Impax IM-MIG120 Instruction Manual
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DECLARATION OF CONFORMITY 1. Product model: IM-MIG120 2. Name and address of the manufacturer or his authorised representative: NAP BRANDS LTD. Office 20, Fleming Court Business Centre, Leigh Road, Eastleigh, Hampshire SO50 9YN Tel: +44 (0)23 8064 9650. Email: [email protected] 3. This declaration of conformity is issued under the sole responsibility of the manufacturer. 4. Object of the declaration: Equipment: 120A MIG Welder Brand name: IMPAX Model/type: IM-MIG120 5. The object of the declaration described above is in conformity with the relevant statutory requirements: Supply of Machinery (Safety) Regulations 2008 Electrical Equipment (Safety) Regulations 2016 Electromagnetic Compatibility Regulations 2016 The Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012 6. References to the relevant designated standards used or references to the other technical specifications in relation to which conformity is declared: BS EN IEC 60974-1 BS EN IEC 60974-10 EN IEC 60974-1 EN IEC 60974-10 7. The person authorized to compile the technical file: Name: Robert Redfern Address: Nap Brands Ltd. Office 20, Fleming Court Business Centre, Leigh Road, Eastleigh, Hampshire SO50 9YN Signed for and on behalf of: Authorised Representative Robert Redfern, Technical Manager 03/03/2022 After sales support: Tel: 0344 264 2485 Website: www.impaxpowertools.com 22 120A MIG WELDER IM-MIG120 Always Read Instruction Manual Retain for Future Reference CERTIFICATE OF GUARANTEE This product is guaranteed for a period of 1 Year, with effect from the date of purchase and applies only to the original purchaser. This guarantee only applies to defects arising from, defective materials and or faulty workmanship that become evident during the guarantee period only and does not include consumable items. The manufacturer will repair or replace the product at their discretion subject to the following. That the product has been used in accordance with the guidelines as detailed in the product manual and that it has not been subjected to misuse, abuse or used for a purpose for which it was not intended. That it has not been taken apart or tampered with in any way whatsoever or has been serviced by unauthorised persons or has been used for hire purposes. Transit damage is excluded from this guarantee, for such damage the transport company is responsible. Claims made under this guarantee must be made in the first instance, directly to the retailer within the guarantee period. Only under exceptional circumstances should the product be returned to the manufacturer. In this case it shall be the consumer’s responsibility to return the product at their cost ensuring that the product is adequately packed to prevent transit damage and must be accompanied with a brief description of the fault and a copy of the receipt or other proof of purchase. The manufacturer shall not be liable for any special, exemplary, direct, indirect, incidental, or consequential loss or damage under this guarantee. This guarantee is in addition to and does not affect any rights, which the consumer may have by virtue of the Sale of Goods Act 1973 as amended 1975 and 1999. INTRODUCTION Thank you for purchasing this product which has passed through our extensive quality assurance process. Every care has been taken to ensure that it reaches you in perfect condition. However, in the unlikely event that you should experience a problem, or if we can offer any assistance or advice please do not hesitate to contact our customer care department. For details of your nearest customer care department please refer to the telephone numbers at the back of this manual. Safety First Before attempting to operate this product the following basic safety precautions should always be taken to reduce the risk of fire, electric shock and personal injury. It is important to read the instruction manual to understand the application, limitations and potential hazards associated with this product. HELPLINE & SPARE PARTS In the unlikely event of a defect occurring please contact our Helpline. Office hours: Monday - Friday 9:00am – 5:00pm. Telephone Number 0344 264 2485 2 SAFETY INFORMATION Your safety and the safety of others are very important. We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word “DANGER” or “WARNING.” These words mean: DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE is used to address practices not related to personal injury. CAUTION CAUTION, without the safety alert symbol, is used to address practices not related to personal injury. All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed. Before attempting to operate the machine, it is essential that you read this manual thoroughly and carefully follow all instructions given. In doing so you will ensure the safety of yourself and that of others around you, and you can also look forward to the welder giving you long and satisfactory service. access visit one of the numerous welding related web sites to be able to use the welding power supply to its full potential. The electrodes used in welding are many and varied. You are advised to seek advice from your local welding equipment supplier for the correct selection of wire electrode for the work being performed. Important Warning! If you have no welding experience, we recommend you seek training from an experienced person. THE QUALITY OF ANY WELDED JOINT IS DEPENDANT ON THE PREPARATION OF THE JOINT THE SELECTION OF THE CORRECT WIRE ELECTRODE AND THE SKILL AND EXPERIENCE OF THE WELDER. Caution: The pages of this manual are restricted to the basic safe use of a MIG welding power supply and very basic welding technique. We recommend you purchase a good quality publication on welding or if you have internet 3 SAFETY INFORMATION General Welding Safety installed or improperly grounded equipment is a hazard. The Workshop Environment Housekeeping is extremely important to avoid injury from slips, trips and falls, damage to equipment and fire. The work area should be kept clean and tidy at all times. Combustible materials must not be discarded or stored in the vicinity of the welding area. 1. Do not touch live electrical parts. 2. Wear dry, hole-free insulating gloves and body protection. 3. Insulate yourself from work and ground using dry insulating mats or covers. Avoid using your welder in the vicinity of: 4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally. a) other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the welding equipment; b) radio and television transmitters and receivers; 5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. c) computer and other control equipment; d) safety critical equipment, e.g. guarding of industrial equipment; 6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service. e) pacemakers and hearing aids etc.; 7. f) equipment used for calibration or measurement; g) other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures; Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode. 8. Do not use worn, damaged, undersized, or poorly spliced cables. It may be possible to avoid the above by changing the time of day that welding or other activities are to be carried out. 9. Do not wrap cables around your body. 10. Ground the workpiece to a good electrical (earth) ground. The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. 11. Do not touch electrode while in contact with the work (ground) circuit. 12. Use only well-maintained equipment. Repair or replace damaged parts at once. Electrical Safety Electric Shock Can Kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and 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 welding wire are electrically live. Incorrectly 13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output. 14. Wear a safety harness to prevent falling if working above floor level. 15. Keep all panels and covers securely in place. 