MWR 135
MWR 135
MWR 135
MWR-135
Input: Current Range: Duty Cycle: Welding Wire Size: Insulation Type: Welding wire spool weight: Weight (tool only): 230-240V ~ 50Hz 40 - 120 Amp 60% @ 40 Amp, 8% @ 120 Amp (0.6-0.8mm General Wire) (0.8-0.9mm Flux-Cored Wire) Earthed Appliance (Class I) 0.2kg to 5kg 22.2kg
Back
4 6 3
2 1
13
8 9 14 12 15
10 11 16
1.On/off switch 2. Overload protection LED 3. Wire feed speed control 4. Carry handle 5. Mains cable and plug 6. Side cover 7. Output voltage control switch 8. Side cover release lever 9. Earth clamp
MIG torch Shroud Torch tip Welder gas intake barb Internal cooling fan Welding mask Combination chipping hammer and wire brush
TABLE OF CONTENTS
SPECIFICATIONS Page 1 INTRODUCTION Page 3 ELECTRICAL SAFETY. Page 3 GENERAL SAFETY INSTRUCTIONS Page 4 ADDITIONAL SAFETY INSTRUCTIONS FOR WELDERS Page 5 ADDITIONAL SAFETY INSTRUCTIONS FOR MIG WELDERS Page 6 ASSEMBLYPage 7 OPERATION Page 14 MAINTENANCE..Page 16 SPARE PARTS.. Page 17 DESCRIPTION OF SYMBOLSPage 17 CONTENTS..Page 18 WARRANTY..Page 19
INTRODUCTION Congratulations on purchasing an Ozito Gas/Gasless MIG Welder. We aim to provide quality tools at an affordable price. We hope you will enjoy using this tool for many years. Your Gas/Gasless MIG Welder MWR-135 has been designed for home projects and is ideal for use on trailers, gates, all steel sections, car panels, thin materials and general fabrication. This product is intended for DIY use only. ELECTRICAL SAFETY
Warning! When using mains-powered equipment, basic safety precautions, including the following, should always be followed to reduce the risk of fire, electric shock, personal injury and material damage. Please read and understand the manual prior to operating this tool. Save these instructions and other documents supplied with this tool for future reference. The electric motor has been designed for 230V and 240V only. Always check that the power supply corresponds to the voltage on the rating plate. Note: The supply of 230V and 240V on Ozito tools are interchangeable for Australia and New Zealand. If the supply cord is damaged, it must be replaced by a qualified electrician or a power tool repairer in order to avoid a hazard. Note: Double insulation does not take the place of normal safety precautions when operating this tool. The insulation system is for added protection against injury resulting from a possible electrical insulation failure within the tool. 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. It is recommended that the extension lead is a maximum of 25m in length. Do Not use multiple extension leads.
ASSEMBLY
Setting the Welding Current in Gasless Welding Wire Mode When welding in the gasless mode, the welding current must be set as follows: To view the polarity terminal knobs, open the side cover (6) of the welder by raising the side cover release lever (8), lift the side cover (6) to view the polarity terminal knobs (see Fig. 1). Ensure that the polarity terminal knobs are connected correctly. The positive (red coloured) lead must be connected to the negative (-) terminal knob and the negative (black coloured) lead must be connected to the positive (+) terminal knob (see Fig. 2).
Fig. 1
Fig. 2
Setting the Welding Current when using a Shielding Gas When welding using a shielding gas ,the welding current must be set as follows: Ensure that the polarity terminal knobs are connected correctly. The positive (red coloured) lead must be connected to the positive (+) terminal knob and the negative (black coloured) lead must be connected to the negative (-) terminal knob (see Fig. 3).
Fig. 3
ASSEMBLY (cont.)
Attaching the Shielding Gas Hose and Regulator to the MWR-135 When using a shielding gas with the MIG welder, you will require additional hoses and gauges. These additional accessories are available at your local gas supplier (these additional hoses and gauges are not included with your MIG welder) (see Fig. 4).
Fig. 4
Ensure that when you are using a shielding gas, you connect the hose to the welder gas intake barb (13) with the appropriate hose clamps (see Fig. 5). Check all of the connections to the gauges and the shielding gas bottle for leaks prior to commencing to weld. Check with your local gas supplier for their recommendations of the required gas mixture and flow rate for your MIG welder.
