Arc WLDMMAROSA2C5 ROSSI 180 Amp Portable MMA Inverter Welder 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 product models. Some

features, options and/or accessories may or may not be

applicable to your specific model.

Colours, models, and appearances may vary

User Manual

[Revision 28.0 January 2024]

READ THIS MANUAL CAREFULLY BEFORE USE –

FAILURE TO DO SO MAY RESULT IN INJURY, PROPERTY

DAMAGE AND MAY VOID WARRANTY. • KEEP THIS

MANUAL FOR FUTURE REFERENCE. • Products covered

by this manual may vary in appearance, assembly, inclusions,

specifications, description, and packaging.

Product Manual – Rossi Welders

Index

Index ............................................................................................................................................................... 1

Safety .............................................................................................................................................................. 2

General Safety .............................................................................................................................................. 12

Parts Diagram ............................................................................................................................................... 13

Which welder do I need? .............................................................................................................................. 29

Types of Welding .......................................................................................................................................... 29

ARC / Stick Welding ...................................................................................................................................................................... 29

MIG Welding / Gas Metal Arc Welding (GMAW) ........................................................................................................................... 30

TIG Welding / Gas Tungsten Arc Welding (GTAW) ...................................................................................................................... 30

Pulsed TIG Welding ...................................................................................................................................................................... 31

Plasma Cutting .............................................................................................................................................................................. 32

Getting Started .............................................................................................................................................. 33

TIG welding Basics ....................................................................................................................................................................... 33

ARC Welding Basics ..................................................................................................................................................................... 34

Installing MIG wire ........................................................................................................................................................................ 35

Troubleshooting ............................................................................................................................................ 38

Arc Welding Faults ........................................................................................................................................................................ 40

Travel Speed Faults ...................................................................................................................................................................... 40

Current Setting Faults ................................................................................................................................................................... 41

TIG Welding Faults ....................................................................................................................................................................... 42

MIG Welding Faults....................................................................................................................................................................... 43

Plasma Cutting Faults ................................................................................................................................................................... 44

Specifications ................................................................................................................................................ 45

Spare Parts ................................................................................................................................................... 56

Glossary ........................................................................................................................................................ 59

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. It is strongly

recommended that a comprehensive training course on the machines use, safe

handling and operation be completed before attempting to use this machine.

It is important you read

and understand the

instruction manual

before use and keep the

manual in a safe place for

future reference.

Safety precautions must

be observed to reduce

the risk of personal injury

when operating this

machine.

It is strongly

recommended that a

comprehensive training

course on machine use,

handling and operation

be completed before

attempting to use this

machine.

IMPORTANT! Like all power

equipment this unit must be

handled carefully.

DANGER! Electric Shock can

kill.

DANGER! Exposure to fumes

and gases can damage the

lungs and respiratory system or

cause asphyxiation.

Work area safety

Keep work area clean and well lit.

Cluttered or dark areas invite

accidents. Do not operate equipment in

explosive atmospheres, such as in the

presence of flammable liquids, gases

or dust. Equipment creates sparks

which may ignite. Keep children and

bystanders away while operating

equipment.

Personal safety

Stay alert, watch what you are doing

and use common sense when

operating equipment. Do not use

equipment while you are tired or under

the influence of drugs, alcohol or

medication. A moment of inattention

while operating equipment may result

in serious personal injury. Use personal

protective equipment. Always wear eye

protection. Protective equipment such

as dust mask, non-skid safety shoes,

hard hat, or hearing protection used for

appropriate conditions will reduce

personal injuries. Ensure the

equipment is switched off before

connecting to power source, picking up

or carrying the equipment. Never carry

equipment with your finger on the

switches or trigger. Remove any

adjusting key or wrench before turning

the equipment on. Do not overreach.

Keep proper footing and balance at all

times. This enables better control of the

equipment in unexpected situations.

Dress properly. Do not wear loose

clothing or jewellery. Keep your hair

and clothing away from the work area.

Loose clothes, jewellery or long hair

can be caught in moving parts. If

devices are provided for the connection

of dust and fume extraction and

collection facilities, ensure these are

connected and properly used.

Equipment use and

care

Do not force the equipment. Use the

c

orrect equipment for your application.

The correct equipment will do the job

better and safer at the rate for which it

was designed. Do not use the

equipment if it is found to be faulty,

faulty equipment that cannot be

controlled is dangerous and must be

repaired. Disconnect the plug from the

power source before making any

adjustments, changing accessories, or

storing equipment. Such preventive

safety measures reduce the risk of

starting the equipment accidentally.

Store idle equipment out of the reach of

children and do not allow persons

unfamiliar with the equipment or these

instructions to operate the equipment.

Electrical equipment is dangerous in

the hands of untrained users. Maintain

equipment. Check for misalignment or

binding of moving parts, breakage of

parts and any other condition that may

affect the equipment’s operation. If

damaged, have the equipment repaired

before use. Many accidents are

caused by poorly maintained

equipment. Use the equipment,

accessories and tool bits etc. in

accordance with these instructions,

taking into account the working

conditions and the work to be

performed. Use of the equipment for

operations different from those

intended could result in a hazardous

situation. Keep handles dry, clean and

free from oil and grease. Slippery

handles do not allow for safe handling

and control of the tool in unexpected

situations.

Electrical Safety.

Equipment plugs must match the outlet.

Never modify the plug in any way. Do

not use any adapter plugs with earthed

(grounded) equipment. Touching live

electrical parts can cause fatal shocks

or severe burns. The electrode and work

circuit is electrically live whenever the

output is on. The input power circuit and

machine internal circuits are also live

when power is on. In semi-automatic or

automatic wire welding, the wire, wire

reel, drive roll housing, and all metal

parts touching the welding wire are

electrically live. Incorrectly installed or

improperly grounded equipment is a

hazard. Keep your gloves and other

protective clothing, dry and free of oil

and grease. Never coil or loop welding

cables around your body. Do not touch

live electrical parts.

Wear dry, hole-free insulating gloves

and body protection. Insulate yourself

from work and ground using dry

insulating mats or covers big enough to

prevent any physical contact with the

work or ground. Do not use AC output in

damp areas, if movement is confined, or

if there is a danger of falling. Don’t weld

while standing on a wet surface or while

standing in water. Use AC output ONLY

if required for the welding process. If AC

output is required, use remote output

control if present on unit.

Additional safety precautions are

required when any of the following

electrically hazardous conditions are

present: in damp locations or while

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

3

Rossi Welders

wearing wet clothing; on metal

structures such as floors, gratings, or

scaffolds; when in cramped positions

such as sitting, kneeling, or lying; or

when there is a high risk of unavoidable

or accidental contact with the work piece

or ground. For these conditions, use the

following equipment in order presented:

1) a semiautomatic DC constant voltage

(wire) welder, 2) a DC manual (stick)

welder, or 3) an AC welder with reduced

open-circuit voltage. In most situations,

use of a DC, constant voltage wire

welder is recommended. Do not work

alone!

Disconnect input power before installing

or servicing this equipment. Properly

install, ground, and operate this

equipment according to its Owner’s

Manual and national, state, and local

codes. Always verify the supply ground

− check and be sure that input power

cord ground wire is properly connected

to ground terminal in disconnect box or

that cord plug is connected to a properly

grounded receptacle outlet. When

making input connections, attach proper

grounding conductor first − double-

check connections. Keep cords dry, free

of oil and grease, and protected from hot

metal and sparks. Frequently inspect

input power cord for damage or bare

wiring − replace cord immediately if

damaged − bare wiring can kill. Turn off

all equipment when not in use. Do not

use worn, damaged, undersized, or

poorly spliced cables. Do not drape

cables over your body. If earth

grounding of the work piece is required,

ground it directly with a separate cable.

Do not touch electrode if you are in

contact with the work, ground, or

another electrode from a different

machine. Do not touch electrode

holders connected to two welding

machines at the same time since double

open-circuit voltage will be present. Use

only well-maintained equipment. Repair

or replace damaged parts at once.

Maintain unit according to manual. Wear

a safety harness if working above floor

level. Keep all panels and covers

securely in place.

Clamp work cable with good metal-to-

metal contact to work piece or worktable

as near the weld as practical.

Insulate work clamp when not

connected to work piece to prevent

contact with any metal object. Do not

connect more than one electrode or

work cable to any single weld output

terminal. SIGNIFICANT DC VOLTAGE

exists in inverter welding power sources

AFTER removal of input power. Do not

abuse the cord. Never use the cord for

carrying, pulling or unplugging the

equipment. Keep cord away from heat,

oil, sharp edges or moving parts.

Damaged or entangled cords increase

the risk of electric shock. When

operating equipment outdoors, use an

extension cord suitable for outdoor use.

Use of a cord suitable for outdoor use

reduces the risk of electric shock. If

operating equipment in a damp location

is unavoidable, use a residual current

device (RCD) protected supply. Use of

an RCD reduces the risk of electric

shock. NOTE: The term “residual

current device (RCD)” may be replaced

by the term “ground fault circuit

interrupter (GFCI)” or “earth leakage

circuit breaker (ELCB)”. Always use a

Residual Current Device (RCD) (GFCI)

/ Earth Leakage Circuit Breaker / Safety

Switch when operating this item

(electrical items only).

Hot Parts can burn.

Don’t touch hot parts bare handed.

Allow cooling period before working on

equipment. To handle hot parts, use

proper tools and/or wear heavy,

insulated welding gloves and clothing to

prevent burns.

Fumes and Gases can be

hazardous.

Welding produces fumes and gases.

Breathing these fumes and gases can

be hazardous to your health. Keep your

head out of the fumes. Do not breathe

the fumes. If inside, ventilate the area

and/or use local forced ventilation at the

arc to remove welding fumes and gases.

If ventilation is poor, wear an approved

air-supplied respirator. Read and

understand the Material Safety Data

Sheets (MSDSs) and the

manufacturer’s instructions for metals,

consumables, coatings, cleaners, and

degreasers. Work in a confined space

only if it is well ventilated, or while

wearing an air-supplied respirator.

Always have a trained watch person

nearby. Welding fumes and gases can

displace air and lower the oxygen level

causing injury or death. Be sure the

breathing air is safe. Do not weld in

locations near degreasing, cleaning, or

spraying operations. The heat and rays

of the arc can react with vapours to form

highly toxic and irritating gases.

Do not weld on coated metals, such as

galvanized, lead, or cadmium plated

steel, unless the coating is removed

from the weld area, the area is well

ventilated, and while wearing an air-

supplied respirator. The coatings and

any metals containing these elements

can give off toxic fumes if welded.

ARC Rays can burn eyes and skin.

