Ross RXT40EP Owner's manual

Brand: Ross

Model: RXT40EP

Category: Welding System

Type: Owner's manual

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!

40 AMP

AIR PLASMA

CUTTER

ROSSWELDING RXT40EP

CAUTION!

THIS is a Caution symbol. This symbol is used throughout the user guide whenever there is a risk of

damaging your product. Ensure that these warnings are read and understood at all times.

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 per-

sonal injury. Ensure that these warnings are read and understood at all times.

GENERAL DESCRIPTION

This unit is a contact type plasma cutter with high frequency start. This means that the tip of the

torch MUST be in contact with the job before the plasma arc will strike. It does NOT have pilot

arc system. It is designed for cutting low carbon steel, stainless steel, high strength steel, alloy

steel and other non-ferrous materials.

PRODUCT SPECIFICATION

Item RXT40EP

Input Voltage 230 V~

Frequency 50 Hz

Phase No.  1

Rated Input Current 22.4 A (I1eff)

Rated Duty Cycle 60% at 40 A

Output current 20-40A

Cooling Type  Fan Cooled

Case Protection Class  IP21S

Air Input pressure 0.4-0.5 Mpa (60 - 75psi)

Air consumption 115l/Min ( 4cfm)

Plasma torch PT31 compatible.

Maximum cut 15mm (Separation cut mild steel).

Normal cutting range 1-12mm (Mild Steel)

The actual cutting range depends on the type and hardness of the material being cut.

Note: This plasma cutter has been ﬁtted with a 15 Amp plug for test and commissioning purposes.

It should be changed to suit to electrical installation at hand.

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

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

When using this plasma cutter, basic safety precautions, including the following, should be fol-

lowed to reduce the risk of re, 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 refer-

ence. Persons who are not familiar with this booklet should not use the cutter.

WARNING! SAFETY INSTRUCTIONS

TRAINING

The operator should be properly trained to use the plasma cutter safely and should be informed

about the risks relating to cutting procedures. This manual does not attempt to cover cutting

technique. Training should be sought from qualied/experienced personnel.

SERIOUS FIRE RISK

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

constitutes a serious re risk. Make sure that the area around the work piece is clear of all inam-

mable materials. It is advisable to have a re extinguisher to hand.

WORK AREA

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

cess 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.

WORK SURFACES

Do not cut containers or pipes that hold, or have held, ammable liquids or combustible gases.

Do not coated, painted or varnished surfaces as the coatings may ignite and or can give off dan-

gerous fumes.

VENTILATE THE WORK AREA

Plasma cutting emits fumes which can be dangerous. Make sure that the work area is well venti-

lated.

AVOID ELECTRICAL CONTACT

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

ble) 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 circumstances.

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.

CONSIDER WORK AREA ENVIRONMENT

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

area well lit.

SAFETY INSTRUCTIONS … cont

DRESS PROPERLY

Use protective gloves and re resistant protective clothing when using the cutter. Avoid exposing

skin to the ultraviolet rays produced by the arc.

ALWAYS USE THE WELDING MASK

Under no circumstances should the cutter 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 produced

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

whilst cutting. Move the torch away from the work piece and release the trigger switch before

removing the welding mask.

SAFETY GLASSES

After cutting 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 people

just passing by. Use screens if necessary, or non reecting 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 nished cutting switch off the plasma cutter. Do not put the torch down with the

welder switch On. When leaving the plasma cutter unattended, move the On/Off switch to the Off

position and disconnect it from the mains supply. Do not leave hot material unattended after cut-

ting

WELDING CABLES

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

damage to the cutting torch.

CHECK DAMAGED PARTS

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

mine 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 prop-

erly repaired, or replaced, by an authorised service centre.

HANDLING

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

CAUTION! - VENTILATE THE Plasma cutter

THERE must always be a sufcient 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 overload cut out protector acti-

vates leave the welder for at least 15 minutes to cool down before further use.

ADDITIONAL PRECAUTIONS

CUTTING OPERATIONS:

In environments with increased risk of electric shock;

In conned spaces; In the presence of ammable 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 plasma cutter on a horizontal surface that is able to support the weight:

otherwise (e.g. inclined or uneven oors etc.) there is danger of overturning.

The plasma cutter MUST NOT be supported by the operator (e.g using belts).

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

forms 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 between 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.

WARNING!

Any maintenance operation carried out ie changing consumable etc. SHALL be carried

out with the plasma cutter machine switched off, disconnected from the power supply

outlet and the air supply disconnected.

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 cutting circuit. The no-load

voltage supplied by the welding machine ARE dangerous.

THE RATING PLATE

The rating plate is tted to the welder and displays the following symbols and information.

Ground Single phase transformer - Rec tified

1 ~50Hz

Mains supp ly single phase A.C.

