OWNER’S OPERATING MANUAL

MMA INVERTER WELDER

MODEL MMA-140

SPE CIFICATIONS
Rated input power supply......................................................AC 230V±5% 50/60Hz
Rated input capacity......................................................................................5.3KVA
Current adjustment range........................................................................... 20-140A
Rated duty cycle................................................................................................ 80%
Rated voltage..........................................................................................20.8-25.6 V
No load voltage.................................................................................................. 63V
Overall efficiency................................................................................................80%
Housing protection grade................................................................................IP21S
Power factor.............................................................................................. 0.73 cosφ
Insulation grade...................................................................................................... F
Electrode diameter...................................................................................1.6-3.2mm
Noise......................................................................................................... <70dB(A)
Dimensions............................................................................... 287 x 120 x 247mm
Net weight........................................................................................................ 3.8kg

THANK YOU FOR BUYING A RYOBI

MMA INVERTER WELDER
Your new inverter generator has been engineered and manufactured to Ryobi’s
high standard of dependability, ease of operation and operator safety. Properly
cared for, it will give you years of rugged, trouble free performance. If you use
your inverter generator properly and only for what it is intended, you will enjoy
years of safe, reliable service.

CAUTION: Carefully read through this entire owner’ s

manual, paying close attention to the general
safety rules and rules for safe operation,
before using.

KE E P THIS MANUAL FOR FUTURE RE FE RE NCE

1
 IMPORTANT SAFETY INSTRUCTIONS
The purpose of safety rules is to attract your 3. Do not coil or drape cables around your body.
attention to possible dangers. The safety symbols
and the explanations with them, require your 4. Keep welding power source and cables as far
careful attention and understanding. The safety away from operator as practical.
warnings do not by themselves eliminate any 5. Connect work clamp to work piece as close
danger. The instruction or warnings they give are to the weld as possible.
not substitutes for proper accident prevention
measures. ABOUT PACEMAKERS
Pacemaker wearers consult your doctor first. If
SAFETY ALERT SYMBOL. Indicates cleared by your doctor, then following the above
danger, caution or warning. May be used procedures is recommended.
in conjunction with other symbols or
pictures. WELDING HAZARDS
The symbols shown below are used throughout this
Failure to obey a safety warning can result in manual to call attention to and identify possible
serious injury to yourself or to others. Always follow hazards. When you see the symbol, watch out, and
the safety precautions to reduce the risk of fire, follow the related instructions to avoid the hazard.
electric shock and personal injury.
Only qualified persons should service, test,
Do not attempt to operate this tool until you have maintain, and repair this unit.
read thoroughly and completely understood the
safety rules, etc. contained in this manual. Failure During servicing, keep everybody, especially
to comply can result in accidents involving fire, children, away.
electric shock or serious personal injury. Save this
Owners Operating Manual and review it frequently
for continual safe operation and for instructing
ARC RAYS
others who may use this tool. Can Burn
EMF INFORMATION
Considerations About Welding And The Effects Of ARC RAYS can burn eyes and skin; NOISE can
Low Frequency Electric And Magnetic Fields. damage hearing. Arc rays from the welding
Welding current, as it flows through welding cables, process produce intense heat and strong
will cause electro- magnetic fields. There has been ultraviolet rays that can burn eyes and skin.
and still is some concern about such fields. Noise from some processes can damage
However, after examining more than 500 studies hearing.
spanning 17 years of research, a special blue
1. Wear a welding helmet fitted with a proper
ribbon committee of the National Research Council
shade of filter (ANSI Z49.1) to protect your
concluded that: “The body of evidence, in the
face and eyes when welding or watching.
committee’s judgment, has not demonstrated that
exposure to power- frequency electric and 2. Wear approved safety glasses. Side shields
magnetic fields is a human-health hazard.” recommended. Never wear contact lenses
However, studies are still going forth and evidence while welding.
continues to be examined. Until the final
conclusions of the research are reached, you may 3. Use protective screens or barriers to protect
wish to minimize your exposure to electromagnetic others from flash and glare; warn others not
fields when welding or cutting. to watch the arc.

To reduce magnetic fields in the workplace, use the 4. Wear protective clothing made from durable,
following procedures: flame-resistant material (wool and leather)
and foot protection.
1. Keep cables close together by twisting or
taping them. 5. Use approved ear plugs or ear muffs if noise
level is high.
2. Arrange cables to one side and away from
the operator.

2
IMPORTANT SAFETY INSTRUCTIONS

3
 IMPORTANT SAFETY INSTRUCTIONS
13. In confined spaces or damp locations, do not
ELECTRIC SHOCK use a welder with AC output unless it is

Can Kill
equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if
Touching live electrical parts can cause fatal working above floor level.
shocks or severe burns. The electrode and
work circuit is electrically live whenever the 15. Keep all panels and covers securely in place.
output is on. The input power circuit and

FUMES & GASES

machine internal circuits are also live when
power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the
Can Be Dangerous
welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is FUMES AND GASES can be hazardous to your
a hazard. health. Welding produces fumes and gases.
Breathing these fumes and gases can be haz-
1. Do not touch live electrical parts. ardous to your health.
2. Wear dry, hole-free insulating gloves and body 1. Keep your head out of the fumes. Do not
protection. breath the fumes.
3. Insulate yourself from work and ground using 2. If inside, ventilate the area and/or use
dry insulating mats or covers. exhaust at the arc to remove welding fumes
4. Disconnect input power or stop engine before and gases.
installing or servicing this equipment. Lock input 3. If ventilation is poor, use an approved air-
power disconnect switch open, or remove line supplied respirator.
fuses so power cannot be turned on
accidentally. 4. Read the Material Safety Data Sheets
(MSDSs) and the manufacturer’s instruction
5. Properly install and ground this equipment for metals, consumables, coatings, and
according to its Owner’s Manual and national, cleaners.
state, and local codes.
5. Work in a confined space only if it is well
6. Turn off all equipment when not in use. ventilated, or while wearing an air-supplied
Disconnect power to equipment if it will be left respirator.
unattended or out of service.
Shielding gases used for welding can displace
7. Use fully insulated electrode holders. Never dip air causing injury or death. Be sure the
holder in water to cool it or lay it down on the breathing air is safe.
ground or the work surface. Do not touch
holders connected to two welding machines at 6. Do not weld in locations near degreasing,
the same time or touch other people with the cleaning, or spraying operations. The heat
holder or electrode. and rays of the arc can react with vapors to
form highly toxic and irritating gases.
8. Do not use worn, damaged, undersized, or
poorly spliced cables. 7. Do not weld on coated metals, such as
galvanized, lead, or cadmium plated steel,
9. Do not wrap cables around your body. unless the coating is removed from the weld
10. Ground the workpiece to a good electrical area, the area is well ventilated, and if
(earth) ground. necessary, while wearing an airsupplied
respirator. The coatings and any metals
11. Do not touch electrode while in contact with containing these elements can give off toxic
the work (ground) circuit. fumes if welded.
12. Use only well-maintained equipment. Repair
or replace damaged parts at once.