Arc rays from the welding process

produce intense visible and invisible

(ultraviolet and infrared) rays that can

burn eyes and skin. Sparks fly off from

the weld. Wear an approved welding

helmet fitted with a proper shade of filter

lenses to protect your face and eyes

from arc rays and sparks when welding

or watching. Wear approved safety

glasses with side shields under your

helmet. Use protective screens or

barriers to protect others from flash,

glare and sparks; warn others not to

watch the arc. Wear protective clothing

made from durable, flame-resistant

material (leather, heavy cotton, or wool)

and foot protection.

Welding can cause fire or

explosion.

Welding on closed containers, such as

tanks, drums, or pipes, can cause them

to blow up. Sparks can fly off from the

welding arc. The flying sparks, hot work

piece, and hot equipment can cause

fires and burns. Accidental contact of

electrode to metal objects can cause

sparks, explosion, overheating, or fire.

Check and be sure the area is safe

before doing any welding. Remove all

flammables within 35 ft (10.7 m) of the

welding arc. If this is not possible, tightly

cover them with approved covers. Do

not weld where flying sparks can strike

flammable material.

Protect yourself and others from flying

sparks and hot metal. Be alert that

welding sparks and hot materials from

welding can easily go through small

cracks and openings to adjacent areas.

Watch for fire, and keep a fire

extinguisher nearby. Be aware that

welding on a ceiling, floor, bulkhead, or

partition can cause fire on the hidden

side. Do not weld on containers that

have held combustibles, or on closed

containers such as tanks, drums, or

pipes unless they are properly prepared

according to AS 1674.1 and AS 1674.2

"Safety in Welding and Allied

Processes". Do not weld where the

atmosphere may contain flammable

dust, gas, or liquid vapours (such as

gasoline). Connect work cable to the

work as close to the welding area as

practical to prevent welding current from

traveling long, possibly unknown paths

and causing electric shock, sparks, and

fire hazards. Do not use welder to thaw

frozen pipes. Remove stick electrode

from holder or cut off welding wire at

contact tip when not in use. Wear oil-

free protective garments such as leather

gloves, heavy shirt, cuff-less trousers,

high shoes, and a cap. Remove any

combustibles, such as a butane lighter

or matches, from your person before

doing any welding. After completion of

work, inspect area to ensure it is free of

sparks, glowing embers, and flames.

Use only correct fuses or circuit

breakers. Do not oversize or bypass

them. Always have a fire watcher and

extinguisher nearby.

Eye Protection

Welding, chipping, wire brushing and

grinding cause sparks and flying metal.

As welds cool, they can throw off slag.

Wear approved safety glasses with side

shields even under your welding helmet.

Flying Metal or Dirt can injure eyes.

Gas Safety

Build-up of gas can injure or kill. Shut off

compressed gas supply when not in

use. Always ventilate confined spaces

or use approved respirator.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

4

Rossi Welders

Electric and Magnetic Fields

(EMP) can affect Implanted

Medical Devices.

Wearers of Pacemakers and other

Implanted Medical Devices should keep

away. Implanted Medical Device

wearers should consult their doctor and

the device manufacturer before going

near arc welding, spot welding, gouging,

plasma arc cutting, or induction heating

operations.

Ear Protection

Noise from some processes or

equipment can damage hearing. Wear

approved ear protection if noise level is

high.

Cylinders can explode if

damaged.

Compressed gas cylinders contain gas

under high pressure. If damaged, a

cylinder can explode. Since gas

cylinders are normally part of the

welding process, be sure to treat them

carefully. Protect compressed gas

cylinders from excessive heat,

mechanical shocks, physical damage,

slag, open flames, sparks, and arcs.

Install cylinders in an upright position by

securing to a stationary support or

cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding

or other electrical circuits. Never drape

a welding torch over a gas cylinder.

Never allow a welding electrode to touch

any cylinder. Never weld on a

pressurized cylinder − explosion will

result. Use only correct compressed gas

cylinders, regulators, hoses, and fittings

designed for the specific application;

maintain them and associated parts in

good condition. Turn face away from

valve outlet when opening cylinder

valve. Keep protective cap in place over

valve except when cylinder is in use or

connected for use.

Use the right equipment, correct

procedures, and sufficient number of

persons to lift and move cylinders. Refer

to Australian Standard 4332-1995 “The

storage and handling of gases in

cylinders” for more detailed guidance on

the location and construction of gas

cylinder stores, including ventilation,

operational and personnel safety and

fire protection and other emergency

measures.

Fire or Explosion Safety

Do not install or place unit on, over, or

near combustible surfaces. Do not

install unit near flammables. Do not

overload building wiring − be sure power

supply system is properly sized, rated,

and protected to handle this unit.

Falling Equipment

Use lifting eye or handle to lift unit only,

NOT running gear, gas cylinders, or any

other accessories. Use equipment of

adequate capacity to lift and support

unit. If using lift forks to move unit, be

sure forks are long enough to extend

beyond opposite side of unit. Keep

equipment (cables and cords) away

from moving vehicles when working

from an aerial location.

Overuse can cause Overheating

Allow cooling period; follow rated duty

cycle. Reduce current or reduce duty

cycle before starting to weld again.

Do not block or filter airflow to unit.

Flying Sparks can injure.

Wear a face shield to protect eyes and

face. Shape tungsten electrode only on

a grinder with proper guards in a safe

location wearing proper face, hand, and

body protection.

Sparks can cause fires — keep

flammables away.

Moving Parts can injure.

Keep away from moving parts. Keep

away from pinch points such as drive

rolls.

Welding Wire can injure.

Do not press gun trigger until instructed

to do so. Do not point gun toward any

part of the body, other people, or any

metal when threading welding wire.

Battery Explosion can injure.

Do not use welder to charge batteries or

jump start vehicles unless it has a

battery charging feature designed for

this purpose.

Moving Parts can injure.

Keep away from moving parts such as

fans. Keep all doors, panels, covers,

and guards closed and securely in

place. Have only qualified persons

remove doors, panels, covers, or guards

for maintenance and troubleshooting as

necessary. Reinstall doors, panels,

covers, or guards when maintenance is

finished and before reconnecting input

power.

EMF Information

Electric current flowing through any

conductor causes localized electric and

magnetic fields (EMF). Welding current

creates an EMF field around the welding

circuit and welding equipment. EMF

fields may interfere with some medical

implants, e.g. pacemakers. Protective

measures for persons wearing medical

implants have to be taken. For example,

restrict access for passers−by or

conduct individual risk assessment for

welders. All welders should use the

following procedures in order to

minimize exposure to EMF fields from

the welding circuit:

• Keep cables close together by

twisting or taping them, or using a

cable cover.

• Do not place your body between

welding cables. Arrange cables to

one side and away from the

operator.

• Do not coil or drape cables around

your body.

• Keep head and trunk as far away

from the equipment in the welding

circuit as possible.

• Connect work clamp to work piece

as close to the weld as possible.

• Do not work next to, sit or lean on

the welding power source.

• Do not weld whilst carrying the

welding power source or wire

feeder.

Implanted Medical Device wearers

should consult their doctor and the

device manufacturer before performing

or going near arc welding, spot welding,

gouging, plasma arc cutting, or

induction heating operations. If cleared

by your doctor, then following the above

procedures is recommended.

Service

Have your equipment serviced by a

qualified repair person using only

identical replacement parts. This will

ensure that the safety of the equipment

is maintained.

Additional Safety requirements

This appliance is not intended for use by

persons (including children) with

reduced physical, sensory or mental

capabilities, or lack of experience and

knowledge. Never allow children to

access the tool. If any non-consumable

part is damaged, it must be replaced by

the manufacturer, its service agent or

similarly qualified persons in order to

avoid a hazard. Read the instructions

carefully. Be familiar with the controls

and proper use of the equipment. Wear

eye protection. Never allow children to

access the machine. Avoid using the

equipment, while people, especially

children or pets, are nearby. Use the

equipment only in daylight or good

artificial light. Never operate the

equipment with damaged guards or

shields or without guards or shields in

place. Use only the manufacturer’s

recommended replacement parts and

accessories. Disconnect power from the

equipment before carrying out

maintenance or cleaning work. Inspect

and maintain the tool regularly. Have the

equipment repaired only by an

authorized repairer. Always ensure that

the ventilation openings are kept clear of

debris. When not in use, store the

equipment out of the reach of children.

Before using the machine and after any

impact, check for signs of wear or

damage and repair as necessary.

Maintenance

When not in use store the machine out

of the reach of children; After use,

disconnect the equipment & check for

damage; Use only manufacturers

recommended replacement parts and

accessories.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

5

Rossi Welders

Warnings

Read the instructions carefully. Be

familiar with the controls and proper use

of the equipment. Welding Safety

Welding and cutting are both specialist

processes, and safety should always be

the number one priority.

Arc Radiation

Arc radiation is a result of ULTRA-

VIOLET (UV) and INFRA-RED (IR)

RAYS and exposure can cause:

- Skin Cancer

-

Thermal Skin Burns (severe sun

burn)

- ARC FLASH (Welders Flash) or

EYE BURN which can result in

inflammation of the cornea,

cataracts or blindness.

A welding flash can occur by indirectly

viewing the arc even for a relatively

short time, for example:

1. Unconsciously looking out the

corner of the eye

2. Looking away from the arc (close

eyes then turn away).

3. Reflections of the arc from shiny

surfaces in the welding area.

Advised Protection Required

Includes:

An approved welding helmet with

the correct filter and shade

number.

Safety glasses which will help to

refract (bend away) the UV and IR

rays away, reducing the chances of

Arc Flash.

Always wear protective full covering

clothing to shield your body from

potential burns, for example:

• Overalls-flame resistant wool or

cotton.

• Leather apron or jacket.

• Always wear leather gloves.

• Skull cap (for overhead welding).

• Screen the welding zone when

welding in open spaces.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

6

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.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

7

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.

Chromium Stainless steel, electrode coatings, platings.

Nickel Stainless steel, nickel-clad steel.

Zinc Fume V

aporisation of zinc alloys, electrode coatings galvanised steel, zinc-primed steel.

Copper Fume Vaporisation of coatings on electrode wires, sheaths on air carbon arc gouging electrodes, copper alloys.

Vanadium, Manganese, Molybdenum W

elding rods, alloying elements in steels.

Tin Tin-coated steel, some nonferrous alloys.

Cadmium P

lating

Lead Fluxes, coatings on electrodes, flux in wires

Carbon Monoxide C

ombustion products of gas metal arc welding, air carbon arc gouging, oxyfuel flames; exhaust from car engines.

Ozone Gas metal arc welding, air carbon arc gouging; titanium and aluminium welding in inert gas atmospheres

Nitrogen Dioxide G

as metal arc welding; oxy fuel flame processes.

Phosgene Welding of metal covered with chlorinated hydrocarbon solvents.

DANGER! Exposure to fumes and gases can damage the lungs and respiratory system or cause asphyxiation.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

8

Rossi Welders

Advised Protection Required Includes:

- A

dequate 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.

