Table of Contents
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User manual
WARNING! Read and understand all
safety warnings and instructions carefully
before using this machine. Failure to
follow the warnings and instructions may
result in electric shock, fire and/or serious
injury. Save this manual for future
reference.
ATTENTION! Products covered by this
manual will vary in appearance, assembly,
inclusions, description and packaging.
NOTE! This manual covers multiple styles
of product as well as options / accessories
that may not be suitable for the machine
you have purchased.
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Table of Contents
Related Manuals for Rossi Welders WLDMIG195RSSACAA
Summary of Contents for Rossi Welders WLDMIG195RSSACAA
- Page 1 User manual WARNING! Read and understand all safety warnings and instructions carefully before using this machine. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save this manual for future reference. ATTENTION! Products covered by this manual will vary in appearance, assembly, inclusions, description and packaging.
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Page 2: Table Of Contents
Product Manual – Rossi Welders Index Index ................................1 Safety ................................2 General Safety ............................12 Parts Diagram ............................13 Which welder do I need? ..........................22 Types of Welding ............................22 ARC / Stick Welding ..................................22 MIG Welding / Gas Metal Arc Welding (GMAW) ........................... 23 TIG Welding / Gas Tungsten Arc Welding (GTAW) ........................ -
Page 3: Safety
Product Manual – Rossi Welders Safety Only qualified persons should install, operate, maintain, and repair this unit. ATTENTION! This manual is provided to assist the owner of the product to understand the functions it provides and how to prepare the equipment. This manual does not seek to teach the user how to perform the actual task it is used for. - Page 4 Product Manual – Rossi Welders structures such as floors, gratings, or unavoidable, use a residual current to blow up. Sparks can fly off from the scaffolds; when in cramped positions device (RCD) protected supply. Use of welding arc. The flying sparks, hot work such as sitting, kneeling, or lying;...
- Page 5 Product Manual – Rossi Welders Electric and Magnetic Fields equipment (cables and cords) away Connect work clamp to work piece from moving vehicles when working as close to the weld as possible. (EMP) can affect Implanted from an aerial location.
- Page 6 Product Manual – Rossi Welders Warnings inflammation cornea, Safety glasses which will help to cataracts or blindness. Read the instructions carefully. Be refract (bend away) the UV and IR familiar with the controls and proper rays away, reducing the chances A welding flash can occur by indirectly use of the equipment.
- Page 7 Product Manual – Rossi Welders IMPORTANT! - Machine, Fuel handling or Electrical Safety; If you are not familiar with safe operation / handling of this machine, or are in any way unsure of any part of this products suitability or correct use for your application you should complete training conducted by a person or organisation qualified in safe use and training related to this product.
- Page 8 Product Manual – Rossi Welders DANGER! Fumes and Gases are caused by the melting, vaporisation and other reactions of the consumables, base metals and gases (where applicable) involved in the welding arc. Some common contaminants: Contaminant Source Iron Fume Vaporisation of iron from base metal and electrode coatings.
- Page 9 Product Manual – Rossi Welders Advised Protection Required Includes: Adequate ventilation. Keep your head out of and away from the fumes. Use a welding fume respirator, or an air supplied respirator (especially in confined space). Use a fume extraction unit/or gun.
- Page 10 Product Manual – Rossi Welders Proper Grounding Grounding of electrical circuits is a safety practice that is documented in various codes and standards. A typical arc welding setup may consist of several electrical circuits. Applying and maintaining proper grounding methods within the welding area is important to promote electrical safety in the workplace.
- Page 11 Product Manual – Rossi Welders Shielding Gas Safety This article is intended to give users some basic information about the recommended safety procedures concerning the use of mig/tig welding shielding gases. It does not cover the use of other gases such as Oxygen or Acetylene as those need much more careful transporting, storage and handling procedures than shielding gases.
- Page 12 Product Manual – Rossi Welders Remove the cylinder from the vehicle at the earliest opportunity, place in the proper storage area and secure it. Visually inspect the cylinder for damage to the body and the valve assembly, if there is any sign of damage, do not use it and inform your supplier immediately.