4
 IMPORTANT SAFETY INSTRUCTIONS

FLYING SPARKS WELDING Can

Can Cause Injury Cause Fire or Injury
FLYING SPARKS AND HOT METAL can cause WELDING can cause fire or explosion.
injury.
Sparks and spatter fly off from the welding arc.
Chipping and grinding cause flying metal. The flying sparks and hot metal, weld spatter,
hot workpiece, and hot equipment can cause
As welds cool, they can throw off slag. fires and burns. Accidental contact of electrode
1. Wear approved face shield or safety goggles. or welding wire to metal objects can cause
Side shields recommended. sparks, overheating, or fire.

2. Wear proper body protection to protect skin. 1. Protect yourself and others from flying sparks
and hot metal.

CYLINDERS Can 2. Do not weld where flying sparks can strike

flammable material.
Explode If Damaged 3. Remove all flammables within 35 ft (10.7 m) of
the welding arc. If this is not possible, tightly
CYLINDERS can explode if damaged. cover them with approved covers.
Shielding gas cylinders contain gas under high 4. Be alert that welding sparks and hot materials
pressure. If damaged, a cylinder can explode. from welding can easily go through small
Since gas cylinders are normally part of the cracks and openings to adjacent areas.
welding process, be sure to treat them
carefully. 5. Watch for fire, and keep a fire extinguisher
nearby.
1. Protect compressed gas cylinders from
excessive heat, mechanical shocks, and arcs. 6. Be aware that welding on a ceiling, floor,
bulkhead, or partition can cause fire on the
2. Install and secure cylinders in an upright hidden side.
position by chaining them to a stationary
support or equipment cylinder rack to 7. Do not weld on closed containers such as
prevent falling or tipping. tanks or drums.

3. Keep cylinders away from any welding or other 8. Connect work cable to the work as close to
electrical circuits. the welding area as practical to prevent
welding current from traveling long, possibly
4. Never allow a welding electrode to touch any unknown paths and causing electric shock and
cylinder. fire hazards.
5. Use only correct shielding gas cylinders, 9. Do not use welder to thaw frozen pipes.
regulators, hoses, and fittings designed for the
specific application; maintain them and 10. Remove stick electrode from holder or cut off
associated parts in good condition. welding wire at contact tip when not in use.

6. Turn face away from valve outlet when opening 11. When not welding, make certain no part of the
cylinder valve. electrode circuit is touching the work or
ground. Accidental contact can cause
7. Keep protective cap in place over valve except overheating and create a fire hazard.
when cylinder is in use or connected for use.

5
 IMPORTANT SAFETY INSTRUCTIONS

MOVING PARTS SPARKS Can Cause

Can Cause Injury BATTERY GASES
TO EXPLODE
Moving parts, such as fans, rotors, and belts
can cut fingers and hands and catch loose
STEAM AND PRESSURIZED HOT COOLANT
clothing.
can burn face, eyes, and skin.
1. Keep all doors, panels, covers, and guards
The coolant in the radiator can be very hot and
closed and securely in place.
under pressure.
2. Stop engine before installing or connecting
1. Do not remove radiator cap when engine is
unit.
hot. Allow engine to cool.
3. Have only qualified people remove guards or
2. Wear gloves and put a rag over cap area when
covers for maintenance and troubleshooting as
removing cap.
necessary.
3. Allow pressure to escape before completely
4. To prevent accidental starting during servicing,
removing cap.
disconnect negative (-) battery cable from
battery.
5. Keep hands, hair, loose clothing, and tools H.F. RADIATION Can
away from moving parts.
Cause Interference
6. Reinstall panels or guards and close doors
when servicing is finished and before starting
engine. 1. High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
SPARKS Can Cause 2. Have only qualified persons familiar with
BATTERY GASES electronic equipment install, test, and service
TO EXPLODE H.F. producing units.
3. The user is responsible for having a qualified
electrician promptly correct any interference
SPARKS can cause BATTERY GASES TO EX-
problem resulting from the installation.
PLODE; BATTERY ACID can burn eyes and
skin. Batteries contain acid and generate explo- 4. If notified by the FCC about interference, stop
sive gases. using the equipment at once.
1. Always wear a face shield when working on 5. Have the installation regularly checked and
a battery. maintained.
2. Stop engine before disconnecting or 6. Keep high-frequency source doors and panels
connecting battery cables. tightly shut, keep spark gaps at correct setting,
and use grounding and shielding to minimize
3. Do not allow tools to cause sparks when
the possibility of interference.
working on a battery.
4. Do not use welder to charge batteries or jump
start vehicles.
5. Observe correct polarity (+ and –) on