NOTE! Welding fume fever caused by breathing fumes formed by the welding of

various metals can occur a few hours after exposure and can last several days.

Symptoms Include:

- N

ausea

- Fatigue

- Fever

- Dry nose and throat

- Chills

- Metallic taste in mouth

- Weakness

- Joint and muscle pain

Note: If any of these symptoms are observed please seek professional medical

attention.

Heat

WARNING! Extreme heat and sparks are created during welding and related

processes. Operators are at continual risk of burns from hot surfaces/materials,

sparks and radiated heat from the arc.

WARNING! Welding sparks can travel long distances and have been known to reach up to 15

metres away from the source of welding on the ground and even further when working in elevated

positions.

DANGER! Sparks can reach combustible materials and start fires, as well as burning unprotected

skin.

DANGER! Burns can result from handling hot just welded work (the most common of welding

burns) and molten weld metal (spatter) falling or spitting onto exposed skin.

Advised Protection Required Includes:

- A

lways wear protective clothing.

- Keep safety glasses on your head where they belong.

- Always mark just welded work with the word “HOT”.

- Know where the nearest fire extinguisher or fire hose is and how to use them.

- Remove combustible materials away from the welding area. (at least 15 metres or 50 feet

away).

- If in an elevated position, post a person on the ground as a fire-watcher.

- Never connect the earth lead to electrical circuits of pipes containing gases or flammable

liquids.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

9

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.

Associated processes such as plasma cutting will also benefit from proper grounding.

Where welding machines that use a plug on the end of a power cord, the grounding conductor

connection is made automatically when the welding machine is plugged into the receptacle. The

grounding pin of the plug makes a connection within the receptacle.

IMPORTANT! You must still earth your work piece / job.

WARNING! The use of adapters that effectively remove the grounding pin

connection at the plug is not recommended.

WARNING! Do not cut off or remove the grounding pin from the plug. All safety

benefit of the grounding conductor is lost without the connection.

Grounding the Work Piece / Job

The welding circuit consists of all conductive material through which the welding current is intended to

flow. Welding current flows through the welding machine terminals, welding cables, work piece / job

connection, gun, torch, electrode holder and work piece / job itself; the welding circuit is not

connected to ground within the welding machine, but is isolated from ground. How do we ground the

welding circuit?

The work piece / job or the metal table that the work piece / job rests upon must be grounded. We

must connect the work piece / job or work

table to a suitable ground, such as a metal

building frame. The ground connection should

be independent or separate from the welding

circuit connection.

Grounding the work piece / job has similar

benef

it to grounding the welding machine

enclosure. When the work piece is grounded,

it is at the same potential as other grounded

objects in the area. In the event of insulation

failure in the arc welding machine or other

equipment, the voltage between the work

piece and ground will be limited.

WARNING! Welding Circuit Shock Hazards.

Utilising proper grounding in the welding environment is a good practice, but it does not remove all

possibility of electrical shock. The welding circuit is energised by welding voltage. A person will

receive a shock if they become the electrical path across the welding circuit. Precautions must be

taken to insulate the welder from the welding circuit. Use dry insulating gloves and other insulating

means. Also maintain insulation on weld cables, electrode holders, guns and torches to provide

protection.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

10

Rossi Welders

Shielding Gas Safety

T

his article is intended to give users some basic information about the recommended safety

procedures concerning the use of 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.

Cylinder identification: Welding shielding gases are commonly one of three types - argon, argon and

carbon dioxide mix, mixes of various compositions and carbon dioxide.

Cylinders are colour coded;

- Argon cylinders are green

- Argon/carbon dioxide mix cylinders are green with a light green shoulder

- Carbon dioxide cylinders are black with a silver/grey shoulder.

Some carbon dioxide cylinders contain a dip tube to extract the liquid from the cylinder. The tube

runs down the centre of the cylinder and draws the liquid carbon dioxide up through the valve. These

can be identified by the white stripe down the side - they are not suitable for use with regulators.

All the three basic types of shielding gases are heavier than air and are asphyxiants so should only be

used in well-ventilated areas.

Industrial gas cylinders typically have to be tested every 10 years to ensure they are in good order

with some having a test period of 5 years.

Transporting and Handling:

- The transporting of gas cylinders is covered by the Carriage of Dangerous Goods and Use of

Transportable Pressure Receptacles Regulations.

- A 2KG fire extinguisher is required by law to be carried whenever you are transporting any

type of gas cylinder.

- Cylinders come in several sizes and fill pressures with some being filled to 300 bar (4350 psi)

so therefore they need careful handling, storage and use.

- Although not required for non-trade users, it is recommended to display a compressed gas

warning diamond on your vehicle whenever you have a cylinder on board to help the

emergency services evaluate any potential hazard in the event of an incident. Removing it

when you don't have a cylinder on board will reduce the likelihood of being stopped by the

authorities.

Basic cylinder safety advice:

- Only keep as much gas as you actually need. More cylinders = more risk

- Always wear appropriate hand and foot protection when moving or transporting cylinders.

- When transporting cylinders, always have an appropriate Material Safety Data Sheet (MSDS)

available and be familiar with the properties of the particular gas you are transporting.

- Always secure cylinders while transporting and wherever possible, transport them upright and

in an open vehicle.

- If transporting cylinders in an enclosed vehicle, always ensure you have adequate ventilation,

i.e. an open window.

- If you suspect a cylinder has developed a leak during transport, park the vehicle in a safe

place with the windows down and telephone the agent or the supplier for advice.

- If you are involved in a road accident, advise the emergency services that gas cylinders are

being carried and show them any information relating to the cylinders, e.g. the Material Safety

Data Sheet (MSDS)

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

11

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.

- Before using any gas cylinder, check that the seal is intact, also check for the proper labelling

to ensure that the gas the correct one you asked for before you remove the seal.

Cylinder Use:

- Store cylinders in a well-protected, dry and well-ventilated area ensuring they do not block

entry or exit routes and are protected from physical damage from striking or falling objects

and from any potential tampering.

- Cylinders should also be stored out of direct sunlight.

- Use cylinders in the order in which they were received, i.e. first in - first out.

- Ensure the valve seat and regulator thread/seat are free from any foreign matter including

dirt, oil or grease. Remove any foreign matter by wiping with a clean, dry cloth, by using

compressed air or by briefly opening and closing the valve (known as "snifting" or "cracking").

When using compressed air or 'snifting', wear eye and ear protection and always ensure that

you point the cylinder valve or air blowgun away from yourself and others.

- Fit the regulator then open the cylinder valve slowly at arm’s length. Check for leaks using

soapy water.

- Always store cylinders in an upright position and secure with a chain or strap above the

centre of the body.

- If a cylinder key is required to open a cylinder, always leave it in place to make it easier to

close the valve after use or in an emergency. Always use the correct key, they cost no more

than a few dollars at most.

- Always close the cylinder valve after use.

- Always close the valve when the cylinder is empty to prevent air or moisture from entering the

cylinder.

Do not attempt to lift a large cylinder single-

handed.

Do not roll a cylinder horizontally to move it.

Do not carry a cylinder by the valve.

Do not leave an open cylinder unattended.

Do not leave a cylinder unsecured.

Do not leave cylinders in hot cars.

Do not force incorrect fittings onto the wrong

cylinder.

Do not disguise any damage to cylinders.

Do not attempt to refill a cylinder or decant

gas from one cylinder to another. This is

especially important with pub type CO2

cylinders; they can suffer from severe internal

corrosion due to any beer or soft drinks in the

gas line being forced into the old cylinder

when a new cylinder is connected.

Do not attempt to mix gases in a cylinder.

Do not fill a cylinder with a gas different to the

one it originally contained.

Do not remove or deface cylinder content

identification labels.

Do not tamper with cylinders in any way.

Do not attempt to repair a cylinder.

Do not repaint cylinders in a different colour to

the original.

Do not discard cylinders; return them to the

correct agent or supplier.

Do not use grease, oil or Teflon tape on the

regulator or valve thread/seat.

Do not use a co2 regulator on an argon or

argon mix cylinder unless the regulator is

specifically designed to handle the higher

pressure.

Disposal of used cylinders:

When you enter into a rental agreement, you are only purchasing the contents of the cylinder, not the

cylinder itself which always remains the property of the supplier (not the agent). Empty cylinders

should be returned to their respective suppliers. If the agent will not accept a returned cylinder, maybe

due to age, missing labels, unknown contents, damage, etc., contact the supplier for assistance. If the

supplier cannot help then it should be taken to a recycling centre for proper disposal.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

12

Rossi Welders

General Safety

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

13

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.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

14

Rossi Welders

Typical MMA (Stick) Welding setup

Typical TIG setup

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

15

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. indicator illuminated. If this

happens do not turn off the machine; leave it on so the welder’s internal fan can continue

running and cool the machine down. Once the O.C. indicator light shuts off you can

continue using your machine as normal.

ARC = Negative

Earth

TIG = Positive Earth PLASMA CUTTER =

Positive Earth

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

16

Rossi Welders

1. “TIG Earth” clamp connection & “ARC rod holder” connection.

2. “Plasma Earth” Clamp.

3. DIN Socket: High frequency start control.

4. “Plasma Torch” connection.

5. “TIG Torch” connection & “ARC earth” clamp connection.

6. Post flow (Gas): The length of time the torch gas flows after the arc terminates.

7. Clean area width (Phase Balance): Applies to AC welding and sets the proportion of time the weld current is positive,

during which time the current has an "oxide penetrating" effect on the aluminium alloy weld pool surface, but which

also tends to heat up and melt the tungsten electrode rather than the weld pool. Maximum heat is delivered to the work

piece/job when the electrode is negative so this setting is used to achieve the best compromise when welding

aluminium.

8. Pulse Duty (duty cycle): The number of minutes out of a 10-minute time period an arc welding machine can be

operated at maximum rated output. An example would be 60% duty cycle at 300 amps. This would mean that at 300

amps the welding machine can be used for 6 minutes and then must be allowed to cool with the fan motor running for

4 minutes.

9. Pulse Frequency: The sequencing and controlling of the amount of current, frequency and duration of the welding arc.

10. 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.

11. Main Power On/Off Switch.

12. Voltage display: Welding voltage display when machine is working. Only shows information when welder is in use.

13. Power indicator: Displays if power supply is on or off.

14. O/C: Overheating alert indicator, this can also indicate power issues.

15. Post Flow: The length of time the torch gas flows before the arc starts.

16. Peak current (pulse) – Peak current is the nominal current for the high energy pulse. It is adjusted to a level that is

set consistently above the globular to spray transition current. Peak current is expressed in units of ampere. During the

time when the peak current is delivered, the molten droplet detaches from the electrode. An increase in peak current

increases the average welding current and the weld penetration.

