Page is loading ...
Input: 230v ~ 50Hz
Current range: 60 - 90A
Welding wire: 0.6mm - 0.9mm
Duty cycle: 10% - 90A, 30% - 60A
Weight: 14kg
Features: Overload protection
Portable
Accessories included
Handle
SPECIFICATIONS - MODEL NO. OZMW90A
2
1. Carry Handle
2. Welding Mask
3. Mig Torch
4. Shroud
5. Control Switches
6. Wire Brush
7. Earth Clamp
8. On/Off Switch
9. Overload LED
10. Wire Feed Speed Control
11. Internal Cooling Fan (not shown)
11
1
8
2
3
9
4
10
7
5
6
SPECIFICATIONS (cont.)
3
OUTPUT SOCKETS
WIRE FEED UNIT
ARM
TENSION SCREW
HUB FEED SPINDLE
ROLLERS
INTRODUCTION
Congratulations on purchasing an Ozito Arc Welder. We aim to provide quality
products at an affordable price. We hope you will enjoy using this product for
many years.
The Ozito Mig Welder OZMW90A has been designed to weld steel alloys. Its
varying current range, light weight and portability make it an ideal welder for
many jobs. It is intended for DIY use only.
With this welding unit you can now experience the many advantages of the
FLUX MIG series welding processes. This unit will enable you, with the help of
this manual and a little practice, to obtain a professional finish in welding car
bodywork, and many other uses for which you'll find it ideal.
This welder produces a direct current output (A.C) with a static flat characteristic,
enabling an arc to be struck between a continuously fed consumable electrode
(wire) and the workpiece, power for the arc is provided by a transformer which
has its output rectified to direct current. The wire is fed through the torch by
feed rollers mounted on a DC drive motor and current is passed to the wire
melts in the arc and is transferred to the weld pool in the form of droplets.
The welding result in low heat input to the workpiece, ensuring minimum heat
spread and distortion which combined with ease of use make them the ideal
process for a multitude of jobs particularly on thin materials.
Fig. 1
4
Warning! When using mains-powered equipment, basic safety precautions,
including the following, should always be followed to reduce risk of fire,
electric shock, personal injury and material damage.
Read and understand the manual prior to operating this product.
Save these instructions and other documents supplied with this product for future reference.
This electrical equipment 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 products are interchangeable for
Australia and New Zealand.
If the supply cord is damaged, it must be replaced by the manufacturer or an
authorised Ozito Service Centre in order to avoid a hazard.
Using an Extension Lead
Always use an approved extension lead suitable for the power input of this
electrical equipment. 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 equipment or which is
damaged or defective may result in a risk of fire and electric shock.
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.
SAFETY INSTRUCTIONS
ELECTRICAL SAFETY
GENERAL
GENERAL (cont.)
5
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
Ozito Authorised Service Agent. 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 authorised OZITO SERVICE AGENT.
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 the manufacturer or an authorised Ozito Service Agent in order to
avoid a hazard.
SAFETY INSTRUCTIONS FOR WELDERS
6
Under no circumstances should the internal components be tampered with.
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 INVENT MIG 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 INVENT MIG process gives direct heat and ultra-
violet 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 desiderable that welding gloves are worn whilst welding. They will protect the
hands from ultra-violet radiation and direct heat of the arc.
OVERALLS should also be worn. They should be of type designed to be buttoned
at the wrists and the neck.
DRESS
In addition to face shield, gloves and overalls, other types of protective clothing
should be worn when working on thicker
OPERATION
7
Setting the Welding Current
The welding current must be regulated in accordance with the diameter of the
electrode and the thickness of the metal being used. Below is a table suggesting
suitable ratios.
Set up assembly
1. Put the wire on the hub feed clockwise. Hub is on hub feed spindle, Secure
the wire with the retainer washer.
2. Then place the tension spring on top of the retaining washer over the spindle.
Insert the keyed locking button into the end of the spindle and push down
turn the keyed locking button clockwise
3. Thread the wire through the feeding rod Loosen off the tension screw, feed the
wire until it comes into the intersection of the two rollers.
4. Apply pressure onto the arm between
the roller and the tension screw. Feed
the wire between the rollers manually
so it holds. Release pressure on arm
and tighten the tension screw.
5. Secure attach earth clamp out of the
way onto a non conductive surface.
(non metal e.g. a dry wooden bench )
6. Unscrew the shroud on the end of the mig torch and remove the welding tip.
Turn the machine onto wire speed feed only and the speed dial onto maximum.