50 Hz

RCM Marking ind ic at ing c omplianc e t o

releva nt Australian standards.

Mig We ld ing Outputs direc t c urrent. D.C.

Duty Cycle

2 Rated Welding Voltage

Rated Input Current

0 Rated no load voltage

Rated Welding Current

IP21S Protection Class

1 Rated Input voltage % Percentage of full rated load

...A/...V~...A/...V: Output Range. Minimum and maximum rated welding current and

related load voltage.

Plasma cutter

Input current

SET UP

• Fittheairregulatortotherearoftheunit.

• Connecttheoutletoftheairregulatorto(8)the

airinputoftheplasmacutter.

• Connectcleanairsupplytotheinput(3)oftheair

regulator.

• Adjusttheairregulator(1)sothattheoutpres-

sureon(11)thegaugeto0.5mpa(75psi)

Note: if the pressure is to low the plasma cut-

ter will automatically shut off.

TYPICAL SETUP.

Note: The compressor MUST

be capable to deliver minimum

of 0.6mpa (90psi) at 115l/min

(4cfm) or the cutter will not be

able to operate continuously.

CAUTION! AIR QUALITY

Do not use the plasma cutter on an air system that includes an oiler. Fine particles of oil WILL

contaminate the internals components of the plasma torch and void you warranty.

• Screwtheplasmatorchto(1)theoutputconnectorandcheckthatthe

ttingistightenedrmly.

WARNING! Check that the yellow cover of the torch

connector is not damaged or loose so the output termi-

nal can not be accidently touched.

• Connectthecontrolplugto(3)theswitchconnector

• Connecttheairsupplytotheairregulatorandcheckthepressure.

• Connect(8)thegroundleadtothejob.

• Connectthemainsandturnonthemainssupply.

• TurntheunitONat(5)thepowerswitch.

• (7)Selectasuitablecuttingcurrentforthejobathand.

You are now ready to commence cutting.

PLASMA TORCH

The plasma torch tted as standard is compatible with industry standard type PT31.

It is a contact type torch that requires the tip be in contact with the work piece before an arc can

be initiated.

Note: The torch head, electrode, distributer, tip

and protective cover are consumable items and

will require regular replacement.

WARNING! Before changing consuma-

bles turn the power off, disconnect the

unit form the mains supply and allow the

torch to cool.

Replace Electrode when it is worn approximately 1.5-2mm

The other components should be replaced as required.

WARNING! Dangerous voltages are contained within the cutting torch while cutting.

DO NOT use the torch if the torch or the cable are damaged. Replace them immediately!

OPERATION

WARNING! Make sure you are wearing suitable cloths, gloves and eye protection before

using the plasma cutter.

• Lineupthetorchwiththedesiredcut.

• Makesurethatthetipisincontactwiththejob.(notethearcwillnotstartunlessthetimeisincontactwith

thejob.)

• Pushthebuttononthetorchtobeginthecut.LED(4)willlightwhencutting.

• Releasethebuttontoendthecut.

For straight edge cutting the torch should be

held at a 90° angle to the plate and dragged

along the job. The cutting speed will depend

on the material thickness, amperage and

airow rate. In general a good cutting speed will

result in the shower of sparks at an angle of 15

to 20 degrees from the cut.

CUTTING TECHNIQUE

PIERCING

To pierce material the cutting torch tip should in

contact with the job but held at an angle of 45°to

the surface. Once the arc is established the torch is

moved to the 90° position.

Piercing thickness is dependent on the output

of the machine and is generally 50% of the rated

cutting thickness of the power source.

It is important to direct the arc away from the

operator when establishing the arc as sparks

and molten material will be ejected from the

point of contact. Care must also be taken to

protect the surrounds from these sparks.

QUALITY CUTS

Dross (slag) is the excess material that spatters and builds up on the underside of the

work-piece as you cut. Dross occurs when the operating procedure and technique is less than

optimal. It will require practice and experience to obtain cuts without dross. Although less than

optimal cuts will contain dross, it is relatively easy to remove by breaking it off using pliers

or chipping off with a chisel or scraping or grinding the nished cut as needed and is generally

only a minor inconvenience.

A combination of factors contribute to the buildup of dross. They include material type, material

thickness, amperage used for the cut, speed of the torch across the work-piece, condition of the

torch tip, air pressure, etc. Generally there is an inversely proportional relationship between out-

put current and speed of cut. Do not use more output current than is necessary and adjust speed

of cut toward minimizing dross buildup on underside of cut. Experiment with adjusting current

and speed to minimize dross.

PROTECTION

This plasma cutter is automatically protected from overheating

by a thermal overload cut out protector The amber LED (6) will

illuminate to show that the cut out has operated.

After cooling the protector will reconnect the supply circuit and

the cutter will be ready for further use.