17. Basic current (Amperage): The amount of electricity flowing past a point in a conductor every second. Basic current

is background current and is the low side of the pulse (1/2, 1/4 or even 1/10 of the peak current).

18. Down-Slope Time: Allows the current to decrease at whatever rate you set on the knob.

19. Pulse/No Pulse switch: For thin welding plate and up-welding etc. place the switch at PULSE position (for normal

TIG welding set at no pulse).

20. Welding Process Selection: This button selects between MMA (ARC), TIG and CUT modes.

21. AC/DC Selector Switch: Select “AC” for Aluminium and Aluminium Alloys. Select “DC” for Stainless Steel, Steel, and

Cast Iron etc.

22. 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. The 2t setting pretty much turns the torch switch into a 2 position switch. Press the switch, you get an arc,

release the switch, arc goes out.

4T: The 4T position is most always used in conjunction with upslope and downslope settings.

For example;

a) Press the button and you get an arc.

b) Release the button and set the arc up-slopes to whatever the main amperage is set to.

c) Press the button and arc down-slopes to lower amperage.

d) Release the button and arc stops.

e) Some machines are different but this is the general principle of 4t operation

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

17

Rossi Welders

TC-205 AC/DC Welders

1. Welding Process Selection: This button selects between MMA/TIG and CUT modes.

2. 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. The 2t setting pretty much turns the torch switch into a 2 position switch. Press the

switch, you get an arc, release the switch, arc goes out.

4T: The 4T position is most always used in conjunction with upslope and downslope settings.

For example;

a. Press the button and you get an arc.

b. Release the button and set the arc up-slopes to whatever the main amperage is set to.

c. Press the button and arc down-slopes to lower amperage.

d. Release the button and arc stops.

e. Some machines are different but this is the general principle of 4t operation

3. AC/DC Selector Switch: Select “AC” for Aluminium and Aluminium Alloys. Select “DC” for Stainless Steel, Steel, and

Cast Iron etc.

4. Pulse selector switch; Selection of the Pulse mode switch provides pulsed welding current output.

5. Voltage display: Welding voltage display when machine is working.

6. Base Current: - Set the amount of electricity flowing past a point in a conductor every second.

7. Power indicator: Displays if power supply is on or off.

8. Pulse Current: is the nominal current for the high energy pulse. It is adjusted to a level that is set consistently above

the globular to spray transition current. Peak current is expressed in units of ampere. During the time when the peak

current is delivered, the molten droplet detaches from the electrode. An increase in peak current increases the average

welding current and the weld penetration.

9. O/C: Overheating alert indicator, this can also indicate power issues.

10. Pulse Frequency: The sequencing and controlling of the amount of current, frequency and duration of the welding arc.

11. Post Flow: The length of time the torch gas flows after the arc terminates.

12. Down-slope: Allows the current to decrease at whatever rate you set on the knob.

13. Pulse width: The time the high pulse amperage stays on. Also known as Pule % on time.

14. AC Frequency: The A/C frequency knob allows you to weld with a much higher frequency. That option stiffens and

focuses the TIG welding arc pinpoints the heat

15. AC Balance: This knob is used to balance DCEP (reverse polarity) and DCEN (straight polarity).

16. “TIG Earth” clamp connection & “ARC rod holder” connection.

17. Remote control connection

18. Torch Control connector

19. Cut Torch Gas Outlet

20. “TIG Torch” connection & “ARC earth” clamp connection.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

18

Rossi Welders

MT 200 Welders

1. O/C: Overheating alert indicator, this can also indicate power issues.

2. Power indicator: Displays if power supply is on or off.

3. Welding Process Selection: This button selects between MMA/TIG and CUT modes.

4. Amperage (current) display: Welding Amperage display during welding.

5. Wire Speed / Speed: The speed at which wire is fed out of the machine.

6. 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. Higher settings make more dig and a "crisper" arc. Lower makes a smoother

arc.

7. Post flow (Gas): The length of time the torch gas flows after the arc terminates.

8. Voltage Adjustment.

9. Voltage display: Welding voltage display when machine is working.

10. Torch connection.

11. NA.

12. Wire feeder spool.

13. Positive connection.

14. Negative (Earth) connection.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

19

Rossi Welders

WELD-MIG185E Welders

1. Current (Amperage) display: Welding Current display during welding.

2. Overheating alert: This indicator, this can also indicate power issues.

3. Welding Process Selection: This button selects between MMA and MIG.

4. Wire Speed / Speed: The speed at which wire is fed out of the machine.

5. Voltage Adjustment

6. Amperage (current) Adjustment

7. Negative (Earth) connection.

8. Positive connection.

9. Torch connection.

WELD-MIG220BZ Welders

1. Amperage (current) Adjustment

2. Wire Speed / Speed: The speed at which wire is fed out of the machine.

3. Overheating alert: This indicator, this can also indicate power issues.

4. Power indicator: Displays if power supply is on or off.

5. Inching Speed: The speed at which wire is fed out when the

6. Welding Process Selection: This button selects between MMA and TIG.

7. Welding Process Selection: This button selects between TIG and MIG.

8. Inching: This button helps feed wire through the MIG and Torch instead of doing so by hand.

9. Negative (Earth) connection.

10. Torch connection.

11. DIN High frequency out.

12. Positive connection.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

20

Rossi Welders

WLDMIG195RSSADJE, WLDMIG185RSSADJE & WLDMIG155RSSADJE Welders

1. Overheating alert: This indicator, this can also indicate power issues.

2. Amperage selection: Set amperage in conjunction with switch 3. 4

amperage levels available – MIN / 1 (low); MIN / 2 (medium-low);

MAX / 1 (medium-high); MAX / 2 (high).

3. Amperage selection: Set amperage in conjunction with switch 2.

4 amperage levels available – MIN / 1 (low); MIN / 2 (medium-low);

MAX / 1 (medium-high); MAX / 2 (high).

4. Wire Speed / Speed: The speed at which wire is fed out of the

machine.

5. Main Power On/Off Switch.

CT-520 Welders

1. Power indicator: Displays if power supply is on or off.

2. O/C: Overheating alert indicator, this can also indicate power issues.

3. TIG indicator: Indicates when TIG mode is enabled.

4. CUT indicator: Indicates when CUT mode is enabled.

5. STICK indicator: Indicates when STICK (ARC) mode is enabled.

6. Welding Process Selection: This button selects between TIG, STICK and CUT.

7. Amperage (current) Adjustment.

8. Negative (Earth) connection.

9. Torch connection.

10. DIN High frequency out.

11. Positive connection.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

21

Rossi Welders

ROSSWELDER WELDER-S200 Welders

1. Amperage (current) Adjustment.

2. Power indicator: Displays if power supply is on or off.

3. O/C: Overheating alert indicator, this can also indicate power issues

.

1. Amperage (current) Adjustment.

2. Power indicator: Displays if power supply is on or off.

3. O/C: Overheating alert indicator, this can also indicate power issues

.

4. Amperage display: Welding Current display during welding.

MIG-130 Welders

1. Overheating alert: This indicator, this can

also indicate power issues.

2. Amperage selection: Set amperage in

conjunction with switch 3. 4 amperage levels

available – MIN / 1 (low); MIN / 2 (medium-

low); MAX / 1 (medium-high); MAX / 2 (high).

3. Amperage selection: Set amperage in

conjunction with switch 2. 4 amperage levels

available – MIN / 1 (low); MIN / 2 (medium-

low); MAX / 1 (medium-high); MAX / 2 (high).

4. Wire Speed / Speed: The speed at which wire

is fed out of the machine.

5. Main Power On/Off Switch

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

22

Rossi Welders

CT-416 Volcan Series Welders

1. Current (Amperage) Display: Displays the current

2. Overheating alert: This can also indicate power issues

3. Amperage: Current adjustment dial

4. Welding process selection: Select between Cut, MMA and TIG

5. Negative (Earth) connection

6. Plasma and TIG torch

7. Din high frequency out

8. Positive connection

MMA-300S Series Welders

1. Current (Amperage) Display: Displays the current

2. Overheating alert: This can also indicate power issues

3. ARC Force: Increase output current

4. Amperage: Current adjustment dial

5. Welding process selection: Select between VRD and MMA

6. Negative (Earth) connection

7. Positive connection

1

2

3

4

5

7

6

8

1

2

3

4

5

6

7

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

23

Rossi Welders

MIG-170N Series Welders

1. Current (Amperage) Display: Displays the current

2. MIG Output adjustment

3. MMA Amperage adjustment

4. Mode Toggle Switch: FCAW / MIX / CO2 / SYN / MMA / MIG

5. Mode indicator lights

6. Negative (Earth) connection

7. Positive connection

WSM-200 Series Welders

1. Overheating Alert. This can also indicate power issues.

2. Welding Process Selection. This button selects between TIG and Stick.

3. Amperage (current) adjustment

4. Negative (Earth) connection

5. Torch connection

6. Female 2 pin socket

7. Positive connection

1

2

3

4

6

5

7

1

2

3

4

5

6

7

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

24

Rossi Welders

MMA 200S Series Welders

1. Current (Amperage) Display: Displays the current

2. Overheating Alert: This can also indicate power issues

3. Amperage: Current adjustment dial

4. Welding Process Selection: Select between TIG and MMA

5. Negative (Earth) Connection

6. Positive Connection

MMA 250S Series Welders

1. Current (Amperage) Display: Displays the current

2. Overheating Alert: This can also indicate power issues

3. Amperage: Current adjustment dial

4. Welding process selection: Select between TIG and MMA

5. Negative (Earth) connection

6. Positive connection

1

2

3

4

5

6

1

2

3

4

5

6

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

25

Rossi Welders

MIG 220N Series Welders

1. Inching: Wire feed button

2. Overheating alert: This can also indicate power issues

3. Power indicator: Displays of power supply is ON or OFF

4. Amperage (current) adjustment

5. Welding process selection: This button selects between MIG and TIG

6. Welding process selection: This button selects between TIG and MIG

7. Wire feed dial: Controls the speed of the wire feed

8. 2 pin female connector

9. Torch connection

10. Negative (Earth) connection

11. Positive connection

1

4

6

2

5

3

7

11

10

9

8

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

26

Rossi Welders

MMA-250N Series Welders

1. Amperage (current) adjustment

2. Overheating alert: This can also indicate power issues

3. Power Indicator: Displays if power supply is ON or OFF

4. Current (Amperage) display: Displays the current

MIG-250G Series Welders

1. Inching: Wire feed button

2. Overheating Alert: This can also

indicate power issues

3. Power indicator: Displays if the power

supply is ON or OFF

4. Welding process selection: This button

selects between MIG and TIG

5. Welding process selection: This button

selects between TIG and MIG

6. Amperage (current) adjustment

7. Wire Feed Dial: Controls the speed of

the wire feed

8. 2 Pin female connector

9. Torch connection

10. Negative (Earth) connection

11. Positive connection

1

2

3

4

1

2

3

4

5

6

7

8

9

10

11

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

27

Rossi Welders

MMA-250P Series Welders

1. Current (Amperage) Display: Displays the current

2. Amperage (Current) Adjustment

3. Positive Connection

4. Negative (Earth) Connection

CT-620iS Series Welders

1. Current (Amperage) Display: Displays the current

2. Overheating alert: This can also indicate power issues

3. Welding process selection: Select between TIG, STICK, CUT

4. Amperage (Current) Adjustment

5. Negative (Earth) Connection

6. Torch gas connection

7. 2 Pin DIN connection

8. Positive Connection

1

2

3

4

8

2

1

4

3

7

6

5

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

28

Rossi Welders

MIG-300P Series Welders

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

29

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. If you have previous welding experience, feel free to

skip ahead. If you are somewhat of a novice, this section will provide you with a better understanding

of the types of welders available, how each performs and degree of welding skill required to operate

each. In addition, we’ll offer examples of specific applications best suited to each process.