4 SAFETY INFORMATION Shock Prevention Exposed live conductors or other bare metal in the welding circuit, or in unearthed, electricallyLIVE equipment can fatally shock a person whose body becomes a conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding, without suitable protection. Electrode Holders Fully insulated electrode holders should be used. Do NOT use holders with protruding screws or with any form of damage. Connectors Fully insulated lock-type connectors should be used to join welding cable. Cables Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable. Keep cable dry, free of oil and grease, and protected from hot metal and sparks. Protection for Wearers of Pacemakers Magnetic fields from high currents can affect pacemaker operation. Persons wearing electronic life support equipment (pacemaker) should consult with their doctor before going near arc welding, gouging, or spot welding operations. To Prevent Against Shock Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when dampness or sweat can not be avoided. Sweat, sea water, or moisture between body and an electrically LIVE part - or earthed metal - reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body. Terminals And Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation. Electrode Equipment With Output On/Off Control (Contactor) Welding power sources for use with the gas metal arc welding, gas tungsten arc welding and similar processes normally are equipped with devices that permit on/off control of the welding power output. When so equipped the electrode wire becomes electrically LIVE when the power source switch is ON and welding gun switch is closed. Never touch the electrode wire or any conducting object in contact with the electrode circuit unless the welding power source is off. Earthing the Equipment When arc welding equipment is earthed according to the National Electrical Code, and the workpiece is earthed, a voltage may exist between the electrode and any conducting object. Examples of conducting objects include, but are not limited to, buildings, electrical tools, work benches, welding power source cases, workpieces, etc. Equipment Without Output On/Off Control (No Contactor) Welding power sources used with shielded metal arc welding and similar processes may not be equipped with welding power output on/off control devices. With such equipment the electrode is electrically LIVE when the power switch is turned ON. Never touch the electrode unless the welding power source is off. Never touch the electrode and any metal object unless the welding power source is off. When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building earth. Conductors must be adequate to carry earth currents safely. Equipment made electrically LIVE by stray current may shock, possibly fatally. Do NOT EARTH to electrical conduit, or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel. 5 SAFETY INFORMATION Changing Electrodes The electrode holder should be isolated when changing the electrode, where a work piece is earthed. If the electrode is changed without isolating the electrode holder, the welder is relying on the insulation properties of the glove to avert shock from the OCV (Open Circuit Voltage) which can be 80V between the electrode and earth. If the glove is wet, the electrode a bad insulator or the welder in contact with a conductive surface, one or more of these layers of insulation may be ineffective. produced in the arc, such as ozone or oxides of nitrogen, and decomposition products from any paint or coating which was on the metal surface. The nature and quantity of this fume depends critically upon the welding process, the materials and the welding parameters. Severe discomfort, illness or death can result from fumes, vapours, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation. NEVER ventilate with oxygen. Lead, cadmium, zinc, mercury and beryllium, bearing materials, when welded (or cut) may produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an airsupplied respirator. For beryllium, both must be used. Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator. Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator. Vapours from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapours to form phosgene. DO NOT WELD or cut where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene. Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out. Before installation, inspection, or service of equipment, shut OFF all power and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Do not open power circuit or change polarity while welding. If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing. Always shut OFF and disconnect all power to equipment. Power disconnect switch must be available near the welding power source. Checking the Equipment Check that the equipment is suitable for the operation and connected in accordance with the manufacturer's recommendations. The welder is responsible for checking the equipment (cable, electrode holder and coupling devices) daily for damage and defects. All external connections should be clean and tight and checked each time a reconnection is made. The welding return clamp should be connected directly to the work piece, as close as possible to the point of welding or to the metal work bench on which the work piece is placed. Any damaged or defective parts must be replaced before continuing the welding operation. 1. Keep your head out of the fumes. Do not breath the fumes. 2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. Fumes And Gases The welding process vapourises metals, and anything that is resting on the surface. This gives rise to fumes, which is condensed fine particulate material. The fume is mostly oxides of the metals, including any alloying elements, but it also contains gases 3. If ventilation is poor, use an approved airsupplied respirator. 4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners. 6 SAFETY INFORMATION 5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot be moved, move combustibles at least 10M, away out of reach of sparks and heat; or protect against ignition with suitable and snug fitting, fireresistant covers or shields. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe. Walls, ceilings, and floor near work should be protected by heat resistant covers or shields. Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if: 6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. 7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. a) appreciable combustibles (including building construction) are within 10m. b) appreciable combustibles are further than 10m but can be ignited by sparks. c) openings (concealed or visible) in floors or walls within 10m can expose combustibles to sparks. Noise d) combustibles adjacent to walls, ceilings, roofs or metal partitions can be ignited by radiant or conducted heat. Welding environments are frequently noisy as other operations such as grinding, etc. may also be taking place. Some operations, such a deslagging may take the noise up to such a level where it will damage hearing. In such cases hearing protection must be used. After work is done, check that area is free of sparks, glowing embers, and flames. An empty container that held combustibles, or that can produce flammable or toxic vapours when heated, must never be welded on or cut, unless container has first been cleaned. This includes a thorough steam or caustic cleaning (or a solvent or water washing, depending on the combustible’s solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment. Fire and Explosion Prevention Causes of fire and explosion are: 1) combustibles reached by the arc, flame, flying sparks, hot slag or heated material; 2) misuse of compressed gases and cylinders; 3) short circuits. Water filling just below working level may substitute for inerting. BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks and slag can fly 10M. A container with unknown contents should be cleaned (see paragraph above), do NOT depend on sense of smell or sight to determine if it is safe to weld or cut. To prevent fires and explosion: keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits. Hollow castings or containers must be vented before welding or cutting - they can explode. In explosive atmospheres, never weld or cut where the air may contain flammable dust, gas, or liquid vapours. If combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. 7 SAFETY INFORMATION Cylinders Can Explode If Damaged Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. through small cracks and openings to adjacent areas. 5. Watch for fire, and keep a fire extinguisher nearby. 6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. 1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs. 7. 2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping. Do not weld on closed containers such as tanks or drums. 8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. 3. Keep cylinders away from any welding or other electrical circuits. 9. Do not use welder to thaw frozen pipes. 4. Never allow a welding electrode to touch any cylinder. 10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. 5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. 11. