OPERATORS MANUAL
Contents
1. OSA 279 2000K Manual qxd 20 11 2006 14 36 Page 1 D E G LOW VOLTAGE DIRECTIVE 73 23 EEC E C ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 9 336 EEC DECLARATION OF CONFORMITY We hereby certify that OSAKI MINI MAX 125 Inverter Welder Complies with all the relevant provisions of the EC Directives 73 23 EEC amp 89 336 EEC 9 OSAK I POWER TOOLS Harmonised Standards Applied EN60974 1 A1 2000 A2 2003 EN50199 Official Agent KENNEDY TOOLS Wigston Works Leicester England ISO 9002 REGISTERED COMPANY sores VAa ole Date 1st October 1999 Name Martin Cooke Position Director The Kennedy Group Ltd Gi 1 6 40 ACE D A Z QUALITY GUARANTEE amp WARRANTY i PQO mnmax zs OSAKI POWER TOOLS carry one years manufacturers warranty TO maman OSAKI POWER TOOLS are designed amp produced i to the highest standards amp specifications DSAKI OSAKI POWER TOOLS are fully guaranteed against faulty materials amp workmanship NENES otsam pna Should they be found to be defective they will either be repaired or replaced free of charge fair wear and tear and or misuse excepted Please retain supplier invoice as proof of purchase ORDER GODE OSA 279 2000K The Kennedy Group Ltd 09 06 OSA 279 2000K Manual qxd 20 11 2006 14 36 Page 2 QOSAK SAFETY INSTRUCTIONS Osaki Power Tools are committed to the Production of Quality Power Tools that are designed for high performanc2. QOSAK MACHINE LABELLING POWER TOOLS Top Labelling i410 he generator is a source of high frequency with rectification EN 60 974 1 machines i 3 The welding method is a manual arc with coated electrodes Protection against the risk of electric shock he welding current is direct Uo 70V7 Vacuum voltage with no welding being carried out is 70V 10a 20v 80a 23 2v Potentiometer scale current settings conventional voltage X Duty cycle is 35 60 amp 100 I2 Corresponding currents U2 Live conventional voltages single phase electrical feeding 50 or 60Hz 1 50 60Hz Ui 230V Mains feed voltage h max 15 5A Maximum Feeding Current he 9 3A Current of the maximum effective feeding p21c Indication P21C protection against the penetration of solid strange AF bodies and vertical water falls but not under the rain T10A_ Electrical installation protection with a fuse 10A It is obligatory to wear the UV protection helmet A Warning Hot sparks are produced during the welding process Front Labelling TD sD Potentiometer for Setting the appropriate Current for F k Biocerode Y mm te diameter of the selected elcetrode 7 A one Green LED for Power ON 80 mm A 125 Yellow LED for Thermal Cut Out aa SON VERTER MAX 5mm refers to the maximum thickness of metal to be welded g Eoo C Positive connection for the Electrode Holder 7T Negat
3. al agent 20 11 2006 14 36 Page 3 OSAKI POWER TOOLS SERVICE amp REPAIR rm r RE CEE A A OEE non fie _ D ie EN ACCESSORIES CONSUMABLES E OSAKI recommends using KENNEDY welding rods available from your nearest KENNEDY QUALITY INDUSTRIAL TOOLING POWER TOOLS Osaki Distribtuor Electrodes for Mild Steels Arc welding rods for mild steel and medium tensile steels Medium rutile coated all positional rods Applications for steel plate and strip including structural steels and pipe work especially under site conditions Superb finish with self releasing slag N B Suitable for AC 50V minimum open circuit and DC Order Code KEN 891 Size mm No of Rods per pack Weight Minimum Maximum per pack Amperage Amperage 3010K 3020K 3030K 2 50 x 300 325X390 4 00 x 450 260 150 100 5 0kg 5 0kg 5 0kg Flat or Downhand position Fillet welding in the horizontal vertical position Butt and fillet welding in the vertical up position Butt and fillet welding using the 5 6 vertical down technique Butt welding in the horizontal position Butt and fillet welding in the overhead position al ka iS toe PAGEMAKER DEFIBRILLATORS All staff personnel with a pacemaker defibrillator fitted must be aware that the electromagnetic energy generated when arc welding may cause your pacemaker to continually pace your heart If you
4. e done more efficiently and safely if the tool is used tor ITs Infended pura repaired and serviced by an authorised Always wear welders gauntlets leather gloves technician a leather fireproof apron and non slip footwear Stay alert at all times Watch what you are Always wear the welding mask provided or doing and use your common sense Do not other propriety protection that includes a Operate when you are tired protective clear glass placed in front of a Do not store the machine in locations where the filtering glass temperature may reach or exceed 50 C 122 F IMPORTANT You must ensure that your inverter is connected to the power source via an earthed plug wire If not you are at high risk of personal electrocution You must take precautions to protect yourself and others from Smoke fumes fire and burns Arc radiance Rain water steam and humidity Electric shock Inflammable environment elements QOSAKI POWER TOOLS ALSO AVAILABLE FROM OSAKI 12 14 4 amp 16 8 Volt Cordless Drill Screwdrivers Multi Purpose Power Tool Power Sheet Sander ve R p Ta iF S ae j Pad ia X EN t d a A 6 lt ey y Circular Saw amp Electric gt Nailer Stapler Mini b EN Milling Drilling Machine OSA 279 2000K Manual qxd o A comprehensive in house repair and service facility is available through your loc