Types of Welding

The most common welding processes include Stick, MIG/Flux-cored and TIG. Each process has its

own unique set of benefits and limitations, works well in some welding applications, and not well in

others.

ARC / Stick Welding

Arc welding is the process of using

electrodes to fuse two pieces of metal.

• Better suited for windy, outdoor conditions

• More forgiving when welding on dirty or rusty metal

• Works well on thicker materials

If you learned to weld years ago, you likely learned

using an arc welder. Stick welding has, for many

years, been the most popular method for most home-

shop welding needs. Stick welding uses an electric

current flowing from a gap between the metal and the welding stick, also known as an arc-welding

electrode. Stick welding is an effective method for welding most alloys or joints and can be used both

indoors and outdoors, or in windy areas. It is also the most economical welding method and largely

popular because of its ability to create an effective bond on rusty or dirty metals.

Arc welding is limited, however, to metals no thinner than 18-gauge, requires frequent rod changing,

emits significant spatter; and welds must be cleaned upon completion. Stick welding is also more

difficult to learn and use, particularly the ability to strike and maintain an arc. Arc welders are available

in either AC or DC or AC/DC; with AC being the most economical. It is used for welding thicker metals

of 1/16-inch or greater.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

30

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

• High welding speeds possible

• Better control on thinner metals

• Cleaner welds possible with no slag to clean

• Same equipment can be used for Flux-Cored Welding

MIG welders use a wire welding electrode on a spool that is fed automatically at a constant pre-

selected speed. The arc, created by an electrical current between the base metal and the wire, melts

the wire and joins it together with the base, producing a high-strength weld with great appearance and

little need for cleaning. MIG welding is clean, easy and can be used on either thin or thicker plate

metals.

A slight variation of MIG welding — Flux-Cored Arc Welding (FCAW) — is similar in that it is also a

wire-feed process but differs in that it does not require a shielding gas. This gas-free welding

application uses Flux-Cored wire to shield the arc, and is a simple, efficient and effective welding

approach, especially when welding outdoors, in windy conditions or on dirty materials. The process is

widely used in construction because of its high welding speed and portability.

Both MIG and Flux-Cored are very easy to learn and can create extremely clean welds on steel,

aluminium and stainless. Both types have the capability to weld materials as thin as 26-gauge.

TIG Welding / Gas Tungsten Arc Welding (GTAW)

TIG Welding is the process of using a

tungsten-electrode and inert gas to fuse

two pieces of metal

• Provides highest quality, precise welds

• Highly aesthetic weld beads

• Allows adjustment of heat input while welding by use of

a foot control.

TIG welding is an arc welding process that uses a

non-consumable tungsten electrode to produce the weld. The weld area is protected from

atmospheric contamination by a shielding gas (usually argon), and a filler metal, though some welds,

known as autogenous welds, do not require it. A constant-current welding power supply produces

energy that is conducted across the arc through a column of highly ionized gas and metal vapours

known as plasma.

TIG welding is most commonly used to weld thin sections of alloy steel, stainless steel and non-

ferrous metals such as aluminium, magnesium, and copper alloys. The process grants the operator

greater control over the weld than other welding processes, allowing for stronger, higher quality

welds. TIG welding is comparatively more complex and difficult to master than other welding types,

and is significantly slower.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

31

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.

Metal

Weld Process

MIG

Stick

TIG

Steel ● ● ●

Stainless Steel

●

Aluminium Alloys ●

●

Cast Iron

●

Chromoloy

●

Copper

●

Brass

●

Exotic metals (Magnesium, Titanium, etc.)

●

Pulsed TIG Welding

Pulsed TIG Welding Reduces Heat Input and Warping on Stainless Steel f

or example stainless steel

exhausts.

• Pulsed TIG lowers heat input; increases precision and quality.

• High-speed pulsing constricts and focuses the arc, which increases arc stability, penetration and travel speed,

while producing a smaller heat affected zone.

• Lower heat input minimises distortion and improves weld quality.

TIG Welding at Warp Speed—Without the Warping!

Every TIG welding machine is slightly different but the concepts are basically the same. There are 4

basic settings to understand:

Pulsed TIG welding requires setting four variables: Peak amperage, Background amperage,

Peak time and Pulse rate. Determining good values for setting peak amperage works much the

same as setting maximum amperage values for regular DC TIG: use 1 amp for every .001 in. of

thickness.

The peak time is simply the percentage of time during one pulsing cycle the power source spends at

the peak amperage (main amperage). With peak time of 80 percent and a pulse rate of 1 pulse per

second (PPS), the inverter will spend 8/10ths of a second at peak amperage and 2/10ths of a second

at the background amperage. Increasing the peak time percentage adds more heat to the part, while

decreasing peak time percentage reduces heat. As general rule of thumb, begin experimenting at 50

to 60 percent peak time.

The background amperage will be a percentage of the main amperage set on the machine. Thus, a

machine set for an output of 150 amps and background amperage of 30 percent produces a

background amperage output of 45 amps. Lowering the background amp percentage reduces the

average heat input, while increasing the background amp percentage raises the overall amperage.

Especially notice how background current adjustments affect weld puddle fluidity. As a rule, use

enough background current to shrink the puddle to about half its normal size while still keeping the

puddle fluid. When welding stainless and carbon steels, start by setting the background amperage at

20 to 30 percent of peak amperage.

Pulse frequency per second (PPS) is simply how many times the machine will complete one pulsing

cycle in a time span of one second. Increasing the number of pulses per second produces a smoother

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

32

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).

Plasma Cutting

Plasma cutting is the use of high velocity

jet of ionised gas to cut through metal.

• Much faster than mechanical cutting

• Neater and more versatile than Oxy cutting

• Can cut a thickness up to 25mm (1”)

• Can cut through a larger range of material than Oxy

cutting

Plasma cutting is a process that uses a high velocity

jet of ionized gas that is delivered from a constricting

orifice. The high velocity ionized gas, that is, the

plasma, conducts electricity from the torch of the plasma cutter to the work piece. The plasma heats

the metal, melting the material. The high velocity stream of ionized gas mechanically blows the molten

metal away, severing the material.

Plasma cutting is ideal for cutting steel and non-ferrous material less than 1 inch thick. Oxy cutting

requires that the operator carefully control the cutting speed so as to maintain the oxidizing process.

Plasma is more forgiving in this regard. Plasma cutting really shines in some niche applications, such

as cutting expanded metal, something that is nearly impossible with oxy. And, compared to

mechanical mean of cutting, plasma cutting is typically much faster, and can easily make non-linear

cuts.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

33

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.

TIG Welders generally use a positive earth – please check and understand your

equipment before use.

TIG welding Basics

Tungsten - For welding steel the tungsten should be ground to a long point with the taper length

about 2 or 3 times the diameter of the tungsten. The long taper and sharp tip improves arc stability.

For a butt weld or open corner weld the stick out would be about 5-6mm.

Gas Shrouds - For general purpose work on steel a number 7 shroud is a good compromise. A

smaller number 4 shroud would be more suitable for fillet welds, and larger shrouds might be used for

aluminium, the larger the shroud the better the gas coverage.

Shielding Gas - Pure Argon is normally used as a TIG shielding gas and is suitable for both steel and

aluminium welding. The shielding gas must be completely inert - MIG shielding gasses cannot be

used as the CO2 would cause the tungsten to oxidise.

Flow Rate - Flow rate will generally be 6 to 7L/min. The rate might be increased slightly to

compensate for windy conditions. TIG uses a lot of shielding gas so it pays to set up the gas flow

accurately. A flow meter attached to the regulator will give a more accurate flow reading than the

gauge on the regulator, or a peashooter type flow meter can be used to measure flow at the torch.

Post-Flow Time - Post flow protects the tungsten and the weld as they cool. The tungsten will take

longer to cool from higher amps, and a rough rule of thumb is to increase post flow time by 1 second

for every 10 amps. Most basic work uses a post flow of 4-5 seconds.

Polarity - DC TIG Welding is carried out with the torch negative and the work positive. That is also

known as DCEN (DC electrode negative) or "straight" polarity for those with older welders. About two

thirds of the heat goes to the positive side or the arc. For TIG the negative torch helps avoid

overheating the tungsten.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

34

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. Electric shock, fumes, burns, and fire are other risks.

The safety page discusses how to minimise these risks.

Starting the Arc - The arc is started by touching the electrode momentarily against the work to

complete the electrical circuit before raising the electrode to establish the arc.

'Tap starting' and 'scratch starting' are the two common methods of starting the arc. Which one to use

is a personal preference, and can be influenced by rod and welder type.

Rod Position, Arc Length and Movement - Arc welding takes some effort to learn, and it

is very sensitive to the position of the work.

Rod Angle – For welding on the flat work piece the rod should be angled 10 to 20 degrees from vertical and pulled in

the direction of the arrow. The angle of the rod prevents the slag overtaking the rod (welding over slag would cause

inclusions in the weld). It's OK to support the top of the electrode with your spare hand and this improves control of

the electrode. Electric shocks aren't a problem, but be careful to reposition your hand away from the heat before the

electrode gets too short.

Arc Length – The arc length is the distance between the electrode and the weld pool. It should be roughly the same

as the diameter of the rod. This is nowhere near as straightforward as it sounds. The weld pool will also be hidden by

molten slag. To achieve the correct arc length using 3.2mm rods the distance between the flux coating on the rod

and the flux on top of the weld might be less than 1mm.

Arc welding faults - When learning any new process you'll likely start off doing things wrong.

Typically the faults encountered are caused by the following:

- Incorrect travel speed

- Incorrect arc length

- Incorrect amps.

Flat Joints and Joint Preparation - Arc welding is especially suitable for joining thick material as

cold joins are easy to avoid. That makes it possible to tackle thicker material using multiple passes of

weld.