6
 IMPORTANT SAFETY INSTRUCTIONS

ELECTRIC AND FOR ELECTRICALLY

MAGNETIC FIELDS Powered Equipment
May Be Dangerous
1. Turn off input power using the disconnect
switch at the fuse box before working on the
1. Electric current flowing through any conductor
equipment.
causes localized Electric and Magnetic Fields
(EMF). Welding current creates EMF fields 2. Install equipment in accordance with the
around welding cables and welding machines. countries National Electrical Code, all local
codes and the manufacturer’s
2. EMF fields may interfere with some
recommendations.
pacemakers, and welders having a pacemaker
should consult their physician before welding. 3. Ground the equipment in accordance with the
countries National Electrical Code and the
3. Exposure to EMF fields in welding may have
manufacturer’s recommendations.
other health effects which are now not known.
4. All welders should use the following
procedures in order to minimize exposure to HOT PARTS Can
EMF fields from the welding circuit:
Cause Severe Burns
5. Route the electrode and work cables together -
Secure them with tape when possible.
1. Do not touch hot parts bare handed.
6. Never coil the electrode lead around your
body. 2. Allow cooling period before working on
welding gun or torch.
7. Do not place your body between the electrode
and work cables. If the electrode cable is on
your right side, the work cable should also be FIRE or EXPLOSION
Hazard
on your right side.
8. Connect the work cable to the workpiece as
close as possible to the area being welded.
9. Do not work next to welding power source. 1. Do not place unit on, over, or near
combustible surfaces.

FALLING UNIT Can

2. Do not service unit near flammables.

Cause Injury STATIC Can Damage

1. Lift unit with handle on top of case.
PC Boards
2. Use handcart or similar device of adequate
capacity. 1. Put on grounded wrist strap BEFORE handling
boards or parts.
3. If using a fork lift vehicle, place and secure
unit on a proper skid before transporting. 2. Use proper static-proof bags and boxes to
store, move, or ship PC boards.

7
 IMPORTANT SAFETY INSTRUCTIONS

OVERUSE Causes READ THE

OVERHEATING INSTRUCTIONS
1. Allow cooling period; follow rated duty cycle. 1. Consult the Owner’s Manual for welding
safety precautions. Do not install, operate or
2. Reduce current or reduce duty cycle before repair this equipment without reading this
starting to weld again. manual and the safety precautions throughout.
3. Do not block or filter airflow to unit. 2. Use only genuine replacement parts

ADDITIONAL SAFETY INSTRUCTIONS

1. ALWAYS ensure that there is full free air 12. NEVER use a damaged cylinder.
circulating around the outer casing of the
machine, and that the louvres are 13. NEVER lift the cylinder by the valve.
unobstructed. 14. NEVER expose the cylinder to a heat source
2. ALWAYS use a proper welding face shield or or sparks.
helmet, with suitable filter lenses. Proper 15. NEVER continue to weld, if, at any time, you
gloves and working clothes should be worn at feel even the smallest electric shock. Stop
all times. welding IMMEDIATELY, and DO NOT attempt
3. ALWAYS check that the pressure regulator and to use the machine until the fault is diagnosed
gauges are working correctly. DO NOT and corrected.
lubricate the regulator. 16. NEVER use the welder with input connections
4. ALWAYS use the correct regulator. Each greater than 10M in length.
regulator is designed to be used with a specific 17. NEVER point the torch at any person or
gas. animal.
5. ALWAYS inspect the hose before use to 18. NEVER touch the torch nozzle until the welder
ensure it is in good condition. is switched OFF and the nozzle has been
6. ALWAYS keep the free length of gas hose allowed to cool off.
outside the work area. 19. NEVER connect, disconnect, or attempt to
7. ALWAYS remove all flammable materials from service the torch, until the machine is switched
the welding area. OFF and disconnected from the mains supply.

8. NEVER remove any of the panels unless the 20. NEVER allow the cables to become wrapped
machine is disconnected from the supply, AND around the operator or any person in the
never use the machine with any of the panels vicinity.
removed. 21. Safety devices such as interlocks and circuit
9. NEVER attempt any electrical or mechanical breakers should not be disconnected or
repair unless your are a qualified technician. shunted out.
If you have a problem with the machine contact 22. Before installation, inspection, or service of
your local RYOBI dealer. equipment, shut OFF all power and remove
10. NEVER use or store in a wet/damp line fuses to prevent accidental turning ON
environment. DO NOT EXPOSE TO RAIN. of power.

11. NEVER use gas from a cylinder, the content 23. Do not open power circuit or change polarity
of which is unknown. It is important to ensure while welding.
the appropriate gas is being used.

8
 ADDITIONAL SAFETY INSTRUCTIONS
24. If, in an emergency, it must be disconnected, 26. Fully insulated lock-type connectors should be
guard against shock burns, or flash from switch used to join welding cable.
arcing. Always shut OFF and disconnect all
power to equipment. Power disconnect switch 27. Frequently inspect cables for wear, cracks and
must be available near the welding power damage. IMMEDIATELY REPLACE those with
source. excessively worn or damaged insulation to
avoid possibly lethal shock from bared cable.
25. Fully insulated electrode holders should be Cables with damaged areas may be taped to
used. Do NOT use holders with protruding give resistance equivalent to original cable.
screws or with any form of damage. Keep cable dry, free of oil and grease, and
protected from hot metal and sparks.

INSTALLATION
ENVIRONMENT • Dirt and dust that can be drawn into the
These units are designed for use in environments machine should be kept to a minimum.
with increased hazard of electric shock.
• This machine has a protection rating of IP21S.
A. Examples of environments with increased Keep it dry and do not place it on wet ground
hazard of electric shock are: or in puddles. Do not use in wet or damp
locations. Store indoors.
1. In locations in which freedom of movement is
restricted, so that the operator is forced to • Locate the machine away from radio controlled
perform the work in a cramped (kneeling, machinery. Normal operation may adversely
sitting or lying) position with physical contact affect the operation of nearby radio controlled
with conductive parts. machinery, which may result in injury or
equipment damage.
2. In locations which are fully or partially limited
by conductive elements, and in which there is Read the section on electromagnetic compatibility
a high risk of unavoidable or accidental contact in this manual.
by the operator.
• Do not operate in areas with an ambient
3. In wet or damp hot locations where humidity temperature greater than 40°C.
or perspiration considerable reduces the skin
resistance of the human body and the TILTING
insulation properties of accessories. Place the machine directly on a secure, level
surface.
B. Environments with increased hazard of electric
shock do not include places where electrically Do not place or operate this machine on a surface
conductive parts in the near vicinity of the with an incline greater than 15° from horizontal.
operator, which can cause increased hazard, The machine may topple over if this procedure is
have been insulated. not followed.