NOTE: If the duty cycle of the machine is exceeded the thermo-

static protection will activate.

There are no user serviceable parts inside the welder. Refer to qualied service personnel if any

internal maintenance is required.

EACH USE

• Eachtimeyouusetheplasmacutter;checkallconsumableitemsthoroughly.

- AwornTip/Nozzleisindicatedbyanelongatedoroversizedorice.AwornTorchTip/Nozzle

contributestoreducedspeed,voltagedropandcrookedcuts.

- Thefaceoftheelectrodeshouldnotberecessedmorethan2mm.Replaceifwornbeyond this point.

- IftheShieldCupdoesnotgooneasily,checkthethreads.

• InspectTorchforanywearing,cracksorexposedwires.Replaceorrepairbeforeuse.

• Checkforproperfanoperation.



WEEKLY

Check your air and moisture lter/separator on the bottom of the air regulator

3 MONTHLY

The units should be serviced by suitable qualied personnel to check for general safety and

clean the unit of dust and other contaminates.

MAINTENANCE

PROBLEM

CAUSE SOLUTION

Torch will not start

• NoPower

• Airsupply

• Jobnotearthedcorrectly



• Tipoftorchnotincontactwith

thejob

• Turnpowerswitchandmains

on.

• Checkthatairisconnectedand

isatcorrectpressure.

• Makesurethereisasolidcon-

nectionbetweenjoband

groundclampoftheofthe

plasmacutter.

• Makesurethetipofthetorchis

incontactwiththejobwhenthe

statbuttonispushed.

Sparks are shooting upward

Instead of down through the

Material.

• PlasmaTorchisnotpiercingthe

material.

• Torchmayhavebeenliftedform

thejob

• Materialmaynotbegrounded

properly

• Cuttingspeedtoofast

• Increasecurrent.

• Keeptipincontactwiththejob

• Checkconnectionsforproper

ground.

• Reducespeed

Beginning of cut not

completely pierced.

• Possibleconnectionproblem • Checkallconnections

Dross build-up on parts of

cut.

• Tool/Materialbuildingupheat

• Cuttingspeedtooslowor

Currenttohigh.

• Worntorchparts

• Allowmaterialtocoolthencon-

tinuecut.

• Increasespeedand/orreduce

currentuntildrossisreducedto

minimum.

• Inspectandrepairorreplace

wornparts

Arc stops while cutting

• Cuttingspeedtooslow

• Lackofairowwhilecutting



• Worntorchparts.

• Dutycycleoftheplasmacutter

exceeded.

• Increasespeeduntilproblem

solved.

• Youmayneedalargeraircom-

pressorwhichcanmaintainthe

requiredpressureandairow.

• Inspectandrepairorreplace

wornparts.

• Allowtheunittocoolfor15

minutesbeforeresuming.

Insufcient penetration

• Cuttingspeedtoofast

• Torchtiltedtoomuch

• Metaltoothick

• Worntorchparts

• Slowcuttingspeed

• Adjusttilt.

• Severalpassesmaybenecessary

• Inspectandrepairorreplace

wornparts

Consumables wear

quickly

• Exceedingunitscapability

• Improperlyassembledtorch

• Inadequateairsupply,pressure

toolow.

• Norecommendtocontinue.

• Checkthetorchandconsuma-

bles.

• Youmayneedalargeraircom-

pressorwhichcanmaintainthe

requiredpressureandairow.

WIRING DIAGRAM

Notes

For information on all ROSS products

please visit: www.rosstools.com.au

The ROSS logo and Bull device are trademarks of J.W. Ross Pty Ltd.

WARRANTY

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law.

You are entitled to a replacement or refund for a major failure and for compensation for any other

reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or re-

placed if the goods fail to be of acceptable quality and the failure does not amount to a major

failure.

This product is guaranteed against faulty materials and workmanship for 12 months from the date

of purchase.

Please retain your receipt as proof of purchase.

This warranty does not cover defects caused by or resulting from:

(a) misuse, abuse or neglect;

(b) trade, professional or hire use;

(d) damage caused by foreign objects, substances or accident.

WARRANTY EXCLUSIONS

Wear parts or service related parts required when performing normal and regular maintenance

of this product are not covered by warranty unless it is found to be defective by an Authorised

Service Centre.

Consumable items such as torch head, electrode, distributor, tip and protective cover, swan

necks, nozzles, contacts tips, wire liners etc are 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

The J.W. Ross policy is one of continuous improvement and the company reserves the right to

alter designs, colours and specications without notice.

Ross RXT40EP Owner's manual

Brand: Ross

Model: RXT40EP

Category: Welding System

Type: Owner's manual

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Ross RXT40EP Owner's manual

Ross RXT40EP Owner's manual

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