OZITO IAW-120 (01) PDF Document

The standard equipment for the OZITO IAW-120 includes:

• Inverter Arc Welder

• Earth Clamp, Arc Electrode Holder & Chipping Hammer/Wire Brush

• Strap, Handle, Welding Mask, Lens Assembly & Fasteners

The main parts of the OZITO IAW-120 are:

1. AC Power Cord

2. On/Off Switch

3. Current Control Dial

4. Negative Output Terminal

5. Positive Output Terminal

6. Digital Display

7. Power ON LED

8. Thermal Overload LED

The accessories included with the OZITO IAW-120 are:

• Earth Clamp

• Arc Electrode Holder

• Chipping Hammer/Wire Brush

• Welding Mask

Before using the OZITO IAW-120, adhere to the following safety precautions:

• Read all safety warnings and instructions before use.

• Always wear appropriate protective equipment: Welding helmets, overalls, welding gloves, closed shoes, leather apron, sock protectors. Overalls should be buttoned at the wrists and neck.

• Remove loose clothing and accessories and tie up or tuck away any loose hair.

• Always weld in a well-ventilated area and use a fume extractor if required, as toxic gases are given off.

• ALWAYS use a face shield or welding helmet with the correct glass filter to protect eyes from direct heat and ultraviolet radiation.

• Inspect the welder, electrodes, and all connecting wires for damage or worn insulation before each use. Replace damaged parts before use.

• Used electrodes and welding material can be extremely hot. Wait for them to cool down before handling, and always wear welding gloves.

• Ensure there is sufficient ventilation, particularly at the front and rear of the unit.

• Have an adequate fire-fighting device on hand.

• Ensure all oil, petrol, and flammable containers have been removed from the welding area.

To assemble the included welding mask for your OZITO IAW-120, follow these steps:

1. Push the plastic pins into the mask from the outside and secure them with the retaining clips from the inside of the mask. Rotate the retaining clips so that the lens assembly can be inserted.

2. Insert the clear glass into the recess of the welding mask, then the dark safety glass, and finally the plastic lens frame.

3. Rotate the retaining clips to lock the lens assembly in place.

4. Bend the sides and top of the welding mask inwards and clip it together at the corners.

5. Insert the 3 screws into the handle mounting holes from the outside. Fit the handle onto the screws on the inside of the mask and secure them using the 3 nuts.

To set up the cables on your OZITO IAW-120, ensure the tool is turned off and disconnected from the power supply, then:

1. Attach the arc electrode holder to the red positive (+) output terminal. Insert and rotate the connector until it is firmly attached.

2. Attach the earth clamp to the black negative (-) output terminal. Insert and rotate the connector until it is firmly attached to the welder.

Note: Only fully insulated lock-type connectors should be used with the inverter welder terminals.

Always ensure the OZITO IAW-120 is switched off when replacing electrodes.

1. Install the thin (uncoated) end of the electrode into the arc electrode holder.

2. Attach the earth clamp to the work piece. Ensure the area on the work piece is free from paint or dirt to allow for a good electrical connection for current flow. This helps achieve more consistent welds.

Note: Avoid the use of extension leads.

The welding current for the OZITO IAW-120 must be regulated according to the electrode diameter and the thickness of the steel being welded. The following is a guide for welding steel:

To adjust the welding current on the OZITO IAW-120, simply turn the current control dial. The welding current can be increased or decreased, and the reading on the digital display will change accordingly to show the set amperage.

The on/off switch for the OZITO IAW-120 is located on the rear of the welder.

1. To turn the unit on, press the on/off switch into the ‘I’ position.

2. To turn the unit off, press the switch to the ‘0’ position.

Note: Check the rating of the circuit breaker. The welder is a high-powered device and it is recommended that it is the only appliance on the circuit. If a 12A circuit is available, it is recommended that the welder be connected to it.

The ON LED on the OZITO IAW-120 illuminates when the power cord is connected to a live mains outlet and the on/off switch is in the ‘I’ (on) position. The cooling fan will also operate when the unit is switched on.

The OZITO IAW-120 has a feature called a duty cycle. This refers to the time in which the welder can operate continuously before it requires to cool down. If the internal components of the welder become too hot, the Thermal Overload Protection feature will automatically shut down the welder to protect it. 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 indicates the welder is too hot and needs to cool down.

If the Thermal Overload LED light turns on, do not turn the welder off. The internal cooling fan will assist in cooling the welder down quicker. Reducing the cooling time will enable you to get back to your welding job sooner. The cooling time may take up to 10 minutes, depending on the amperage used and the intensity of the welding job.

To strike an arc with the OZITO IAW-120, 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 an arc, try to maintain a distance from the work piece equal to the diameter of the electrode being used (e.g., for a 2mm electrode, maintain a 2mm gap). The electrode angle should be 70-80° to the work piece.

Slag is the refuse left around the weld after welding. It should only be removed after the weld has cooled down and is no longer glowing. Always wear a face shield during slag removal. Use the included chipping hammer/wire brush to break off and clean the slag from the weld.

You can perform several common weld types with the OZITO IAW-120:

• Butt Joint: Joining two pieces of material together along a single edge in a single plane.

• Fillet Joint: Welding pieces or plates where the angle between them varies from 0° to 180°. The edge of one plate is brought against the surface of another.

• Lap Joint: The edges of two plates are lapped one over the other, and the edge of one is welded to the surface of the other.

• Corner Joint: Two pieces of material are joined at their edges to form an “L” shape.

