ozito AWG-964 ARC Welder Instruction Manual

ARC
WELDER
140 Amp
INSTRUCTION MANUAL

SPECIFICATIONS

ozito.com.au

WHAT’S IN THE BOX

WARRANTY

IN ORDER TO MAKE A CLAIM UNDER THIS WARRANTY YOU MUST RETURN THE PRODUCT TO YOUR NEAREST BUNNINGS WAREHOUSE WITH YOUR BUNNINGS REGISTER RECEIPT. PRIOR TO RETURNING YOUR PRODUCT FOR WARRANTY PLEASE TELEPHONE OUR CUSTOMER SERVICE HELPLINE:
Australia 1800 069 486
New Zealand 0508 069 486

TO ENSURE A SPEEDY RESPONSE PLEASE HAVE THE MODEL NUMBER AND DATE OF PURCHASE AVAILABLE. A CUSTOMER SERVICEREPRESENTATIVE WILL TAKE YOUR CALL AND ANSWER ANY QUESTIONS YOU MAY HAVE RELATING TO THE WARRANTY POLICY OR PROCEDURE.
The benefits provided under this warranty are in addition to other rights and remedies which are available to you at law. Our goods come with guarantees that cannot be excluded at law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. Generally you will be responsible for all costs associated with a claim under this warranty, however, where you have suffered any additional direct loss as a result of a defective product you may be able to claim such expenses by contacting our customer service helpline above.
3 YEAR REPLACEMENT WARRANTY
Your product is guaranteed for a period of 36 months from the original date of purchase. If a product is defective it will be replaced in accordance with the terms of this warranty.
Warranty excludes consumable parts, for example: welding masks and combination wire brush/chipping hammers.

WARNING
The following actions will result in the warranty being void.

• If the tool has been operated on a supply voltage other than that specified on the tool.
• If the tool shows signs of damage or defects caused by or resulting from abuse, accidents or alterations.
• Failure to perform maintenance as set out within the instruction manual.
• If the tool is disassembled or tampered with in any way.
• Professional, industrial or high frequency use.

KNOW YOUR PRODUCT

ARC WELDER

1. Carry Handle
2.  Internal Cooling Fan
3.  Overload LED
4.  Current Setting Gauge
5. On/Off Switch
6. Current Regulator Knob
7. Electrode Holder
8.  Earth Clamp

ACCESSORIES

9. Wire Brush / Chipping Hammer
10. Welding Mask

ONLINE MANUAL
Scan this QR Code with your mobile device to take you to the online manual.

http://www.ozito.com.au/awg-964

SETUP & PREPARATION

1. ASSEMBLY

WARNING: ENSURE THE TOOL IS SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY BEFORE PERFORMING ANY OF THE FOLLOWING STEPS.
Before starting you will require a suitable Electrode according to the specific material type and thickness.

1. Install thin (uncoated) end of Electrode into the arc electrode holder.
   WARNING: DO NOT TOUCH THE ELECTRODE WHILE THE WELDER IS ON.

2.  Attach the Earth Clamp to the work piece ensuring area is free from paint or dirt so that there is a good electrical connection.

3. Connect the Arc Welder power cord into a power outlet.
   NOTE: AVOID THE USE OF EXTENSION CORDS.

OPERATION

2. CONTROLS

WARNING: THE POWER SUPPLY FOR THIS PRODUCT SHOULD BE PROTECTED BY A RESIDUAL CURRENT DEVICE (RATED AT 30MA OR LESS). A RESIDUAL CURRENT DEVICE REDUCES THE RISK OF ELECTRIC SHOCK.

Welding Current Control
The welding current can be increased or decreased by turning the welding current control knob. The welding current should be set according to the specific application and material.

1. To increase the welding current turn the current regulating knob in a clockwise direction.

2. To decrease the welding current turn the current regulating knob in a anticlockwise direction.

On/Off Switch
To turn the welder on press the on/off switch to the On position (“I”).
To turn the welder of press the on/ off switch to the Off position (“0”).
Note: The cooling fan will only operate when the welder is switched On (“I”).

Thermal Overload LED
When illuminated, wait for the LED to extinguish before resuming welding.
Note: This can occur in heavy use and does not indicate a fault.

3. ARC WELDING

Preparation
Before welding ensure that:

• You have read and understand the safety section of this manual.
• There is sufficient ventilation, particularly at the front and rear of the unit.
•  You have an adequate fire-fighting devices on hand.

WARNING: ENSURE ALL OIL, PETROL AND FLAMMABLE CONTAINERS HAVE BEEN REMOVED FROM WELDING AREA.

Electrodes & Welding Current
The welding current must be regulated in accordance with the diameter of the electrode and the thickness of the steel being used.
This will vary with the type of electrodes and material you are using.
Below is a guide suggesting suitable currents & thickness for welding steel.