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 6. Turn face away from valve outlet when opening cylinder valve. Moving Parts Can Cause Inury Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing. 7. Keep protective cap in place over valve except when cylinder is in use or connected for use. Welding Can Cause Fire Or Injury Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire. 1. Keep all doors, panels, covers, and guards closed and securely in place. 2. Stop engine before installing or connecting unit. 3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. 1. Protect yourself and others from flying sparks and hot metal. 4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery. 2. Do not weld where flying sparks can strike flammable material. 5. Keep hands, hair, loose clothing, and tools away from moving parts. 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. 6. Reinstall panels or guards and close doors when servicing is finished and before starting engine. 4. Be alert that welding sparks and hot materials from welding can easily go 8 SAFETY INFORMATION Sparks Can Cause Battery Gases To Explode SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin. Batteries contain acid and generate explosive gases. Falling Unit Can Cause Injury 1. Lift unit with handle on top of case. 1. Always wear a face shield when working on a battery. 3. If using a fork lift vehicle, place and secure unit on a proper skid before transporting. 2. Stop engine before disconnecting or connecting battery cables. Optical Radiation The welding process produces a large quantity of visible light, ultraviolet and infrared. Exposure to the radiation from an arc causes damage to the eyes (Arc Eye). For this reason, welders need to wear efficient eye protection, which is usually supplied in the form of a protective shield. 2. Use handcart or similar device of adequate capacity. 3. Do not allow tools to cause sparks when working on a battery. 4. Do not use welder to charge batteries or jump start vehicles. 5. Observe correct polarity (+ and –) on batteries. The precise choice of the shade of glass filter in these shields depends on the type of welding operation, since they vary in their light output. Flying Sparks Can Cause Injury FLYING SPARKS AND HOT METAL can cause injury. ARC RAYS can burn eyes and skin; NOISE can damage hearing. Chipping and grinding cause flying metal. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing. As welds cool, they can throw off slag. 1. Wear approved face shield or safety goggles. Side shields recommended. 1. Wear a welding helmet fitted with a proper shade of filter (ANSI Z49.1) to protect your face and eyes when welding or watching. 2. Wear proper body protection to protect skin. Steam And Pressurised Hot Coolant Can Burn STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin. 2. Wear approved safety glasses. Side shields recommended. Never wear contact lenses while welding. The coolant in the radiator can be very hot and under pressure. 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. 1. Do not remove radiator cap when engine is hot. Allow engine to cool. 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. 2. Wear gloves and put a rag over cap area when removing cap. 5. Use approved ear plugs or ear muffs if noise level is high 3. Allow pressure to escape before completely removing cap. 9 SAFETY INFORMATION 10 SAFETY INFORMATION H.F. Radiation Can Cause Interference 1. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. 7. 8. Connect the work cable to the workpiece as close as possible to the area being welded. 2. Have only qualified persons familiar with electronic equipment install, test, and service H.F. producing units. 9. Do not work next to welding power source. For Electrically Powered Equipment 1. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 3. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. 4. If notified by the FCC about interference, stop using the equipment at once. 2. Install equipment in accordance with the countries National Electrical Code, all local codes and the manufacturer’s recommendations. 5. Have the installation regularly checked and maintained. 6. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. 3. Ground the equipment in accordance with the countries National Electrical Code and the manufacturer’s recommendations. Electric And Magnetic Fields May Be Dangerous 1. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines 2. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding. 3. Exposure to EMF fields in welding may have other health effects which are now not known. Hot Parts Can Cause Severe Burns 1. Do not touch hot parts bare handed. 2. Allow cooling period before working on welding gun or torch. Fire Or Explosion Hazard 1. Do not place unit on, over, or near combustible surfaces. 2. Do not service unit near flammables. Static Can Damage PC Boards 1. Put on grounded wrist strap BEFORE handling boards or parts. 2. Use proper static-proof bags and boxes to store, move, or ship PC boards. 4. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 5. Route the electrode and work cables together - Secure them with tape when possible. 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 on your right side. Overuse Causes Overheating 1. Allow cooling period; follow rated duty cycle. 2. Reduce current or reduce duty cycle before starting to weld again. 6. Never coil the electrode lead around your body. 3. Do not block or filter airflow to unit. 11 SAFETY INFORMATION Specific Safety Instructions Use the welding power supply as indicated in the instruction manual. Improper use of this welding power supply can be dangerous for persons, animals or objects. Do not weld on containers or pipes that hold or have held flammable liquid or gases (danger of explosion) or on materials cleaned with chlorinated solvents or on varnished surfaces (danger of toxic fumes). The user of the welding power supply is responsible for his own safety and the safety of others. It is important to read and understand this instruction manual. Remove all flammable materials from the work area. Repair and maintenance must be carried out by qualified persons. Maintain the machine in good condition (keep clean and dry etc). During welding do not locate the machine in a confined space or close to a wall, which will block air outlets. Avoid stretching the supply cable, disconnect from the mains supply before moving the machine. Keep welding cables, earth clamp and electrode holder in good condition. Welders should not wear jewellery (especially rings) or metallic watch straps Appropriate clothing should be worn. Gloves, boots and overalls will provide some protection from electric shock The welder should check daily, and after each reconnection, that all external connections are clean and tight When changing the electrode, the electrode holder should be isolated When welding stops for a short time, the electrode holder should not be put on the face shield or flammable material as it may still be 'live' at 80V or hot enough to cause damage Arc welding produces fumes, sparks and fused metal projectiles. Remove all flammable substances and materials from the work area. Ensure adequate ventilation in areas where welding is being performed. Ensure there is adequate fire fighting equipment close by. Avoid direct contact with welding circuit, the OCV (Open Circuit Voltage) between the electrode and the earth clamp can be dangerous. Do not use the welding power supply in damp or wet places or weld in the rain. Always protect your eyes with an approved face mask. Use gloves and proper protective clothing which are dry and not soiled by oil or grease. Avoid exposing skin to the ultra violet rays produced by the arc. Working in the Open Air When welding outside, the equipment should have the appropriate level of waterproofing; see manufacturer's Rating Plate (IP) codes for enclosures: IP 23 protection against limited spraying IP 24 protection against spraying from all directions If there is a risk of heavy rain, a cover for the welding power supply, equipment and workpiece should be in place. Additional Safety Instructions 1. ALWAYS ensure that there is full free air circulating around the outer casing of the machine, and that the louvres are unobstructed. 2. ALWAYS use a proper welding face shield or helmet, with suitable filter lenses. Proper gloves and working clothes should be worn at all times. 3. ALWAYS check that the pressure regulator and gauges are working correctly. DO NOT lubricate the regulator. 12 SAFETY INFORMATION 4. ALWAYS use the correct regulator. Each regulator is designed to be used with a specific gas. 20. NEVER allow the cables to become wrapped around the operator or any person in the vicinity. 5. ALWAYS inspect the hose before use to ensure it is in good condition. 21. Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out. 6. ALWAYS keep the free length of gas hose outside the work area. 7. ALWAYS remove all flammable materials from the welding area. 8. NEVER remove any of the panels unless the machine is disconnected from the supply, AND never use the machine with any of the panels removed. 9. NEVER attempt any electrical or mechanical repair unless your are a qualified technician. If you have a problem with the machine contact your local IMPAX dealer. 10. NEVER use or store in a wet/damp environment. DO NOT EXPOSE TO RAIN. 11. NEVER use gas from a cylinder, the content of which is unknown. It is important to ensure the appropriate gas is being used. 12. NEVER use a damaged cylinder. 13. NEVER lift the cylinder by the valve. 14. NEVER expose the cylinder to a heat source or sparks. 15. NEVER continue to weld, if, at any time, you feel even the smallest electric shock. Stop welding IMMEDIATELY, and DO NOT attempt to use the machine until the fault is diagnosed and corrected. 22. Before installation, inspection, or service of equipment, shut OFF all power and remove line fuses to prevent accidental turning ON of power. 23. Do not open power circuit or change polarity while welding. 24. If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing. Always shut OFF and disconnect all power to equipment. Power disconnect switch must be available near the welding power source. 25. Fully insulated electrode holders should be used. Do NOT use holders with protruding screws or with any form of damage. 26. Fully insulated lock-type connectors should be used to join welding cable. 27. Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable. Keep cable dry, free of oil and grease, and protected from hot metal and sparks. 16. NEVER use the welder with input connections greater than 10M in length. 17. NEVER point the torch at any person or animal. 18. NEVER touch the torch nozzle until the welder is switched OFF and the nozzle has been allowed to cool off. 19. NEVER connect, disconnect, or attempt to service the torch, until the machine is switched OFF and disconnected from the mains supply. 13 SAFETY INFORMATION The following types of welding operation must be performed by a qualified coded welder and approved by a qualified welding inspector. • The welding of pressure vessels for liquid and gaseous substances. • The welding of pressurised pipe work for liquid and gaseous substances. • The repair of containers for flammable liquids and corrosive chemicals. • Structural support and load bearing steelwork in buildings. • Load lifting and moving equipment. • Load lifting slings, chains, hooks and shackles. • Hydraulic systems. • Any type of safety critical equipment. In addition to the above it is strongly recommended that the following welding operations are checked by a competent person. • The repair of vehicle chassis and suspension and steering components. • Vehicle load bearing attachment points ie, engine mounts seat and seat belt anchor points. • Motor Cycle frames and components. General Safety Rules Warning! Read all instructions Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term "power tool" in all of the warnings listed below refers to your mains operated welder. Save These Instructions 1) Work Area a) Keep work area clean and well lit. Cluttered and dark areas invite accidents. b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes. c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. 2) Electrical Safety a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. 3) Personal Safety a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury. b) Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. 14 SAFETY INFORMATION c) Avoid accidental starting. Ensure the switch is in the off position before plugging in. Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents. Power tools are dangerous in the hands of untrained users. e) Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tools operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury. f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts. g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of these devices can reduce dust related hazards. 4) Power Tool Use And Care a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. g) Use the power tool, accessories and tool bits etc., in accordance with these instructions and in the manner intended for the particular type of power tool, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from intended could result in a hazardous situation. 5) Service a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. c) Disconnect the plug from the power source before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. 15 INSTALLATION Environment These units are designed for use in environments with increased hazard of electric shock. A. Examples of environments with increased hazard of electric shock are: 1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts. 2. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator. 3. In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories. B. Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated. Location This machine can operate in harsh environments. However, it is important that simple preventative measures are followed to assure long life and reliable operation: • This machine must be located where there is free circulation of clean air without restrictions for air movement to and from the air vents. Do not cover the machine with paper, cloth or rags when switched on. • Dirt and dust that can be drawn into the machine should be kept to a minimum. • This machine has a protection rating of IP21S. Keep it dry and do not place it on wet ground or in puddles. Do not use in wet or damp locations. Store indoors. • Locate the machine away from radio controlled machinery. Normal operation may adversely affect the operation of nearby radio controlled machinery, which may result in injury or equipment damage. Read the section on electromagnetic compatibility in this manual. • Do not operate in areas with an ambient temperature greater than 40°C. Tilting Place the machine directly on a secure, level surface. Do not place or operate this machine on a surface with an incline greater than 15° from horizontal. The machine may topple over if this procedure is not followed. Ventilation Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated. Machine Grounding And High Frequency Interference Protection The Capacitor Discharge Circuit used in the high frequency generator, may cause many radio, TV and electronic equipment interference problems. These problems may be the result of radiated interference. Proper grounding methods can reduce or eliminate radiated interference. 1. Direct interference radiated from the welder. 2. Direct interference radiated from the welding leads. 3. Direct interference radiated from feedback into the power lines. 4. Interference from re-radiation of “pickup” by ungrounded metallic objects. Keeping these contributing factors in mind, installing equipment as per the following instructions should minimize problems. 1. Keep the welder power supply lines as short as possible and enclose as much of them as possible in rigid metallic conduit or equivalent shielding for a distance of 50 feet (15.2m). There should be good electrical contact between this conduit and the welder case ground. Both ends of the conduit should be connected to a driven ground and the entire length should be continuous. 16 INSTALLATION 2. Keep the work and electrode leads as short as possible and as close together as possible. Input Connections Be sure the voltage, phase, and frequency of the input power is as specified on the rating plate, located on the machine. Lengths should not exceed 7.6m. Tape the electrode and work leads together into one bundle when practical. WARNING 3. Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high frequency leakage. Cables with high natural rubber content better resist high frequency leakage than neoprene and other synthetic rubber insulated cables. DO NOT TOUCH live electrical parts. 4. Keep the torch in good repair and all connections tight to reduce high frequency leakage. Have a qualified electrician provide suitable input power as per national electrical codes. Make sure machine is earthed / grounded. 