LOCATION VENTILATION
This machine can operate in harsh environments. This cutting machine can create powerful cutting
However, it is important that simple preventative current and has strict cooling requirements that
measures are followed to assure long life and reli- cannot be met with natural ventilation. Therefore
able operation: the built-in fan is very important in enabling the
machine to work stable with effective cooling. The
• This machine must be located where there is operator should make sure that the louvers be
free circulation of clean air without restrictions uncovered and unblocked. The minimum distance
for air movement to and from the air vents. Do between the machine and nearby objects should
not cover the machine with paper, cloth or rags be 25cm.
when switched on.

9
 INSTALLATION
CONNECTION OF INPUT CABLE The Mains supply voltage should be within ± 5% of
In order to ensure personal safety and avoid the rated Mains supply voltage. Too low a
electric shock, please ground the machine reliably voltage may cause poor welding performance. Too
by connecting the ground wire of the machine to high a supply voltage will cause components to
the grounding device in the switching box. overheat and possibly fail.
The primary cable should be tightly connected to The Welding Power Source must be:
the correct socket to avoid oxidization.
• Correctly installed, if necessary, by a qualified
Check whether the voltage value varies in electrician.
acceptable range with a multi-meter.
• Correctly earthed (electrically) in accordance
with local regulations.

DUTY CYCLE
The rated duty cycle of a Welding Power Source, is minutes in a ten minute period although the actual
a statement of the time it may be operated at its duty cycle will depend on the amperage used. If the
rated welding current output without exceeding the Welding Power Supply is used for longer than the
temperature limits of the insulation of the duty cycle or if you are welding using large welding
component parts. rods you may experience a temporary current shut
off. This is to protect the transformer inside the
This product has a rated duty cycle of 80%. The Welding Power Supply from overheating.
percentage represents the welding time in a 10
minute period for example 80% means that the Welding longer than rated duty cycle can
welding time is 8 minutes with a rest time of 2 damage gun and void the warranty.

ELECTROMAGNETIC COMPATIBILITY
WARNING. Extra precautions for person who is competent to assess whether the
Electromagnetic Compatibility may be changes will increase the risk of injury, e.g. by
required when this Welding Power allowing parallel welding current return paths which
Source is used in a domestic situation. may damage the earth circuits of other equipment.
Further guidance is given in IEC 974-13 Arc
A. Installation and Use - Users Responsibility Welding Equipment - Installation and use (under
The user is responsible for installing and using the preparation).
welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are B. Assessment of Area
detected then it shall be the responsibility of the Before installing welding equipment, the user shall
user of the welding equipment to resolve the make an assessment of potential electromagnetic
situation with the technical assistance of the problems in the surrounding area. The following
manufacturer. In some cases this remedial action shall be taken into account:
may be as simple as earthing the welding circuit,
see Note below. In other cases it could involve 1. Other supply cables, control cables, signalling
constructing an electromagnetic screen enclosing and telephone cables; above, below and
the Welding Power Source and the work, complete adjacent to the welding equipment.
with associated input filters. In all cases, 2. Radio and television transmitters and
electromagnetic disturbances shall be reduced to receivers.
the point where they are no longer troublesome.
3. Computer and other control equipment.
Note: The welding circuit may or may nor be
earthed for safety reasons. Changing the earthing 4. Safety critical equipment, e.g. guarding of
arrangements should only be authorised by a industrial equipment.

10
 ELECTROMAGNETIC COMPATIBILITY
5. The health of people around, e.g. the use of 3. Welding Cables
pacemakers and hearing aids.
The welding cables should be kept as short as
6. Equipment used for calibration and possible and should be positioned close
measurement. together, running at or close to the floor level.
7. The time of day that welding or other activities 4. Equipotential Bonding
are to be carried out.
Bonding of all metallic components in the
8. The immunity of other equipment in the welding installation and adjacent to it should be
environment: the user shall ensure that other considered. However. Metallic components
equipment being used in the environment is bonded to the work piece will increase the risk
compatible: this may require additional that the operator could receive a shock by
protection measures. touching the metallic components and the
electrode at the same time. The operator
The size of the surrounding area to be considered should be insulated from all such bonded
will depend on the structure of the building and metallic components.
other activities that are taking place. The surround-
ing area may extend beyond the boundaries of the 5. Earthing of the Workpiece
premises.
Where the workpiece is not bonded to earth for
C. Methods of Reducing Electromagnetic electrical safety, nor connected to earth
Emissions because of it’s size and position, e.g. ship’s
hull or building steelwork, a connection
1. Mains Supply bonding the workpiece to earth may reduce
Welding equipment should be connected to emissions in some, but not all instances. Care
the mains supply according to the should be taken to prevent the earthing of the
manufacturer’s recommendations. If workpiece increasing the risk of injury to users,
interference occurs, it may be necessary to or damage to other electrical equipment.
take additional precautions such as filtering Where necessary, the connection of the work
of the mains supply. Consideration should be piece to earth should be made by direct
given to shielding the supply cable of connection to the workpiece, but in some
permanently installed welding equipment in countries where direct connection is not
metallic conduit or equivalent. Shielding should permitted, the bonding should be achieved by
be electrically continuous throughout it’s suitable capacitance, selected according to
length. The shielding should be connected to national regulations.
the Welding Power Source so that good 6. Screening and Shielding
electrical contact is maintained between the
conduit and the Welding Power Source Selective screening and shielding of other
enclosure. cables and equipment in the surrounding area
may alleviate problems of interference.
2. Maintenance of Welding Equipment Screening the entire welding installation may
The welding equipment should be routinely be considered for special applications.
maintained according to the manufacturer’s
recommendations. All access and service
doors and covers should be closed and
properly fastened when the welding equipment
is in operation.
The welding equipment should not be modified
in any way except for those changes and
adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of arc
striking and stabilising devices should be
adjusted and maintained according to the
manufacturer’s recommendations.

