Ross RXT150E General Instructions Manual

Brand: Ross

Model: RXT150E

Category: Welding System

Type: General Instructions Manual

Ross RXT150E is an inverter welder suitable for manual arc welding up to 7mm in mild steel using 3.2mm welding rods. It has a thermal protector which switches off the welder if the transformer overheats and self-resets when its temperature has cooled to a normal level. The device is not suitable for larger welding rods, use with generators or in rain (case protection class IP21S).

Page 1

RXT150E

Protect yourself and others by observing all safety information, warnings, and cautions.

Failure to comply with instructions could result in personal injury and/or damage to product

or property.

Please retain instructions for future reference.

Inverter Welder

Model: RXT150E

General instruction for installation use and maintenance

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RXT150E

IMPORTANT

Please read all of the safety and operating instructions carefully before using this product.

Please pay particular attention to all sections of this manual that carry warning symbols and

notices.

WARNING!

This is a Warning symbol. This symbol is used throughout the manual whenever

there is a risk of personal injury. Ensure that these warnings are read and under-

stood at all times.

CAUTION!

This is a Caution symbol. This symbol is used throughout the user guide when-

ever there is a risk of damaging your product. Ensure that these warnings are

read and understood at all times.

GENERAL DESCRIPTION

This unit is a limited duty power source for manual arc welding. The power for the arc comes from an

electronic circuit know as an inverter. The welding current output can be adjusted by means of a control

knob on the front panel.

It is suitable for welding up to 7mm in mild steel using 3.2mm welding rods. It is not suitable for larger

welding rods nor use with generators.

Caution! Using this product with welding rods greater than 3.2mm or with a generator will void

your warranty.

Each unit is fitted with a thermal protector which switches off the welder if the transformer

overheats and self-resets when its temperature has cooled to a normal level.

A yellow pilot lamp in the front panel will light to indicate thermal protection intervention.

Item RXT150E

Input Power V 230 AC

Frequency Hz 50

Phase No. 1

Rated No-load Voltage V 78 DC

Effective Input Current Amps 7.9

Rated Duty Cycle

10% @ 140 Amps

Output current Amps 20 - 140 (Peak 150)

Electrode size mm 1.6 - 3.2

Cooling Type

Fan Cooled

Case Protection Class IP21S (Not suitable for use in rain)

Net Weight kg 4.6

PRODUCT SPECIFICATION

Note: This unit is suitable for connection to standard domestic 10amp power outlet.

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RXT150E

The user of this welder is responsible for his own and the safety of others. It is most impor-

tant to read, learn and respect the rules in this user guide.

When using this welder, basic safety precautions, including the following, should be followed

to reduce the risk of fire, electric shock and personal injury. Make sure that you have read all

of these instructions before using this welder. Keep this booklet in a safe place for future ref-

erence. Persons who are not familiar with this booklet should not use the welder.

TRAINING

The operator should be properly trained to use the welding machine safely and should be in-

formed about the risks relating to arc welding procedures. This manual does not attempt to

cover welding technique. Training should be sought from qualified/experienced personnel on

this aspect especially for any welds requiring high integrity for safety.

SERIOUS FIRE RISK

The welding process produces sparks, droplets of fused metal, metal projectiles and fumes.

This constitutes a serious fire risk. Make sure that the area around the work piece is clear of

all inflammable materials. It is advisable to have a fire extinguisher to hand.

WORK AREA

Ensure a clear work area with unrestricted movement for the operator. Always maintain easy

access to the On/Off switch and the mains supply.

THE WORK PIECE

The work piece will remain at a high temperature for a relatively long period. Do not touch

the weld or the work piece unless you are wearing welding gloves. Always use pliers or tongs.

Never touch the welded material with bare hands until it has been allowed to cool.

WARNING! SAFETY INSTRUCTIONS

VENTILATE THE WORK AREA

Arc welding (especially using fluxed core wire) emits fumes which can be dangerous. Make

sure that the work area is well ventilated.

WELDING SURFACES

 Do not weld on containers or pipes that hold, or have held, flammable liquids or com-

bustible gases.

 Do not weld coated, painted or varnished surfaces as the coatings may ignite and or can

give off dangerous fumes.

CONSIDER WORK AREA ENVIRONMENT

Do not expose the welder to rain. Do not use it in damp, or wet locations. Keep the work area

well lit.

