Ryobi MMA-140 Operation manual

OWNER’S OPERATING MANUAL
MMA INVERTER WELDER
MODEL MMA-140
KEEP THIS MANUAL FOR FUTURE REFERENCE
Your new inverter generator has been engineered and manufactured to Ryobi’s
high standard of dependability, ease of operation and operator safety. Properly
cared for, it will give you years of rugged, trouble free performance. If you use
your inverter generator properly and only for what it is intended, you will enjoy
years of safe, reliable service.
SPECIFICATIONS
Rated input power supply......................................................AC 230V±5% 50/60Hz
Rated input capacity......................................................................................5.3KVA
Current adjustment range........................................................................... 20-140A
Rated duty cycle................................................................................................ 80%
Rated voltage..........................................................................................20.8-25.6
No load voltage.................................................................................................. 63V
V
Overall efficiency................................................................................................80%
Housing protection grade................................................................................IP21S
Power factor..............................................................................................0.73 cosφ
Insulation grade...................................................................................................... F
Electrode diameter...................................................................................1.6-3.2mm
Noise......................................................................................................... <70dB(A)
Dimensions............................................................................... 287 x 120 x 247mm
Net weight........................................................................................................ 3.8kg
THANK YOU FOR BUYING A RYOBI
MMA INVERTER WELDER
CAUTION: Carefully read through this entire owner’s
manual, paying close attention to the general
safety rules and rules for safe operation,
before using.
1

2
IMPOR AN SAFE Y INS RUC IONS
The purpose of safety rules is to attract your
attention to possible dangers. The safety symbols
and the explanations with them, require your
careful attention and understanding. The safety
warnings do not by themselves eliminate any
danger. The instruction or warnings they give are
not substitutes for proper accident prevention
measures.
SAFE Y ALER SYMBOL. Indicates
danger, caution or warning. May be used
in conjunction with other symbols or
pictures.
Failure to obey a safety warning can result in
serious injury to yourself or to others. Always follow
the safety precautions to reduce the risk of fire,
electric shock and personal injury.
Do not attempt to operate this tool until you have
read thoroughly and completely understood the
safety rules, etc. contained in this manual. Failure
to comply can result in accidents involving fire,
electric shock or serious personal injury. Save this
Owners Operating Manual and review it frequently
for continual safe operation and for instructing
others who may use this tool.
EMF INFORMA ION
Considerations About Welding And The Effects Of
Low Frequency Electric And Magnetic Fields.
Welding current, as it flows through welding cables,
will cause electro- magnetic fields. There has been
and still is some concern about such fields.
However, after examining more than 500 studies
spanning 17 years of research, a special blue
ribbon committee of the National Research Council
concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that
exposure to power- frequency electric and
magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence
continues to be examined. Until the final
conclusions of the research are reached, you may
wish to minimize your exposure to electromagnetic
fields when welding or cutting.
To reduce magnetic fields in the workplace, use the
following procedures:
1. Keep cables close together by twisting or
taping them.
2. Arrange cables to one side and away from
the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far
away from operator as practical.
5. Connect work clamp to work piece as close
to the weld as possible.
ABOU PACEMAKERS
Pacemaker wearers consult your doctor first. If
cleared by your doctor, then following the above
procedures is recommended.
WELDING HAZARDS
The symbols shown below are used throughout this
manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and
follow the related instructions to avoid the hazard.
Only qualified persons should service, test,
maintain, and repair this unit.
During servicing, keep everybody, especially
children, away.
ARC RAYS can burn eyes and skin; NOISE can
damage hearing. Arc rays from the welding
process produce intense heat and strong
ultraviolet rays that can burn eyes and skin.
Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper
shade of filter (ANSI Z49.1) to protect your
face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields
recommended. Never wear contact lenses
while welding.
3. Use protective screens or barriers to protect
others from flash and glare; warn others not
to watch the arc.
4. Wear protective clothing made from durable,
flame-resistant material (wool and leather)
and foot protection.
5. Use approved ear plugs or ear muffs if noise
level is high.
ARC RAYS
Can Burn