5. The work terminal must be connected to a ground within ten feet of the welder, using one of the following methods. Make sure fuse or circuit breaker is correct rating for machine. Using fuses or circuit breakers smaller than recommended will result in ‘nuisance’ shut off from welder inrush currents even if welding at low amperages. a) A metal underground water pipe in direct contact with the earth for ten feet or more. b) A 3/4” (19mm) galvanized pipe or a 5/8” (16mm) solid galvanized iron, steel or copper rod driven at least eight feet into the ground. The ground should be securely made and the grounding cable should be as short as possible using cable of the same size as the work cable, or larger. Grounding to the building frame electrical conduit or a long pipe system can result in re-radiation, effectively making these members radiating antennas. ELECTRIC SHOCK can kill. SIGNIFICANT DC VOLTAGE is present after removal of input power. Failure to follow these instructions can cause immediate failure within the welder and void machines warranty. Turn the input power OFF at the mains switch & fuse box before working on this equipment. Have a qualified electrician install & service this equipment. Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment. Do not touch electrically live parts 6. Keep all panels securely in place. 7. All electrical conductors within 50 ft (15.2m) of the welder should be enclosed in grounded, rigid metallic conduit or equivalent shielding. Flexible metallic conduit is generally not suitable. 8. When the welder is enclosed in a metal building, several earth driven electrical grounds connected (as in 5b above) around the periphery of the building are recommended. The IM-MIG120 Welder requires a 230V 50Hz supply. Connect wires according to national coding. Brown wire – Live Blue wire – Neutral Green/Yellow Wire – Earth (Ground) THIS MACHINE IS FITTED WITH A 13A PLUG Failure to observe these recommended installation procedures can cause radio or TV interference problems. 17 ELECTRICAL INFORMATION WARNING! THIS APPLIANCE MUST BE EARTHED Models Fitted Without Plug 230V Supply Connect the mains lead to a suitably fused 230 Volt (50Hz) electrical supply. The fuse rating should correspond to that shown on the technical specification below. Models Fitted With 13A Plug Welders fitted with a standard 13 amp BS 1363 plug, should be connected to a to a 230 volt (50Hz) domestic electrical supply and we strongly recommend that this be done via a Residual Current Device (RCD). The wires in the mains lead are coloured in accordance with the following code: IMPORTANT: If the welder is fitted with a plug which is moulded onto the electric cable (i.e. non- re-wirable) please note: Green & Yellow: Earth Blue: Neutral 1. The plug must be thrown away if it is cut from the electric cable. There is a danger of electric shock if it is subsequently inserted into a socket outlet. Brown: Live As the colours of the flexible cord of this appliance may not correspond with the coloured markings identifying terminals in your plug, proceed as follows: 2. Never use the plug without the fuse cover fitted. 3. Should you wish to replace a detachable fuse carrier, ensure that the correct replacement is used (as indicated by marking or colour code). Replacement fuse covers can be obtained from your local dealer or most electrical stockists. Fuse Rating The fuse in the plug must be replaced with one of the same rating (13 amps) and this replacement must be ASTA approved to BS1362. Technical specification Input power: Rated input capacity: Output current range: Output voltage range: Rated duty cycle: No-load voltage: Applicable electrode: Efficiency: 230V~50Hz 4.15kVA 40-120A 16-20V 20% 69V 0.8/0.9/1.0mm 85% • Connect GREEN & YELLOW cord to plug terminal marked with a letter “E” or Earth symbol “ ”, or coloured GREEN or GREEN & YELLOW. • Connect BROWN cord to plug terminal marked letter “L” or coloured RED. • Connect BLUE cord to plug terminal marked letter “N” or coloured BLACK. Case protection class: Power factor: Insulation grade: Cooling type: Fuse: External dimensions: Weight: 18 IP21S 0.68 cosφ H Fan cooling 13A 355 x 155 x 256mm 5.2kg COMPONENTS 2 1 3 4 5 7 18 19 6 8 9 10 11 12 17 13 15 16 Component List 1. Earth clamp 2. Face mask 3. Carry handle 4. Power cable 5. On/Off switch 6. Gas inlet 7. Fan 8. Digital display 9. Wire selection button (0.8, 0.9, 1.0) 10. Welding mode button (MIG/MMA/TIG) 11. Current control knob 12. Release clasp x 2 13. Welding power lead 14. Negative ‘-’ output terminal 15. Positive ‘+’ output terminal 16. MIG torch 17. Mig accessories: 1 x wrench 2 x contact tips (0.8/0.9) 2 x wire feed drive rollers (25mm OD, 7mm ID square centre, 0.8/0.9mm knurled groove) 18. Wire spool holder 19. Wire feeder 19 13 14 UNPACKING Caution! This packaging contains sharp objects. Take care when unpacking. Remove the machine, together with the accessories supplied, from the packaging. Check carefully to ensure that the machine is in good condition and account for all the accessories listed in this manual. Also make sure that all the accessories are complete. If any parts are found to be missing, the machine and its accessories should be returned together in their original packaging to the retailer. Do not throw the packaging away, keep it safe throughout the guarantee period, then recycle if possible, otherwise dispose of it by the proper means. Do not let children play with empty plastic bags due to the risk of suffocation. MMA ASSEMBLY WARNING Fig 1 ELECTRIC SHOCK can kill. Keep the electrode holder and cable insulation in good condition. 1.0 0.9 WIRE SELECTION 0.8 MIG Do not touch electrically live parts or electrode with skin or wet clothing. MMA WELDING MODE 1 A TIG 10 Insulate yourself from work and ground. Turn the input line switch on the welder “OFF” before connecting or disconnecting output cables or other equipment. IP21S enclosure protection grade, please do not operate it in rain. Output Connections Electrode polarity In general when using manual arc welding electrodes the electrode holder is connected the the positive terminal and the work return to the negative terminal. Always consult the electrode manufacturer’s data sheet if you have any doubts. Electrode Holder MMA Welding Insert the cable plug with electrode holder (not provided) into the “+” socket on the front panel of the welding machine, and tighten it clockwise. Insert the cable plug of the earth clamp into the “-” socket on the front panel of the welding machine, and tighten it clockwise (Fig.1) Earth Clamp 20 MIG ASSEMBLY (WITH GAS) MIG Welding with GAS Insert the cable plug with the earth clamp into the “-” socket on the front panel of the welding machine, and tighten it clockwise. The MIG torch is permanently attached to the connector socket on the front panel of the machine. Connect the welding power lead to the “+” socket on the front panel of the welding machine, and tighten it clockwise. Connect the gas hose to the regulator / flowmeter located on the shield gas cylinder (not supplied) and connect the other end to the gas inlet on the rear of the machine (Fig.2). Use the hose clamps to secure the gas hose. Fig 2 1.0 0.9 WIRE SELECTION 0.8 MIG MMA WELDING MODE 1 A GAS IN TIG 10 ON AC230V OFF GAS IN MIG Torch Earth Clamp 21 Gas Hose MIG ASSEMBLY (NO GAS) MIG Welding (No Gas) Insert the cable plug with the earth clamp into the “+” socket on the front panel of the welding machine, and tighten it clockwise. Connect the welding power lead to the “-” socket on the front panel of the welding machine, and tighten it clockwise, Fig.3. The MIG torch is permanently attached to the connector socket on the front panel of the machine. Fig 3 1.0 0.9 WIRE SELECTION 0.8 MIG MMA WELDING MODE 1 A GAS IN TIG 10 ON AC230V OFF GAS IN MIG Torch Earth Clamp 22 TIG ASSEMBLY TIG Welding Insert the cable plug with the earth clamp into the “+” socket on the front panel of the welding machine, and tighten it clockwise. Connect the gas hose to the regulator / flowmeter located on the shield gas cylinder and connect the other end to the machine (Fig.4). Insert the cable plug of the TIG torch (not provide) into the “-” socket on the front panel of the machine and tighten clockwise. Fig 4 1.0 0.9 WIRE SELECTION 0.8 MIG MMA WELDING MODE 1 A TIG 10 Gas Hose TIG Torch Earth Clamp 23 MIG ASSEMBLY Assembly Note: Before carrying out any assembly or disassembly of the unit please ensure that the unit is not connected to the electrical supply. Unscrew and remove the plastic knob (A), followed by the spring (B) and collar (C) from the hub, Fig.8. Fig 8 Assembling the Face Mask To assemble the mask bend in the top and side flaps (Fig.5) and clip into place then attach the handle and mask glass shield as shown in Fig.6 A B Fig 5 C Slide the spool (not provided) over the hub, ensuring that it sits snugly, and replace the collar, spring and plastic knob, tightening it sufficiently to allow the spool to rotate smoothly but with a slight