve welding results.

• Arc Dynamics – Used to regulate the intensity of the welding arc. Lower arc control settings make the arc softer, resulting in less spatter and better wetting of the weld pool. Higher arc control settings provide a stronger, more directed arc, which can increase weld penetration. The setting range is -9 to +9.
• Preflow Time – The time during which shielding gas flows before the welding arc is established. The setting range is 0.0 to 5.0 s.
• Creep Start – Feeds wire at a slower speed than the preset feed speed until it makes electrical contact with the workpiece, then switches to the preset wire feed speed. Set as a percentage of the preset wire feed speed.
• Burnback Time – The time elapsed from when the wire starts to break until the power source turns off the welding voltage. The setting range is 0.01 to 0.35 s. Too short a burnback time results in a long wire stick-out after welding is completed and the risk of the wire sticking to the weld pool. Too long a burnback time results in a shorter wire stick-out and an increased risk of arc back to the contact tip.
• Postflow Time – The time during which shielding gas flows after the welding arc has been extinguished. The setting range is 0.0 to 10.0 s.

5. GMAW Modes:

1. GMAW Synergic Mode:

Synergic Settings – Allows the user to configure the machine for a specific wire type, wire diameter, and gas combination. This optimizes welding parameters for minimal to maximum material thickness that the machine or process can weld.

ATTENTION! The example below uses mild steel (Fe). Other combinations are available.

GMAW Manual Mode:

Arc Dynamics – Used to regulate the intensity of the welding arc. Lower arc control settings make the arc softer, resulting in less spatter and better wetting of the weld pool. Higher arc control settings provide a stronger, more directed arc, which can increase weld penetration. The setting range is -9 to +9.

6. Jobs

Allows the user to easily save and recall specific welding conditions that are frequently used.

• Create Jobs – To create jobs, you must create special welding parameters for the desired Synergic or Manual mode.
• Save Jobs – To save jobs, you must first create welding parameters. Open the menu and select the Jobs panel. You can create 10 individual jobs for each process setting. Press the pushbutton encoder to select the desired job number. Once the desired job number is selected, press and hold the encoder for 2 seconds. The job is now saved. The parameters created here will be displayed on the job panel and the active job will be recalled. The job number will be displayed on the home screen.
• Delete Jobs – To delete jobs, open the menu and select the Jobs panel. Press the pushbutton encoder to select the desired job number. Once the desired job number is selected, press the Back button and hold it for 5 seconds. The job is now deleted.
• Trigger Job Call – Allows the user to alternately activate preset jobs during welding. Individual jobs must be created before use. Activate the Trigger Job Call function under the Setting Tile settings panel. From this menu, you can select "1 and 2" or "1, 2 and 3" depending on the number of jobs the user wishes to select. Allows the user to alternately activate jobs between "1 and 2" or "1, 2 and 3" during welding with the trigger. The "Activate Job Call" function only works with the 4T trigger configuration.

7. Trigger Selection

Allows the user to control the trigger functionality.

• 2-Taktiline
• In 2-stroke mode, welding begins with pre-flow gas when the torch trigger is pressed, if this function is activated. The welding process then starts. When the trigger is released, welding stops and post-flow gas starts, if this function is activated.
• 4-Taktiline
• In 4-stroke mode, welding begins with pre-flow gas when the torch trigger is pressed, and wire feed starts when the trigger is released, initiating welding. The welding process continues until the torch trigger is pressed again, stopping the wire feed and welding. When the switch is released, post-flow gas starts.
• Punkt (Spot)
• The Spot function allows the user to set a specific weld length each time the torch trigger is pressed. The setting range is 0–10.0 s.
• Stitch (Stitch)
• The Stitch function allows the user to set two independent times, the stitch time and the delay time. These times repeat as long as the torch trigger is pressed. Setting range: stitch time 0.0-10.0 s, delay time 0.0–10.0 s

SMAW (MMA) Mode

GMAW Manual mode is a constant voltage welding process where voltage and wire feed speed are set independently of each other.