11
SYMBOL CHART

12
 DE SCRIPTION

1 2 3 4

12

11

13 6

10

9 8 7

1. Carry handle 8. Electrode holder

2. On/Off switch 9. Earth clamp
3. Current control knob 10. Chipping hammer and wire brush
4. Power indicator 11. Cooling fan
5. Thermal cutout indicator 12. Power lead
6. Earth clamp connection point (- negative) 13. Electrode holder connection point (+ positive)
7. Welding mask

13
 UNPACKING
CAUTION. This packaging contains If any parts are found to be missing, the machine
sharp objects. Take care when and its accessories should be returned together in
unpacking. Remove the machine, their original packaging to the retailer. Do not throw
together with the accessories supplied, from the the packaging away, keep it safe throughout the
packaging. Check carefully to ensure that the guarantee period, then recycle if possible,
machine is in good condition and account for all the otherwise dispose of it by the proper means. Do
accessories listed in this manual. Also make sure not let children play with empty plastic bags due to
that all the accessories are complete. the risk of suffocation.

ASSE MBLY
WARNING. E LE CTRIC SHOCK can kill. FITTING THE E ARTH CLAMP AND E LE CTRODE
Keep the electrode holder and cable HOLDE R
insulation in good condition. Insert the plug on the end of the earth clamp lead
into the negative (-) socket (Fig.1) and twist in a
Do not touch electrically live parts or electrode clockwise direction to secure into position.
with skin or wet clothing.
The plug on the end of the electrode holder can be
Insulate yourself from work and ground. fitted into the positive (+) socket (Fig.1) in the same
Turn the input line switch on the welder “OFF” way.
before connecting or disconnecting output
cables or other equipment.

20
A 140

Fig. 1

14
 ASSEMBLY
Note: Before carrying out any assembly or
disassembly of the unit please ensure that the unit
is not connected to the electrical supply. Round

ASSEMBLING THE WELDING MASK

B B Tab

Attach the handle to the Welding Shield by lining

A A

up the two rectangular tabs on the handle with the

corresponding holes in the welding shield and: Handle

A. press the tabs through the holes and then Welding Shield

B. slide the tabs forward from the back, locking the

(viewed from front)

round tab in place.

Insert the clear glass panel followed by the dark Fig. 2
glass panel into the recess in the shield, refer to
Fig.2 & Fig.3.
The dark panel is a certified, specific optical class,
and should not be exchanged for any other type.
The clear glass panel should be replaced when it
becomes badly pitted.
Filter Lens

WARNING! NEVER look at an electric

arc without eye protection as this can
injure the eyes permanently. ALWAYS
use a protection mask or welding helmet.
Welding Shield
(viewed from back)

Fig. 3

OPERATION
DESCRIPTION CAUTION: This manual is a basic guide
Your Welding Power Supply features a single to welding. We recommend you
phase transformer suitable for welding with an purchase a good quality publication on
alternating current using stick electrodes with welding or if you have internet access visit one of
diameters from 1.6mm to 5mm. The welding cur- the numerous welding related web sites to be able
rent is regulated by using the welding current con- to use the welding power supply to its full potential.
trol (regulator).
THE QUALITY OF ANY WELDED JOINT IS
ELECTRODE SELECTION DEPENDANT ON THE PREPARATION OF THE
The pages of this manual are restricted to the basic JOINT THE SELECTION OF THE CORRECT
safe use of an MMA welding power supply and very ELECTRODE AND THE SKILL AND
basic welding technique. The electrodes used in EXPERIENCE OF THE WELDER.
MMA welding are many and varied. You are
advised to seek advise from your local welding Ensure the Welding Power Supply is disconnected
equipment supplier for the correct selection of from the mains supply.
electrode for the work being performed. Ensure that the area of the work piece where the
OPERATION earth clamp is to be connected is clean using a file
WARNING! If you have no welding or a grinder, to ensure a good electrical contact.
experience, we recommend you seek Ensure the earth lead is connected to the
training from an experienced person. workpiece, and the other lead to the electrode
holder.

15
 OPERATION
Important: Ensure also that the earth clamp is
attached to clean, solid metal. If necessary
thoroughly clean with a wire brush or similar to
guarantee a good connection.
The earth clamp must only be connected to the
work piece. The area to be welded must be clean
and free from dirt, rust, paint, grease and oil.
Insert an electrode into the electrode holder (Fig.4)
ensuring there is a good connection.
Set the amperage (see Table 1) by adjusting the
regulator (Fig.5)(A) until the desired setting is Fig. 4
reached.
The chart below is an indicator of the electrode
diameter and the corresponding welding current.
This is intended as a guide only. B

Table 1
A
Electrode Material Welding
size (mm) thickness current (A)
20
A 200

(mm)

1.6 1 - 1.6 25 - 40

2.0 1.6 - 2.6 40 - 70 Fig. 5

2.5 2.6 - 4.0 60 - 100

3.2 3.0 - 5.0 80 - 130

4.0 5.0 - 7.0 130 - 170

5.0 7.0 - 9.0 170 - 200

WARNING! Always wear a full welding

mask, welding gloves and protective
clothing. Wear goggles while chipping
slag.
Do not switch on the power supply until you are Fig. 6
ready to start welding. Practice welding on a piece
of scrap material. normally occurs when the duty cycle of the
machine has been exceeded. Leave the machine
Connect to the mains supply and press the On/Off on to allow the internal components to cool. When
switch (Fig.6) to the ON position (l) The power the indicator turns off, normal operation is again
indicator lamp on the front panel (Fig.5)(B) will possible.
illuminate. To stop the machine, press the On/Off
switch to the OFF position (0).
Note: If the machine stops at any time and the
thermal cut out indicator on the front panel
illuminates, the thermal cutout has intervened.
This indicator will turn on when the machine is
overheated and the output has been disabled. This