Fig. 5
When using a shielding gas with a standard size argon gas bottle, you should be able to connect the hose directly to the welder gas intake barb (13). If you are using a disposable argon gas bottle, you may need to purchase a hose reducing adaptor from your gas supplier. A gas hose adaptor will reduce the larger flexible rubber Fig. 6 hose (used with standard regulators) to the smaller 4mm hard poly tube supplied when you purchase the disposable argon gas bottle set up (see Fig. 6). Note: The adaptor, disposable argon cylinder, regulator and hose are available form your local gas supplier. The MWR-135 MIG welder is supplied with a 0.2kg coil of 0.8mm gasless welding wire (b) (see Fig. 7). Welding wire up to 5.0kg can be fitted to this MIG welder using the 5.5kg coil adaptor (e) as described below.
ASSEMBLY (cont.)
Fitting the Welding Wire 0.2kg coil (Fig. 7) Remove the wing nut (d) by rotating anti-clockwise and remove the drive washer (c) from the welding wire drive shaft (a). Slide the 0.2kg coil onto the wire drive shaft (a). Align the drive washer (c) lug with the slot in the drive shaft (a) and slide the drive washer (c) onto the wire drive shaft (a). Re-fit the wing nut (d) by rotating clockwise onto the wire drive roller (a), do not over tighten. Note: Over tightening of the wing nut will restrict the wire feed rate and can cause damage to the wire feed motor or irregular welding.
Drive washer (c) d
b c
Fitting the Welding Wire 5.0kg coil (Fig. 7) Remove the wing nut (d) by rotating anti-clockwise and remove the drive washer (c) from the welding wire drive shaft (a). Slide the 5.0kg coil adaptor (e) onto the wire drive shaft (a) and then the 5.0kg coil of wire onto the coil adaptor (e). Align the drive washer (c) lug with the slot in the drive shaft (a) and slide the drive washer onto the wire drive shaft (a). Re-fit the wing nut (d) by rotating clockwise onto the wire drive roller (a) but do not over tighten. Note: Over tightening of the wing nut will restrict the wire feed rate and can cause damage to the wire feed motor or irregular welding.
ASSEMBLY (cont.)
Wire Drive Roller Size Caution: It is critical that you choose the right wire drive roller (I) size (see Fig. 8). There are two different size rollers included with the Gas/Gasless MIG welder, a roller to suit gasless flux-cored welding wire (0.8mm and 0.9mm) and general purpose wire (0.6mm and 0.8mm). Open the side cover (6) of the welder by raising the side cover release lever (8), lift and open the side cover (6) to reveal the drive roller assembly.
B Pressure Roller
D Pressure Arm
Fig. 8
10
ASSEMBLY (cont.)
Setting the Wire Drive Roller Size Release the pressure of the pressure roller (B) by loosening the adjustable pressure screw (C) anti-clockwise (see Fig. 9). Push the pressure arm (D) down towards the base of the welder and swing the arm away form the welder (see Fig. 10). This will release the pressure of the pressure roller (B) and allow access when changing the wire drive roller bracket (H) or feeding the welding wire to the MIG torch (10) (see Fig. 11).
Fig. 9
Fig. 10
Fig. 11
Remove the two screws (F & G) from the wire drive roller bracket (H) (see Fig. 12a) and then remove the wire drive roller bracket (H) (see Fig. 12b & 12c). Lift the wire drive roller (I) off the drive shaft (a) and inspect it to confirm the wire groove size is stamped on either face of the roller (see Fig. 13). Always ensure the wire drive roller size you require is facing outward when assembled on the MIG welder. Note: Always ensure that the welding wire size you are using matches the wire drive roller (I) size. If you use the incorrect drive roller size then you will experience issues such as the wire not feeding correctly or irregular welding. Re-fit the welding wire drive roller (I) and wire feed bracket (H), then tighten the screws (F & G). Caution: Do not over tighten screws (F & G) as this could result In damage to the MIG welder.
Fig. 12b
Fig. 12a
Fig. 12c
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ASSEMBLY (cont.)
