ESAB Rogue ET 200i PRO CE TIG Welding Machine Instruction Manual

Rogue
ET 200iP PRO Instruction manual
0463 712 101 GB 20201113
Valid for: HA027-xxxx-xxxx

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

5. General precautions:
   ○ Make sure the return cable is connected securely
   ○ Work on high voltage equipment may only be carried out by a qualified electrician
   ○ Appropriate fire extinguishing equipment must be clearly marked and close at hand
   ○ Lubrication and maintenance must not be carried out on the equipment during operation

If equipped with ESAB cooler
Use ESAB approved coolant only. Non-approved coolant might damage the equipment and jeopardize product safety. In case of such damage, all warranty undertakings from ESAB cease to apply.
Recommended ESAB coolant ordering number: 0465 720 002.
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

• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS – Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.

EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to EMF:
  ○ Route the electrode and work cables together on the same side of your body. Secure them with tape when possible. Do not place your body between the torch and work cables. Never coil the torch or work cable around your body. Keep welding power source and cables as far away from your body as possible.
  ○ Connect the work cable to the workpiece as close as possible to the area being welded.

FUMES AND GASES – Can be dangerous to health

• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area.

ARC RAYS – Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
  NOISE – Excessive noise can damage hearing Protect your ears. Use earmuffs or other hearing protection.

MOVING PARTS – Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only qualified people remove covers for maintenance and troubleshooting as necessary. Reinstall panels or covers and close doors when service is finished and before starting engine.
• **** Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable materials nearby.
• Do not use on closed containers.

HOT SURFACE – Parts can burn

• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to prevent burns.

MALFUNCTION – Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

NOTE!
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

INTRODUCTION

Overview
Rogue ET 200iP PRO is an inverter-based power source intended for MMA (Manual Metal Arc) and TIG (Tungsten Inert Gas) welding, HF TIG (High Frequency Tungsten Inert Gas) welding.
ESAB accessories for the product can be found in the “ACCESSORIES” chapter of this manual.
2.1 Equipment
Rogue ET 200iP PRO includes:

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

TECHNICAL DATA

| Rogue ET 2001P PRO
---|---
Outlet voltage| 230 V±15% 1- 50/60 Hz| 115 V±15% 1- 50/60 Hz
Primary current
‘max MMA| 30A| 29A
im„ Live TIG| 19.5A| 24A
No-load power demand when in energy-saving mode| 50 W| 50 W
Setting range
MMA| 20-200 A| 20-110 A
Live TIG| 10-200A| 10-140A
Permissible load at MMA
25% duty cycle| 200A/28 V| 110A/24.4 V
60% duty cycle| 129A/ 25.2 V| 70A/ 22.8 V
100% duty cycle| 100A/24 V| 55A/ 22.2 V
Permissible load at Live TIG
25% duty cycle| 200A/18 V| 140A/ 15.6V
60% duty cycle| 129A/ 15.2 V| 90A/ 13.6 V
100% duty cycle| 100A/14 V| 70A/12.8 V
Apparent power 12 at maximum current| 6.9 kVA| 3.3 kVA
Active power 12 at maximum current| 6.8 kW| 3.26 kW
Power factor at maximum current
Live TIG| 0.99| 0.99
MMA| 0.99| 0.99
Efficiency at maximum current
MMA| 82%| 85%
Live TIG| 82%| 85%
Open-circuit voltage U0 max
VRD 35 V deactivated| 78 V| 78 V
VRD 35 V activated| <30 V| <30 V
Operating temperature| -10 to +40 °C (+14 to 104 °F)| -10 to +40 °C (+14 to 104 °F)
Transportation temperature| -20 to +55 °C (-4 to +131 °F)| -20 to +55 °C (-4 to +131 °F)
Continual sound pressure at no-load| <70 dB| <70 dB
Dimensions Ix w x h| 403 x 153 x 264 mm (15.9 x 6 x 10.4 in.)
Weight| 9.6 kg
Insulation class transformer| H
Enclosure class| IP23S
Application class|

Mains supply, Ssc min
Minimum short circuit power on the network in accordance with IEC 61000-3-12.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without overloading. The duty cycle is valid for 40 °C / 104 °F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water.
Equipment marked IP23S is intended for indoor and outdoor use; however, should not be operated in precipitation.
Application class
The symbol indicates that the power source is designed for use in areas with increased electrical hazard.

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. A. Minimum 200 mm (8 in.)
B. Minimum 200 mm (8 in.)
WARNING!
Secure the equipment – particularly if the ground is uneven or sloping.
4.2 Lifting instructions
These units are equipped with a handle for carrying purposes.
WARNING!
Electric shock can kill. Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.
WARNING!
Falling equipment can cause serious personal injury and equipment damage.
Lift the unit with handle on top of case. 4.3 Mains supply
NOTE!
Rogue ET 200iP PRO** 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.
The power source will automatically adjust to the supplied input voltage. Make sure that it is protected by the correct fuse rating. A protective ground connection must be made, in accordance with regulations.