3
IMPOR AN SAFE Y INS RUC IONS

4
IMPOR AN SAFE Y INS RUC IONS
ouching live electrical parts can cause fatal
shocks or severe burns. he electrode and
work circuit is electrically live whenever the
output is on. he input power circuit and
machine internal circuits are also live when
power is on. In semiautomatic 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.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from work and ground using
dry insulating mats or covers.
4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line
fuses so power cannot be turned on
accidentally.
5. Properly install and ground this equipment
according to its Owner’s Manual and national,
state, and local codes.
6. Turn off all equipment when not in use.
Disconnect power to equipment if it will be left
unattended or out of service.
7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the
ground or the work surface. Do not touch
holders connected to two welding machines at
the same time or touch other people with the
holder or electrode.
8. Do not use worn, damaged, undersized, or
poorly spliced cables.
9. Do not wrap cables around your body.
10. round the workpiece to a good electrical
(earth) ground.
11. Do not touch electrode while in contact with
the work (ground) circuit.
12. Use only well-maintained equipment. Repair
or replace damaged parts at once.
13. In confined spaces or damp locations, do not
use a welder with AC output unless it is
equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if
working above floor level.
15. Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous to your
health. Welding produces fumes and gases.
Breathing these fumes and gases can be haz-
ardous to your health.
1. Keep your head out of the fumes. Do not
breath the fumes.
2. If inside, ventilate the area and/or use
exhaust at the arc to remove welding fumes
and gases.
3. If ventilation is poor, use an approved air-
supplied respirator.
4. Read the Material Safety Data Sheets
(MSDSs) and the manufacturer’s instruction
for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well
ventilated, or while wearing an air-supplied
respirator.
hielding gases used for welding can displace
air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing,
cleaning, or spraying operations. The heat
and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. 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 if
necessary, while wearing an airsupplied
respirator. The coatings and any metals
containing these elements can give off toxic
fumes if welded.
ELEC RIC SHOCK
Can Kill
FUMES & GASES
Can Be Dangerous

FLYING SPARKS AND HO ME AL can cause
injury.
Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles.
Side shields recommended.
2. Wear proper body protection to protect skin.
CYLINDERS can explode if damaged.
Shielding 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.
1. Protect compressed gas cylinders from
excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright
position by chaining them to a stationary
support or equipment cylinder rack to
prevent falling or tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
4. Never allow a welding electrode to touch any
cylinder.
5. Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the
specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except
when cylinder is in use or connected for use.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc.
he flying sparks and hot metal, weld spatter,
hot workpiece, and hot equipment can cause
fires and burns. Accidental contact of electrode
or welding wire to metal objects can cause
sparks, overheating, or fire.
1. Protect yourself and others from flying sparks
and hot metal.
2. Do not weld where flying sparks can strike
flammable material.
3. Remove all flammables within 35 ft (10.7 m) of
the welding arc. If this is not possible, tightly
cover them with approved covers.
4. Be alert that welding sparks and hot materials
from welding can easily go through small
cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher
nearby.
6. Be aware that welding on a ceiling, floor,
bulkhead, or partition can cause fire on the
hidden side.
7. Do not weld on closed containers such as
tanks or drums.
8. 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 and
fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
11. When not welding, make certain no part of the
electrode circuit is touching the work or
ground. Accidental contact can cause
overheating and create a fire hazard.
5
IMPOR AN SAFE Y INS RUC IONS
FLYING SPARKS
Can Cause Injury
CYLINDERS Can
Explode If Damaged
WELDING Can
Cause Fire or Injury

6
IMPOR AN SAFE Y INS RUC IONS
Moving parts, such as fans, rotors, and belts
can cut fingers and hands and catch loose
clothing.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Stop engine before installing or connecting
unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from
battery.
5. Keep hands, hair, loose clothing, and tools
away from moving parts.
6. Reinstall panels or guards and close doors
when servicing is finished and before starting
engine.
SPARKS can cause BA ERY GASES O EX-
PLODE; BA ERY ACID can burn eyes and
skin. Batteries contain acid and generate explo-
sive gases.
1. Always wear a face shield when working on
a battery.
2. Stop engine before disconnecting or
connecting battery cables.
3. Do not allow tools to cause sparks when
working on a battery.
4. Do not use welder to charge batteries or jump
start vehicles.
5. Observe correct polarity (+ and –) on
S EAM AND PRESSURIZED HO COOLAN
can burn face, eyes, and skin.
he coolant in the radiator can be very hot and
under pressure.
1. Do not remove radiator cap when engine is
hot. Allow engine to cool.
2. Wear gloves and put a rag over cap area when
removing cap.
3. Allow pressure to escape before completely
removing cap.
1. High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
2. Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
3. The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
4. If notified by the FCC about interference, stop
using the equipment at once.
5. Have the installation regularly checked and
maintained.
6. Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting,
and use grounding and shielding to minimize
the possibility of interference.
MOVING PAR S
Can Cause Injury
SPARKS Can Cause
BA ERY GASES
O EXPLODE
SPARKS Can Cause
BA ERY GASES
O EXPLODE
H.F. RADIA ION Can
Cause Interference

1. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields
(EMF). Welding current creates EMF fields
around welding cables and welding machines.
2. EMF fields may interfere with some
pacemakers, and welders having a pacemaker
should consult their physician before welding.
3. Exposure to EMF fields in welding may have
other health effects which are now not known.
4. All welders should use the following
procedures in order to minimize exposure to
EMF fields from the welding circuit:
5. Route the electrode and work cables together -
ecure them with tape when possible.
6. Never coil the electrode lead around your
body.
7. Do not place your body between the electrode
and work cables. If the electrode cable is on
your right side, the work cable should also be
on your right side.
8. Connect the work cable to the workpiece as
close as possible to the area being welded.
9. Do not work next to welding power source.
1. Lift unit with handle on top of case.
2. Use handcart or similar device of adequate
capacity.
3. If using a fork lift vehicle, place and secure
unit on a proper skid before transporting.
1. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
2. Install equipment in accordance with the
countries National Electrical Code, all local
codes and the manufacturer’s
recommendations.
3. round the equipment in accordance with the
countries National Electrical Code and the
manufacturer’s recommendations.
1. Do not touch hot parts bare handed.
2. Allow cooling period before working on
welding gun or torch.
1. Do not place unit on, over, or near
combustible surfaces.
2. Do not service unit near flammables.
1. Put on grounded wrist strap BEFORE handling
boards or parts.
2. Use proper static-proof bags and boxes to
store, move, or ship PC boards.
7
IMPOR AN SAFE Y INS RUC IONS
ELEC RIC AND
MAGNE IC FIELDS
May Be Dangerous
FALLING UNI Can
Cause Injury
FOR ELEC RICALLY
Powered Equipment
HO PAR S Can
Cause Severe Burns
FIRE or EXPLOSION
Hazard
S A IC Can Damage
PC Boards

8
IMPOR AN SAFE Y INS RUC IONS
1. Allow cooling period; follow rated duty cycle.
2. Reduce current or reduce duty cycle before
starting to weld again.
3. Do not block or filter airflow to unit.
1. Consult the Owner’s Manual for welding
safety precautions. Do not install, operate or
repair this equipment without reading this
manual and the safety precautions throughout.
2. Use only genuine replacement parts
OVERUSE Causes
OVERHEA ING
READ HE
INS RUC IONS
ADDI IONAL SAFE Y INS RUC IONS
1. ALWAYS ensure that there is full free air
circulating around the outer casing of the
machine, and that the louvres are
unobstructed.
2. ALWAYS use a proper welding face shield or
helmet, with suitable filter lenses. Proper
gloves and working clothes should be worn at
all times.
3. ALWAYS check that the pressure regulator and
gauges are working correctly. DO NOT
lubricate the regulator.
4. ALWAYS use the correct regulator. Each
regulator is designed to be used with a specific
gas.
5. ALWAYS inspect the hose before use to
ensure it is in good condition.
6. ALWAYS keep the free length of gas hose
outside the work area.
7. ALWAYS remove all flammable materials from
the welding area.
8. NEVER remove any of the panels unless the
machine is disconnected from the supply, AND
never use the machine with any of the panels
removed.
9. NEVER attempt any electrical or mechanical
repair unless your are a qualified technician.
If you have a problem with the machine contact
your local RYOBI dealer.
10. NEVER use or store in a wet/damp
environment. DO NOT EXPOSE TO RAIN.
11. NEVER use gas from a cylinder, the content
of which is unknown. It is important to ensure
the appropriate gas is being used.
12. NEVER use a damaged cylinder.
13. NEVER lift the cylinder by the valve.
14. NEVER expose the cylinder to a heat source
or sparks.
15. NEVER continue to weld, if, at any time, you
feel even the smallest electric shock. Stop
welding IMMEDIATELY, and DO NOT attempt
to use the machine until the fault is diagnosed
and corrected.
16. NEVER use the welder with input connections
greater than 10M in length.
17. NEVER point the torch at any person or
animal.
18. NEVER touch the torch nozzle until the welder
is switched OFF and the nozzle has been
allowed to cool off.
19. NEVER connect, disconnect, or attempt to
service the torch, until the machine is switched
OFF and disconnected from the mains supply.
20. NEVER allow the cables to become wrapped
around the operator or any person in the
vicinity.
21. Safety devices such as interlocks and circuit
breakers should not be disconnected or
shunted out.
22. Before installation, inspection, or service of
equipment, shut OFF all power and remove
line fuses to prevent accidental turning ON
of power.
23. Do not open power circuit or change polarity
while welding.

