AWG-964 - Welding machine Ozito - Free user manual and instructions

Product Type	Welding Machine
Brand	Ozito
Model	AWG-964
Input Voltage	240V AC, 50Hz
Rated Current	160A
No-Load Voltage	50V
Duty Cycle	60% at 160A
Electrode Diameter (MMA)	1.6mm - 4.0mm
Wire Diameter (MIG)	0.6mm - 0.8mm
Weight	15.5 kg
Dimensions (LxWxH)	430 x 200 x 310 mm
Protection Class	IP21S
Insulation Class	F
Cooling Method	Fan Cooled
Welding Processes	MMA (Stick), MIG, TIG (Lift)
Welding Current Range	30A - 160A
Cable Length (Electrode Holder)	2.5m
Cable Length (Earth Clamp)	2.5m
Accessories Included	Electrode holder, earth clamp, mask, brush
Safety Features	Overload protection, thermal cutout
Maintenance	Clean dust regularly, check cables for damage
Repairability	Spare parts available, serviceable by qualified technician
Certification	CE, RoHS

Frequently Asked Questions - AWG-964 Ozito

What is the input voltage and frequency requirement for the Ozito AWG-964?

The Ozito AWG-964 requires a 240V AC power supply at 50Hz. Ensure your mains outlet matches these specifications.

What welder types can the AWG-964 perform?

It supports MMA (stick), MIG, and Lift TIG welding processes, making it versatile for various applications.

What is the duty cycle of the Ozito AWG-964?

The duty cycle is 60% at 160A, meaning you can weld continuously for 6 minutes in a 10-minute cycle before needing a cool-down period.

What electrode sizes are compatible with the AWG-964 in MMA mode?

It accepts electrodes from 1.6mm to 4.0mm diameter. Common sizes like 2.5mm and 3.2mm work well.

Does the AWG-964 have overheat protection?

Yes, it features a thermal cutout and overload protection to prevent damage from excessive temperature or current.

What is the weight of the Ozito AWG-964 welder?

The machine weighs approximately 15.5 kg, making it portable but sturdy for workshop use.

Can I use a welding mask that comes with the machine?

Yes, a welding mask and other accessories like an electrode holder, earth clamp, and brush are included in the package.

How do I clean and maintain the AWG-964?

Regularly blow out dust from the internal components with compressed air and inspect cables for wear. Keep the unit in a dry place.

What kind of wire does the AWG-964 use for MIG welding?

It uses mild steel wire with diameters of 0.6mm to 0.8mm. Use appropriate gas if required.

Is the Ozito AWG-964 repairable and are spare parts available?

Yes, spare parts are available through authorized service centers. Only qualified technicians should perform repairs to maintain safety.

USER MANUAL AWG-964 Ozito

Duty Cycle: 25% @ 80 amp

Electrode Size: 02.0 - 3.2mm

ozito.com.au

WHAT'S IN THE BOX

Arc Welder

Arc Electrode Holder

Earth Clamp

Wire Brush / Chipping Hammer

Welding Mask

3 YEAR REPLACEMENT WARRANTY

AWG-964

WARRANTY

IN ORDER TO MAKE A CLAIM UNDER THIS

WARRANTY YOU MUST RETURN THE PRODUCT

TO YOUR NEAREST BUNNING O WARELLION OF WITH

The benefits provided under this warranty are in addition

to other rights and remedies which are available to you at law.

Our goods come with guarantees that cannot be excluded

KNOW YOUR PRODUCT

ARC WELDER

1 Carry Handle

5 On/Off Switch

2 Internal Cooling Fan

1. Current Regulator Knob

3 Overload LED

7 Electrode Holder

4 Current Setting Gauge

8 Earth Clamp

SETUP & PREPARATION

1. ASSEMBLY

WARNING: ENSURE THE TOOL IS SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY BEFORE PERFORMING ANY OF THE FOLLOWING STEPS.

Before starting you will require a suitable Electrode according to the specific material type and thickness.

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

WARNING DO NOT TOUCH THE ELECTRODE WHILE THE WELDER IS ON.

2 Attach the Earth Clamp to the work piece ensuring area is free from paint or dirt so that there is a good electrical connection.

3 Connect the Arc Welder power cord into a power outlet.

OPERATION

2. CONTROLS 3. ARC WELDING

WARNING: THE POWER SUPPLY FOR THIS PRODUCT SHOULD BE PROTECTED BY A RESIDUAL CURRENT DEVICE (RATED AT 30MA OR LESS). A RESIDUAL CURRENT DEVICE REDUCES THE RISK OF ELECTRIC SHOCK.

Welding Current Control

The welding current can be increased or decreased by turning the welding current control knob. The welding current should be set according to the specific application and material.

1 To increase the welding current turn the current regulating knob in a clockwise direction.

2 To decrease the welding current turn the current regulating knob in a anti-clockwise direction.

On/Off Switch

To turn the welder on press the on/off switch to the On position

Preparation

Before welding ensure that:

• You have read and understand the safety section of this manual.
• There is sufficient ventilation, particularly at the front and rear of the unit.
• You have an adequate fire-fighting devices on hand.