1. Rating plate with supply connection data.

Recommended fuse sizes and minimum cable area for the ET 200iP PRO

Supply voltage| 230 VAC| 115 VAC
Electrical cable area| 2.5 mm2| 2.5 mm2
Maximal current rating I max
MMA/Stick (SMAW)| 30 A| 29 A
Recommended fuse sizes and minimum cable area for the ET 200iP PRO

I1eff MMA/Stick (SMAW)| 15 A| 14.5 A
Fuse anti-surge type D MCB| 20 A| 20 A
Recommended fuse sizes and minimum cable area for the ET 200iP PRO

Supply voltage| 230 VAC| 115 VAC
Maximum recommended extension cord length| 100 m (328 ft)| 100 m (328 ft)
Minimum recommended extension cord size| 4 mm2| 4 mm2

NOTE!
Different variants of Rogue ET 180i, ET 200i, ET 200iP PRO are certified for different outlet voltages. Always refer to the rating plate for the specification of the power source in use.
NOTE!
Use the power source in accordance with the relevant national regulations.
Supply from power generators
The power source can be supplied from different types of generators. However, some generators may not provide sufficient power for the welding power source to operate correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power of 7 kW are recommended.

OPERATION

5.1 Overview
General safety regulations for handling the equipment can be found in the “SAFETY” chapter of this manual. Read it through before you start using the equipment!
NOTE!
When moving the equipment use intended handle. Never pull the cables.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
5.2 Connections and control devices

1. Setting panel
2. Positive welding terminal
3. Negative welding terminal
4. Power cable| 5. Mains power supply switch, I/O
6. Remote socket
7. Gas supply output
8. Gas supply input
---|---

5.3 Connecting welding and return cables
The power source has two outputs, a positive welding terminal (+) and a negative welding terminal (-), for connecting welding and return cables. The output to which the welding cable is connected depends on the welding method or type of electrode used.
Connect the return cable to the other output on the power source. Secure the return cable’s contact clamp to the workpiece, and make sure that there is a good contact between the workpiece and the output for the return cable on the power source.

• For TIG welding, the negative welding terminal (-) is used for the welding torch and the positive welding terminal (+) is used for the return cable.
• For MMA welding, the welding cable can be connected to the positive welding terminal (+) or negative welding terminal (-), depending on the type of electrode used. The connection polarity is stated on the electrode packaging.

5.4 Turning the power on/off
Turn on the power by turning the switch to the “ON” (I) position.
Turn the unit off by turning the switch to the “O” position.
Whether the power supply is interrupted or the power source is switched off in the normal manner, weld programs are stored so that they are available the next time the unit is started.
CAUTION!
Do not turn off the power source during welding (with load).
5.5 Fan control
The ET 200iP PRO is fitted with a fan as needed feature. Fan as needed automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimize the amount of contaminants such as dust that are drawn into the power source.
Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required.
5.6 Thermal protection
The power source includes thermal protection against overheating. When overheating occurs the welding is stopped and overheating indicator on the panel will be lit and an error message shows in the display. The protection is automatically reset when the temperature has been sufficiently reduced.
5.7 Functions and symbols
MMA welding
MMA welding may also be referred to as welding with coated electrodes. Striking the arc melts the electrode, and its coating forms protective slag. For MMA welding the power source shall be supplemented with:

• welding cable with electrode holder
• return cable with clamp

Arc force
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.
Arc force only applies to MMA welding.
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.
Arc force only applies to MMA welding.
Hot start
Hot Start The hot start function temporarily increases the current in the beginning of the weld. Use this function to reduce risk of insufficient fusion and electrode sticking and scratching.
Hot start only applies to MMA welding.
TIG welding
TIG welding melts the metal of the workpiece, an arc initiated from a non- consuming tungsten electrode. The weld pool and electrode are protected by shielding gas.
For TIG welding, the welding power source shall be supplemented with:

• a TIG torch with gas valve
• an argon gas cylinder
• an argon gas regulator
• tungsten electrode

This power source performs Live TIG start (TIG Live).
The tungsten electrode is placed against the workpiece. When lifted away from workpiece the arc is struck at a limited current level. HF start
The HF (High Frequency) start function strikes the arc by means of a spark from the tungsten electrode to the workpiece as the electrode is brought closer to the workpiece and the trigger on the TIG torch is pressed.
Voltage Reduction Device (VRD)
VRD The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding is not being carried out. This is indicated by a lit VRD indicator on the panel. Contact an authorised ESAB service technician to activate this function.
5.8 Setting panel

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

Process selection button (9):