9
ADDI IONAL SAFE Y INS RUC IONS
24. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch
arcing. Always shut OFF and disconnect all
power to equipment. Power disconnect switch
must be available near the welding power
source.
25. Fully insulated electrode holders should be
used. Do NOT use holders with protruding
screws or with any form of damage.
26. Fully insulated lock-type connectors should be
used to join welding cable.
27. Frequently inspect cables for wear, cracks and
damage. IMMEDIATELY REPLACE those with
excessively worn or damaged insulation to
avoid possibly lethal shock from bared cable.
Cables with damaged areas may be taped to
give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and
protected from hot metal and sparks.
INS ALLA ION
ENVIRONMEN
These units are designed for use in environments
with increased hazard of electric shock.
A. Examples of environments with increased
hazard of electric shock are:
1. In locations in which freedom of movement is
restricted, so that the operator is forced to
perform the work in a cramped (kneeling,
sitting or lying) position with physical contact
with conductive parts.
2. In locations which are fully or partially limited
by conductive elements, and in which there is
a high risk of unavoidable or accidental contact
by the operator.
3. In wet or damp hot locations where humidity
or perspiration considerable reduces the skin
resistance of the human body and the
insulation properties of accessories.
B. Environments with increased hazard of electric
shock do not include places where electrically
conductive parts in the near vicinity of the
operator, which can cause increased hazard,
have been insulated.
LOCA ION
This machine can operate in harsh environments.
However, it is important that simple preventative
measures are followed to assure long life and reli-
able operation:
• This machine must be located where there is
free circulation of clean air without restrictions
for air movement to and from the air vents. Do
not cover the machine with paper, cloth or rags
when switched on.
• Dirt and dust that can be drawn into the
machine should be kept to a minimum.
• This machine has a protection rating of IP21S.
Keep it dry and do not place it on wet ground
or in puddles. Do not use in wet or damp
locations. Store indoors.
• Locate the machine away from radio controlled
machinery. Normal operation may adversely
affect the operation of nearby radio controlled
machinery, which may result in injury or
equipment damage.
Read the section on electromagnetic compatibility
in this manual.
• Do not operate in areas with an ambient
temperature greater than 40°C.
IL ING
Place the machine directly on a secure, level
surface.
Do not place or operate this machine on a surface
with an incline greater than 15° from horizontal.
The machine may topple over if this procedure is
not followed.
VEN ILA ION
This cutting machine can create powerful cutting
current and has strict cooling requirements that
cannot be met with natural ventilation. Therefore
the built-in fan is very important in enabling the
machine to work stable with effective cooling. The
operator should make sure that the louvers be
uncovered and unblocked. The minimum distance
between the machine and nearby objects should
be 25cm.

10
INS ALLA ION
CONNEC ION OF INPU CABLE
In order to ensure personal safety and avoid
electric shock, please ground the machine reliably
by connecting the ground wire of the machine to
the grounding device in the switching box.
The primary cable should be tightly connected to
the correct socket to avoid oxidization.
Check whether the voltage value varies in
acceptable range with a multi-meter.
The Mains supply voltage should be within ± 5% of
the rated Mains supply voltage. Too low a
voltage may cause poor welding performance. Too
high a supply voltage will cause components to
overheat and possibly fail.
The Welding Power Source must be:
• Correctly installed, if necessary, by a qualified
electrician.
• Correctly earthed (electrically) in accordance
with local regulations.
DU Y CYCLE
The rated duty cycle of a Welding Power Source, is
a statement of the time it may be operated at its
rated welding current output without exceeding the
temperature limits of the insulation of the
component parts.
This product has a rated duty cycle of 80%. The
percentage represents the welding time in a 10
minute period for example 80% means that the
welding time is 8 minutes with a rest time of 2
minutes in a ten minute period although the actual
duty cycle will depend on the amperage used. If the
Welding Power Supply is used for longer than the
duty cycle or if you are welding using large welding
rods you may experience a temporary current shut
off. This is to protect the transformer inside the
Welding Power Supply from overheating.
Welding longer than rated duty cycle can
damage gun and void the warranty.
ELEC ROMAGNE IC COMPA IBILI Y
WARNING. Extra precautions for
Electromagnetic Compatibility may be
required when this Welding Power
Source is used in a domestic situation.
A. Installation and Use - Users Responsibility
The user is responsible for installing and using the
welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are
detected then it shall be the responsibility of the
user of the welding equipment to resolve the
situation with the technical assistance of the
manufacturer. In some cases this remedial action
may be as simple as earthing the welding circuit,
see Note below. In other cases it could involve
constructing an electromagnetic screen enclosing
the Welding Power Source and the work, complete
with associated input filters. In all cases,
electromagnetic disturbances shall be reduced to
the point where they are no longer troublesome.
Note: The welding circuit may or may nor be
earthed for safety reasons. Changing the earthing
arrangements should only be authorised by a
person who is competent to assess whether the
changes will increase the risk of injury, e.g. by
allowing parallel welding current return paths which
may damage the earth circuits of other equipment.
Further guidance is given in IEC 974-13 Arc
Welding Equipment - Installation and use (under
preparation).
B. Assessment of Area
Before installing welding equipment, the user shall
make an assessment of potential electromagnetic
problems in the surrounding area. The following
shall be taken into account:
1. Other supply cables, control cables, signalling
and telephone cables; above, below and
adjacent to the welding equipment.
2. Radio and television transmitters and
receivers.
3. Computer and other control equipment.
4. Safety critical equipment, e.g. guarding of
industrial equipment.