5. e and long service life If safety and maintenance procedures are observed they will last for many years Thank you for choosing our welder In order to make the most of your equipment please read the following very carefully POWER TOOLS Man Earth and the Universe are forces that create an immovable centre of balance PoweR toos the balance of power 7 The MINI MAX 5mm is a portable mono phase air cooled direct current DC Inverter welder for electrode welding MMA using all types of electrodes rutile basic stainless steel etc GENERAL SAFETY Always run the power cable away from the ee back of the welder to guard it from damage as rae res e et When working outdoors only use suitably 2 PE ep oes SOE IVETE Oe ae approved extension cables with a minimum damp conditions Ensure work area is well lit ae conductor cross section of 1 5mm The plug Do not use near flammable liquids or gases connectors must have earthing contacts and Do not let people who are not familiar with the be waterproof equipment handle it without supervision Secure work with a clamp or vice This will Store in a dry secure place away from allow both hands free to carry out the work children Disconnect from the power source when not in use or when changing accessories electrodes Before using the welder ensure that all parts are functional A damaged part should be Use the correct tool for the job The job will b
6. ive connection for the Earth Clamp ales Oe unless specified otherwise by the elec trode manufacturer Nemee 4 The equipment complies with Standard EN60974 1 relating to welding QOSAKI START UP Connect the machine to the mains via a 240v plug with a 10A fuse and an earth connection Connect the current return lead earth lead and the electrode holder to the welder according to the polarity specified for the chosen electrode to be used The welder is activated by turning the potentiometer knob from 0 to the desired current for the diameter of the selected electrodes to be used POWER TOOLS gOS QSA AKI Be sure to observe all classical welding rules Leave the machine connected after welding in order to let it cool down Thermal protection the yellow LED comes on when the thermal cut out trips due to the unit overheating The cooling down time is approx 5 minutes signalled when the light goes out The machine is equipped with the following functions HOT START allows a super intensity of roughly 25 on the setting ARC FORCE allows a super intensity of roughly 55 on the setting to avoid sticking when the electrode enters the pool and ANTI STICKING allows you to remove your electrode easily from the pool without it sticking QOSAKI PROBLEMS POWER TOOLS If you are ready to weld and the machine does not produce current please study the following possible solutions If both LEDs are on wai
7. r heart is beating on its own this may result in an irregular heart rate The intense energy created when spot welding or starting a bead may cause your pacemaker including the pacemaker function of an implantable defibrillator to pause temporarily if it were pacing your heart Your implantable defibrillator could detect the electromagnetic energy from the welder especially when spot welding as a fast heart rhythm causing it to deliver a shock SPECIFICATIONS Electrode capacity Rutile Basic Stainless Steel Cast Iron Weight Duty Cycle 100 OA Duty Cycle 60 A Nominal Voltage 230v 50Hz7 QOSAKI INSTALLATION The user is responsible for the installation and use of the equipment in accordance with the manufacturers instructions Before installation the user should assess the risk of electromagnetic interference on persons and the environment If electromagnetic interference is detected it is the user s responsibility to remedy the situation with the help of a professional electrical engineer This may be remedied by the introduction of filtering on the supply cable The welding machine should not be modified in any way and should be used only for the purpose for which it is intended When using the machine it is advisable to arrange cables tidily and together where IS possible to minimise risk of tripping OS POWER TOOLS the balance of power 7 OSA 279 2000K Manual qxd 20 11 2006 14 36 Page 4
8. t for the cooling down period until the yellow light thermal cut out switches off reintroducing the required working current If there is still no current return the machine to your OSAKI distributor for repair lf the POWER green light is off check the supply connections If none are found to be faulty return the machine to your OSAKI distributor for repair If you touch the workpiece after you have finished welding and get a tingling sensation this means that the unit is incorrectly earthed check for faulty connections on all plugs and MAINTENANCE Disconnect the welder and wait until the cooling fans have stopped because the internal voltage and current are high are dangerous Take the steel cover off regularly to inspect and clean dust from the internal components using compressed air be sure you wear eye protection and a dust mask making sure that the machine is no longer coneted to the mains supply QOSAK POWER TOOLS
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