AVOID ELECTRICAL CONTACT

Use adequate electrical insulation with regard to the electrode, the work piece and any acces-

sible) earthed metal parts in the vicinity. Avoid direct contact with the welding circuit. The no

load voltage between the earth clamp and the torch can be dangerous under certain circum-

stances.

EXTENSION LEADS

In general these are best avoided. If used however make sure that the extension lead used

with the welder is of a suitable current rating and has an earth connection. If using the welder

outdoors make sure that the extension cable is suitable for outdoor use. Always keep cables

and extension leads away from the welding zone and any hot materials.

FOR ADDITIONAL PROTECTION FROM ELECTRIC SHOCK

It is recommended that this tool be used in conjunction with a residual current device (RCD)

with a rated residual current of 30mA or less.

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RXT150E

SAFETY INSTRUCTIONS … cont

CHECK DAMAGED PARTS

Before further use of the welder, any part that is damaged should be carefully checked to de-

termine that it will operate properly and perform its intended function. Check for breakage of

parts and any other conditions that may affect its operation. Any part that is damaged should

be properly repaired, or replaced, by an authorised service centre.

ALWAYS USE THE WELDING MASK

Under no circumstances should the welder be operated unless the welding mask is protecting

the eyes and face. There is a serious risk of eye damage if the mask is not used. The sparks

and metal projectiles can cause serious damage to the eyes and face. The light radiation pro-

duced by the arc can cause damage to eyesight and burns on the skin. Never remove the

welding mask whilst welding. Move the torch away from the work piece and release the trig-

ger switch before removing the welding mask.

SAFETY GLASSES

After welding use safety glasses when brushing, chipping grinding the slag from the weld.

OTHER PERSONS

Ensure that other persons are screened from the welding arc and are at least 15 metres away

from the work piece. Always ensure that the welding arc is screened from onlookers, or peo-

ple just passing by. Use screens if necessary, or non reflecting curtains.

KEEP CHILDREN AND ANIMALS AWAY

Do not let children or animals have access to the welding equipment or to the work area.

SWITCHING OFF

When you have finished welding switch off the welder. Do not put the torch down with the

welder switch On and with the wire fitted. When leaving the welder unattended, move the

On/Off switch to the Off position and disconnect the welder from the mains supply. Do not

leave hot material unattended after welding.

WELDING CABLES

Keep the welding cables, earth clamp and torch in good condition. Failure to can result in

poor welding quality and could be dangerous in structural situations.

DRESS PROPERLY

Use protective gloves and fire resistant protective clothing when using the welder. Avoid ex-

posing skin to the ultraviolet rays produced by the arc.

CAUTION! VENTILATE THE WELDER

There must always be a sufficient air passage around the welder to allow for the

cooling of the transformer. If the cooling process is obstructed the welder will

overheat and the overload cut out protector will activate and cut off the welding

current.

If the thermal protector activates leave the welder for at least 15 minutes to cool down.

IMPROPER USE

Do not use this welder for pipe thawing.

HANDLING

Ensure the handle is correctly fitted and always use safe lifting practices when lifting.

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RXT150E

ADDITIONAL PRECAUTIONS

WELDING OPERATIONS:

 In environments with increased risk of electric shock;

 In confined spaces;

 In the presence of flammable or explosive materials;

MUST BE evaluated in advance by an “expert supervisor” and must always be

carried out in the presence of other people trained to intervene in emergencies.

POSITION and HANDLING

Position the welding machine on a horizontal surface that is able to support the

weight: otherwise (e.g. inclined or uneven floors etc.) there is danger of over-

turning.

The operator MUST NOT BE ALLOWED to weld in raised positions unless safety

platforms are used.

VOLTAGE BETWEEN ELECTRODE HOLDERS OR TORCHES:

Working with more than one welding machine on a single piece or on pieces that

are connected may generate a dangerous accumulation of no-load voltage be-

tween two different electrode holders or torches, the value of which may reach

double the allowed limit.

IMPROPER USE:

It is hazardous to use the welding machine for any work other than that for

which it was designed. Example do not use this welder for pipe thawing. The

safety guards and moving parts of the covering of the welding machine and of

the wire feeder should be in their proper positions before connecting the welding

machine to the power supply.