Warning! Make sure the earth clamp is not touching you and out of the way
and not touching an earth conductive surface
7. Turn the machine on pull the trigger on the torch gently and give short bursts
to feed the wire through the wire inlet. Once the wire is feed into the inlet
hold the trigger down until the wire is feed through the torch this can take
time. Allow around 20 secounds for this.
8. If the wire does not feed, increase the pressure on tension screw. Once the
wire is through the mig torch leave a few centimetres spare. Using pliers cut
excess wire to make it easier to attatch the welding tip.
Approximate Welding Electrode Diameter Suggested Filter Lens
Current Range
30 to 100 amps 0.6mm Hard wire Shade 8
50 to 165 amps 0.8mm Hard wire Shade 10
70 to 165 amps 0.9mm Hard & Soft wire Shade 10
90 to 165 amps 0.8-0.9 Flux cored wire Shade 10
Rollers
Hub
Feed
Spindle
Tension
Screw Arm
OPERATION (cont.)
8
Fig 1
9. Take your welding tip and thread over the wire and screw onto the gun. Take
your shroud and screw over the welding tip. Using pliers to cut flush with
shroud end.
• Position the two pieces of metal you wish to join.
• Hold the mig torch approximately 2 cm away from the desired join area. Lower
or hold the welding mask over your face. Using the mig torch, proceed to
strike the wire tip against the desired join area on the work piece as if you are
striking a match. This is the correct strike up method.
Note: Hitting the electrode on the work piece can damage the electrode and
make strike up difficult.
1. The welding power source has two main control settings. These are the wire
speed control and the current (amps) control.
2. The combination of these settings requires alteration depending on the
material and other conditions that affect the weld. It is advisable to practice
on scrap pieces of material to clarify which settings are going to give you the
best weld.
3. The wire speed and current control needs to be set at the correct speed and
power for a smooth and a consistent weld. There are many variables that
affect the weld including the style, speed of the operator, the material being
welded and the diameter of the wire.
4. When welding with large diameter wire it is advisable to use the high amps
setting selector on the front of the welder.
5. When welding with thinner diameter wire it is advisable to use the low amps
setting selector on the front of the welder.
If the Wire Speed is set too fast “stubbing” will occur as the wire dips into the
molten pool and does not melt. Welding in there conditions normally produces a
poor weld due to lack of fusion. If however the welding speed is too slow, large
drops will form on the end of the electrode wire, causing splatter. The correct
setting of wire speed can be seen in the shape of the weld deposit and heard by a
smooth regular are sound.
3. Postion of MIG Torch The angle of MIG
torch to the weld has an effect on the
width of the weld run. Refer to Fig 1.
4. Distance from the MIG Torch Nozzle to
the Work Piece The electrode stick out
from the MIG Torch nozzle should be
between 2.0mm to 5.0mm. This distance
may vary depending on the type of joint
that is being welded.
Forehand Vertical
OPERATION (cont.)
9
Warning! Failure to use a welding mask can result in “eye flashing” where
your naked eye sees the arc. Eye flashing is harmful and can damage your
eyes. Always look through the tinted glass of the welding mask when
observing the arc.
The welding mask protects your face from the welding sprays and ultra violet rays
produced by the arc. The tinted glass is essential for protecting your eyes while
observing the arc.
Warning! During and immediately after welding the weld will be extremely
hot. Ensure it has cooled before touching with your hands. If it needs to be
moved while still hot use a clamping device.
5. Once the weld has been completed turn the welders on/off switch to the “Off”
position and disconnect the welder from the power supply.
6. 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. Remove using the
combination wire brush and chipping hammer provided in the kit.
Electricity
The electricity flows through the wire to the attached torch. The electricity will not
leave the wire 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 wire
makes contact with the earthed work piece an arc is created. The electricity flows
through the wire, the metal work piece and then through the earth cable straight
back to the welder.
Overload Protection
If the internal components of the welder should become hot and the
welder over heats the overload LED will light up and the welder will
automatically shut down. If this should happen leave the welder
connected to the power supply. Leaving it connected to the power supply
will allow the fan to continue to operate which will aid cooling. After
approximately 6 minutes the overload LED should turn off and the welder
should be ready for operation.
OPERATION (cont.)
10
Starting to weld
BEFORE WELDING ENDURE THAT:
You have read the safety section of this manual.