16
 STICK (MMAW) BASIC WELDING TECHNIQUE
A WORD TO BEGINNERS
For those who have not yet done any welding, the
simplest way to commence is to run beads on a
piece of scrap plate. Use mild steel plate about
6.0mm thick and a 3.2mm electrode. Clean any 2mm
paint, loose scale or grease off the plate and set it
firmly on the work bench so that welding can be
carried out in the downhand position. Make sure
that the work clamp is making good electrical
contact with the work, either directly or through the
work table. For light gauge material, always clamp
the work lead directly to the job, otherwise a poor
circuit will probably result. Fig. 7
THE WELDER
Place yourself in a comfortable position before
beginning to weld. Get a seat of suitable height and 20º-30º
do as much work as possible sitting down. Don't
tense your body. Relax and you will find that the job
becomes much easier. Wear a leather apron and
gauntlets. This will protect you from being burnt or
sparks setting alight to your clothes.
Place the work so that the direction of welding is
across, rather than to or from, your body. The
electrode holder lead should be clear of any
obstruction so that you can move your arm freely Fig. 8
along as the electrode burns down. If the lead is
If the electrode is not withdrawn quickly enough
slung over your shoulder, it allows greater freedom
once the arc is primed, there is a possibility that the
of movement and takes a lot of weight off your
electrode will weld itself to the workpiece. Should
hand. Be sure the insulation on your cable and
this happen, give it a sharp tug to free it, and try
electrode holder is not faulty, otherwise you are
again. If this fails to free it, turn off the machine
risking an electric shock.
immediately as it will quickly overheat.
STRIKING THE ARC
If you withdraw the electrode too far once the arc is
Holding a face mask in front of your face stroke the
primed, you will lose the arc and have to try again.
electrode point on the workpiece as if striking a
match. Inspect the job carefully. With a correct
combination of electrode size and current setting
Maintain a steady gap between the end of the
the area of weld should be complete fusion of the
electrode and the workpiece of approximately 2mm
electrode and parent metal/s. Any slag which forms
(Fig.7).
on the surface should be chipped away with the
Maintain this distance as constantly as possible pick/brush supplied.
during the weld remember that the angle of the
If the resultant weld looks messy and irregular, this
electrode to the work piece must be 20-30° (Fig.8).
is an indication of porosity or slag contamination,
Do not hit the electrode on the workpiece as this and you have almost certainly failed to achieve the
may damage the electrode. Withdraw with a clean correct combination. This is a common problem, so
movement at the end of the welding run. do not worry as practice will quickly cure this.

Note: This is the most difficult aspect for most

beginners. It is recommended that you practice on
some scrap material in order to get a feel of the
operation.

17
 STICK (MMAW) BASIC WELDING TECHNIQUE
ARC LENGTH
The securing of an arc length necessary to produce
a neat weld soon becomes almost automatic. You
will find that a long arc produces more heat. A very 7mm
long arc produces a crackling or spluttering noise
and the weld metal comes across in large, irregular
blobs. The weld bead is flattened and spatter
increases. A short arc is essential if a high quality 2-3mm
weld is to be obtained although if it is too short
there is the danger of it being blanketed by slag
and the electrode tip being solidified in. If this
should happen, give the electrode a quick twist
back over the weld to detach it. Contact or "touch- Fig. 9
weld" electrodes do not stick in this way, and make
welding much easier. 60º
RATE OF TRAVEL
After the arc is struck, your next concern is to >30mm
maintain it, and this requires moving the electrode
tip towards the molten pool at the same rate as it is
melting away. At the same time, the electrode has 2-3mm
to move along the plate to form a bead. The 5 6
electrode is directed at the weld pool at about 20º 4
3
2
from the vertical. The rate of travel has to be
1
adjusted so that a well-formed bead is produced. If
the travel is too fast, the bead will be narrow and
strung out and may even be broken up into
Fig. 10
individual globules. If the travel is too slow, the
weld metal piles up and the bead will be too large. 60º
MAKING WELDED JOINTS
Having attained some skill in the handling of an >30mm
electrode, you will be ready to go on to make up
welded joints.
2-3mm
When welding material up to 7mm in thickness
place the pieces 2-3mm apart, run the welding
bead along the join. A second bead can go along
the underside for extra strength (Fig.9).
When welding material from 7mm to 30mm thick Fig. 11
prepare the material as shown in Fig.10 filling up
the space with several layers of weld. THE MANUAL METAL ARC PROCESS
When an arc is struck between the metal rod
When welding together material over 30mm in (electrode) and the workpiece, both the rod and
thickness prepare the material as shown in Fig.11 workpiece surface melt to form a weld pool.
filling up the space with several layers of weld, Simultaneous melting of the flux coating on the rod
welding each side in turn with each welding pass. will form gas and slag which protects the weld pool
from the surrounding atmosphere. The slag will
Disconnect the Welding Power Supply from the
solidify and cool and must be chipped off the weld
mains supply before changing or removing
bead once the weld run is complete (or before the
electrodes. Use pliers to remove used electrodes
next weld pass is deposited). The process allows
from the electrode holder or to move the welded
only short lengths of weld to be produced before a
pieces.
new electrode needs to be inserted in the holder.