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RXT150E

WARNING SYMBOLS

The following warning symbols are to remind you of the safety precautions you should take

when using the welder.

WARNING!

Read this User Guide carefully before using the welder and keep it in a safe

place for future reference.

WARNING!

When using this welder, avoid direct contact with the welding circuit. The no-load

voltage supplied by the welding machine can be dangerous in certain circumstances.

WARNING!

When using this welder, provide adequate ventilation or facilities for the removal of

welding fumes near the arc; a systematic approach is needed in evaluating the ex-

posure limits for the welding fumes, which will depend on their composition, con-

centration and the length of the exposure itself. Do not operate on materials

cleaned with chlorinated solvents or near such substances. Remove all flammable

materials (e.g. wood, paper, rags etc.) from the working area.

WARNING!

Do not weld on containers or piping that contains or has contained flammable liq-

uids or gaseous products. Do not weld on containers under pressure.

WARNING!

This welding machine complies with the requirements of the technical standard for

the product for use only and exclusively in industrial environments and for profes-

sional purposes. It is not guaranteed to meet electromagnetic compatibility require-

ments in the home.

WARNING!

When using this welder, always use a welding helmet . Use special fire resistant

protective clothing and do not allow the skin to be exposed to the ultra violet and

infrared rays produced by the arc; other people in the vicinity of the arc should be

protected by shields of non-reflecting curtains.

WARNING! Do not use in rain or store in locations affected by rain.

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RXT150E

Single phase frequency conversion and

rectifier

Output open circuit voltage

Three pin attachment plug

Manual metal arc welding with covered

electrodes

Rated input voltage

IP21S

Degree of protection against intrusion

of water and solid bodies

50 Hz

Rated input frequency

Regulatory compliance mark

I1 MAX

Maximum input current

I1 Eff

Rated input current

Duty Cycle at rated current

Conventional output current range

Welding voltage at rated current

THE RATING PLATE

The rating plate is shown on the side of the welder and displays the following symbols and

information.

Caution! Read operator’s manual

Model: RXT150E SN:

AS 60974 –1

X 10% 35% 60%

= 78V

140A 76A 58A

25.6V 23.0V 22.3V

20A/20.8V ~ 140A/25.6V (150A Peak)

= 230V I

1max

= 25A I

1eff

= 7.9A

IP21S

1~50/60Hz

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RXT150E

Know you welder.

1) ON/OFF Switch

2) Carry handle

3) Output current control.

The position of the knob will indicate the approximate welding current.

Note: Set the welding current based on the size of welding electrode to be used. See

page 9. Keep the welding current as low as possible for the job at hand to maintain

the best duty cycle and easy removal of slag.

4) Power indicator light.

Illuminates when output voltage is available.

5) Protection light.

Illuminates when the thermal protection circuit has activated. The unit will not weld

until it has cooled down.

6) Negative (-) output terminal

For ARC welding connect the earth clamp to this terminal.

7) Positive (+) output terminal.

For ARC welding connect the electrode holder to this terminal.

Note: For TIG welding reverse the connections in 6 and 7.

8) Welding mode switch

Selection switch for ARC or TIG welding

CAUTION! When fitting the welding leads to the unit, twist the plugs

clockwise and ensure that they are tight in the sockets. Loose connectors

will overheat, damage the unit and void warranty.

1 At Rear

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RXT150E

ARC WELDING PROCEDURE

Before commencing, make sure that your hand held welding mask or welding helmet is in po-

sition to protect your eyes. It is also advisable to wear gloves and clothing, which cover the

hands and arms to prevent flash burns.

1. Striking Arc. This is done by bringing the electrode into contact with the work piece us-

ing a light tapping action and withdrawing to create a gap of (1.5 mm – 3.00 mm.).

2. Maintaining Arc. Having created an arc, all that is necessary to maintain it is to proceed

steadily in one direction keeping the gap between the electrode and the work piece con-

stant. The electric current will flow through the electrode, across the arc gap, and in do-

ing so will melt the electrode core wire and protective flux. The electrode length will

gradually decrease as the metal is transferred to the work piece under a protective slag

formed by the flux. This slag can then be removed when cooled by lightly tapping with a

pointed tool or a welders chipping hammer.