Adjusting the Drive Roller Pressure The pressure roller (B) applies pressure to the drive roller (I) through an adjustable pressure screw (C) and pressure arm (D). It is recommended that you adjust the adjustable pressure screw (C) in order to apply sufficient pressure to the wire drive roller (I), this will provide satisfactory wire feed and prevent the wire from slipping in the wire groove of the wire drive roller (I). If the welding wire appears to be slipping and not feeding correctly do as follows: Inspect the wire torch tip (12) to ensure that there is no wear, distortion or welding slag stopping the welding wire from feeding through the tip. Inspect the drive shaft (a) (this is the flexible inner tube that carries the welding wire between the welder and the Fig. 14 welding torch) for bends, kinks and clogging by metal filings or welding wire left in the drive shaft (a). If this is not the cause of the slipping, the pressure of the pressure roller (B) should be increased by rotating the adjustable pressure screw (C) clockwise (see Fig. 14).
Fig. 13
Caution: Over tightening the adjustable pressure screw (C) can apply excessive pressure to the wire drive roller (I), this can cause excessive wear to the wire drive roller (I), pressure rollers (B), shafts and bearing.
Welding Wire Maintenance Caution: It is critical to make sure that your welding wire is free from kinks, bends and sharp points at the end of the wire. Kinks and bends in the welding wire will cause the wire to jam or drag in the welding torch lead inner tube (A). The flexible inner tube (A) allows the MIG wire to pass between the MIG welder and the MIG torch (10) without creating drag. Kinks and bends can also cause the welding wire to become jammed in the torch tip (12).
Cutting Welding Wire (Fig.15) When cutting the welding wire, avoid cutting the welding wire on an angle (e.g. leaving a sharp point on the end), it is recommended you lightly file a flat end of the welding wire prior to feeding the wire into the flexible inner tube (A).
Warning! Ensure that you KINKED OR DAMAGED POINT ON THE END OF THE WELDING WIRE WELDING WIRE do not make contact with Fig. 15 the earth clamp at any stage when feeding the welding wire through to the MIG torch (10). The electrode wire will be at welding voltage whilst it is being fed through to the MIG torch (10). Keep the MIG Torch (10) away from your eyes and face.
12
ASSEMBLY (cont.)
Feeding the Welding Wire (Fig. 17) 1. Remove the shroud (11) and then unscrew the torch tip (12) from the MIG torch (10) by turning the torch tip (12) anti-clockwise. This will allow the welding wire to pass through the MIG torch (10) without catching on the back of the torch tip (12) (see Fig. 16).
Fig. 16
2. Release the tension of the pressure arm (D) by turning the adjustable pressure screw (C) anti-clockwise, this will reduce the tension of the pressure arm (D). 3. Push the pressure arm (D) downward and then swing the pressure arm (D) away from the MIG welder. This will allow the pressure roller (B) to swing away from the drive roller, allowing access to feed your welding wire into the flexible inner tube (A). 4. Lift up the pressure arm (D) and pass the electrode wire through the inlet guide (E), between the feed rollers and into the flexible inner tube (A). 5. Lower the pressure arm (D) and adjust the pressure accordingly ,using the adjustable pressure screw (C).
E Inlet guide
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ASSEMBLY (cont.)
Feeding the Welding Wire through to the MIG Torch (Fig.18) Ensure the MIG torch (10) lead is straight, and the welder On/off switch (1) is turned on (see Fig. 17). Feed the welding wire through to the MIG torch (10) by depressing the MIG torch (10) trigger switch. Continue depressing the trigger switch on the MIG torch (10) until the welding wire protrudes out of the end of the MIG torch (10) where the torch tip (12) has been removed.
ALWAYS EXTEND THE WELDING TORCH FULLY AND REMOVE THE TORCH TIP WHEN FEEDING THE WELDING WIRE
Fit the appropriate welding wire torch tip (12). Fig. 18 Once you have re-fitted the correct welding wire torch tip (12) size cut off any excess welding wire by leaving approximately 10mm protruding from the end of the torch tip (12). Replace the MIG torch shroud (11).
OPERATION
Adjusting the Wire Speed (Fig. 19) The wire speed can be controlled using the wire feed speed control (3). The wire feed speed control (3) controls the welding current via the welding wire, this adjusts the speed of the wire feed motor and the rate at which the welding wire feeds to your welding job.