WARNING: ENSURE ALL OIL, PETROL AND FLAMMABLE CONTAINERS HAVE BEEN REMOVED FROM WELDING AREA.

Electrodes & Welding Current

The welding current must be regulated in accordance with the diameter of the electrode and the thickness of the steel being used.

This will vary with the type of electrodes and material you are using. Below is a guide suggesting suitable currents & thickness for welding steel.

Electrode Diameter Welding Current (Amps) Thickness of Steel

∅2.0mm 55 - 75 1.5 - 2mm

∅2.5mm 80 - 105 3 - 5mm

∅3.2mm 105 - 130 4 - 6mm

Striking the Arc

WARNING: ENSURE APPROVED PROTECTIVE CLOTHING AND WELDING HELMET/MASK IS WORN AT ALL TIMES TO PROTECT YOUR FACE AND EYES FROM ARC UV RADIATION AND SPARKS.

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 the arc, try to maintain a distance from

ARC WELDING

Butt Joint

Is the joining of two pieces of material together along a single edge in a single plane. Two sheets of metal are laid side-by-side and joined together along a single joint.

Fillet Joint

Is a type of joint used for welding pieces or plates in which the angle between them varies from 0^ to 180^ . The edge of one plate is brought against the surface of another not in the same plane. The joint can be welded on one or both sides.

Lap Joint

The edges of a plate are lapped one over the other and the edge of one is welded to the surface of the other.

5. WELDING PROPERTIES4. WELDED JO

Arc Length

To strike the arc, the electrode should be gently scraped on the work until the arc is established. A simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs and gives a rough surface finish to the weld. A short arc is essential if a high quality weld is to be obtained but a excessively short arc will cause sticking of the electrode and result in poor quality welds.

Electrode Angle

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

Travel Speed

The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion and lack of penetration. While too slow a rate of travel will frequently lead to arc instability, slag inclusions and poor mechanical properties.

Electricity

The electricity flows through the electrode cable to the attached electrode. The electricity will not leave the electrode 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 electrode makes contact with the earthed work piece an arc is created. The electricity flows through the electrode, the metal work piece and then through the earth cable straight back to the welder.

Earth Clamp

Prior to connecting the earth clamp it may be necessary to clean the surface of the work piece using the metal brush. Attach the earth clamp firmly to the work piece ensuring there is good metal to metal contact. Clamp it where it will not be in the way. This clamp provides an earth connection back to the welder. Always

IMPORTANT INFORMATION

Thermal Overload

IF YOUR WELDER OVERHEATS AND THE THERMAL OVERLOAD PROTECTION ENGAGES DO NOT TURN YOUR WELDER OFF AS THE FAN WILL ASSIST IN REDUCING THE COOLING TIME.

All Welders have a feature called a duty cycle.

Duty cycle on a welder refers to the time in which the welder operates during normal welding.

A welder can only weld for a certain continuous period of time before it requires to cool down.

If the internal components of the welder should become hot the welder could overheat. If the welder overheats the Thermal Overload Protection feature will automatically shut down the welder.

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 LED indication light is just to inform you that your welder is becoming too hot and requires to cool down to protect the internal components of the welder. Do Not turn your welder Off as the welder has an internal cooling fan and this will assist your welder to cool down quicker. Reducing the cooling time will enable you to get back to your welding job quicker.

Depending on how many Amps or how heavy the welding you are doing the cooling time may take up to 10 Minutes for your welder to cool down so you can return to your welding job.

TROUBLESHOOTING

PROBLEM	CAUSE	REQUIRE
SUBTOTAL OPERATION
No Power	Power supply	Test specialty with another product, wood making carbon nanocrack.
	Circal lubricator trapped	Check the using of the circular plastic on the supply and other aged layers compared to the circuit. The wireline is a high power device used in a recommended method to be the only appliance on the circuit or measure that has enough current inspection.
Details and notes	Barium clamp conduction not adequate	Check with charging has good condition on material being worked. Soldering the charging prevents on work to have work, increase its power level.
	Working vs. mixture	Make suitable at correct shape, discrete on ground material.
Mechanical use	Thermal worked active	The thermal conductivity will then be the load pond cell above and the water will not depend on soil and above and the chloroplast out. This is normal in heavy working, allowing the underwood drain.
ARC UTILITIES
Power working	Power conversion and shifting electrons	Select an electronic to test mechanical electrodes need to action.
Packing working in a low dose	Settings	Increase current to measurement.
	Internal	Clean any being worked to paint metal.
	Electrostatic power and dye	Check the electrical single and two corresponding low for the restricted heating unit.
	Electrostatic damage	Exceeds with new welding rod.
Balance working in a low dose consumption	Warning components, adding high light electric inputs due to small or minimal material	Buses and insulating materialsChange to larger electrode

EQUIPMENT CLASSIFICATION

This product is classified as Group 1 & 2, Class B welding equipment. • Group 2 - This product generates radio frequency energy in the frequency range 9KHz to 400GHz.