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Page 13: General Safety
Product Manual – Rossi Welders General Safety 110914123000 Rossi Welders... -
Page 14: Parts Diagram
Product Manual – Rossi Welders Parts Diagram ATTENTION! Products covered by this manual will vary in appearance, assembly, inclusions, description and packaging. A Typical Metal inert gas (MIG) / Flux-cored arc welding (FCAW) and Metal-cored Arc Welding (MCAW) setup NOTE! The wire feed unit is shown separately for clarity. Most welders have wire feed units built into the welder. -
Page 15: Typical Mma Welding/Tig Setup
Product Manual – Rossi Welders Typical MMA (Stick) Welding setup Typical TIG setup 110914123000 Rossi Welders... -
Page 16: Super 200P Ac/Dc Welders
Product Manual – Rossi Welders SUPER 200P AC/DC Welders IMPORTANT! ARC Welding uses a negative ground (earth) connection. TIG / Plasma Cut use a positive ground (earth). IMPORTANT! This welder is fitted with overheating protection. If the welder overheats it will go into protection mode and stop working with the O.C. - Page 17 Product Manual – Rossi Welders “TIG Earth” clamp connection & “ARC rod holder” connection. “Plasma Earth” Clamp. DIN Socket: High frequency start control. “Plasma Torch” connection. “TIG Torch” connection & “ARC earth” clamp connection. Post flow (Gas): The length of time the torch gas flows after the arc terminates.
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Page 18: Tc-205 Ac/Dc Welders
Product Manual – Rossi Welders TC-205 AC/DC Welders Welding Process Selection: This button selects between MMA/TIG and CUT modes. 2T/4T Switch: 2T: for using a switch on the torch handle…when you plug in the foot pedal or torch amperage control, most TIG inverters are designed to bypass the 2t and 4t settings because the amperage control overrides all the upslope and downslope. - Page 19 Product Manual – Rossi Welders MT 200 Welders O/C: Overheating alert indicator, this can also indicate power issues. Power indicator: Displays if power supply is on or off. Welding Process Selection: This button selects between MMA/TIG and CUT modes. Amperage (current) display: Welding Amperage display during welding.
- Page 20 Product Manual – Rossi Welders WELD-MIG185E Welders Current (Amperage) display: Welding Current display during welding. Overheating alert: This indicator, this can also indicate power issues. Welding Process Selection: This button selects between MMA and MIG. Wire Speed / Speed: The speed at which wire is fed out of the machine.
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Page 21: Wldmig195/185/155Rssadje Welders
Product Manual – Rossi Welders WLDMIG195RSSADJE, WLDMIG185RSSADJE & WLDMIG155RSSADJE Welders Overheating alert: This indicator, this can also indicate power issues. MIN/MAX switch: - 1/2 switch: - Wire Speed / Speed: The speed at which wire is fed out of the machine. - Page 22 Product Manual – Rossi Welders ROSSWELDER WELDER-S200 Welders Amperage (current) Adjustment. Power indicator: Displays if power supply is on or off. O/C: Overheating alert indicator, this can also indicate power issues Amperage (current) Adjustment. Power indicator: Displays if power supply is on or off.
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Page 23: Which Welder Do I Need
Product Manual – Rossi Welders Which welder do I need? Unfortunately, there is no single welding process suitable for all applications, so let’s begin with an overview of the basic processes and highlight the capabilities and advantages of each. This will help us better match a process to your specific needs. -
Page 24: Mig Welding / Gas Metal Arc Welding (Gmaw)
Product Manual – Rossi Welders MIG Welding / Gas Metal Arc Welding (GMAW) MIG Welding is the process of using welding wire either with or without shielding gas to fuse two pieces of metal. Easiest process to learn ... -
Page 25: Pulsed Tig Welding
Product Manual – Rossi Welders The chart below identifies which weld process you can use for each type of metal. Keep in mind that many of these materials are also processed using varying combinations of two or more metals, a process that is helpful to reinforce strength and functionality. -
Page 26: Plasma Cutting
Product Manual – Rossi Welders the ripple effect in the weld bead, narrows the weld bead and adds more “cooling effect.” Reducing the number of pulses per second widens the weld bead. Slower pulsing also helps agitate the puddle and release any porosity or gas trapped in the weld (this is very helpful when welding aluminium with AC pulsed TIG). -
Page 27: Getting Started
Product Manual – Rossi Welders Getting Started IMPORTANT! The actual Earth can vary from positive to negative depending on the type of function / machine you are using! Be sure to check you have configured your welder with the correct earthing terminal before starting your project. -
Page 28: Arc Welding Basics
Product Manual – Rossi Welders ARC Welding Basics Arc welding (short for Manual Metal Arc (MMA) welding and also known as Stick and SMAW) is a very involved subject and this below information is only a basic introduction. Arc Welding Safety - As with any other electric welding process, skin and eyes need to be properly protected from UV light. -
Page 29: Installing Mig Wire
Product Manual – Rossi Welders Installing MIG wire IMPORTANT! MIG welders are very sensitive to wire feeder settings and liner condition. The wire liner is a service item and should be replaced regularly especially if rusty wire has been run through it. - Page 30 Product Manual – Rossi Welders The wire feed roller itself will normally have two grooves, and is secured either by a grub screw in the side of the roller, or a knurled plastic cap as in the photo. The groves on welders are normally matched to 0.6mm, 0.8mm and 1mm wire and the roller can be reversed / swapped to line up the...