11
ELEC ROMAGNE IC COMPA IBILI Y
5. The health of people around, e.g. the use of
pacemakers and hearing aids.
6. Equipment used for calibration and
measurement.
7. The time of day that welding or other activities
are to be carried out.
8. The immunity of other equipment in the
environment: the user shall ensure that other
equipment being used in the environment is
compatible: this may require additional
protection measures.
The size of the surrounding area to be considered
will depend on the structure of the building and
other activities that are taking place. The surround-
ing area may extend beyond the boundaries of the
premises.
C. Methods of Reducing Electromagnetic
Emissions
1. Mains Supply
Welding equipment should be connected to
the mains supply according to the
manufacturer’s recommendations. If
interference occurs, it may be necessary to
take additional precautions such as filtering
of the mains supply. Consideration should be
given to shielding the supply cable of
permanently installed welding equipment in
metallic conduit or equivalent. Shielding should
be electrically continuous throughout it’s
length. The shielding should be connected to
the Welding Power Source so that good
electrical contact is maintained between the
conduit and the Welding Power Source
enclosure.
2. Maintenance of Welding Equipment
The welding equipment should be routinely
maintained according to the manufacturer’s
recommendations. All access and service
doors and covers should be closed and
properly fastened when the welding equipment
is in operation.
The welding equipment should not be modified
in any way except for those changes and
adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of arc
striking and stabilising devices should be
adjusted and maintained according to the
manufacturer’s recommendations.
3. Welding Cables
The welding cables should be kept as short as
possible and should be positioned close
together, running at or close to the floor level.
4. Equipotential Bonding
Bonding of all metallic components in the
welding installation and adjacent to it should be
considered. However. Metallic components
bonded to the work piece will increase the risk
that the operator could receive a shock by
touching the metallic components and the
electrode at the same time. The operator
should be insulated from all such bonded
metallic components.
5. Earthing of the Workpiece
Where the workpiece is not bonded to earth for
electrical safety, nor connected to earth
because of it’s size and position, e.g. ship’s
hull or building steelwork, a connection
bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care
should be taken to prevent the earthing of the
workpiece increasing the risk of injury to users,
or damage to other electrical equipment.
Where necessary, the connection of the work
piece to earth should be made by direct
connection to the workpiece, but in some
countries where direct connection is not
permitted, the bonding should be achieved by
suitable capacitance, selected according to
national regulations.
6. Screening and Shielding
Selective screening and shielding of other
cables and equipment in the surrounding area
may alleviate problems of interference.
Screening the entire welding installation may
be considered for special applications.

12
SYMBOL CHAR

13
1. Carry handle
2. On/Off switch
3. Current control knob
4. Power indicator
5. Thermal cutout indicator
6. Earth clamp connection point (- negative)
7. Welding mask
8. Electrode holder
9. Earth clamp
10. Chipping hammer and wire brush
11. Cooling fan
12. Power lead
13. Electrode holder connection point (+ positive)
DESCRIPTION
4
6
5
1
7
12
11
2
13
89
10
3

14
UNPACKING
CAUTION. This packaging contains
sharp objects. Take care when
unpacking. Remove the machine,
together with the accessories supplied, from the
packaging. Check carefully to ensure that the
machine is in good condition and account for all the
accessories listed in this manual. Also make sure
that all the accessories are complete.
If any parts are found to be missing, the machine
and its accessories should be returned together in
their original packaging to the retailer. Do not throw
the packaging away, keep it safe throughout the
guarantee period, then recycle if possible,
otherwise dispose of it by the proper means. Do
not let children play with empty plastic bags due to
the risk of suffocation.
ASSEMBLY
WARNING. ELECTRIC SHOCK can kill.
Keep the electrode holder and cable
insulation in good condition.
Do not touch electrically live parts or electrode
with skin or wet clothing.
Insulate yourself from work and ground.
Turn the input line switch on the welder “OFF”
before connecting or disconnecting output
cables or other equipment.
FITTING THE EARTH CLAMP AND ELECTRODE
HOLDER
Insert the plug on the end of the earth clamp lead
into the negative (-) socket (Fig.1) and twist in a
clockwise direction to secure into position.
The plug on the end of the electrode holder can be
fitted into the positive (+) socket (Fig.1) in the same
way.
A1402 0
Fig. 1

