0 A MP

4 S M A
PL A
A I R
U T TER
C

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!

ROSSWELDING RXT40EP
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.
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.

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.
 WARNING! SAFETY INSTRUCTIONS

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.
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 qualified/experienced personnel.

SERIOUS FIRE RISK

The 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 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, 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 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 fire 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 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 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 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 HANDLING

Position 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 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 fitted to the welder and displays the following symbols and information.

Ground Single phase transformer - Rectified

Mains supply single phase A.C. RCM Marking indicating compliance to

50 Hz relevant Australian standards.
1 ~50Hz
Plasma
Mig cutter
Welding Outputs direct current. D.C.

x Duty Cycle U2 Rated Welding Voltage

I1 Input current
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.
SET UP

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.

• 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.

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.
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

• Screw the plasma torch to (1) the output connector and check that the
fitting is tightened firmly.

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.

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.
CUTTING TECHNIQUE
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
airflow 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.

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 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.
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 qualified service personnel if any
internal maintenance is required.

MAINTENANCE
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 orifice. 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 filter/separator on the bottom of the air regulator

3 MONTHLY
The units should be serviced by suitable qualified personnel to check for general safety and
clean the unit of dust and other contaminates.
PROBLEM
Torch will not start
Sparks are shooting upward
Instead of down through the
Material.
Beginning of cut not
completely pierced.
Dross build-up on parts of
cut.
Arc stops while cutting
Insufficient penetration
Consumables wear
quickly
CAUSE
• No Power
• Air supply
• Job not earthed correctly
• Tip of torch not in contact with
the job
• 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
• Possible connection problem
• Tool/Material building up heat
• Cutting speed too slow or
Current to high.
• Worn torch parts
• Cutting speed too slow
• Lack of air flow while cutting
• Worn torch parts.
• Duty cycle of the plasma cutter
exceeded.
• Cutting speed too fast
• Torch tilted too much
• Metal too thick
• Worn torch parts
• Exceeding units capability
• Improperly assembled torch
• Inadequate air supply, pressure
too low.
SOLUTION
• 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.
• Increase current.
• Keep tip in contact with the job
• Check connections for proper
ground.
• Reduce speed
• Check all connections
• 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
• Increase speed until problem
solved.
• You may need a larger air com-
pressor which can maintain the
required pressure and air flow.
• Inspect and repair or replace
worn parts.
• Allow the unit to cool for 15
minutes before resuming.
• Slow cutting speed
• Adjust tilt.
• Several passes may be necessary
• Inspect and repair or replace
worn parts
• 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 flow.
WIRING DIAGRAM
Notes
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.

For information on all ROSS products

please visit: www.rosstools.com.au
The ROSS logo and Bull device are trademarks of WHITE INTERNATIONAL Pty Ltd.