• TIG HF (12)
• TIG Live (11)
• MMA (10)
• Navigation
• Parameter selection

Press the Process selection button (9) for 3 sec to go to the advanced feature menu and press Process selection button (9) to select the values. Use the Welding current control knob (8) to change the values.
In TIG HF or TIG Live mode:

• Gas pre flow time (PREG 0 – 5 s)
• Start current (IGNA 10 – 100%)
• Up slope time (SLPU 0 – 10 s)
• Down slope time (SLPD 0 – 10 s)
• End current (FINA 10 – 100%)
• Gas post flow time (POSG 0.5 – 15 s)
• Background current (BKGA 10 – 100%)

In MMA mode:

• Hot start (HOTS -10 – +10)
• Arc force (ARCF -10 – +10)
• Cellulose electrode (CELL On / Off)

Press the Options button (7) to set the following:

• Trigger mode (4): 2 stroke / 4 stroke
• Pulse mode (5): (On / Off)
• Frequency (6): (0.2 – 500 Hz) – only if Pulse mode is ON.

5.9 Remote control
Connect the remote control to the front of the power source. When the remote control is connected, it is automatically activated. The maximum setting of the power source will be determined by the respective front panel control, irrespective of the remote control device setting.

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.

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

Check or replace weld cables.
Every 6 months| Clean inside equipment. Use dry compressed air with reduced pressure.| |

6.2 Cleaning instruction
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

CAUTION!
Make sure that the cleaning procedure is done in a suitable prepared workspace.
CAUTION!
During cleaning, always wear recommended personal safety equipment, such as ear plugs, safety glasses, masks, gloves and safety shoes.

1. Disconnect the power source from the mains supply.
2. Open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal filings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current.

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.

Check that the welding and return cables are correctly connected to the power source.
Make sure that the return clamp has good contact with the workpiece.
Check that the correct electrodes and polarity are being used. For polarity, check electrode packaging.
Check that the correct Welding current (A) is set.
Adjust Arc Force and Hot start.
TIG welding problems| Check the welding process is set for Live TIG as necessary.
Check that the TIG torch and return cables are correctly connected to the power source.
Make sure that the return clamp has good contact with the workpiece.
Make sure that the TIG torch lead is connected to the negative welding terminal.
Make sure that the correct shielding gas, gas flow, welding current, filler rod placement, electrode diameter and welding mode on power source is used.
No arc| Check that the electrical power supply switch is turned on.
Check that the display is on to verify that the power source has power.
Check that the setting panel is displaying correct values.
Check that welding and return cables are correctly connected.
Check the electrical power supply fuses.
Welding current is interrupted during welding| Check whether the Over Temperature LED (Thermal Protection) on the setting panel is on.
Continue with Troubleshooting “No Arc”.
The thermal protection trips frequently| Make sure that the recommended duty cycle for the weld current has not been exceeded.
Refer to power source “Duty cycle” section in the TECHNICAL DATA chapter.
Make sure that the air inlets or outlets are not clogged.
Clean the inside of the machine using routine maintenance methods.

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 Rogue ET 200iP PRO is designed and tested in accordance with the international and European standards EN60974-1 and EN60974-10. On completion of service or repair work, it is the responsibility of the person(s) performing the work to ensure that the product still complies with the requirements of the above standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list. This facilitates dispatch and ensures correct delivery.
DIAGRAM
From serial number HA027-xxxx-xxxx ORDERING NUMBERS

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

ACCESSORIES

A WORLD OF PRODUCTS AND SOLUTIONS. EU DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2014/35/EU
The EMC Directive 2014/30/EU
The Rolls Directive 2011/65/EU
Type of equipment
Welding power source
Type designation
ET200iP Pro
with serial number from HA027-xxxx-xxxx
Brand name or trademark
ESAB
Manufacturer or his authorised representative established within the EEA Name, address, and telephone No:
ESAB AB
Lindholmsallen 9, Box 80C4, SE-402 77 Goteborg. Sweden
Phone: +46 31 50 90 00, www.esab.com
The following harmonised standard In force within the EEA has been used in the design:
EN 60974-12012, Arc Welding Equipment – Part 1: Welding Power Sources
EN 60974-3:2007. Arc Welding Equipment – Part 3: Arc striking and stabilizing devices
EN 60974-10:2014, A1:2015 Arc, Welding Equipment – Part 10: Electromagnetic Compatibility (EMC) requirements
Additional Information:
Restrictive use, Class A equipment, intended for use in location other than residential The ET200i Pro is part of the ESAB Rogue product family
By signing this document, the undersigned declares as manufacturer, or the manufacturers authorised representative established within the EEA, that the equipment in question complies with the safety requirements stated above.
Date
Gothenburg
2020-09-07

****in 2020

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

References

• ESAB | Home
• ESAB Manual Finder
• ESAB | Home

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