18
 STICK (MMAW) BASIC WELDING TECHNIQUE
Weld penetration is low and the quality of the weld Basic electrodes contain a high proportion of
deposit is highly dependent on the skill of the calcium carbonate (limestone) and calcium fluoride
welder. (fluorspar) in the coating. This makes their slag
coating more fluid than rutile coatings - this is also
TYPES OF FLUX/ELECTRODES fast-freezing which assists welding in the vertical
Arc stability, depth of penetration, metal deposition and overhead position. These electrodes are used
rate and positional capability are greatly influenced for welding medium and heavy section fabrications
by the chemical composition of the flux coating on where higher weld quality, good mechanical
the electrode. Electrodes can be divided into three properties and resistance to cracking (due to high
main groups: restraint) are required.
• Cellulosic Features:
• Rutile • Low hydrogen weld metal

• Basic • Requires high welding currents/speeds

Cellulosic electrodes contain a high proportion of • Poor bead profile (convex and coarse surface
cellulose in the coating and are characterised by a profile)
deeply penetrating arc and a rapid burn-off rate • Slag removal difficult
giving high welding speeds. Weld deposit can be
coarse and with fluid slag, deslagging can be Iron powder electrodes contain an addition of
difficult. These electrodes are easy to use in any metal powder to the flux coating to increase the
position and are noted for their use in the stovepipe maximum permissible welding current level. Thus,
(vertical down position) welding technique. for a given electrode size, the metal deposition rate
and efficiency (percentage of the metal deposited)
Features: are increased compared with an electrode
• Deep penetration in all positions containing no iron powder in the coating. The slag
• Suitability for vertical down welding is normally easily removed. Iron powder electrodes
are mainly used in the flat and horizontal/vertical
• Reasonably good mechanical properties positions to take advantage of the higher
deposition rates. Efficiencies as high as 130 to
• High level of hydrogen generated - risk of
140% can be achieved for rutile and basic
cracking in the heat affected zone
electrodes without marked deterioration of the
Rutile Electrodes contain a high proportion of arcing characteristics but the arc tends to be less
titanium oxide (rutile) in the coating. Titanium oxide forceful which reduces bead penetration.
promotes easy arc ignition, smooth arc operation
CARE OF ELECTRODES
and low spatter. These electrodes are general
The quality of weld relies upon consistent
purpose electrodes with good welding properties.
performance of the electrode. The flux coating
They can be used with AC and DC power sources
should not be chipped, cracked or, more
and in all positions. The electrodes are especially
importantly, allowed to become damp.
suitable for welding fillet joints in the horizontal/
vertical position. DRYING OF ELECTRODES
Drying is usually carried out following the
Features: manufacturer's recommendations and
• Moderate weld metal mechanical properties requirements will be determined by the type of
electrode.
• Good bead profile produced through the
viscous slag

• Positional welding possible with a fluid slag

(containing fluoride)

• Easily removable slag

19
 STICK (MMAW) WELDING TROUBLESHOOTING
Problem Possible Cause Remedy
Welding current Control knob is set at a value that Reduce the control knob until welding
varying. causes the welding current to vary current is reasonably constant while
excessively with the arc length. prohibiting the electrode from sticking
to the workpiece when you “dig” the
electrode into the workpiece.

A gap is left by failure of Welding current too low. Increase welding current.
the weld metal to fill the
root of the weld. Electrode too large for joint. Use smaller diameter electrode.

Insufficient gap. Allow wider gap.

Non-metallic particles Non-metallic particles may be If a bad undercut is present clean slag
are trapped in the weld trapped in undercut from previous bout and cover with a run from a
metal. run. smaller gauge electrode.

Joint preparation too restricted. Allow for adequate penetration and

room for cleaning out the slag.

Irregular deposits allow slag to be If very bad, chip or grind out

trapped. irregularities.

Lack of penetration with slag Use smaller electrode with sufficient

trapped beneath weld bead. current to give adequate penetration.
Use suitable tools to remove all slag
from corners.

Rust or mill scale is preventing Clean joint before welding.

full fusion.

Wrong electrode for position in Use electrodes designed for position in

which welding is done. which welding is done, otherwise
proper control of slag is difficult.

A groove has been Welding current is too high. Reduce welding current.
formed in the base
metal adjacent to the Welding arc is too long. Reduce the length of the welding arc.
toe of a weld and has
not been filled by the Angle of the electrode is incorrect. Electrode should not be inclined less
weld metal (undercut). than 45° to the vertical face.
Joint preparation does not allow
correct electrode angle. Allow more room in joint for
manipulation of the electrode.
Electrode too large for joint.
Use smaller gauge electrode.
Insufficient deposit time at edge of
weave. Pause for a moment at edge of weave
to allow weld metal buildup.

20
 STICK (MMAW) WELDING TROUBLESHOOTING
Problem Possible Cause Remedy
Portions of the weld run Small electrodes used on heavy Use larger electrodes and preheat the
do not fuse to the cold plate. plate.
surface of the metal or
edge of the joint. Welding current is too low. Increase welding current.

Wrong electrode angle. Adjust angle so the welding arc is

directed more into the base metal.

Travel speed of electrode is too Reduce travel speed of electrode.

high.

Scale or dirt on joint surface. Clean surface before welding.

Gas pockets or voids in High levels of sulphur in steel. Use an electrode that is designed for
weld metal (porosity). high sulphur steels.

Electrodes are damp. Dry electrodes before use.

Welding current is too high. Reduce welding current.

Surface impurities such as oil, Clean joint before welding.

grease, paint, etc.

Welding in a windy environment. Shield the weld area from the wind.

Electrode damaged ie. flux Discard damaged electrodes and only

coating incomplete. use electrodes with a complete flux
coating.

Crack occurring in weld Rigidity of joint. Redesign to relieve weld joint of

metal soon after severe stresses or use crack
solidification resistance electrodes.
commences.
Insufficient throat thickness. Travel slightly slower to allow greater
build up in throat.

Weld current is too high. Decrease welding current.

Excessive spatter Improper welding polarity Make sure the electrode holder is
plugged into the positive “+” output
terminal.

Long Arc Length. Move the electrode closer into the

weld joint.

Weld current is too high. Decrease welding current.