amount of braking friction. Do not over tighten as this will exert undue pressure on the wire drive motor and may cause serious damage. Fig 6 Threading the Welding Wire (Fig.9) Loosen the plastic knob (A) by turning it anticlockwise, (this device maintains pressure on the wire). Installing the Welding Wire Unscrew the shroud from the end of the torch then unscrew the contact tip (Fig.7). Fig 7 Pull, on the plastic knob, so that the screw rod hinges out of its slot. This releases the pivoted pressure roller bracket (C). Raise the bracket and pull out any wire that has been left in the wire liner (D), pulling it from the nozzle end of the hose. Fig 9 C Contact tip Shroud Open up the top cover of the welder by unhooking the two latches on the sides of the machine. B A D Pull out the end of the wire from the rim of the spool, taking care NOT to release it. The spool is wound firmly and should remain this way. 24 MIG OPERATION Fig 12 Ensuring the wire is straight and not kinked in any way, clip off the end cleanly, ensuring there are no burrs or sharp edges. If it is remove the end using sharp wire cutters. Proceed to feed it through the guide tube (E), over the groove on the roller (B), and into the wire liner (D), by about 10 - 15 cm (Fig.10). Fig 10 D Holding the torch straight out from the welder press the trigger on the torch (Fig.13). The wire feed roller will operate feeding the welding wire through the torch. Fig 13 E B Reposition the pressure roller bracket (C, Fig.9) and plastic knob (A, Fig.5) and tighten slightly. Caution: Tightening the knob too tightly will crush the wire and damage the wire feed. Close the top panel of the machine and secure in place with the two latches on the sides of the machine. Plug into a 230-240V, 50HZ outlet. Turn the welder On using the On/Off switch (Fig. 11). Fig 11 Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of the torch head and nip it up tightly. Select the correct sized wire diameter by pressing the wire selection button, Fig.14. The indicator light should be illuminated next to the selected wire diameter (0.8/0.9/1.0). Fig 14 Press the MIG/MMA/TIG switch to MIG mode, Fig.12. The indicator light should be illuminated next to MIG. 25 MIG ASSEMBLY Set the amperage using the current control knob, Fig.15, based on the material thickness. Fig 15 Attaching A Gas Bottle & Regulator Fit a suitable regulator and gas supply tube onto your gas bottle (Please note; regulator, gas bottle & gas tube not supplied). Attach the other end of your gas supply tube onto the gas pipe attachment point on the back of the welder (Fig.16). Fig 16 The recommended electrode size for the fluxcord, self-shielded process is 0.8 or 0.9mm diameter spools. Flux-cord wire is excellent for single pass lap fillet and butt welding of thin guaged galvanised and mild steels. Converting To MIG Gas Welding For welding stainless steel or aluminium, it is necessary to convert your NO-GAS machine to GAS operation. This is a simple process once you have purchased the following parts: Set up the machine as per Fig.2 on page 21. Welding Wire: Either Mini or 5kg wire spools, at 0.8mm, 0.9mm & 1mm diameter. Contact Tips: The appropriate tip must be used to suit the thickness of wire being used. i.e., 0.8mm wire requires a 0.8mm tip and 1.0mm wire requires a 1.0mm tip. Note: shielding gas is not required when using flux cored welding wire. Adjusting The Gas Flow Turn the control knob on your gas regulator until the required gas flow is achieved. Set the flow rate to between 5-10L/min Installing the Welding Wire Install the welding wire as previous stated on pages 24 & 25. Plug into a 230-240V, 50HZ outlet. Turn the welder On using the On/Off switch (Fig. 17). Fig 17 Gas Regulator: Decide in advance whether you are going to use disposable or rechargable gas bottles as this will effect the type of regulator purchased. Gas: Disposable gas bottles are available from your dealer, or rechargeable bottles from your welding supply shop. Always use the appropriate gas for the material being welded. Carbon Dioxide (CO2): For Mild Steel Argon: For Aluminium CO2/Argon Mix: For Thin Sheet & Stainless Steel Press the MIG/MMA/TIG switch to MIG mode, Fig.18. The indicator light should be illuminated next to MIG. 26 MIG ASSEMBLY Fig 18 Fig 21 Holding the torch straight out from the welder press the trigger on the torch (Fig.19). The wire feed roller will operate feeding the welding wire through the torch. Set the amperage using the current control knob, Fig.22, based on the material thickness. Fig 22 Fig 19 Fit the correct sized contact tip and feed the wire through it, screw the contact tip into the tip holder of the torch head and nip it up tightly. Fit the shroud to the torch head, Fig.20. Fig 20 The recommended electrode size for the GMAW process are 0.6 or 0.8mm diameter mild and low alloy steel spools. General purpose welding wire is suitable for all positional Gas Metal Arc Welding (GMAW) of mild and low alloy steels, used in general fabrication and for welding of light to medium gauge sheet and tubular steel sections. Shroud Select the correct sized wire diameter by pressing the wire selection button, Fig.21. The indicator light should be illuminated next to the selected wire diameter (0.8/0.9/1.0). 27 MIG OPERATION MIG Operation The operation method is the same as the above MIG operation except there are no gas options and the output polarity is reversed (see pg 22). If you choose to do Gasless MIG welding, set up the welder as detailed on page 22. If you choose to do MIG welding with gas, set up the welder as detailed on page 21. WARNING! If you have no welding experience, we recommend you seek training from an experienced person. Press the MMA/TIG/MIG switch to MIG mode. CAUTION: This manual is a basic guide to welding. We recommend you purchase a good quality publication on welding or if you have internet access visit one of the numerous welding related web sites to be able to use the welding power supply to its full potential. Ensuring the standard/spool gun switch is set to standard. IMPORTANT! It is VITAL that the workpiece is perfectly clean at the point of weld. Any coating, plating or corrosion MUST be removed, otherwise a good weld will be impossible to achieve. Connect to the mains supply and press the On/Off switch to the ON position (l) to stop the machine press the switch to the OFF position (0). Fig.23. Fig 23 Select the correct sized wire diameter by pressing the wire selection button to the size you require. If using gas, the gas shield required will be either CO2 or Argon or a mix of CO2 & Argon. Use the correct gas (when required) for the material to be welded. When welding outside it may be necessary to create a windbreak as a break down in the gas shield can result in a poor weld. Important: If you are welding on a vehicle disconnect the vehicles battery or fit an electronic circuit protector. Adjust the “current control knob” on the front panel of the machine to get the correct welding current. Position the tip about 6mm from the material to be welded, hold a face mask in front of your face then press the trigger on the torch. When the arc strikes move the torch along the workpiece. WARNING! Always wear a full face mask, welding gloves and protective clothing. Wear goggles while chipping slag. Do not switch on the power supply until you are ready to start welding. Practice welding on a piece of scrap material. The workpiece must be prepared correctly and the area must be free from dirt, grease, oil, paint and rust. Position the earth clamp as close to the welding point as possible ensuring there is good contact. Maintain a steady gap between the end of the contact tip and the workpiece. Maintain this distance as constantly as possible during the weld. The position of the welding rod is critical to obtain the best result and achieve a good quality bead. The torch should be positioned 75° horizontally and 35° vertically. Make sure the gas shroud remains clear of spatter as a build up of spatter will reduce the flow / effect of the gas shield. Keep the contact tip clean to ensure smooth unrestricted wire feed. The use of an anti-spatter spray will help to ensure a good result. 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.24). 