- Page 31 Product Manual – Rossi Welders Setting the reel tensioner - Finally check the tension on the wire reel. The tensioner on the reel is there to stop the wire becoming loose and tangled, but the tension should be as light as possible to make life easy for the wire feed mechanism.
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Page 32: Troubleshooting
Product Manual – Rossi Welders Troubleshooting 110914123000 Rossi Welders... - Page 33 Product Manual – Rossi Welders 110914123000 Rossi Welders...
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Page 34: Arc Welding Faults
Product Manual – Rossi Welders Arc Welding Faults Arc Length Too Short This weld was laid with the end of the rod covered by the molten slag. The surface of the weld is uneven where it has been dragged along by the rod, and the weld will be low on power and contain slag inclusions. -
Page 35: Current Setting Faults
Product Manual – Rossi Welders Current Setting Faults Amps too low - Setting the amps too low will result in a tall, narrow bead lacking in penetration. The weld will be difficult to start and the arc prone to straying towards one side of a joint in preference to the other. -
Page 36: Tig Welding Faults
Product Manual – Rossi Welders TIG Welding Faults Poor Gas Coverage Leads to Contamination - The shielding gas is not turned on, there is either too little or too much gas shielding, or the gas shielding is blown away. Check the gas cylinder label to be sure you’re using the right type of gas for TIG welding, generally 100 percent argon (or perhaps an argon/helium blend for thick aluminium). -
Page 37: Mig Welding Faults
Product Manual – Rossi Welders MIG Welding Faults No Shielding Gas on Steel - A lack of or inadequate shielding gas is easily identified by the porosity and (pinholes) in the face and interior of the weld. On aluminium, a sooty looking weld can be caused by using a drag vs. a push technique. The soot can be removed, but cutting the weld open will reveal pinholes where impurities are trapped in the weld. -
Page 38: Plasma Cutting Faults
Product Manual – Rossi Welders Feeding aluminium: Because of its low columnar strength, feeding aluminium wire has been likened to pushing a wet noodle through a straw. Bird-nesting or the tangling of the wire between the drive roll and the liner is a common, time-consuming and costly problem. Clearing it requires the operator to stop welding, cut the wire, discard the wire in the gun, and re-feed new wire through the liner. -
Page 39: Specifications
Product Manual – Rossi Welders Specifications WLDMIG195RSSACAA Process: MIG / MAG / MMA Input power: 240V, 50Hz Rated output (duty cycle): 195A-10%, 74A-60%, 60A-100% Welding amperage range: 40-195Amps (Max) No load voltage: 33V Single pass weld: Weldable metals: Wire diameter range:... - Page 40 Product Manual – Rossi Welders WELD-CT416 Process: TIG / MMA / CUT Input power: 240V, 50Hz (15A plug) Rated output (duty cycle): Welding amperage range: TIG 10-160 Amps / MMA 20-160 Amps / CUT 20-40 Amps No load voltage: Single pass weld:...
- Page 41 Product Manual – Rossi Welders WELD-ROSSI-205TC Process: TIG/CUT/MMA Input power: 240V, 50Hz Rated output (duty cycle): TIG 60%@200Amps / MMA 35%@160Amps Welding amperage range: TIG 10-200Amps / MMA 10-160Amps No load voltage: Single pass weld: Weldable metals: Wire diameter range: -...
- Page 42 Product Manual – Rossi Welders WLDMIG185RSSADJE Process: MIG/MAG Input power: 240V, 50Hz (15A Plug) Rated output (duty cycle): 185a-10%, 68a-60%, 55a-100% Welding amperage range: 40-185Amps (Max) No load voltage: 33V Single pass weld: Weldable metals: Wire diameter range: 0.6-0.8mm to 0.8-1.0mm...
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Page 43: Glossary
Product Manual – Rossi Welders Glossary AC Welders – Aluminium & Magnesium DC Welders – All other metals Arc Force – This function enables operators to tailor the shape of the volt/amp curve to better suit the different joint configurations and electrode types. -
Page 44: Appendix
Product Manual – Rossi Welders Appendix © Copyright 2012 - Mills International Trading Pty Ltd. 110914123000 Rossi Welders...
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