Electrodes:

Always store electrodes in a dry place to protect them from moisture. The flux coating on electrodes provides a gaseous shield, gives a steady arc, removes oxygen, provides a cleansing action, and can introduce alloys into the weld.

Arc Length:

To strike the arc, gently scrape the electrode on the work piece. The proper arc length should be the shortest arc that gives a good surface to the weld. A very long arc produces a crackling noise and irregular blobs, while an excessively short arc can cause the electrode to stick. For down-hand welding, the arc length should be no greater than the diameter of the electrode.

Electrode Angle:

The angle of the electrode is important for a smooth transfer of metal. When welding in down-hand, fillet, horizontal, or overhead positions, the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel. When performing vertical up welding, the angle of the electrode should be between 70 and 80 degrees to the work piece.

Additional Specifications:

• I,max: 23.6A

• I,eff: 9.5A

• Welder Characteristics: Constant Current-Drop Characteristic

• Carrying Method: Strap

• Cooling System: Fan Cooling

• Power Cable: 3 x 1.5-2mm²

• Welding Cable: 1 x 10mm²

• Recommended External Fuse: 16A

Equipment Classification:

This product is classified as Group 2, Class A welding equipment.

• Group 2 – This product generates radio frequency energy in the frequency range 9KHz to 400GHz.

• Class A – This product is intended for use in an industrial environment. It is not intended for use in residential environments and may not provide adequate protection to radio reception in such environments.

The OZITO IAW-120 has been designed for 230V and 240V only. Always check that the power supply corresponds to the voltage on the rating plate.

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 it is damaged or defective.

When using an extension lead on a reel, always unwind the lead completely. Use of an extension lead not suitable for the power input of the tool or which is damaged or defective may result in a risk of fire and electric shock.

The power supply for this product must be protected by a residual current device (rated at 30mA or less). A residual current device reduces the risk of electric shock.

• Under no circumstances should the housing of the welder be opened.

• Never attempt to repair or modify the welder.

• Screen off the work place to protect others working nearby from UV rays.

• Do not use the welder in damp or wet conditions.

• Do not use the welder for pipe thawing.

• 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.

• Never pull on the welding leads or the power cord to move the welder.

• Ensure the welding materials are securely clamped down/fastened before welding.

• Always place the electrode holder and clamp on a flat stable surface when not in use.

• Never put the electrode holder and the electrode down until the welder is switched off.

• Store all spare electrodes in a safe place, away from the welding area.

• Welding materials with contaminated surfaces may generate toxic fumes. Ensure the surface is clean before welding.

• 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 weld painted / oiled materials. Ensure all welding surfaces are stripped / cleaned down to the bare metal.

• Always check the welding material before welding to see if it is compatible with arc welding.

• Do not use the welder near food or food preparation areas.

• Use only one welder to weld at all times.

• Only connect the welding machine to an earthed electric network.

• Never touch live parts or the welding rod with wet hands/gloves/clothing.

• Ensure there is a level of insulation (welding mats) between yourself and the ground as well as the workpiece when welding.

Radio Electromagnetic Compatibility:

Extra precautions may be required if this welding power source is used in a domestic situation. If electromagnetic disturbances are detected, it is the user’s responsibility to resolve the situation. To reduce disturbances, keep welding cables short and consider using an electromagnetic filter if connected to a residential low voltage power network.

Fumes:

Toxic gases are given off during the ARC welding process. Be alert to the possibility of fume build-up. Provide adequate ventilation or a means for removal of fumes, such as forced circulation using a blower or fan. In small or confined areas, use a fume extractor.

Glare:

The electric arc generates direct heat and ultraviolet radiation. It is essential that the eyes of the operator and bystanders are protected. ALWAYS USE A FACESHIELD OR WELDING HELMET FITTED WITH THE CORRECT GLASS FILTER.

Position and Handling:

• Position the welding machine on a horizontal surface that can support its weight to avoid overturning.

• The welder MUST NOT be supported by the operator (e.g., using belts).

• Do not weld materials in overhead positions.

Heat and Dress:

• Wear welding gloves to protect hands from ultraviolet radiation and direct heat.

• In addition to a face shield, welding gloves, and overalls, other protective clothing like a leather apron, sock protectors, and a hat should be worn.

• Overalls should be the type designed to be buttoned at the wrists and neck.

• Avoid exposing skin as UV rays are produced by the arc.

Spatter and Fire:

• Welding spark can cause accidental fire. Ensure there is no welding working position nearby and have a fire extinguisher on hand.

• Welding is classified as hot work; pay attention to fire safety regulations during and after work.

• Fire can break out from sparks even hours after welding is completed.

• Remove flammable materials from the vicinity and supply the site with adequate fire fighting equipment.

• Never direct spark spray from a grinder toward the welding machine or flammable materials.

• Welding in flammable or explosive sites is absolutely forbidden.

Cleaning:

Before cleaning, ensure the appliance is disconnected from the power supply.

1. It is recommended to clean the appliance immediately after use.

2. Keep the safety devices free of dirt and dust. Wipe the equipment with a clean cloth.

3. Clean the appliance regularly with a damp cloth and some soft soap. Do not use cleaning agents or solvents, as they may be aggressive to the plastic parts. Ensure no water gets into the interior of the appliance.

Storage:

Pull the mains plug out of the socket, switch off the tool, and make sure it is secured so it cannot be started up by an unauthorised person. Store the tool in a dry location that is not accessible to unauthorised persons.