Fillet Joints – Filet Joints are beyond the scope of this manual.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

35

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.

1. W

ire Feed Tensioner

2. Wire roller (change to suit wire diameter)

3. Feed tensioner adjuster knob.

4. Wire Sleeve

5. Wire roller locking cap

6. Wire Spool

7. Wire spool spring tensioner

Preparing the wire - The wire reel mounting normally includes a spring tensioner. This tensioner

should be initially tightened to the point where the reel of wire doesn't unravel under its own spring

tension.

The first 3 inches of wire should be as straight as possible to reduce the chance of damage to the

liner or snagging as the wire is fed through. Sharp wire cutters can be used for trimming.

Letting go of the end of the wire would cause it to unravel and tangle.

Feeding the wire to the torch - The wire is inserted through the guide tube and over the roller. On

the torch side of the welder the small hole of the end of the wire liner should be visible. The end of the

wire can be aligned with that hole using a small screwdriver or the piece of wire that was removed at

the start.

The wire can then be pushed into the liner manually for a few inches, and should feed easily and

without any force. If force is required it is likely that the wire has missed the liner.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

36

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

appropriate groove for the wire size being used.

Rust or grease on the wire can reduce the effectiveness of the rollers, and they need to be cleaned

with a dry cloth before inserting the wire.

With the wire pushed a couple of inches into the liner replace the tensioner clamp, switch on the

welder and use the wire feed mechanism to push the wire through the liner. The torch should be a

straight as possible especially near the torch to reduce the chance of the end of the wire catching

inside the liner.

On some welders it can help to remove the contact tip from the end of the torch before feeding the

wire through. The gas shroud is secured by a spring and can be removed by pulling and twisting in a

clockwise direction, and the tip has a standard screw thread that unscrews in an anti-clockwise

direction. Never unscrew the tip when it is still hot or it may break or strip the thread inside the torch.

If the wire snags in the torch it may be possible to withdraw a little wire onto the reel, and use a

rotating motion with the torch to get the wire past the snagging point.

Setting the roller tensioner - The wire is driven by friction between the wire feed drive roller and the

wire. Care in tensioning the wire feed can prolong the life of the tensioner mechanism.

Tightening the tensioner fully can cause the tensioners or tensioner mountings to bend and could also

shear the motor gear if the wire were to stick in the tip during welding. The minimum tension that will

ensure good wire feed is recommended.

One way to judge the wire feed tension is to grip

the wire very lightly between your fingers and pull

the trigger. Care is needed with this approach as

if the wire were to touch the earth clamp it would

arc, resulting in burned fingers and possibly arc

eye.

Starting with very little tension on the wire feed

mechanism, Increase the tension until the wire

feed stops slipping, but do not grip the wire so

tightly that the wire feed motor slows.

The wire should ideally start to slip inside the

rollers before the motor stalls.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

37

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.

Set your wire speed to the maximum you are likely to use, and

press the trigger on the torch. The wire reel should stop without

unravelling when you lift off the trigger.

Avoiding wire feed problems - Wire feed problems are commonly

caused by rusty welding wire. The rust acts as a lubricant on the

feed rollers causing slip, and as an abrasive on the wire liner which

increases resistance.

Wire can quickly go rusty when left unused inside a welder. Ideally

the wire should be removed and stored indoors when the welder is

not in use. This wire in the photo was reusable after the top couple

of layers of wire had been removed. Liners damaged by rusty wire

can be replaced fairly cheaply.

Other wire feed info - Wire liners do wear and are considered to

be a service item. Professional welders might replace the liner after

every 100kg of wire. On most welders the liner can be unscrewed

at each end and pulled out of the cord.

Click here for a brief video showing how to change the spool

on a typical MIG welder.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

38

Rossi Welders

Troubleshooting

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

39

Rossi Welders

s

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

40

Rossi Welders

Arc Welding Faults

Arc Length Too Short

T

his 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.

Arc Length is OK.

This is a normal arc weld. The weld has a consistent profile and minimal spatter.

Arc Length Too Long

Too great a distance between the rod and the work will increase the voltage resulting in a flat and

wide weld with a great deal of spatter. It also makes the arc unstable, and the slag will be difficult to

remove from the edges of the weld. Sectioning this weld reveals undercutting to the left side.

Travel Speed Faults

S

peed is OK. - The bead is fairly consistent. The ridges in the weld are semi-circular.

Speed Too Fast - Excessive speed results in a thin, weak bead. The ridges in the weld are elongated

and triangular. Had the current been increased to compensate for the speed the ridges would still

remain elongated.

Speed Too Slow - Welding too slowly results in a wide tall build-up of weld. The shape of the weld is

not consistent as the weld pool has built up and then collapsed into the crater. The poor control of the

weld pool can result in cold joints and slag inclusions.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

41

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.

Amps too high - The bead is wide, flat and irregular, and a small undercut can be seen on the right

of the weld in the sectioned photo. A deep crater has formed at the end of the weld, and the slag is

difficult to remove from the edges of the weld.

Excessive current should not be compensated by excessive travel speed. This can result in slag

inclusions due to rapid cooling of the weld.

Amps are OK. - With the amps set correctly the bead is a consistent rounded shape, and the slag is

easy to remove.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

42

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.

Ch

eck 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). Attempting to weld with an

AR/CO2 mix (used for MIG welding) will cause immediate contamination.

Set the proper gas flow rate, which should be 15 to 20 cubic feet per hour (cfh). Welders

commonly—and incorrectly—assume that a higher gas flow/pressure provides greater protection. In

fact, excessive gas flow creates turbulence and swirling currents that pull in unwanted airborne

contaminants (and it can cause arc wandering).

Check all the fittings and hoses for leaks. Any breach may pull air into the shielding gas stream,

which can cause the weld to be contaminated (and you’ll waste money if gas escapes). Rub soapy

water over the hose and all fittings. If bubbles form, you have a leak and need to replace the defective

components. You may have a tank contaminated with moisture. Check with your gas supplier to

resolve this issue.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

43

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. Aluminium builds up an oxide that needs to be removed before welding. Wire brushing is the

most common method of cleaning aluminium, but it needs to be done with a stainless steel brush to

avoid contaminating the weld with the impurities of a steel brush. Push vs. drag technique. On steel,

either pushing or dragging the gun is acceptable, but with aluminium, the drag technique will lead to

weld defects.

La

ck of Fusion: Lack of fusion can occur when the voltage or wire feed speed is set too low, or when

the operator's travel speed is too fast. Because aluminium conducts heat much faster than steel, it is

prone to lack of fusion at the start of a weld until enough energy is put into the weld. Some welding

equipment addresses this by automatically ramping up the current at the start of a weld and then

decreasing it to avoid too much heat build-up.

Craters: With aluminium, craters can form at the end of a weld. If they are not filled in, they create a

stress point, which can lead to cracking. This requires the user to quickly trigger the gun again to fill in

the crater, although some welding machines offer a crater timer that will fill in the crater when the gun

trigger is released.

Burn Through: Too much heat input can be caused by setting voltage or wire feed speed too high or

by too slow of a travel speed. This can lead to warping or burn through especially on the thinner

materials found in the sign industry, aluminium being more prone to the effects than steel. Generally

aluminium requires a faster travel speed than steel to avoid heat build-up.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

44

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. It also

may require cleaning or changing the contact tip because of the burn back caused when the wire

stops feeding. There are several ways to feed aluminium wire: Push only, spool gun, push-pull

system and continuous feed push only system.

Push only: Feeding aluminium wire through a push only system can be difficult, but it can be done on

a limited basis. It requires u-groove drive rolls to provide more surface contact with the wire, a Teflon

liner, adequate drive-roll pressure, the ability to keep the gun cable straight and a high tolerance for

pain.

Spool Gun: A spool gun eliminates the possibility of bird-nesting by putting a 10 cm (2.5kg.) spool on

the gun, so the wire only feeds a few inches. Spool guns can accommodate aluminium wire diameters

from .06 to .08mm and allow the operator to use longer cables (4.5 m-15 m).

A spool gun needs to have the roll changed after every pound of wire is used, compared with the 3.5-

or 7 kg spool on a push-pull system.

Push-pull gun: With a push-pull gun, a motor in the gun pulls the wire through the liner, while the

motor in the welder or feeder control becomes an assist motor. By maintaining consistent tension on

the wire, the push-pull system helps eliminate bird-nesting. It is more ergonomic than the spool gun,

since the weight of the spool is not in the operator's hands.

Also, the spool needs to be changed less often than on a spool gun and allows the purchase of larger

spools. However, remember that aluminium builds up an oxide layer after being exposed to air for a

while. If you only go through a pound or two of aluminium a week, the smaller spool may be a better

choice.

Plasma Cutting Faults

I

nstances where the metal was not fully cut indicate a few different problems. If the ground clamp was

not properly attached to the material this can happen. A similar cut can happen if there was a drop in

air pressure, moisture in the air line, or a drop in power. A third cause is if the torch contacts the

material, most plasma cutters will go into a low power mode when this happens causing the cut not to

penetrate all the way.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

45

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: -

Max spool size: 5kg

Other Specifications: Refer to brochure or advertisement

CT-520

Process: TIG / MMA / CUT

Input power: 240V, 50Hz

Rated output (duty cycle): -

Welding amperage range: TIG 15-200 Amps / MMA 18V / 15-200 Amps /

CUT 28V / 20-50 Amps /125V

No load voltage: -

Single pass weld: -

Weldable metals: Welds Steel, Stainless, Copper, Iron + more

Wire diameter range: -

Max spool size: -

Other Specifications: Refer to brochure or advertisement

ROSSWELDER

Process: ARC

Input power: 240V, 50Hz (15A plug)

Rated output (duty cycle): 35% @ 200A / 60% @ 160A / 100% @ 120A

Welding amperage range: 5-200 Amps

No load voltage: 72V

Single pass weld: -

Weldable metals: -

Wire diameter range: -

Max spool size: -

Other Specifications: Refer to brochure or advertisement

WELD-CT312

Process: TIG / MMA / CUT

Input power: 240V, 50Hz (15A plug)

Rated output (duty cycle):

Welding amperage range: TIG 10-120 Amps / MMA 20-120 Amps / CUT

20-30 Amps

No load voltage: -

Single pass weld: -

Weldable metals: -

Wire diameter range: -

Max spool size: -

Other Specifications: Refer to brochure or advertisement

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

46

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: -

Weldable metals: -

Wire diameter range: -

Max spool size: -

Other Specifications: Refer to brochure or advertisement

WELD-MIG185E

Process: MIG / MAG / MMA

Input power: 220-240V 50Hz (15A Plug)

Rated output (duty cycle): 180A-15%, 90A-60%

Welding amperage range: 60-185Amps (Max)