Striking the Arc

WARNING: ENSURE APPROVED PROTECTIVE CLOTHING AND WELDING HELMET/MASK IS WORN AT ALL TIMES TO PROTECT YOUR FACE AND EYES FROM ARC UV RADIATION AND SPARKS.
Lower the electrode slowly and proceed to strike the electrode tip against the desired join area on the work piece as if you are striking a match. As soon as you have the arc, try to maintain a distance from the work piece equal to the diameter of the electrode being used, eg Ø2.0mm electrode, 2.0mm gap.

Slag
Slag is refuse left around the weld after welding, this should only be removed after the weld has cooled down and is no longer glowing. Face shield must be worn during removal of slag.

ARC WELDING

4. WELDED JOINTS

Butt Joint
Is the joining of two pieces of material together along a single edge in a single plane. Two sheets of metal are laid side-by-side and joined together along a single joint.

Fillet Joint
Is a type of joint used for welding pieces or plates in which the angle between them varies from 0° to 180°. The edge of one plate is brought against the surface of another not in the same plane. The joint can be welded on one or both sides.

Lap Joint
The edges of a plate are lapped one over the other and the edge of one is welded to the surface of the other.

Corner Joint
A corner joint consists of two pieces of material joined at their edges to form an “L” shape.

5. WELDING PROPERTIES

Arc Length
To strike the arc, the electrode should be gently scraped on the work until the arc is established. A simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs and gives a rough surface finish to the weld. A short arc is essential if a high quality weld is to be obtained but a excessively short arc will cause sticking of the electrode and result in poor quality welds.
Electrode Angle
The angle that the electrode makes with the work is important to ensure a smooth, even transfer of metal. When welding in down hand, fillet, horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel. When vertical up welding the angle of the electrode should be between 70 and 80 degrees to the work piece.
Travel Speed
The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion and lack of penetration. While too slow a rate of travel will frequently lead to arc instability, slag inclusions and poor mechanical properties.
Electricity
The electricity flows through the electrode cable to the attached electrode. The electricity will not leave the electrode unless it touches an earthed object.
Electricity always finds the fastest path to the earth. When the earth cable clamp is connected to the metal work piece a direct earth connection is created back to the welder. When the electrode makes contact with the earthed work piece an arc is created. The electricity flows through the electrode, the metal work piece and then through the earth cable straight back to the welder.
Earth Clamp
Prior to connecting the earth clamp it may be necessary to clean the surface of the work piece using the metal brush. Attach the earth clamp firmly to the work piece ensuring there is good metal to metal contact. Clamp it where it will not be in the way. This clamp provides an earth connection back to the welder. Always ensure the welder is disconnected from the power supply before attaching electrodes into the holder.
Electrodes
Always store the electrodes in a dry place protecting them from moisture. Should electrodes become damp or moist, bake them in an oven at 200 – 250˚C for 2 hours. Unless the electrodes are vacuum packed, basic coated electrodes will always require such baking prior to use.

Metal arc welding electrodes consist of a core wire surrounded by a flux coating.
The flux coating is applied to the core wire by an extrusion process.
The coating on arc welding electrodes has a number of purposes:

• To provide a gaseous shield for the weld metal, and preserve it from contamination by the atmosphere whilst in a mol ten state.
• To give a steady arc by having ‘arc stabilisers’ present, which provide a bridge for current to flow across.
•  To remove oxygen from the weld metal with ‘deoxidised’.
• To provide a cleansing action on the work piece and a protective slag cover over the weld metal to prevent the formation of oxides while the metal is solidifying. The slag also helps to produce a bead of the desired contour.
• To introduce alloys into the weld deposits in special type electrodes.

ELECTRICAL SAFETY

**WARNING! When using mains-powered tools, basic safety precautions, including the following, should always be followed to reduce risk of fire, electric shock, personal injury and material damage.
Read the whole manual carefully and make sure you know how to switch the tool off in an emergency, before operating the tool.
Save these instructions and other documents supplied with this tool for future reference.
The electric motor has been designed for 230V and 240V only. Always check that the power supply corresponds to the voltage on the rating plate.
Note: The supply of 230V and 240V on Ozito tools are interchangeable for Australia and New Zealand.
If the supply cord is damaged, it must be replaced by an electrician or a power tool repairer in order to avoid a hazard.
Using an Extension Lead**
Always use an approved extension lead suitable for the power input of this tool. Before use, inspect the extension lead for signs of damage, wear and ageing. Replace the extension lead if damaged or defective.
When using an extension lead on a reel, always unwind the lead completely. Use of an extension lead not suitable for the power input of the tool or which is damaged or defective may result in a risk of fire and electric shock.
It is recommended that the extension lead is a maximum of 25m in length. Do Not use multiple extension leads.
The power supply for this product should be protected by a residual current device (rated at 30mA or less). A residual current device reduces the risk of electric shock.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING!
Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery- operated (cordless) power tool.

