Ross RXT175ET User 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!
175 AMP
GAS/GASLESS MIG
WITH EURO TORCH
ROSSWELDING RXT175ET

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 welder is a power source for light duty manual arc welding only. It has been designed and manu-
factured specically for continuous MIG welding of carbon or mild steels with and without protective gas using
appropriate cored (tubular) electrode wire or solid wire. Power for the arc is given by a single phase transformer
with a drooping characteristic. It is suitable for use with 0.6/0.9mm solid or 0.8/0.9mm core wire and for welding
materials up to 8mm.
PRODUCT SPECIFICATION
Item RXT175ET
Input Power V 230
Frequency Hz 50
Phase No.  1
Rated No-load Voltage V 35 DC
Rated Input Capacity KVA 5.75
Rated Duty Cycle % 15
Output current A 30-145A — Peak 175A
Insulation Grade  H
Cooling Type  Fan Cooled
Case Protection Class  IP21S
Note: This welder requires a 15 mains supply.

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 welder, basic safety precautions, including the following, should be followed
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 reference.
Persons who are not familiar with this booklet should not use the welder.
WARNING! SAFETY INSTRUCTIONS
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 qualied/experienced personnel on this as-
pect 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 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.
WELDING SURFACES
Do not weld on containers or pipes that hold, or have held, ammable liquids or combustible
gases.
Do not weld coated, painted or varnished surfaces as the coatings may ignite and or can give off
dangerous fumes.
VENTILATE THE WORK AREA
Arc welding (especially using uxed core wire) emits fumes which can be dangerous. Make sure
that the work area is well ventilated.
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 welder 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 welder. Avoid exposing
skin to the ultraviolet rays produced by the arc.
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 produced
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 trigger 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 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 welding switch off the welder. Do not put the torch down with the welder
switch On and with the wire tted. 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.
CHECK DAMAGED PARTS
Before further use of the welder, 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.
IMPROPER USE
Do not use this welder for pipe thawing.
HANDLING
Ensure the handle is correctly tted and always use safe lifting practices when lifting.
CAUTION! - VENTILATE THE WELDER
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 activates leave
the welder for at least 15 minutes to cool down before further use.

ADDITIONAL PRECAUTIONS
WELDING 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 welding machine 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 welder 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. 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.
WARNING!
Any manual operation carried out on the moving parts of the wire feeder, for example:
Replacing rollers and/or the wire guide; Inserting wire in the rollers; Loading the wire reel;
Cleaning the rollers and the area underneath them.
Should be carried out with the welding machine switched off and disconnected from the
power supply outlet . Never lift the welding machine when connected to the mains
supply.

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
exposure limits for the welding fumes, which will depend on their composition,
concentration and the length of the exposure itself. Do not operate on materials
cleaned with chlorinated solvents or near such substances. Remove all ammable
materials (e.g. wood, paper, rags etc.) from the working area.
WARNING!
Do not weld on containers or piping that contains or has contained ammable 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 re 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-reecting curtains.
WARNING! Do not use in rain or store in locations affected by rain.

THE RATING PLATE
The rating plate is tted to the welder and displays the following symbols and information.
Ground Single phase transformer -Rec t ified
1 ~50Hz
Mains supply single p hase A.C.
50 Hz
RCM Markin g ind ic at ing c omp lianc e t o
releva nt Australian standards.
Mig We ld ing Outputs direc t current. D.C.
x Duty Cycle U2Rated Welding Voltage
I1Rated Input Current U0Rated no load voltage
I2Rated W elding Current IP21S Protect ion Class
U1Rated Input voltage % Percentage of full rated load
...A/...V~...A/...V: Output Range. Minimum and maximum rated welding current and
related load voltage.

KNOW YOUR WELDER
1) On/off switch
When the switch is in the “ O” position means the power OFF.
When the switch in the “1” position means the power is ON.
2) Output power settings
Adjust this knob to increase or decrease the welding current.
CAUTION! Do NOT change the switch position while welding.
3) Wire speed adjustment knob
Adjust this knob to set the wire feeding speed.
4) Earth cable
Use earth clamp to connect earth cable with work piece
5)Welding outlet for euro torch
The torch is installed at the end of the cable.
6)Overload light
If welding a long time the duty cycle may be exceeded, the overload lamp will turn ON(orange)
and the machine will stop working until the unit has cooled.
7) Welding Gas Hose and Mains Cable
(Not Shown) are located at the rear of the unit.
1
2
3
4
7
6
5