No load voltage: -

Single pass weld: -

Weldable metals: -

Wire diameter range: 0.8 - 1.0mm, 0.6 - 0.8mm

Max spool size: 5kg

Other Specifications: Refer to brochure or advertisement

WELD-MIG195-ORANGE

Process: MIG / MAG

Input power: 240V, 50Hz

Rated output (duty cycle):

Welding amperage range: 40-200Amps (Max)

No load voltage: 23-38V

Single pass weld: -

Weldable metals: -

Wire diameter range: 0.6mm - 1.0mm

Max spool size: 5kg

Other Specifications: Refer to brochure or advertisement

WELD-MIG220BZ

Process: MIG/MAG/TIG/MMA

Input power: 220-240V 50Hz (15A Plug) +/- 15%

Rated output (duty cycle): -

Welding amperage range: 50-220A

No load voltage: 38

Single pass weld: -

Weldable metals: -

Wire diameter range: 0.8-1.0mm

Max spool size: 2.5kg

Other Specifications: Refer to brochure or advertisement

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

47

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: -

Max spool size: 5kg

Other Specifications: Refer to brochure or advertisement

WELD-ROSSI-MT200

Process: MIG/TIG/MMA

Input power: 240V, 50Hz (15A)

Rated output (duty cycle):

Welding amperage range: MIG 30-200A

No load voltage: 60

Single pass weld: -

Weldable metals: -

Wire diameter range: -

Max spool size: 1Kg

Other Specifications: Refer to brochure or advertisement

WELD-WSM200

Process: TIG/MMA

Input power: 240V, 50Hz (15A Plug)

Rated output (duty cycle):

Welding amperage range: MMA 5-160Amps / TIG 10-200 Amps @ 18V

No load voltage: -

Single pass weld: -

Weldable metals: -

Wire diameter range: NA

Max spool size: NA

Other Specifications: Refer to brochure or advertisement

WLDMIG155RSSADJE

Process: MIG/MAG

Input power: 240V, 50Hz (15A Plug)

Rated output (duty cycle): 155A-10%, 62A-60%, 50A-100%

Welding amperage range: 30-155Amps (Max)

No load voltage: 23-38V

Single pass weld: -

Weldable metals: -

Wire diameter range: NA

Max spool size: NA

Other Specifications: Refer to brochure or advertisement

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

48

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

Max spool size: 5kg

Other Specifications: Refer to brochure or advertisement

WLDMIG195RSSADJE

Process: MIG/ MAG/ MMA

Input power: 240V, 50Hz (15A Plug)

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: 0.6-0.8mm to 0.8-1.0mm

Max spool size: 5kg

Other Specifications: Refer to brochure or advertisement

WLDPAA200ROSADJB

Process: AC/DC/TIG

Input power: 240V, 50Hz (15A Plug)

Rated output (duty cycle): TIG 60%@200Amps / MMA

35%@160Amps / Plasma Cutter 60%@50Amps

Welding amperage range: MMA 10-160A / Plasma Cutter 15-50A

No load voltage: -

Single pass weld: -

Weldable metals: -

Wire diameter range: NA

Max spool size: NA

Other Specifications: Refer to brochure or advertisement

WLDMIGROSA130

I

nput power voltage (V): 240V, 50Hz

Wire Spool Diameter: 0.6 - 0.9mm

Spool Capacity: 1kg

Current Range: 30-130Amps (Max)

Welder Type: Gas/Gasless Metal Inert/Active Gas (MIG/MAG)

Duty Cycle: 125A-20%, 96A-35%, 74A-60%

Power Plug: 15A

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

49

Rossi Welders

WLDMIG280BROS

I

nput power voltage (V): 220-240V 50Hz (15A Plug)

Input Capacity: 6.1KVa

Current Range: 50-280Amps (Max)

Welder Type: Metal Inert Gas/Metal Active Gas (MIG/MAG) and

Manual Metal Arc (MMA/ARC)

Welding spool: 0.6 - 1.0mm

Duty Cycle: 280A-12%, 89A-100%

Power Plug: 15 Amp

WLDPTAROSA620

Rated Input Voltage: AC240V+15%

Input Capacity: 7.1KVA

Frequency: 50/60HZ

No-load Loss: 40W

Power Factor: 0.93

Efficiency: 85%

Class of Insulation: B

Case Protection Degree: IP21

Power Plug: 15A

Input Current TIG: 21A MMA: 32A CUT: 28.6A

Rated Output Current TIG: 200A MMA: 200A CUT: 50A

Current Range TIG: 15-200A MMA: 15-200A CUT: 20-50A

No-load Voltage TIG: 62V MMA: 62V CUT: 250V

Working Voltage TIG: 18V MMA: 28V CUT: 125V

Nozzle Internal: 1.3mm

Air Pressure: 0.45MPA

Gas Flow TIG: 2-5L/min CUT: 80L/min

Cut Thickness: 1-12mm

Arc-leading TIG: HF Vibrate MMA: Touch CUT: HF Vibrate

WELD-CUT40

Input Voltage: 220-240V 50Hz (10A Plug)

Output Current: 20-40 Amps

Post Flow Timer: 2.5-5 Seconds

Output Voltage: 100V

Duty Cycle: 60%

Input Air Pressure: 0.45Mpa

Cutting Capacity: 1-8mm

Pilot Arc Mode: HF

Efficiency: 85%

GENERATOR SAFE - 5.5kVA recommended

Power Plug: Australian Standard

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

50

Rossi Welders

WELD-CT312

Input Voltage: 240V 50Hz (10A Plug) +/- 15%

Output:

TIG: 10-120 Amps

MMA: 20-120 Amps

CUT: 20-30 Amps

Duty Cycle: 60%

Input Air Pressure: 0.4Mpa

Cutting Capacity: 1-9mm

Rod Capacity: 4mm

Pilot Arc Mode: HF

Efficiency: 85%

Generator Safe - 5.5kVA recommended

Power Plug: Australian Standard

WLDMIG185BROS

Input power voltage: 240V, 10amp, 50Hz

Current Range: 40-185A (Max)

Welder Type: Metal in Gas (MIG/MAG) and Manual Metal

Arc (MMA/ARC)

Operation: Gas and Gasless

No Load Voltage: 33V

Duty Cycle: 185a-14%, 69A-100%

Insulation Class: IP21

Note: This welder can be used with flux wire/ CO2 wire

WLDMIGROSB195

Input power voltage (V): 240V, 50Hz

Current Range: 40-195Amps (Max)

Welder Type: Metal in Gas (MIG/MAG) / MMA

No Load Voltage: 33V

Insulation Class: IP21

Power Plug: 15A

Torch Cable: 1.85m

Earth Lead Cable: 1.75m

Note: This welder can be used with flux wire/ CO2 wire

Power Plug: Australian Standard

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

51

Rossi Welders

WLDMIG195BROS

Input power voltage (V): 240V, 50Hz

Current Range: 40-195Amps (Max)

Welder Type: Metal in Gas (MIG/MAG) and Manual Metal

Arc (MMA/ARC)

Operation: Gas and Gasless

No Load Voltage: 33V

Insulation Class: IP21

Power Plug: 10A Australian Standard

Torch Cable: 2.1m

Earth Lead Cable: 2m

Electrode Holder Cable: 2m

Note: This welder can be used with flux wire/ CO2 wire

WLDPTAROSA160

Power Voltage: 240V 50Hz

No-Load Voltage: 50V

Output Current Range: 20-160 Amps

Protection Class: IP21

Duty Cycle: 60% @ 160A / 100% @ 130A

Power Plug: 15A

Power Plug: Australian Standard

WLDMPTROSB416

Input Voltage: 240V 50Hz

TIG (Amps/Duty Cycle): 123A @ 100%, 160A @ 60%

MMA (Amps/Duty Cycle): 123A @ 100%, 160A @60%

CUT: 20-40 Amps @ 60% Duty Cycle

Operating Temp: -5 to +40°C

Transportation Temp: -20 to +55°C

Input Air Pressure: 0.4Mpa

Cutting Capacity: 1-12mm

Rod Capacity: 4mm

Pilot Arc Mode: HF

Efficiency: 85%

Plug: 10A

Generator Safe - 8kVA recommended

Power Plug: Australian Standard

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

52

Rossi Welders

WLDMIGROSA220

Input Voltage: 220-240V 50Hz (10A Plug) +/- 15%

No Load Voltage (V): 38

Input Capacity: 7.5KVa

Output Current: 50-220A

Wire Spool Diameter: 0.6mm- 0.8mm

Torch Length: 1.6m

Insulation Class: F

Spool Capacity: 2.5kg

Rod Capacity: 4mm

Max Rated Input: 10 Amp (Require 10Amp Socket)

Duty Cycle: 30% @ 220A

Efficiency: 85%

Generator Safe - 8kVA recommended

Power Plug: Australian Standard

WLDMMAROSB200

Voltage: 240V 50Hz (15A Plug)

No-Load Voltage: 72V

Output Current Range: 20-200 Amps

Protection Class: IP21

Duty Cycle: 30% @ 200A 100% @ 108A

No-load Power: 62W

Single Pass Weld: 2-6mm

Weldable metals: Stainless Steel, Carbon Steel and Cast

Steel

Wire diameter range: 1.6-2.5mm

Power Factor: COS 0.93

Generator Recommended: 5.5kVA

Power Plug: 15A

WLDWSMROSA200

Input Voltage: 240V 50Hz (15A Plug)

Output: TIG 10-200 Amps / 18V

MMA 5-160 Amps

Duty Cycle: 60%

Protection Class: IP21

Pilot Arc Mode: HF

Air Hose Fitting: 1/4"

Efficiency: 85%

Generator Safe: 5.5kVA recommended

Power Plug: Australian Standard

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

53

Rossi Welders

WLDMIGROSA1C7

Voltage: 240V 50Hz (15A Plug)

Output Current Range: 20 - 170 Amps

Protection Class: IP21

Duty Cycle: 38% @ 170A

No-Load Power: 50W

Weldable Metals: Stainless Steel, Steel, Cast Iron,

Aluminium and Alloys

Wire Diameter Range: 0.6-0.8mm (1kg spool)

Suitable electrodes: 1.6-4.0mm

Electrode Cord Length: 1.8m

Power Factor: COS 0.93

Generator Recommended: 4.6kVA

Power cord length: 1.8m

Power Plug: 15A

WLDTIGROSA2C5

Voltage: 240V 50Hz

Output Current Range: 10 - 250 Amps

Protection Class: IP21

Duty Cycle: 35% @ 250A

Polarity: AC/DC

Efficiency: 85%

Power Factor: COS 0.93

Generator Recommended: 8kVA

No-Load Voltage: 65V

Weldable Metals: Stainless Steel, Steel, Cast Iron,

Aluminium, Aluminium Alloys, Chromoly, Copper, Brass,

Magnesium, Titanium

TIG Torch Length: 4m

Suitable electrodes: Up to 4mm

Electrode Cord Length: 1.8m

Earth Clamp length: 1.5m

Power cord length: 1.8m

Power Plug: 15A

WLDMMAROSB2C5

Model: MMA-250N

Voltage: 220V 50/60Hz (15A Plug)