1. Keep work areas clean. Cluttered work areas and benches can cause accidents.

2.  Consider work area environment. Do not expose your equipment to high humidity or rain. Do not use your equipment in damp or wet conditions. Keep the work area well lit. Do not use your tool where there is a risk of causing fire or explosion, e.g. in the presence of flammable liquids and gases.

3.  Keep children away. Do not allow children, visitors or animals to come near the work area or to touch the equipment or accessories.

4. Dress appropriately. Wear the appropriate protective clothing. Wear a protective hair covering to keep long hair out of the way.

5.  Guard against electric shock. Prevent body contact with earthed or grounded surfaces. Electrical safety can be further improved by using a high sensitivity (30 mA / 30 mS) residual current device (RCD).

6.  Do not overreach. Keep proper footing and balance at all times.

7.  Stay alert. Watch what you are doing. Use common sense. Do not operate the equipment when tired.

8.  Secure work piece. If required, use clamps or a vice to hold the work piece.

9.  Extension leads. Before use inspect the extension leads and replace if damaged. When using the equipment outdoors, only use extension leads intended for outdoor use and marked accordingly.

10.  Use appropriate equipment. Only use the equipment as outlined within this instruction manual. Do not force the equipment to the job of heavier duty equipment. The equipment will do the job better and safer at the rate for which it was intended. Do not force the equipment.
    WARNING! The use of any accessory or attachment, or performance of any operation with this equipment other than those recommended in this instruction manual may present a risk of personal injury.

11. Check for damaged parts. Before use carefully check the equipment and power lead for damage. Check for misalignment and seizure of moving parts, breakage of parts, damage to guards and switches and any other conditions that may affect its operation. Ensure the equipment will operate properly and perform its intended function. Do not use the equipment if any parts are damaged or defective. Do  not use the equipment if the switch does not turn it on and off. Have any damaged or defective parts
    repaired or replaced by an electrician or a power tool repairer. Never attempt any repairs yourself

12. Unplug the equipment. Unplug the equipment when it is not in use, before changing any parts, accessories or attachments and before servicing.

13. Do not abuse the cord. Never carry the equipment by its cord or pull it to disconnect from the socket. Keep the cord away from heat, oil and sharp edges.

14. Store equipment. When not in use, equipment should be stored in a dry, locked up or high place,out of reach of children.

15.  Maintain mains equipment with care. Keep the equipment clean and in good condition for better and safer performance. Follow the instructions for maintenance and changing accessories. Keep handles and switches dry, clean and free from oil and grease.

16. Have your tool repaired by an electrician or a power tool repairer. This power tool complies with relevant safety requirements. To avoid danger, electrical equipment must only be repaired by qualified technicians using original spare parts; otherwise this may result in considerable danger to the user.

17. Users. This equipment is not intended for use by young children or infirmed persons without supervision. Young children should be supervised to ensure that they do not play with this equipment.

18. Replacement of the supply cord. If the supply cord is damaged, it must be replaced by an electrician or a power tool repairer in order to avoid a hazard.

WELDER SAFETY WARNINGS

• Under no circumstances should the housing of the welder be opened.
• Always protect your eyes and face with a welding mask.
•  Wear appropriate protective clothing such as a welding apron and sleeved gloves etc.
• Avoid exposing skin as UV rays are produced by the arc.
•  Screen off the work place to protect others working nearby from UV rays.
•  Welding materials with contaminated surfaces may generate toxic fumes. Ensure the surface is clean before welding. Avoid operating on materials cleaned with chlorinated solvents or near such solvents.
• Do not weld metal equipment that holds/contains flammable materials, gases or liquid combustibles.
• Zinc-plated or galvanized material should not be welded as the fumes created are highly toxic.
• Do not use the welder in damp or wet conditions.
• Do not use cables with worn insulation or loose connections.
•  Disconnect from the power supply before replacing electrodes.
• Avoid direct contact with the welding circuit.
•  Do not use the welder to defrost piping.
• Ensure the welder is placed on a level surface to prevent overturning.
•  Provide adequate ventilation or a means for removal of the welding fumes produced (forced circulation using a blower or fan).