LOADING THE WIRE
Open the side cover of the unit
Remove the back tension knob from the wire reel holder and t the wire spool onto the wire reel
so that the wire will exit the spool from the top.
Note the reel holder can be reversed to cater for 100mm or 200mm reels.
Ret the back tension knob. (keep the adjustment of this knob as light as possible but sufciently
strong to prevent the wire roll from self un-spooling)
Fit the torch to the euro tting and rmly tighten.
Release the tension screw and open the upper roller arm
Without letting the wire un-spool, cut the end of the wire of cleanly leaving no kinks the feed
about 30cm of the wire through the guide tube and into the wire liner by hand.
The wire feed roller has two different size groves. Check that the wire is aligned with the correct
size grove in the wire feed roller for the type of wire and then careful close the upper roller and
tension screw. If necessary remove the wire feed roller and turn it over to access the other grove
and ret.
At the end of the torch
Twist the nozzle clockwise and pull to remove
Unscrew the contact tip counterclockwise and remove. Check that the correct tip size is being
used for the wire being tted.
Lay the torch sheath out in a straight line so that the wire move through it easily
WARNING! The following steps require applying power to the welder. Do not touch anything with the
torch or wire as it may result in accidental arcing.
Wire reel holder
Tension screw
Polarity selection
Upper roller arm
Wire feed roller
Guide tube Back tension knob

Plug the power cord into its electrical outlet, turn the current switch to Max and turn the welder
ON.
Lift the torch handle and continue pressing the trigger until the wire feeds through about 50mm
Note: If the wire does not feed through, view the wire feed unit and see if the wire is being
pushed. If it is not, turn the welder OFF and add more tension to the wire feed adjusting spring
and try again.
Once the wire is exposed, turn the welder OFF
Slide the contact tip over the wire and screw it into torch handle
Replace the nozzle and cut off any excess wire over 10mm
POLARITY SELECTION
The correct polarity must be set for the type of
welding.
When using solid wire in conjunction with weld-
ing gas, connect the torch to the positive ter-
minal and the earth clamp to the negative. See
diagram A.
When using ux cored wire (gasless) connect
the negative terminal to the welding torch and
the earth clamp to the positive. see diagram B.
CAUTION! Check that terminals are tight before commencing to weld to prevent burning
To commence the welding process proceed as follows.
Make sure that the earth clamp is rmly connected to the Work piece.
WARNING! Ensure that you have your protective clothes, gloves and welding helmet
correctly tted before welding. Do not start welding before your eyes are properly pro-
tected by the welding helmet.
Turn the welder switched ON and the welding gas if applicable.
You are now ready to execute the weld.
Select the required welding power setting weld.
Bring the wire into close proximity of the required weld start position. Keep the tip approximately
10-15 mm away from the work piece and squeeze the trigger on the torch to commence welding.
Adjust the wire feed rate to obtain the optimum weld
CAUTION! - (Do not adjust the welding power setting while welding)
Release the trigger to stop welding.
When nished welding turn the welder off and the welding gas if applicable.
Allow the weld to cool, the slag can be removed by tapping it lightly with the chipping hammer/
wire brush. Always wear safety glasses when brushing or chipping slag from the weld.
AB

THERMOSTATIC PROTECTION
This welder is automatically protected from overheating by a thermal overload cut out protector. 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 fur-
ther use.
NOTE: If the duty cycle of the machine is exceeded the thermostatic protection will activate.
There are no user serviceable parts inside the welder. Refer to qualied service personnel if any
internal maintenance is required.
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.
TORCH
Do not put the torch or its cable on hot work pieces; this would cause the insulating materials to
melt, making the torch unusable.
Every time the wire reel is changed, clean out the wire-guide and check the wire liner for build up
of dust and other contaminants. This increases friction and can lead to erratic wire feed and jam-
ming. Replace when necessary.
Daily: Check the wear and correct assembly of the consumable parts at the end of the torch;
swan neck, nozzle, contact tip. Replace when necessary.
WIRE FEEDER
Make frequent checks on the state of wear of the wire feed rollers, regularly remove the metal
dust deposited in the feeder area (rollers and wire-guide in-feed and out- feed)
OTHER
Make sure that the earth clamp is kept clean and in good working order.
Keep the cooling vents clear and clean the outer casing with a soft cloth.

GAS BOTTLE AND REGULATOR
For gas shield welding connect the
output of the regulator to the barb at the
rear of the unit and secure.
Welding gas
Eg.
Co2 or Co2/ Argon
WARNING! - Secure the gas bottle
CIRCUIT DIAGRAM

TROUBLESHOOTING GUIDE
No. Breakdown Analysis Solutions
1 No current output No voltage input Check the fuse and or
circuit breaker
Wrong Fuse or break-
er rating
Replace with correct
rating fuse or breaker
Thermal over load
lamp lit
Allow the unit to cool
2 Bad wire feed Low wire feed pres-
sure
Tighten the wire ten-
sion adjustment nut
No back tension on
reel
Check the wire spool
clip
Wire is oxidised Replace wire spool.
Replace liner
3 Poor weld penetration Low input voltage Check that if input
voltage is the same
with rated voltage
Bad connection Check grounding ca-
ble/ clamp, make sure
of a good connection.
Contact tip worn Replace contact tip
4 Porosity in weld No gas ,little gas or
wrong gas
Check all gas
Blockage of gas line Use compress air to
clear the Blockage
Torch valve has been
blocked
Open the welding
torch and check
Bad gas and wire Gas must be dry, use
another type wire
5 No wire feed Control wire broken
or Faulty switch in the
handle
Check by inspection
Wire Control PCB
faulty
Replace the PCB

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;
(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 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 [phone]
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.