1. Process Selection
2. Settings
3. Information
4. Electrode Type – Allows the user to select between cellulosic (6010) or basic/rutile electrodes (most others). This determines the arc type that is best suited for operating this type of electrode.
5. Remote – If the unit is paired with the MMA-4 handheld remote control, the welding current can be increased or decreased at the welding location.
6. Jobs
7. Hot Start – Controls the additional current at the start of the arc to prevent the electrode from sticking to the workpiece and to avoid cold starts at the beginning of the weld seam. Increase the hot start value if you have difficulty striking the arc, or decrease the hot start value if the electrode seems to be burning too much at the beginning of the weld. (Range 0–10.)
8. Arc Force – Controls the amount of additional current in case of a short arc. Increase the arc force percentage for a dense or narrow weld joint, or decrease the arc force percentage for normal weld joint welding. (Range 0–10.)

Live GTAW Mode

In GTAW welding, the workpiece metal is melted using a non-consumable tungsten electrode with an ignited arc. The weld pool and electrode are protected by shielding gas.

1. Process Selection
2. Settings
3. Information
4. Remote – If the unit is paired with the TWECO TIG foot control, the welding current can be increased or decreased at the welding location.
5. Jobs

Icon Explanations

GMAW Manual

GMAW Synergic

Stick

LIVE GTAW

2T, trigger on/off

4T, trigger hold/lock

Arc Dynamics

Welding arc force

For stick welding – increasing the current when shortening the arc to reduce or prevent the electrode from sticking to the weld pool.

Hot Start

Increasing the current when striking the electrode to reduce sticking.

Jobs

Settings

Synergic Mode Settings

Electrode Type

Gas Cylinder

Wire Diameter

+/- Polarity

Information

Remote Control

Spot Welding

Weld Variables

Voltage

Wire Feed Speed

Material

Maintenance

ATTENTION! Regular maintenance ensures safe and reliable operation of the equipment. Repairs and electrical work must be performed by an ESAB-authorized service technician. Use only ESAB original spare and wear parts.

ATTENTION! All supplier warranty obligations will be void if the customer attempts to repair any fault independently during the warranty period.

WARNING! Disconnect the mains power before cleaning and maintenance.

ATTENTION! Perform maintenance more frequently in dusty environments.

Always ensure the following before using the equipment:

• The product and cables are undamaged.
• The torch is clean and undamaged.

Routine Maintenance

Maintenance schedule under normal conditions. Check the equipment before each use.

Power Source and Wire Feeder Maintenance

It is good practice to clean the power source whenever the wire spool is changed.

WARNING! Always wear protective gloves and safety glasses when cleaning.

Power Source and Wire Feeder Cleaning Procedure:

1. Disconnect the power source from the socket.
2. Open the spool side cover and release the pressure roller by turning the tension screw (1) counterclockwise and then pulling it towards you.
3. Remove the torch, wire, and wire spool.
4. Use a low-pressure air jet to clean the inside of the power source and the locking devices for the power source air inlet and outlet.
5. Check the wire inlet guide (4), drive roll (3), and torch inlet (2) for wear. If any part is worn, replace it immediately. See "CONSUMABLES", page 40 for ordering parts.
6. Remove the drive roll (3) and clean it with a soft brush. Clean the pressure roller attached to the wire feed mechanism with a soft brush.

Torch and Lead Cleaning

Torch and lead cleaning procedure:

1. Disconnect the power source from the socket.
2. Open the spool side cover and release the pressure roller by turning the tension screw counterclockwise and then pulling it towards you.
3. Remove the wire and wire spool.
4. Remove the torch from the power source and remove the contact tip and nozzle.
5. Clean the lead by directing a low-pressure air jet through the lead from the end that was closer to the power source.
6. Reinstall the contact tip and nozzle.

Error Codes

Error codes indicate that a fault has occurred in the equipment. Faults are indicated by the text "Error" followed by the error code number displayed on the screen.

Error Code Descriptions

The following lists the error codes that the user can handle. If an error is displayed, contact an ESAB-authorized service technician.

Troubleshooting

Before calling an authorized service technician, try these control and monitoring methods.

Ordering Spare Parts

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

The Rogue EMP 210 PRO is designed and tested according to international standards IEC / EN 60974-1 and IEC / EN 60974-1 Class A. Upon completion of maintenance or repair work, the person(s) performing the work are responsible for ensuring that the product complies with the above-mentioned standards.

You can order spare parts and consumables from your nearest ESAB dealer. For more information, see the website esab.com. When ordering, please specify the product type, serial number, intended use, and part number as listed in the spare parts list. This will facilitate delivery and ensure correct delivery.

The spare parts list is published in a separate document, which can be downloaded from the Internet:

www.esab.com

Consumables

Accessories

Electrical Diagram

Wiring Diagram