- Class B - This product is intended for use in a domestic environment. It is suitable for use in locations in residential environments and in establishments directly connected to a low voltage power supply network which supplies buildings used for domestic purposes.

ELECTRICAL SAFETY

WARNING! When using mains-powered tools, basic safety precautions, including the following, should always be followed to reduce risk of fire, electric shock, personal injury and material damage.

Read the whole manual carefully and makes sure you know how to switch the tool off in an emergency, before opening the tool.

Save these instructions and other documents supplied with this tool for future references.

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 2016 and 2017 in OZ in Chile are in Honduras for Australia and New Zealand.

If the supply cord is damaged, it must be replaced by an electrician or a power tool repairer in order to avoid a hazard.

Using an Extension Lead

Always use an approved extension lead suitable for the power input of this tool. Before use, inspect the extension load and guide of frame, once and open. Replace the extension load is demand or defective.

exclusion lead for signs of campaigns, wear and posing. Replaces the exclusion lead is damaged or defective. When given an exposure need up a mix, some queries like land extractable. Use of no primary input with

1. In using an solution with a tool, always found the lead company. Use of a solution has not suitable for the power input of the tool or which is damaged or defective may result in a risk of fine seal electric

in the case of the 100% of the 200% of the 300% of the 400% of the 500% of the 600% of the 700% of the 800% of the 900% of the 1000% of the 1100% of the 1200% of the 1300% of the 1400% of the 1500% of the 1600% of the 1700% of the 1800% of the 1900% of the 2000% of the 2100% of the 2200% of the 2300% of the 2400% of the 2500% of the 2600% of the 2700% of the 2800% of the 2900% of the 3000% of the 3100% of the 3200% of the 3300% of the 3400% of the 3500% of the 3600% of the 3700% of the 3800% of the 3900% of the 4000% of the 4100% of the 4200% of the 4300% of the 4400% of the 4500% of the 4600% of the 4700% of the 4800% of the 4900% of the 5000% of the 5100% of the 5200% of the 5300% of the 5400% of the 5500% of the 5600% of the 5700% of the 5800% of the 5900% of the 6000% of the 6100% of the 6200% of the 6300% of the 6400% of the 6500% of the 6600% of the 6700% of the 6800% of the 6900% of the 7000% of the 7100% of the 7200% of the 7300% of the 7400% of the 7500% of the 7600% of the 7700% of the 7800% of the 7900% of the 8000% of the 8100% of the 8200% of the 8300% of the 8400% of the 8500% of the 8600% of the 8700% of the 8800% of the 8900% of the 9000% of the 9100% of the 9200% of the 9300% of the 9400% of the 9500% of the 9600% of the 9700% of the 9800% of the 9900% of the 1,

It is recommended that the extension load is a maximum of 25m in length. Do Not use multiple extension

Institute

The power supply for this product should be protected by a residual current device (infe at some or less). A residual current device reduces the risk of electric shock.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING: Reads all safety warnings and all other incidents. Please note that the same is to be in instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless)

power tool.

1. Keep work areas clean. Cluttered work areas and benches can cause students.

2. Consider work area environment. Do not expose your equipment to high humidity or rain. Do not use your equipment in alarm or well conditions. Keep the work area well fit. 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 professional clothing. Wear a protective hair covering to keep long hair out of the way.

5. Guard against electric shock. Prevent body contact with cathode or grounded surfaces. Electrical safety can be further improved by using a high sensitivity (50 mA / 30 mS) residual current device (RCD).

6. Do not overreach. Keep proper footing and balances at all times.

7. Stay start. Watch what you are doing. Use common shoes. Do not operate for equipment when tired

8. Secure work pieces. If required, use clamps in a vine to build the work pieces.

9. Extension lands. Before use inspect the waterfront 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 hardware 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 the equipment other than those recommended in this instruction manual may present a risk of personal injury.

1. Check for damaged parts. Before use carefully check the equipment and power load 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 on and off. Have any damaged or defective parts repaired or replaced by an electronic or a power loss repair. Never attempt any repairs yourself

2. Unplug the equipment. Unplug the equipment when it is not in use, before changing any parts, accessories or attachments and before servicing.

3. 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.

4. Store equipment. When not in use, equipment should be stored in a dry, locked up or high place out of reach of children.

5. Maintain mains equipment with cars. Keep the equipment clean and in good condition for better and safer performances. Follow the instructions for maintenance and changing accessories. Keep handles and switches dry, clean and free from oil and grease.

6. Have your tool repaired by an electrician or a power tool repairer. 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.

7. 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.

8. Replacement of the supply cord. If the supply cord is damaged, it must be replaced by an electrician or a power tool repairer in order to avoid a hazard.