15
ASSEMBLY
Note: Before carrying out any assembly or
disassembly of the unit please ensure that the unit
is not connected to the electrical supply.
ASSEMBLING HE WELDING MASK
Attach the handle to the Welding Shield by lining
up the two rectangular tabs on the handle with the
corresponding holes in the welding shield and:
A. press the tabs through the holes and then
B. slide the tabs forward from the back, locking the
round tab in place.
Insert the clear glass panel followed by the dark
glass panel into the recess in the shield, refer to
Fig.2 & Fig.3.
The dark panel is a certified, specific optical class,
and should not be exchanged for any other type.
The clear glass panel should be replaced when it
becomes badly pitted.
WARNING! NEVER look at an electric
arc without eye protection as this can
injure the eyes permanently. ALWAYS
use a protection mask or welding helmet.
Handle
Welding Shield
(viewed from front)
AA
BB
Round
Tab
Fig. 2
Welding Shield
(viewed from back)
Filter Lens
Fig. 3
OPERA ION
DESCRIP ION
Your Welding Power Supply features a single
phase transformer suitable for welding with an
alternating current using stick electrodes with
diameters from 1.6mm to 5mm. The welding cur-
rent is regulated by using the welding current con-
trol (regulator).
ELEC RODE SELEC ION
The pages of this manual are restricted to the basic
safe use of an MMA welding power supply and very
basic welding technique. The electrodes used in
MMA welding are many and varied. You are
advised to seek advise from your local welding
equipment supplier for the correct selection of
electrode for the work being performed.
OPERA ION
WARNING! If you have no welding
experience, we recommend you seek
training from an experienced person.
CAU ION: This manual is a basic guide
to welding. We recommend you
purchase a good quality publication on
welding or if you have internet access visit one of
the numerous welding related web sites to be able
to use the welding power supply to its full potential.
HE QUALI Y OF ANY WELDED JOIN IS
DEPENDAN ON HE PREPARA ION OF HE
JOIN HE SELEC ION OF HE CORREC
ELEC RODE AND HE SKILL AND
EXPERIENCE OF HE WELDER.
Ensure the Welding Power Supply is disconnected
from the mains supply.
Ensure that the area of the work piece where the
earth clamp is to be connected is clean using a file
or a grinder, to ensure a good electrical contact.
Ensure the earth lead is connected to the
workpiece, and the other lead to the electrode
holder.

16
OPERA ION
Important: Ensure also that the earth clamp is
attached to clean, solid metal. If necessary
thoroughly clean with a wire brush or similar to
guarantee a good connection.
The earth clamp must only be connected to the
work piece. The area to be welded must be clean
and free from dirt, rust, paint, grease and oil.
Insert an electrode into the electrode holder (Fig.4)
ensuring there is a good connection.
Set the amperage (see Table 1) by adjusting the
regulator (Fig.5)(A) until the desired setting is
reached.
The chart below is an indicator of the electrode
diameter and the corresponding welding current.
This is intended as a guide only.
WARNING! Always wear a full welding
mask, welding gloves and protective
clothing. Wear goggles while chipping
slag.
Do not switch on the power supply until you are
ready to start welding. Practice welding on a piece
of scrap material.
Connect to the mains supply and press the On/Off
switch (Fig.6) to the ON position (l) The power
indicator lamp on the front panel (Fig.5)(B) will
illuminate. To stop the machine, press the On/Off
switch to the OFF position (0).
Note: If the machine stops at any time and the
thermal cut out indicator on the front panel
illuminates, the thermal cutout has intervened.
This indicator will turn on when the machine is
overheated and the output has been disabled. This
normally occurs when the duty cycle of the
machine has been exceeded. Leave the machine
on to allow the internal components to cool. When
the indicator turns off, normal operation is again
possible.
Fig. 4
A20020
Fig. 5
Fig. 6
A
B
able 1
Electrode Material Welding
size (mm) thickness current (A)
(mm)
1.6 1 - 1.6 25 - 40
2.0 1.6 - 2.6 40 - 70
2.5 2.6 - 4.0 60 - 100
3.2 3.0 - 5.0 80 - 130
4.0 5.0 - 7.0 130 - 170
5.0 7.0 - 9.0 170 - 200

