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.

IMPORTANTPLEASE 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 DESCRIPTIONThis 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 RXT40EPInput Voltage 230 V~Frequency 50 HzPhase No.   1Rated Input Current 22.4 A (I1eff)Rated Duty Cycle 60% at 40 AOutput current 20-40A Cooling Type   Fan CooledCase 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 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 refer-ence. Persons who are not familiar with this booklet should not use the cutter.

WARNING! SAFETY INSTRUCTIONS

TRAININGThe 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 qualified/experienced personnel.

SERIOUS FIRE RISKThe cutting 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 inflam-mable materials. It is advisable to have a fire extinguisher to hand.

WORK AREAEnsure 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 PIECEThe 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 SURFACESDo not cut containers or pipes that hold, or have held, flammable 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 AREAPlasma cutting emits fumes which can be dangerous. Make sure that the work area is well venti-lated.

AVOID ELECTRICAL CONTACTUse 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 SHOCKIt 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 ENVIRONMENTDo 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 PROPERLYUse protective gloves and fire resistant protective clothing when using the cutter. Avoid exposing skin to the ultraviolet rays produced by the arc.

ALWAYS USE THE WELDING MASKUnder 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 GLASSESAfter cutting use safety glasses when brushing, chipping grinding the slag from the weld.

OTHER PERSONSEnsure 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 reflecting curtains.

KEEP CHILDREN AND ANIMALS AWAYDo not let children or animals have access to the welding equipment or to the work area.

SWITCHING OFFWhen you have finished 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 CABLESKeep 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 PARTSBefore 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 fitted and always use safe lifting practices when lifting.

CAUTION! - VENTILATE THE Plasma cutter

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 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 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 HANDLINGPosition the plasma cutter on a horizontal surface that is able to support the weight: otherwise (e.g. inclined or uneven floors 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 SYMBOLSThe 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 PLATEThe rating plate is fitted to the welder and displays the following symbols and information.

Ground Single phase transformer - Rectified

1 ~50Hz

Mains supply single phase A.C. 50 Hz

RCM Marking indicating compliance to relevant Australian standards.

Mig Welding Outputs direct current. D.C.

x Duty Cycle U2 Rated Welding Voltage

I1 Rated Input Current U0 Rated no load voltage

I2 Rated Welding Current IP21S Protection Class

U1 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

• Fittheairregulatortotherearoftheunit.• Connecttheoutletoftheairregulatorto(8)the

airinputoftheplasmacutter.• Connectcleanairsupplytotheinput(3)oftheair

regulator.• Adjusttheairregulator(1)sothattheoutpres-

sureon(11)thegaugeto0.5mpa(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 QUALITYDo 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.

• Screwtheplasmatorchto(1)theoutputconnectorandcheckthatthefittingistightenedfirmly.

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.

• Connectthecontrolplugto(3)theswitchconnector• Connecttheairsupplytotheairregulatorandcheckthepressure.• Connect(8)thegroundleadtothejob.• Connectthemainsandturnonthemainssupply.• TurntheunitONat(5)thepowerswitch.• (7)Selectasuitablecuttingcurrentforthejobathand.

You are now ready to commence cutting.

PLASMA TORCH

The plasma torch fitted 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.

• Lineupthetorchwiththedesiredcut.• Makesurethatthetipisincontactwiththejob.(notethearcwillnotstartunlessthetimeisincontactwith

thejob.)• Pushthebuttononthetorchtobeginthecut.LED(4)willlightwhencutting.• Releasethebuttontoendthecut.

For straight edge cutting the torch should beheld at a 90° angle to the plate and draggedalong the job. The cutting speed will dependon the material thickness, amperage andairflow 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

PIERCINGTo 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 outputof the machine and is generally 50% of the ratedcutting thickness of the power source.It is important to direct the arc away from theoperator when establishing the arc as sparksand molten material will be ejected from thepoint of contact. Care must also be taken toprotect the surrounds from these sparks.