All oil. Petrol and flammable containers have been removed from the area.
There is good all round ventilation. Particularly at the front and rear of the unit.
You have an adequate fire-fighting appliance on hand.
1. Connect the work earth clamp onto the metal to be welded (scrap material for
first attempt).
2. Set output and wire feed speed by turning or pressing the appropriate controls
taking into account the material type and thickness and the wire size.
3. Plug in and switch on the machine.
4. Clip off any protruding wire to 3mm(1/8)from the tip
5. Positions tip 6mm(1/4) from the point where the welding is to commence.
6. Hold the mask in front of your eyes.
7. Press the tigger and when the arc strikes move the torch slowly in the
chosen direction.
8. If the arc gives a humming sound and a blob tends to form on the end of the
wire, you have insufficient wire speed and it should be
Starting to weld
Increased; or if t gives an erratic sound with possibly a feel that the wire is stubbing
against the work and excessive spatter, you have too much wire speed and it should
be reduced. When the speeds correct you will get a steady smooth crackling sound.
•the unit can be set to deliver different output currents at a duty cycle that is
written as a percentage on Its rating plate printed on the cover. This percentage
represent the welding time in a 10minutes cycle, e.g.60% means that the
welding time is 6minutes and rest time is 4minutes.if the unit is used beyond Its
duty cycle, the temperatures of some components might become too high due
to over use, the internal thermal protector will then prevent the unit from
operating. It’s intervention is indicated by a yellow lamp in the front panel. If this
happens leave the machine connected to the power supply. The machine will
automatically cool down. The thermal protector will reset automatically after a
short period when the components have cooled, and you will be able to restart
welding. The machine will cool down more quickly if left switched on with the
fan running.
Never splash or clean the welder with water.
Store the welder in a dry place.
If necessary, clean the welder using a damp/moist rag, disconnect from the power
supply prior to cleaning.
Keep the ventilation slots of the welder clear at all times and prevent foreign matter
from entering the housing.
Torch
The contact tip and shroud must be cleaned regularly to remove spatter which will
eventually disturb the wire flow anti-spatter spray sprayed onto the shroud and the tip
will reduce the build up of spatter. Replace the tip regularly as a good electrical contact
between the top and wire is essential. Avoid kinking the torch and never use it to pull
the machine around to ensure the wire passes freely through the torch tip and liner.
Note: Ozito Industries will not be responsible for any damage or injuries caused by the
repair of the welder by an unauthorised person or by mishandling of the welder.
11
MAINTENANCE
CONTENTS
OZITO INDUSTRIES PTY LTD
AUSTRALIA (Head Office)
5 Chestnut Crt, Dingley, Victoria, Australia, 3172
Telephone: 03 9558 3999
Facsimile: 03 9558 0583
www.ozito.com.au
1 x Mig Welder OZMW90A
1 x Combination wire brush
and chipping hammer
1 x Welding Mask
1 x Instruction Manual
WARRANTY
THIS WARRANTY FORM AND CONFIRMED BUNNINGS REGISTER RECEIPT SHOULD
BE RETAINED BY THE CUSTOMER AT ALL TIMES
The warranty is only made available by returning the product to your nearest
Bunnings Building Supplies with a confirmed Bunnings register receipt.
PURCHASED FROM:________________________________________________
DATE PURCHASED: ________________________________________________
3 YEAR REPLACEMENT WARRANTY
Your Ozito product is guaranteed for a period of 36 months from the original date
of purchase and is intended for DIY (Do it yourself) use only.
WARNING
The following actions will result in the warranty being void.
•Professional, Industrial or high frequency use.
•If the product has been operated on a supply voltage other than that specified
on the product.
• If the product shows signs of damage or defects caused by or resulting from
abuse, accidents or alterations.
• If the product is disassembled or tampered with in any way.
Note: Warranty excludes accessories and consumable parts such as welding masks
and combination wire brush and chipping hammers.
YOUR WARRANTY FORM SHOULD BE RETAINED
BY YOU AT ALL TIMES.
SHOULD YOU HAVE ANY QUESTIONS PRIOR TO
RETURNING YOUR PRODUCT FOR WARRANTY OR
REPAIR 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. AN OZITO CUSTOMER SERVICE
REPRESENTATIVE WILL TAKE YOUR CALL AND ANSWER ANY QUESTIONS
YOU MAY HAVE RELATING TO THE WARRANTY POLICY OR PROCEDURE.
/