17
S ICK (MMAW) BASIC WELDING ECHNIQUE
A WORD O BEGINNERS
For those who have not yet done any welding, the
simplest way to commence is to run beads on a
piece of scrap plate. Use mild steel plate about
6.0mm thick and a 3.2mm electrode. Clean any
paint, loose scale or grease off the plate and set it
firmly on the work bench so that welding can be
carried out in the downhand position. Make sure
that the work clamp is making good electrical
contact with the work, either directly or through the
work table. For light gauge material, always clamp
the work lead directly to the job, otherwise a poor
circuit will probably result.
HE WELDER
Place yourself in a comfortable position before
beginning to weld. et a seat of suitable height and
do as much work as possible sitting down. Don't
tense your body. Relax and you will find that the job
becomes much easier. Wear a leather apron and
gauntlets. This will protect you from being burnt or
sparks setting alight to your clothes.
Place the work so that the direction of welding is
across, rather than to or from, your body. The
electrode holder lead should be clear of any
obstruction so that you can move your arm freely
along as the electrode burns down. If the lead is
slung over your shoulder, it allows greater freedom
of movement and takes a lot of weight off your
hand. Be sure the insulation on your cable and
electrode holder is not faulty, otherwise you are
risking an electric shock.
S RIKING HE ARC
Holding a face mask in front of your face stroke the
electrode point on the workpiece as if striking a
match.
Maintain a steady gap between the end of the
electrode and the workpiece of approximately 2mm
(Fig.7).
Maintain this distance as constantly as possible
during the weld remember that the angle of the
electrode to the work piece must be 20-30° (Fig.8).
Do not hit the electrode on the workpiece as this
may damage the electrode. Withdraw with a clean
movement at the end of the welding run.
Note: This is the most difficult aspect for most
beginners. It is recommended that you practice on
some scrap material in order to get a feel of the
operation.
If the electrode is not withdrawn quickly enough
once the arc is primed, there is a possibility that the
electrode will weld itself to the workpiece. Should
this happen, give it a sharp tug to free it, and try
again. If this fails to free it, turn off the machine
immediately as it will quickly overheat.
If you withdraw the electrode too far once the arc is
primed, you will lose the arc and have to try again.
Inspect the job carefully. With a correct
combination of electrode size and current setting
the area of weld should be complete fusion of the
electrode and parent metal/s. Any slag which forms
on the surface should be chipped away with the
pick/brush supplied.
If the resultant weld looks messy and irregular, this
is an indication of porosity or slag contamination,
and you have almost certainly failed to achieve the
correct combination. This is a common problem, so
do not worry as practice will quickly cure this.
Fig. 7
Fig. 8
2mm
20º-30º

18
S ICK (MMAW) BASIC WELDING ECHNIQUE
ARC LENG H
The securing of an arc length necessary to produce
a neat weld soon becomes almost automatic. You
will find that a long arc produces more heat. A very
long arc produces a crackling or spluttering noise
and the weld metal comes across in large, irregular
blobs. The weld bead is flattened and spatter
increases. A short arc is essential if a high quality
weld is to be obtained although if it is too short
there is the danger of it being blanketed by slag
and the electrode tip being solidified in. If this
should happen, give the electrode a quick twist
back over the weld to detach it. Contact or "touch-
weld" electrodes do not stick in this way, and make
welding much easier.
RA E OF RAVEL
After the arc is struck, your next concern is to
maintain it, and this requires moving the electrode
tip towards the molten pool at the same rate as it is
melting away. At the same time, the electrode has
to move along the plate to form a bead. The
electrode is directed at the weld pool at about 20º
from the vertical. The rate of travel has to be
adjusted so that a well-formed bead is produced. If
the travel is too fast, the bead will be narrow and
strung out and may even be broken up into
individual globules. If the travel is too slow, the
weld metal piles up and the bead will be too large.
MAKING WELDED JOIN S
Having attained some skill in the handling of an
electrode, you will be ready to go on to make up
welded joints.
When welding material up to 7mm in thickness
place the pieces 2-3mm apart, run the welding
bead along the join. A second bead can go along
the underside for extra strength (Fig.9).
When welding material from 7mm to 30mm thick
prepare the material as shown in Fig.10 filling up
the space with several layers of weld.
When welding together material over 30mm in
thickness prepare the material as shown in Fig.11
filling up the space with several layers of weld,
welding each side in turn with each welding pass.
Disconnect the Welding Power Supply from the
mains supply before changing or removing
electrodes. Use pliers to remove used electrodes
from the electrode holder or to move the welded
pieces.
HE MANUAL ME AL ARC PROCESS
When an arc is struck between the metal rod
(electrode) and the workpiece, both the rod and
workpiece surface melt to form a weld pool.
Simultaneous melting of the flux coating on the rod
will form gas and slag which protects the weld pool
from the surrounding atmosphere. The slag will
solidify and cool and must be chipped off the weld
bead once the weld run is complete (or before the
next weld pass is deposited). The process allows
only short lengths of weld to be produced before a
new electrode needs to be inserted in the holder.
Fig. 9
Fig. 10
7mm
60º
Fig. 11
2-3mm
>30mm
2-3mm
1
2
4
3
56
60º
>30mm
2-3mm