Fumes
Toxic gases are given off during the ARC welding process, which may collect in the welding area if the ventilation is poor. Be alert at all times to the possibility of fume build-up. In small or confined areas use a fume extractor.
Glare
The electric arc generated by the arc process gives direct heat and ultraviolet radiation. It is essential that the eyes of the operator and bystanders are protected from the glare during welding.
ALWAYS USE A FACESHIELD OR WELDING HELMET FITTED WITH THE CORRECT GLASS FILTER.
Heat
It is desirable that welding gloves are worn whilst welding. They will protect the hands from ultra-violet radiation and direct heat of the arc.
Dress
In addition to face shield, welding gloves and overalls, other types of protective clothing should be worn when welding. Additional protective clothing such as a leather apron, sock protectors and a hat will all assist in reducing any injuries due to heat, sparks and slag produced during welding.
OVERALLS should also be worn. They should be of type designed to be buttoned at the wrists and the neck.

IMPORTANT INFORMATION

Thermal Overload
IF YOUR WELDER OVERHEATS AND THE THERMAL OVERLOAD PROTECTION ENGAGES DO NOT TURN YOUR WELDER OFF AS THE FAN WILL ASSIST IN REDUCING THE COOLING TIME.
All Welders have a feature called a duty cycle.
Duty cycle on a welder refers to the time in which the welder operates during normal welding.
A welder can only weld for a certain continuous period of time before it requires to cool down.
If the internal components of the welder should become hot the welder could overheat. If the welder overheats the Thermal Overload Protection feature will automatically shut down the welder.
THIS CAN OCCUR IN HEAVY USE AND DOES NOT INDICATE A FAULT.
The Welder will cease to weld and the Thermal Overload LED light will turn on. This LED indication light is just to inform you that your welder is becoming too hot and requires to cool down to protect the internal components of the welder. Do Not turn your welder Off as the welder has an internal cooling fan and this will assist your welder to cool down quicker. Reducing the cooling time will enable you to get back to your welding job quicker.
Depending on how many Amps or how heavy the welding you are doing the cooling time may take up to 10 Minutes for your welder to cool down so you can return to your welding job.

DESCRIPTION OF SYMBOLS

U 0

| ****

Non-load voltage

U 1| Rated AV input voltage (with tolerance ±10%)| ****

U 2

| ****

On-load voltage

I 1 max| Rated maximum input current| ****| Max. effective input current

I 2

| Current rating| **| MAG welding
t W| Load time| t r| Reset time
V max| Max. wire feeding speed| IP| Protection class
X| Load duration rate| | Direct Current (DC)
A/V**| Electric current adjustment range, and the relevant on-load voltage|

| ****

Do not operate in the rain

| Read operator’s manual|

| Regulator compliance mark
| Symbol of single-phase AV power and rated frequency
| Single-phase transformer – Rectifier

| Suitable for welding in an environment which has high risk of electric shock

TROUBLESHOOTING

extension leads.
Circuit breaker tripped| Check the rating of the curcuit breaker on the supply and other appliances connected to the circuit.
The welder is a high power device and it is
recommended that is be the only appliance on the circuit to ensure it has enough power to operate.
Difficulty starting arc| Earth clamp conenction not adequate|

Check earth clamp has good connection to material being welded. Surface for clamp conenction needs to be bare metal, remove rust or paint.

Welding technique| Hold electrode at correct angle, practice on scrap material
Welder cuts out|

Thermal overload active

| ** The thermal overload light on the front panel will be on and the welder will not operate until cooled down and the light goes out. This is normal in heavy welding, allow the welder to cool down.
ARC WELDING**| |
Poor welding| Incorrect or wet welding electrodes| Select electrode type to suit material, electrodes need to be dry.
Sticking welding electrode| Settings| Increase current to recommended
Material| Clean area being welded to bare metal
Electrode type and size| Check the electrode type and size is appropriate for the material being used.
Electrode damage| Replace with new welding rod
Excessive welding electrode consumption| Welding current setting too high| Reduce welding current
Electrode size to small for material| Change to larger electrode

CARING FOR THE ENVIRONMENT

Power tools that are no longer usable should not be disposed of with household waste but in an environmentally friendly way. Please recycle where facilities exist. Check with your local council authority for recycling advice.
Recycling packaging reduces the need for landfill and raw materials. Reuse of recycled material decreases pollution in the environment. Please recycle packaging where facilities exist. Check with your local council authority for recycling advice.

SPARE PARTS

Spare parts can be ordered from the Special Orders Desk at your local Bunnings Warehouse.
For further information, or any parts not listed here, visit
www.ozito.com.au or contact Ozito Customer Service:
Australia 1800 069 486
New Zealand 0508 069 486
E-mail: enquires@ozito.com.au

References

• Premium tools for DIY enthusiasts and gardeners | Ozito.com.au
• Premium tools for DIY enthusiasts and gardeners | Ozito.com.au
• Manual-Hub.com – Free PDF manuals!

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