21
 MAINTENANCE
WARNING. ELECTRIC SHOCK can kill. If the supply cord requires replacing, the task must
Have an electrician install and service be carried out by the manufacturer, the
this equipment. manufacturer’s agent, or an authorised service
centre to avoid a safety hazard.
Turn the input power off at the fuse box, disconnect
supply lines and allow machine to sit for five WELDING MASK MAINTENANCE
minutes minimum to allow the power capacitors to Always maintain your welding mask in good
discharge before working inside this equipment. condition. If the clear glass protection lens be-
comes badly pitted, sufficient to interfere with vi-
Do not touch electrically hot parts. sion, or cracked, have it replaced immediately.
WARNING. Do not open this machine NEVER use any dark filter lens other than that
and do not introduce anything into its provided by RYOBI, or one with the same certified
openings. Power supply must be ‘Optical class’ (degree of protection).
disconnected from the machine before each
maintenance and service. After each repair, The shield should always be cleaned with a clean
perform proper tests to ensure safety. soft cloth after use, ensuring the lenses are clean.
Remove any dust that may have accumulated and
CAUTION. The power supply must be store it in a safe place where it cannot be
disconnected from the machine before damaged.
each maintenance and service. Always
use gloves in compliance with the safety NEVER use a shield that is not in perfect condition.
standards.
ELECTRODE STORAGE
ROUTINE MAINTENANCE Electrodes should always be kept in a dry and
The welder must be kept clean and dry at all times. well-ventilated store. It is good practice to stack
Use a dry cloth to clean the welder. packets of electrodes on wooden pallets or racks
well clear of the floor. Also, all unused electrodes
Keep the electrodes clean and dry and ensure all which are to be returned should be stored so they
cables are in good condition. are not exposed to damp conditions to regain
Keep the louvre passages clean to avoid a build up moisture. Good storage conditions are 10°C above
of dirt and oxides inside the machine, which can external air temperature. As the storage conditions
reduce machine output. are to prevent moisture from condensing on the
electrodes, the electrode stores should be dry
The nozzle will occasionally need to be cleaned of rather that warm. Under these conditions and in
spatter from welding. Clean it with a metal brush. original packaging, electrode storage time is
When the nozzle deteriorates or can no longer be practically unlimited. It should be noted that
cleaned, it will need to be replaced. Unscrew the electrodes are now available in hermetically sealed
nozzle and replace it with a new one. packs which obviate the need for drying. However,
if necessary, any unused electrodes must be
Always try to avoid getting particles of metal inside
redried according to manufacturer's instructions.
the machine since they could cause short circuits.
Periodically clean the inside of the welder with
compressed air, ensuring you wear a mask during
the operation.
Caution: Water must never come into contact with
the welder.
Regularly check the general condition of the tool.
Check for loose screws, misalignment or binding of
moving parts, cracked or broken parts, damaged
electrical wiring, and any other condition that may
affect its safe operation.

22
 TROUBLESHOOTING
DANGER! Follow all safety precautions whenever diagnosing or servicing the tool. Dis
connect power supply before service.

Problem Possible Cause Remedy

The welding arc cannot The primary supply voltage has not Switch ON the primary supply voltage.
be established. been switched ON.

The welding power source Switch ON the welding power source.

switch is switched OFF.

Loose connections internally. Have an qualified service technician

repair the connection.

Maximum output Defective control circuit. Have an qualified service technician in-
welding current cannot spect then repair the welder.
be achieved with
nominal mains supply
voltage.

Welding current Bad work clamp to workpiece Ensure that the work lead has a
reduces when welding. connection. positive electrical connection to the
work piece.

Welder will not start. No power at outlet. Check power at outlet.

Cord not connected. Check that cord is plugged in.

Line voltage incorrect. Make sure the welder is plugged into a

230V electrical outlet.

No weld output with Weld cable loose. Tighten weld cable connection at
ready light on. welder.

Bad work clamp to workpiece con- Make sure the area where the clamp is
nection. attached is clean, exposed metal; free
of dirt, paint and oil.

No weld output; high Welder overheated. Allow unit to cool with the fan on.
temperature light on.
Duty cycle or amps too high. Reduce duty cycle or amps.

Airflow is blocked. Clean vents and fan out with

compressed air.

Fan not operating. Fan blocked/dirty. Remove obstruction and clean with
compressed air.
Fan broken.
Have the fan replaced by a qualified
service technician.

23
 TROUBLESHOOTING
Problem Possible Cause Remedy
Erratic or improper arc Bad weld connections. Clean and tighten weld connections.
or welding output.
Polarity incorrect. Connect polarity correctly.

Workpiece painted or dirty. Clean workpiece thoroughly.

Nozzle obstructed by welding Clean or replace nozzle.

spatter.

Main supply fuse shuts Circuit Breaker rating is too low. Install a circuit breaker rated for
off frequently. greater than ?? Amps.

SYMBOLS
Some of the following symbols may be used on this tool. Please study them and learn their meaning.
Proper interpretation of these symbols will allow you to operate the tool better and safer.
SYMBOLS DESIGNATION/EXPLANATION

Conforms to relevant safety standards.

To reduce the risk of injury, the user must read and understand the operator’s manual before
using this product.

Warning! Electrical welding process.

Do not use this welder in damp conditions.

Protect operator and passerby from the effect of uV radiation. This can cause permanent
damage to the eye. Make sure the arc and resulting flash is shielding at all times.

Waste electrical products should not be disposed of with household waste. Please recycle
where facilities exist. Check with your Local Authority or retailer for recycling advice.

Keep bystanders and pets clear of the welding power supply when in use.

Always wear approved face mask with correct filter, gloves and apron to protect against
welding operation.

24
 SYMBOLS
Symbols and Technical Data

EN 60974-1 European standard relating to Welding Power Supply’s for limited use

MMA-140 Type ID

Single phase transformer

Symbol for manual arc welding and covered electrodes

50Hz Nominal mains frequency

Ø Diameter of electrodes

U0 No load voltage

…A/…V to …A/…V Range of output

X% Duty cycle

I2 Conventional welding current

U2 Conventional load voltage

U1 Mains voltage

I1 max Maximum absorbed current

I1 eff Effective supply current

IP21S Grade of protection

Standardised plug

S Suitable for welding in an environment with increased hazard of electric shock

25
NOTES

26
NOTES

27