S ICK (MMAW) BASIC WELDING ECHNIQUE
Weld penetration is low and the quality of the weld
deposit is highly dependent on the skill of the
welder.
YPES OF FLUX/ELEC RODES
Arc stability, depth of penetration, metal deposition
rate and positional capability are greatly influenced
by the chemical composition of the flux coating on
the electrode. Electrodes can be divided into three
main groups:
• Cellulosic
• Rutile
• Basic
Cellulosic electrodes contain a high proportion of
cellulose in the coating and are characterised by a
deeply penetrating arc and a rapid burn-off rate
giving high welding speeds. Weld deposit can be
coarse and with fluid slag, deslagging can be
difficult. These electrodes are easy to use in any
position and are noted for their use in the stovepipe
(vertical down position) welding technique.
Features:
•Deep penetration in all positions
• Suitability for vertical down welding
• Reasonably good mechanical properties
• High level of hydrogen generated - risk of
cracking in the heat affected zone
Rutile Electrodes contain a high proportion of
titanium oxide (rutile) in the coating. Titanium oxide
promotes easy arc ignition, smooth arc operation
and low spatter. These electrodes are general
purpose electrodes with good welding properties.
They can be used with AC and DC power sources
and in all positions. The electrodes are especially
suitable for welding fillet joints in the horizontal/
vertical position.
Features:
• Moderate weld metal mechanical properties
• ood bead profile produced through the
viscous slag
• Positional welding possible with a fluid slag
(containing fluoride)
• Easily removable slag
Basic electrodes contain a high proportion of
calcium carbonate (limestone) and calcium fluoride
(fluorspar) in the coating. This makes their slag
coating more fluid than rutile coatings - this is also
fast-freezing which assists welding in the vertical
and overhead position. These electrodes are used
for welding medium and heavy section fabrications
where higher weld quality, good mechanical
properties and resistance to cracking (due to high
restraint) are required.
Features:
• Low hydrogen weld metal
• Requires high welding currents/speeds
• Poor bead profile (convex and coarse surface
profile)
• Slag removal difficult
Iron powder electrodes contain an addition of
metal powder to the flux coating to increase the
maximum permissible welding current level. Thus,
for a given electrode size, the metal deposition rate
and efficiency (percentage of the metal deposited)
are increased compared with an electrode
containing no iron powder in the coating. The slag
is normally easily removed. Iron powder electrodes
are mainly used in the flat and horizontal/vertical
positions to take advantage of the higher
deposition rates. Efficiencies as high as 130 to
140% can be achieved for rutile and basic
electrodes without marked deterioration of the
arcing characteristics but the arc tends to be less
forceful which reduces bead penetration.
CARE OF ELEC RODES
The quality of weld relies upon consistent
performance of the electrode. The flux coating
should not be chipped, cracked or, more
importantly, allowed to become damp.
DRYING OF ELEC RODES
Drying is usually carried out following the
manufacturer's recommendations and
requirements will be determined by the type of
electrode.
19

S ICK (MMAW) WELDING ROUBLESHOO ING
20
Problem Possible Cause Remedy
Welding current
varying.
A gap is left by failure of
the weld metal to fill the
root of the weld.
Non-metallic particles
are trapped in the weld
metal.
A groove has been
formed in the base
metal adjacent to the
toe of a weld and has
not been filled by the
weld metal (undercut).
Control knob is set at a value that
causes the welding current to vary
excessively with the arc length.
Welding current too low.
Electrode too large for joint.
Insufficient gap.
Non-metallic particles may be
trapped in undercut from previous
run.
Joint preparation too restricted.
Irregular deposits allow slag to be
trapped.
Lack of penetration with slag
trapped beneath weld bead.
Rust or mill scale is preventing
full fusion.
Wrong electrode for position in
which welding is done.
Welding current is too high.
Welding arc is too long.
Angle of the electrode is incorrect.
Joint preparation does not allow
correct electrode angle.
Electrode too large for joint.
Insufficient deposit time at edge of
weave.
Reduce the control knob until welding
current is reasonably constant while
prohibiting the electrode from sticking
to the workpiece when you “dig” the
electrode into the workpiece.
Increase welding current.
Use smaller diameter electrode.
Allow wider gap.
If a bad undercut is present clean slag
bout and cover with a run from a
smaller gauge electrode.
Allow for adequate penetration and
room for cleaning out the slag.
If very bad, chip or grind out
irregularities.
Use smaller electrode with sufficient
current to give adequate penetration.
Use suitable tools to remove all slag
from corners.
Clean joint before welding.
Use electrodes designed for position in
which welding is done, otherwise
proper control of slag is difficult.
Reduce welding current.
Reduce the length of the welding arc.
Electrode should not be inclined less
than 45° to the vertical face.
Allow more room in joint for
manipulation of the electrode.
Use smaller gauge electrode.
Pause for a moment at edge of weave
to allow weld metal buildup.