28 MIG OPERATION piece of material with the same characteristics as that of your workpiece until you are satisfied with the result, and you have fine tuned your welder to produce a satisfactory weld. Fig 24 7mm 2-3mm When welding material from 7mm to 30mm thick prepare the material as shown in Fig.25 filling up the space with several layers of weld. Fig 25 60º >30mm One of the problems experienced with novice welders, is the welding wire sticking to the contact tip. This is as a result of the wire feed speed being too slow. It is always better therefore to start with too high a speed, and back off slightly, to avoid the possibility of the wire welding itself to the tip. This is the reason position 6 is recommended for start up. The Wire Feed control is for fine tuning the wire speed. The speed of wire delivery will increase automatically as the current is increased. Therefore, once the ideal speed is achieved, by fine tuning, it should not be necessary to adjust this control when the welding current is changed. Listen to the sound made. An irregular crackling sound denotes too high a wire speed. Decrease the speed until a regular, strong buzzing sound is heard. 2-3mm 5 6 4 3 2 1 When welding together material over 30mm in thickness prepare the material as shown in Fig.26 filling up the space with several layers of weld. Fig 26 60º >30mm 2-3mm Disconnect the welder from the mains power supply before changing or removing wire reels. Use pliers to move the welded pieces as they will be extremely hot. Note: As MIG welding is an aquired skill, it is strongly advised that, if you are not fully familiar with this type of welding, you practice on a 29 MIG OPERATION Tips Try to maintain the tip of the nozzle at an angle of approx. 45º and at a constant distance of approx 5-7mm from the workpiece. shooting tips to determine if you are using a correct electrode. Try to maintain a constant speed of movement with the torch. a. The bead will lay smoothly over the work without ragged edges. Do not weld in windy conditions or in an area where ventilation is a problem, or where air flow fluctuates. b. The base metal puddle will be as deep as the bead that rises above it. 1. When proper rod is used: c. The welding operation will make a crackling sound similar to the sound of eggs frying. ALWAYS keep the wire and nozzle clean. NEVER use rusted wire. 2. When a rod too small is used: Avoid sharp bends or kinks in the welding hose. a. The bead will be high and irregular. Periodically remove the dust, using LOW PRESSURE compressed air, within the casing. Adequate heat dissipation is essential during the welders operation. 3. When the rod is too large: Electrodes The welding electrode is a rod coated with a layer of flux. When welding, electrical current flows between the electrode (rod) and the grounded metal work piece. The intense heat of the arc between the rod and the grounded metal melts the electrode and the flux. The most popular electrodes are: E6011 60,000 PSI tensile strength deep penetrating applications. E6013 60,000 PSI tensile strength used for poor fit up applications E7014 70,000 PSI tensile strength used for high deposition and fast travel speeds with light penetration E7018 70,000 PSI tensile strength, used for out of position and tacking. Selecting The Proper Electrodes There is no golden rule that determine the exact rod or heat setting required for every situation. The type and thickness of metal and the position of the work piece determine the electrode type and the amount of heat needed in the welding process. Heavier and thicker metals required more amperage. It is best to practice your welds on scrap metal which matches the metal you intend to work with to determine correct heat setting and electrode choice. See the following helpful trouble b. The arc will be difficult to maintain. a. The arc will burn through light metals. b. The bead will undercut the work. c. The bead will be flat and porous. d. Rod may be freeze or stick to work piece. Note: Rate of travel over the work also affects the weld. To ensure proper penetration and enough deposit of rod, the arc must be moved slowly and evenly along the weld seam. IMPORTANT – Thermostatic Protection (Duty Cycle) This product has a rated duty cycle of 20%. The percentage represents the welding time in a 10 minute period for example 20% means that the welding time is 2 minutes with a rest time of 8 minutes in a ten minute period although the actual duty cycle will depend on the amperage used. If the welder is used for longer than the duty cycle you may experience a temporary current shut off. This is to protect the transformer inside the welder from overheating. The thicker the material being welded, the greater the current required, therefore, the hotter the machine will become and the quicker it will cut out. When the windings reach performance temperature the cut out switch will operate illuminating the overheat indicator on the front panel. After a few minutes the cut out switch will reset and the welder will be ready for use. 30 MIG TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY Porosity (within or outside the bead) Poor material Check the material is clean Insufficient shield gas flow Check hoses and MIG torch for blockages Gas flow too low/high Check the regulator setting or that it is not frozen due to a high flow Leaking hoses Check all hoses for leaks Faulty gas valve Call a service engineer Working in open area with drafts Put screens up around the weld area Incorrect pressure on wire drive causing burn back to contact tip or bird nesting at the feed roll Re-adjust the upper feed pressure. Increase the pressure to eliminate burn back to tip. Decrease pressure to eliminate bird nesting Damage to torch liner Replace torch liner Welding wire contaminated or rusty Replace wire Worn welding tip Check and replace welding tip Torch switch faulty Check the torch switch continuity and replace if faulty Fuse blown Check fuses and replace if necessary Faulty PCB inside the equipment Call a service engineer Loose or defective work clamp Tighten/replace clamp Loose cable plug Re-fix plug Power source faulty Call a service engineer No operation and mains lamp not lit Check mains fuse and replace if required Faulty power source Call a service engineer Excessive spatter Wire feed speed too high or welding voltage too low Reset the parameters according to the weld to be made Excessive penetration, the weld metal is below the surface level of the material and hangs below Heat input too high Reduce the amperage or use a smaller electrode and lower amperage Poor weld technique Use correct welding travel speed Poor or inconsistent wire feed No operation when the torch switch is operated Low output current No operation 31 MIG TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY Burning through – Holes within the material where no weld exists. Heat input too high. Use lower amperage or smaller electrode. Use correct welding travel speed Poor fusion – Failing of weld material to fuse either with the material to be welded or previous weld beads Insufficient heat level Increase the amperage or increase the electrode size and amperage Poor welding technique Joint design must allow for full access to the root of the weld Alter welding technique to ensure penetration such as weaving, arc positioning or stringer bead technique Irregular weld bead and shape Your weld is cracking Work piece dirty Remove all contaminant from the material i.e. oil, grease, rust, moisture prior to welding Incorrect voltage. If it’s convex, voltage is too low and if it’s concave then voltage is too high. Adjust voltage Insufficient or excessive heat input Adjust the voltage control Wire is wandering Replace contact tip Incorrect shielding gas Check and change the shielding gas as required The weld beads too small Try decreasing the travel speed Weld penetration narrow and deep Try reducing voltage or increase MIG torch travel speed Excessive voltage Decrease voltage control dial Weld/material cooling rate too fast Slow the cooling rate by preheating part to be welded or cool slowly 32 MMA ASSEMBLY Description Your Welding Power Supply features a single phase transformer suitable for welding with an alternating current using stick electrodes with diameters from 1.6mm to 4mm. The welding current is regulated by using the welding current control (regulator). 