No-Load Voltage: 65-70V

Output Current Range: 20-250 Amps

Protection Class: IP21

Duty Cycle: 30% @250A / 100% @ 136A

No-load Power: 62W

Weldable metals: Stainless Steel, Carbon Steel and Cast

Steel

Wire diameter range: 1.6-4.0mm

Power Factor: COS 0.93

Generator Recommended: 5.4kVA

Power Plug: 15A

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

54

Rossi Welders

WLDMIGROSA3C0

Model: MIG-300P

Input Capacity: 8.8kVA

Current Range: 20A - 300Amps (Max)

Welding Spool: 0.6 - 1.0mm

Welder Type: Metal Inert Gas/Metal Active Gas (MIG/MAG)

and Manual Metal Arc (MMA/ARC)

Duty Cycle: I2, 300A-25%, 150A-100%

Power Plug: 15 Amp

MIG Torch Length: 2m

Wire Diameter: Takes up to 5kg spools from 0.6-1.0mm

Generator Recommended: 8.8kVA (real power)

Input: 220-240V 50Hz

WLDPTAROSA2C5

Power Voltage: 240V 50Hz

Output Current Range: 20-250 Amps

Protection Class: IP21

Duty Cycle: 35% 250A, 100% 136A

No-Load Voltage: 65-70V

Power Plug: 15 Amp

Power Cord length: 1.8m

Insulation Class: F

Welding Metal Thickness: 1.5-12mm

Recommended Generator Power: 7.0kVA

Power Plug: Australian Standard

WLDMIGROSA2C2

Voltage: 240V 50Hz (15A Plug)

Output Current Range: 20-220 Amps

Rated Output Voltage: 20.8 - 28.8V

Protection Class: IP21

Duty Cycle: 35% @ 220A, 100% @ 130A

Weldable Metals: Stainless Steel, Steel, Cast Iron,

Aluminium and Alloys

Wire Diameter Range: 0.6-1.0mm (5kg spool)

Suitable electrodes: Up to 4.0mm

MIG Cord Length: 2m

Electrode Cord Length: 1.8m

TIG Cord Length: 4m

TIG and MMA connections: Quick-connect brass fittings

Power Factor: COS 0.93

Generator Recommended: 5.3kVA

Power cord length: 1.8m

Polarity: DC

Power Plug: 15A

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

55

Rossi Welders

WLDMIGROSA2C5

Model: MIG-250G

Input Voltage: 220-240V 50Hz (15A Plug) +/- 15%

No Load Voltage (V): 38

Input Capacity: 7.5KVa

Output Current: 50-250A

Wire Spool Diameter: 0.6mm- 0.8mm

Torch Length: 1.6m

Insulation Class: F

Spool Capacity: 2.5kg

Rod Capacity: 4mm

TIG and MMA Connections: Quick Connect Brass Fittings

MIG Torch Connection: Hard Wired

Max Rated Input: 15 Amp (Require 15 Amp Socket)

Duty Cycle: 30% @ 250A

Efficiency: 85%

Generator Safe - 8kVA recommended

Polarity: DC

Power Plug: 15 Amp

TOLWDRROB1C7

Model: MIG-170N

Voltage: 240V 50Hz (15A Plug)

Output Current Range: 20 - 170 Amps

Protection Class: IP21

Duty Cycle: 38% @ 170A

No-Load Power: 50W

Weldable Metals: Stainless Steel, Steel, Cast Iron,

Aluminium and Alloys

Wire Diameter Range: 0.6-0.8mm (1kg spool)

Suitable electrodes: 1.6-4.0mm

Electrode Cord Length: 1.8m

Power Factor: COS 0.93

Generator Recommended: 4.6kVA

Power cord length: 1.8m

Power Plug: 15A

WLDMMAROSA2C0

Model: MMA-200S

Input Voltage: 240V / 50Hz

No-load Power: 62W

Power Factor: COS 0.93

Output Current Range: 20 - 200 Amps

Protection Class: IP21

Duty Cycle: 35% @ 200A

Welder Type: MIG/ARC

Weldable Metals: Cast Iron, Stainless Steel, Steel

Wire Diameter Range: 1.5-12mm

Suitable Electrodes: 1.6-3.2mm

Electrode Cord Length: 1.5m

Generator Recommended: 7kVA

Power Cord Length: 1.8m

Power Plug: 15A

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

56

Rossi Welders

Spare Parts

Spare parts available for purchase, scan QR codes below:

QR Code SKU QR Code SKU

WLDMIG155BROS

WLDMPTROSB416

WLDPTAROSA620

WLDMIGROSA130

WLDARCROSA200

WLDWSMROSA200

WLDMIGROSB195

WLDMIGROSC185

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

57

Rossi Welders

QR Code SKU QR Code SKU

WLDMMAROSA2C0

WLDMMAROSA2C5

WLDMMAROSA3C0

WLDMIGROSA1C7

WLDMIGROSA2C2

WLDTIGROSA2C2

WLDTIGROSA2C5

WLDCUTROSA1C4

WLDMIGROSA3C0

WLDPTAROSA2C5

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

58

Rossi Welders

QR Code SKU QR Code SKU

WLDMMAROSB2C5

WLDMIGROSA2C5

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Product Manual – Rossi Welders

240124144900

59

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.

DCEP – Reverse Polarity

DCEN – Straight Polarity

AC Balance – Alternating current contains both electrode positive and electrode negative changing rapidly back

and forth. With Old school machines, you get what you get and roughly 50 /50 dcep/dcen…and you don’t always

need all that cleaning action that you get from the dcep but with most TIG inverters, you can adjust the ac

balance to more than 90 % dcen. Rule of thumb: for nasty aluminium like a boat prop that has some corrosion,

adjust the ac balance to where you use more dcep .For brand new clean aluminium diamond plate, set the ac

balance to where you have around 70-80 percent dcen.

AC Frequency – power from the power company is roughly 50-60 Hz in different countries. An inverter steps the

frequency of the incoming AC power up before it even converts it to DC. That’s why the transformer is so small

light compared to older TIG welders the A/C frequency knob allows you to weld with a much higher frequency.

That option stiffens and focuses the TIG welding arc pinpoints the heat.

Basic current / Base current (Amperage) - The amount of electricity flowing past a point in a conductor every

second.

Clean area width (Phase Balance) – Applies to AC welding and sets the proportion of time the weld current is

positive, during which time the current has an "oxide penetrating" effect on the aluminium alloy weld pool surface,

but which also tends to heat up and melt the tungsten electrode rather than the weld pool. Maximum heat is

delivered to the work piece/job when the electrode is negative so this setting is used to achieve the best

compromise when welding ally.

Down-Slope Time – Allows the current to decrease at whatever rate you set on the knob.

Peak current – Peak current is the nominal current for the high energy pulse. It is adjusted to a level that is set

consistently above the globular to spray transition current. Peak current is expressed in units of ampere. During

the time when the peak current is delivered, the molten droplet detaches from the electrode. An increase in peak

current increases the average welding current and the weld penetration.

Pre flow - The length of time the torch gas flows before the arc terminates.

Post Gas – The length of time the torch gas flows after the arc terminates.

Pulse Duty (duty cycle) – The number of minutes out of a 10-minute time period an arc welding machine can be

operated at maximum rated output. An example would be 60% duty cycle at 300 amps. This would mean that at

300 amps the welding machine can be used for 6 minutes and then must be allowed to cool with the fan motor

running for 4 minutes.

Pulse Frequency – The sequencing and controlling of the amount of current, frequency and duration of the

welding arc.

Pulse width (Pule % on time) - The time the high pulse amperage stays on.

Up-Slope Time – Allows the current to climb at whatever rate you set…from start amperage to operating main

amperage setting on the machine

Wire Speed / Speed – The speed at which wire is fed out of the machine.

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 stuff. The 2t setting pretty much turns the torch switch into a 2 position switch. Press the switch,

you get and arc, let off the switch, arc goes out.

4T - The 4T position is most always used in conjunction with upslope and downslope settings. For example;

a. Press the button and you get an arc.

b. Let off the button and the arc upslope to whatever the main amperage is set to Weld.

c. Press the button and arc downslopes to lower amperage

d. Let off the button and arc quits.

e. Some machines are different but this is the general principle of 4t operation

Start Amps - allows for a really low amperage start-up or a hot one

End Amps - determines the final amperage before the arc quits.

ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI ROSSI

Some experts believe that the incorrect or prolonged use of almost any product may

cause serious injury or death. To help reduce your risk of serious injury or death,

refer to the information below. For more information, see

www.datastreamserver.com/safety



Consult all documentation, packaging

and product labelling before use. Note

that some products feature

documentation available online. It is

recommended to print and retain the

documentation.



Before each use, check the product for

loose/broken/damaged/missing parts,

wear or leaks (if applicable). Never use a

product with

loose/broken/damaged/missing parts,

wear or leaks.



Products must be inspected and serviced

(if applicable) by a qualified technician

every 6 months. This is based on

average residential use by persons of

average size and strength, and on a

property of average metropolitan size.

Use beyond these recommendations may

require more frequent

inspections/servicing.



Ensure that all users of the product have

completed a suitable industry recognised

training course before being allowed

access to the product.



The product has been supplied by a general merchandise

retailer that may not be familiar with your specific

application or description of application. Be sure to attain

third-party approval from a qualified specialist for your

application before use, regardless of any assurances from

the retailer or its representatives.



This product is not intended for use where fail-safe

operation is required. As with any product (for example,

automobile, computer, toaster), there is the possibility of

technical issues that may require the repair or

replacement of parts, or the product itself. If the possibility

of such failure and the associated time it may take to

rectify could in any way inconvenience the user, business

or employee, or financially affect the user, business or

employee, then the product is not suitable for your

requirements. This product is not intended for use where

incorrect operation or a failure of any kind, including but

not limited to, a condition requiring product return,

replacement, parts replacement or service by a technician

may cause financial loss, loss of employee time or an

inconvenience requiring compensation.



If this product has been purchased in error when

considering the information presented here, contact the

retailer directly for details of their returns policy, if

required.

diagrams or images may be reproduced or transmitted in any form or by any means, electronic or

mechanical, including photocopying, scanning or recording, or any information storage and retrieval system,

without express permission or consent from the publisher.

Arc WLDMMAROSA2C5 ROSSI 180 Amp Portable MMA Inverter Welder

Product's Documents

Product manual

Specifications

ROSSI WLDMMAROSA2C5 Questions and Answers