Ozito AWG-964 User manual

ONOVERLOAD
OFF
ONOVERLOAD
OFF
ARC
WELDER
140 Amp
INSTRUCTION MANUAL
SPECIFICATIONS
Input Voltage: 240V ~ 50Hz
Current Range: 55 - 130A
Peak Current: 140A
Duty Cycle: 25% @ 80 amp
Electrode Size: Ø2.0 - 3.2mm
AWG-964
WHAT’S IN THE BOX
Arc Welder
Earth Clamp
Wire Brush / Chipping
Hammer
Welding Mask
Arc Electrode Holder
ozito.com.au
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
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.
WARRANTY
TO ENSURE A SPEEDY RESPONSE PLEASE
HAVE THE MODEL NUMBER AND DATE OF
PURCHASE AVAILABLE. A CUSTOMER SERVICE
REPRESENTATIVE WILL TAKE YOUR CALL
AND ANSWER ANY QUESTIONS YOU MAY
HAVE RELATING TO THE WARRANTY POLICY
OR PROCEDURE.
OZITO Australia/New Zealand (Head Office) 1-23 Letcon Drive, Bangholme, Victoria, Australia 3175.
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.
1118

ONLINE MANUAL
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the online manual.
ARC WELDER
ACCESSORIES
1 Carry Handle
2 Internal Cooling Fan
3 Overload LED
4 Current Setting Gauge
5 On/O󰀨Switch
6 Current Regulator Knob
7 Electrode Holder
8 Earth Clamp
9 Wire Brush / Chipping
Hammer
10 Welding Mask
KNOW YOUR PRODUCT
1. ASSEMBLY
1 Install thin (uncoated)
end of Electrode into the
arc electrode holder.
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.
SETUP & PREPARATION
3 Connect the Arc Welder power
cord into a power outlet.
Before starting you will require a suitable Electrode according to the
specicmaterialtypeandthickness.
1
2
3
4
8
6
5
9 10
7
WARNING: ENSURE THE TOOL IS SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY BEFORE
PERFORMING ANY OF THE FOLLOWING STEPS.
WARNING: DO NOT TOUCH THE ELECTRODE WHILE
THE WELDER IS ON.
NOTE: AVOID THE USE OF EXTENSION CORDS.

2. CONTROLS 3. ARC WELDING
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.
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specicapplicationandmaterial.
OPERATION
Preparation
Before welding ensure that:
• You have read and understand the safety section of this manual.
• Thereissu󰀩cientventilation,particularlyatthefrontandrearof
the unit.
• Youhaveanadequatere-ghtingdevicesonhand.
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.
Electrode Diameter Welding Current (Amps) Thickness of Steel
¯2.0mm 55 - 75 1.5 - 2mm
¯2.5mm 80 - 105 3 - 5mm
¯3.2mm 105 - 130 4 - 6mm
Striking the Arc
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.
WARNING: ENSUREALL OIL, PETROLAND FLAMMABLE
CONTAINERS HAVE BEEN REMOVED FROM WELDING
AREA.
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.
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anti-
clockwise direction.
ON
OVERLOAD
OFF
ON
OVERLOAD
OFF
On/O󰀨 Switch
Thermal Overload LED
To turn the welder on press the
on/o󰀨switchtotheOnposition
("I").
To turn the welder of press the on/
o󰀨switchtotheO󰀨position("0").
When illuminated, wait for
the LED to extinguish before
resuming welding.
Note: The cooling fan will only
operate when the welder is
switched On ("I").
Note: This can occur in heavy use
and does not indicate a fault.
ON
OVERLOAD
OFF
ON
OVERLOAD
OFF
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.
70-80º
Strike
Keep Consistant
Height
2.0mm
Welding Direction

5. WELDING PROPERTIES4. WELDED JOINTS
AWG-964
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nish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,llet,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owsthroughtheelectrodecabletotheattachedelectrode.The
electricity will not leave the electrode unless it touches an earthed object.
Electricityalwaysnds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ows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rmly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.
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 weld-
ing 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.
ARC WELDING
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uxcoating.
Theux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ow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.

DESCRIPTION OF SYMBOLS
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: [email protected]
SPARE PARTS
TROUBLESHOOTING
Thermal Overload
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 O󰀨 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.
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.
IMPORTANT INFORMATION
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landll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.
VVolts
~Alternating current
U0Non-load voltage
U2On-load voltage
t
WLoad time
ø Diameter
X Load duration rate
U1Rated AV input voltage
(with tolerance ±10%)
A/V Electric current adjustment
range, and the relevant
on-load voltage
IP Protection class
Direct Current (DC)
Warning
Symbol of single-phase AV power and rated frequency
I1max
Rated maximum input current
Vmax Max. wire feeding speed
Regulator compliance mark
A Amperes
Do not operate in the rain
Read operator’s manual
Hz Hertz
WWatts
t
rReset time
I
2Current rating MAG welding
Max. effective input current
Single-phase transformer - Rectifier
Suitable for welding in an environment which has high risk of
electric shock
PROBLEM CAUSE REMEDY
GENERAL OPERATION
No Power Power supply Test supply with another product, avoid using
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.
Diculty 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
Welding current setting too highExcessive welding
electrode consumption
Reduce welding current
Electrode size to small for material Change to larger electrode
ThisproductisclassiedasGroup1&2,ClassBweldingequipment.
• Group2-Thisproductgeneratesradiofrequencyenergyinthe
frequencyrange9KHzto400GHz.
• ClassB-Thisproductisintendedforuseinadomestic
environment. It is suitable for use in locations in residential
environments and in establishments directly connected to a low
voltage power supply network which supplies buildings used for
domestic purposes.
EQUIPMENT CLASSIFICATION

• 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o󰀨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ammable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o󰀨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conned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.
WELDER SAFETY WARNINGS
WARNING! When using mains-powered tools, basic safety precautions, including the
following, should always be followed to reduce risk of re, electric shock, personal injury
and material damage.
Readthewholemanualcarefullyandmakesureyouknowhowtoswitchthetoolo󰀨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re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.
WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and
instructionsmayresultinelectricshock,re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reorexplosion,e.g.inthepresenceofammable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a󰀨ect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o󰀨.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qualied
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inrmed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.
GENERAL POWER TOOL SAFETY WARNINGS
ELECTRICAL SAFETY