Fig. 19
Output Voltage Control Switch (Fig. 20) The Output Voltage Control Switch (7) sets the voltage level of the welding terminals. Adjust to one of the five positions available. OFF disconnects the power from the controls. A 16V B 17.3V C 18.2V D 19.75V
Fig. 20
Caution: The output voltage control switch (7) MUST NOT BE CHANGED during the welding operation. Some internal electrical components are at mains voltage potential when the switch is adjusted to the OFF position. Switching the output voltage control switch (7) during the welding process can damage internal components of the MIG welder.
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OERATION (cont.)
Switching the Welder On and Off (Fig. 21) The On/Off Switch (1) will illuminate when the ON/OFF switch (1) is in the ON position. To turn the welder on, select the ON position. To turn the welder off, select the OFF position.
Fig. 21
Overload Protection LED Light (Fig. 21) The MIG welder features a self re-setting thermostat that helps protect the internal components of the MIG welder. The overload protection LED (2) will illuminate and welding current will stop once the duty cycle of the power source has been exceeded. If the overload protection LED (2) illuminates, wait for it to turn off before returning to welding operation.
Fig. 22
Choosing the Correct Size and Type of Welding Wire There are many variables that you will need to take into account when choosing your welding wire size and type. Below are some of the things you need to take into account when choosing the welding wire: Thickness of the material to be welded. Position and type of welding joint. Maximum welding capacity of your welder. How much penetration will be required for strength. Type of bead desired for the weld. Whether you are using a shielding gas or not. Type of material to be welded.
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MAINTENANCE
Warning! There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the welding power source from the mains supply voltage before disassembling. Welding equipment should be regularly checked by a qualified electrical tradesperson to ensure that: The main earth wire of the electrical installation is intact. The power point for the welding power source is effectively earthed and of adequate current rating. Plugs and cord extension sockets are correctly wired. Flexible cord is of the 3-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in good condition. Welding terminals are shrouded to prevent inadvertent contact or short circuit. The frame of the welding power source is effectively earthed. Welding leads and electrode holder are in good condition. The welding power source is clean internally, especially from metal filing, slag, and loose material. If any parts are damaged for any reason, replacement is recommended. Cleaning the Welding PowerSource Warning! To clean the welding power source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal filings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current. Cleaning the Drive Rolls Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or clean the grooves on the upper drive roll. After cleaning, tighten the drive roll retaining screws. Caution: Do not use compressed air to clean the welding power source. Compressed air can force metal particles to lodge between live electrical parts and earthed metal parts within the welding power source. This may result in arcing between the parts and their eventual failure. Note: Ozito Industries will not be responsible for any damage or injuries caused by the repair of the tool by an unauthorised person or by mishandling of the tool.
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SPARE PARTS
Please contact your local Bunnings Special Orders Desk to order the required spare parts. Most common spare parts listed below Spare Part Welding torch assembly On/off switch Wire drive roller 0.6-0.8mm Pressure roller Wire drive roller 0.8-.09mm Part No. SPMWR135-04 SPMWR135-12 SPMWR135-56 SPMWR135-59 SPMWR135-92
DESCRIPTION OF SYMBOLS
V ~ m/min U1 Volts Alternating current Revolutions or reciprocation per minute Rated AV input voltage (with tolerance 10%) Rated maximum input current Non-load voltage Max. wire feeding speed Electric current adjustment range, and the relevant on-load voltage Symbol of single-phase AV power and rated frequency Do not operate in the rain Read operators manual Double insulated
1
Hz W
Hertz Watts Amperes load duration rate Maximum effective input current On-load voltage Protection class Used in the environment which has high risk of electric shock
A
X I1eff U2 IP
1 ~ 50Hz
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CONTENTS
1 1 1 1 1 1 1 1 1 1 1 x x x x x x x x x x x Gas/Gasless MIG Welder MWR-135 Welding mask Combination chipping hammer and wire brush 0.6mm-0.8mm Wire feed roller (fitted to the welder) 0.8mm-0.9mm Wire feed roller 0.2kg Welding wire 0.6mm Contact torch tip 0.8mm Contact torch tip 0.9mm Contact torch tip Torch shroud Instruction manual
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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 Warehouse with a confirmed Bunnings register receipt.
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:
Note: Warranty excludes accessories and consumable parts such as Welding tips, torch nozzles, flexible inner tube, welding wire, wire feed rollers, welding lenses, wire brushes and chipping hammer.