QUALITY CUTSDross (slag) is the excess material that spatters and builds up on the underside of thework-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 pliersor chipping off with a chisel or scraping or grinding the finished 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.

PROTECTIONThis 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 qualified service personnel if any internal maintenance is required.

EACH USE• Eachtimeyouusetheplasmacutter;checkallconsumableitemsthoroughly.- AwornTip/Nozzleisindicatedbyanelongatedoroversizedorifice.AwornTorchTip/Nozzle

contributestoreducedspeed,voltagedropandcrookedcuts.

- Thefaceoftheelectrodeshouldnotberecessedmorethan2mm.Replaceifwornbeyond this point.- IftheShieldCupdoesnotgooneasily,checkthethreads.

• InspectTorchforanywearing,cracksorexposedwires.Replaceorrepairbeforeuse.• Checkforproperfanoperation.

WEEKLYCheck your air and moisture filter/separator on the bottom of the air regulator

3 MONTHLYThe units should be serviced by suitable qualified personnel to check for general safety and clean the unit of dust and other contaminates.

MAINTENANCE

PROBLEM CAUSE SOLUTIONTorch will not start • NoPower

• Airsupply

• Jobnotearthedcorrectly

• Tipoftorchnotincontactwiththejob

• Turnpowerswitchandmainson.

• Checkthatairisconnectedandisatcorrectpressure.

• Makesurethereisasolidcon-nectionbetweenjobandgroundclampoftheoftheplasmacutter.

• Makesurethetipofthetorchisincontactwiththejobwhenthestatbuttonispushed.

Sparks are shooting upwardInstead of down through theMaterial.

• PlasmaTorchisnotpiercingthematerial.

• Torchmayhavebeenliftedformthejob

• Materialmaynotbegroundedproperly

• Cuttingspeedtoofast

• Increasecurrent.

• Keeptipincontactwiththejob

• Checkconnectionsforproperground.

• Reducespeed

Beginning of cut not completely pierced.

• Possibleconnectionproblem • Checkallconnections

Dross build-up on parts of cut.

• Tool/Materialbuildingupheat

• CuttingspeedtoosloworCurrenttohigh.

• Worntorchparts

• Allowmaterialtocoolthencon-tinuecut.

• Increasespeedand/orreducecurrentuntildrossisreducedtominimum.

• Inspectandrepairorreplacewornparts

Arc stops while cutting • Cuttingspeedtooslow

• Lackofairflowwhilecutting

• Worntorchparts.

• Dutycycleoftheplasmacutterexceeded.

• Increasespeeduntilproblemsolved.

• Youmayneedalargeraircom-pressorwhichcanmaintaintherequiredpressureandairflow.

• Inspectandrepairorreplacewornparts.

• Allowtheunittocoolfor15minutesbeforeresuming.

Insufficient penetration • Cuttingspeedtoofast• Torchtiltedtoomuch• Metaltoothick• Worntorchparts

• Slowcuttingspeed• Adjusttilt.• Severalpassesmaybenecessary• Inspectandrepairorreplace

wornparts

Consumables wearquickly

• Exceedingunitscapability• Improperlyassembledtorch

• Inadequateairsupply,pressuretoolow.

• Norecommendtocontinue.• Checkthetorchandconsuma-

bles.• Youmayneedalargeraircom-

pressorwhichcanmaintaintherequiredpressureandairflow.

WIRING DIAGRAM

Notes

For information on all ROSS productsplease visit: www.rosstools.com.auThe ROSS logo and Bull device are trademarks of WHITE INTERNATIONAL 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;(c) repairs attempted by anyone other than our authorised repair centres; or(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 WHITE INTERNATIONAL PO Box 304 Milperra LPO, NSW, Australia, 2214 Inquiries phone 1800 251 338

THE WHITE INTERNATIONAL policy is one of continuous improvement and the company reserves the right to the alter designs, colours and specifications without notice.