3. To stop welding, all that is required is to withdraw the electrode from the work piece -

thus breaking the circuit. Be careful with the end of the electrode, as it will be hot! Pro-

vided the current setting is correct, the surface of the work piece will also melt by the

intensity of the electric arc. A degree of “penetration” is thereby obtained and a com-

plete “fusion” of the work piece and the deposited electrodes met

4. Selection of electrode. There is no hard and fast rule by which a particular gauge of

electrode is selected. Usually this is determined by, the type of weld required and the

thickness of the work piece. E.g. a butt weld in (1.5mm.) sheet metal can be done by a

1.6mm or 2.5mm electrode, the difference being that the 2.5mm electrode will do the

job quicker. The table below Gives guidance as to which electrode is most suitable ac-

cording to the material thickness. This table is only a guide, and values given are an in-

dication only.

Tip! Keep the welding current as low as possible for the job at hand to maintain the best duty

cycle from you welding machine, prevent the flux from burning and make removal of slag

easier.

Rod Size Weld Welding Current

1.6mm 40 - 50 Amps

2.0mm 50 - 75 Amps

2.5mm 75 - 105 Amps

Amperage Selection Guide

3.2mm 105 - 135 Amps

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RXT150E

TIG WELDING PROCEDURE

Before commencing, make sure that your hand held welding mask or welding helmet is in po-

sition to protect your eyes. It is also advisable to wear gloves and clothing, which cover the

hands and arms to prevent flash burns.

Note: TIG welding is a specialised procedure and it may take some time to become profi-

cient. Further reading and /or training is recommended.

TIG is defined as a welding process whereby the arc, during the working process, is main-

tained through an infusible metallic electrode (normally tungsten). The area of the arc

(electrode and weld pool) is protected against atmospheric contamination through an inert

gas, such as argon which continuously flows through the welding torch.

Filler Rod

The TIG welding torch is connected directly to the

(-)outlet of the welding machine and the gas flow

is controlled manually by the valve built into the

torch. The earth clamp is connected to the (+)

outlet.

A filler rod is when introduced to the weld pool.

General procedure.

 Ensure that the tungsten electrode is correctly sharpened before commencing.

 Turn the gas valve on to allow the gas to flow.

 Initiate the arc (scratch start).

Note: A copper striker plate can assist in starting the arc and reduce electrode

contamination.

 Pull the electrode away from the workpiece to form the arc.

 Once the weld pool is created, the welding can commence

 Depending on the type of weld etc, filler rod may be required.

 Once the weld is complete, pull the electrode away from the workpiece and close the

gas valve to stop the flow of gas.

Caution: Beginners are advised to practice on a scrap piece of metal (of the same

type as that to be welded) in order to set the output power to the correct level for the

ideal penetration.

Welding

Power

source

Page 11

RXT150E

THERMOSTATIC PROTECTION

This welder is automatically protected from overheating by a thermal overload cut out protec-

tor. If the transformer overheats the overload cut out protector will activate and cut off. The

amber light will illuminate to show that the cut out has operated.

After cooling the protector will reconnect the supply circuit and the welder will be ready for

further use.

NOTE: If the duty cycle of the machine is exceeded the thermostatic protection will activate.

MAINTENANCE

WARNING!

Before starting any cleaning, or maintenance procedures on the welding ma-

chine, make sure that it is switched Off and disconnected from the mains

supply.

There are no user serviceable parts inside the welder. Refer to qualified service personnel if

any internal maintenance is required.

WARRANTY:

This product has been manufactured to a high quality standard. It is guaranteed against

faulty materials and workmanship for 12 months from the date of purchase. Please retain

your receipt as proof of purchase.

If the product is found to be defective within the relevant time period, we will either replace

all defective parts or, at our discretion, replace the unit free of charge.

This guarantee does not cover defects caused by or resulting from: misuse, abuse or ne-

glect; trade, professional or hire use; repairs attempted by anyone other than our authorised

service agent; or damage caused by foreign objects, substances or accident.

Note: Consumable items such as clamps and electrode holders not covered by warranty.

Distributed in Australia by J W Ross and Sons ( Australia ) Pty Ltd.

PO Box 352 North Ryde BC, NSW, 1670

Inquiries phone 1800 251 338

Ross RXT150E General Instructions Manual

Brand: Ross

Model: RXT150E

Category: Welding System

Type: General Instructions Manual

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Ross RXT150E General Instructions Manual

Ross RXT150E General Instructions Manual

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