Ozito OZMW90A Operating Instructions Manual

Brand: Ozito

Model: OZMW90A

Category: Welding System

Type: Operating Instructions Manual

Ozito OZMW90A is a portable welding machine that can weld steel alloys with a direct current output. It has an adjustable current range from 60 to 90A, making it suitable for welding thin materials. The wire feed speed can also be adjusted to control the amount of wire fed into the weld pool. This welder has built-in overload protection and an internal cooling fan to prevent overheating. It comes with a welding mask, mig torch, shroud, earth clamp, and wire brush, making it a complete welding solution.

MIG WELDER

90 Amps MODEL NO. OZMW90A

OPERATING INSTRUCTIONS

Always Wear Eye, Face & Ear Protection www.ozito.com.au

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

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)

SPECIFICATIONS (cont.)

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

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.)

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

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

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.)

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.)

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.)

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.

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.

Ozito OZMW90A Operating Instructions Manual

Brand: Ozito

Model: OZMW90A

Category: Welding System

Type: Operating Instructions Manual

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Ozito OZMW90A Operating Instructions Manual

Ozito OZMW90A Operating Instructions Manual

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