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.27) ensuring there is a good connection. Fig 27 Electrode Selection The pages of this manual are restricted to the basic safe use of an MMA welding power supply and very basic welding technique. The electrodes used in MMA welding are many and varied. You are advised to seek advise from your local welding equipment supplier for the correct selection of electrode for the work being performed. Operation WARNING! If you have no welding experience, we recommend you seek training from an experienced person. Press the MIG/MMA/TIG switch to MMA mode, Fig.28. The indicator light should be illuminated next to MMA. CAUTION: This manual is a basic guide to welding. We recommend you purchase a good quality publication on welding or if you have internet access visit one of the numerous welding related web sites to be able to use the welding power supply to its full potential. Fig 28 THE QUALITY OF ANY WELDED JOINT IS DEPENDANT ON THE PREPARATION OF THE JOINT THE SELECTION OF THE CORRECT ELECTRODE AND THE SKILL AND EXPERIENCE OF THE WELDER. Ensure the Welding Power Supply is disconnected from the mains supply. Ensure that the area of the work piece where the earth clamp is to be connected is clean using a file or a grinder, to ensure a good electrical contact. Turn the welder On using the On/Off switch (Fig.29) Ensure the earth lead is connected to the workpiece, and the other lead to the electrode holder. 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. Attach the electrode holder (not suppled) and earth clamp as per Fig.1 on page 20. 33 Fig 29 MMA ASSEMBLY & OPERATION Set the amperage using the current control knob, Fig.30, until the desired setting is reached. Fig 30 the end of the electrode and the workpiece of approximately 2mm (Fig.31). Fig 31 2mm The chart below is an indicator of the electrode diameter and the corresponding welding current. This is intended as a guide only as results can vary depending on material, work piece thickness, welding position and joint form. Maintain this distance as constantly as possible during the weld remember that the angle of the electrode to the work piece must be 20-30° (Fig.32). Table 1 Electrode size (mm) Fig 32 Welding voltage (V) Welding current (A) 1.0 20.8 - 22.4 20 - 60 1.6 21.7 - 23.3 44 - 84 2.0 22.4 - 24.0 60 - 100 2.5 23.2 - 24.8 80 - 120 3.2 23.3 - 24.9 108 - 148 4.0 24.6 - 27.2 140 - 180 20º-30º Do not hit the electrode on the workpiece as this may damage the electrode. Withdraw with a clean movement at the end of the welding run. WARNING! Always wear a full welding mask, welding gloves and protective clothing. Wear goggles while chipping slag. 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. Note: If the machine stops at any time and the overheat 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 normally occurs when the duty cycle of the machine has been exceeded. Leave the machine on to allow the internal components to cool. When the indicator turns off, normal operation is again possible. Holding a face mask in front of your face stroke the electrode point on the workpiece as if striking a match. Maintain a steady gap between If the electrode is not withdrawn quickly enough once the arc is primed, there is a possibility that the electrode will weld itself to the workpiece. Should this happen, give it a sharp tug to free it, and try again. If this fails to free it, turn off the machine immediately as it will quickly overheat. If you withdraw the electrode too far once the arc is primed, you will lose the arc and have to try again. 34 MMA OPERATION Inspect the job carefully. With a correct combination of electrode size and current setting the area of weld should be complete fusion of the electrode and parent metal/s. Any slag which forms on the surface should be chipped away with the pick/brush supplied. Fig 35 >30mm If the resultant weld looks messy and irregular, this is an indication of porosity or slag contamination, and you have almost certainly failed to achieve the correct combination. This is a common problem, so do not worry as practice will quickly cure this. 2-3mm Disconnect the Welding Power Supply from the mains supply before changing or removing electrodes. Use pliers to remove used electrodes from the electrode holder or to move the welded pieces. 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.33). The Manual Metal Arc Process When an arc is struck between the metal rod (electrode) and the workpiece, both the rod and workpiece surface melt to form a weld pool. Simultaneous melting of the flux coating on the rod will form gas and slag which protects the weld pool from the surrounding atmosphere. The slag will solidify and cool and must be chipped off the weld bead once the weld run is complete (or before the next weld pass is deposited). Fig 33 7mm 2-3mm When welding material from 7mm to 30mm thick prepare the material as shown in Fig.34 filling up the space with several layers of weld. Fig 34 60º >30mm 2-3mm 5 6 4 3 2 1 60º The process allows only short lengths of weld to be produced before a new electrode needs to be inserted in the holder. Weld penetration is low and the quality of the weld deposit is highly dependent on the skill of the welder. Types of Flux/Electrodes Arc stability, depth of penetration, metal deposition rate and positional capability are greatly influenced by the chemical composition of the flux coating on the electrode. Electrodes can be divided into three main groups: • Cellulosic • Rutile • Basic When welding together material over 30mm in thickness prepare the material as shown in Fig.35 filling up the space with several layers of weld, welding each side in turn with each welding pass. 35 MMA OPERATION Cellulosic electrodes contain a high proportion of cellulose in the coating and are characterised by a deeply penetrating arc and a rapid burn-off rate giving high welding speeds. Weld deposit can be coarse and with fluid slag, deslagging can be difficult. These electrodes are easy to use in any position and are noted for their use in the stovepipe (vertical down position) welding technique. Features: • Deep penetration in all positions • Suitability for vertical down welding • Reasonably good mechanical properties • High level of hydrogen generated - risk of cracking in the heat affected zone Rutile Electrodes contain a high proportion of titanium oxide (rutile) in the coating. Titanium oxide promotes easy arc ignition, smooth arc operation and low spatter. These electrodes are general purpose electrodes with good welding properties. They can be used with AC and DC power sources and in all positions. The electrodes are especially suitable for welding fillet joints in the horizontal/vertical position. Features: • Moderate weld metal mechanical properties • Good bead profile produced through the viscous slag • Positional welding possible with a fluid slag (containing fluoride) • Easily removable slag Basic electrodes contain a high proportion of calcium carbonate (limestone) and calcium fluoride (fluorspar) in the coating. This makes their slag coating more fluid than rutile coatings - this is also fast-freezing which assists welding in the vertical and overhead position. These electrodes are used for welding medium and heavy section fabrications where higher weld quality, good mechanical properties and resistance to cracking (due to high restraint) are required. Features: • Low hydrogen weld metal • Requires high welding currents/speeds • Poor bead profile (convex and coarse surface profile) • Slag removal difficult Iron powder electrodes contain an addition of metal powder to the flux coating to increase the maximum permissible welding current level. Thus, for a given electrode size, the metal deposition rate and efficiency (percentage of the metal deposited) are increased compared with an electrode containing no iron powder in the coating. The slag is normally easily removed. Iron powder electrodes are mainly used in the flat and horizontal/vertical positions to take advantage of the higher deposition rates. Efficiencies as high as 130 to 140% can be achieved for rutile and basic electrodes without marked deterioration of the arcing characteristics but the arc tends to be less forceful which reduces bead penetration. Care of Electrodes The quality of weld relies upon consistent performance of the electrode. The flux coating should not be chipped, cracked or, more importantly, allowed to become damp. Storage Electrodes should always be kept in a dry and well-ventilated store. It is good practice to stack packets of electrodes on wooden pallets or racks well clear of the floor. Also, all unused electrodes which are to be returned should be stored so they are not exposed to damp conditions to regain moisture. Good storage conditions are 100°C above external air temperature. As the storage conditions are to prevent moisture from condensing on the electrodes, the electrode stores should be dry rather that warm. Under these conditions and in original packaging, electrode storage time is practically unlimited. It should be noted that electrodes are now available in hermetically sealed packs which obviate the need for drying. However, if necessary, any unused electrodes must be redried according to manufacturer's instructions. 36 MMA OPERATION Drying of Electrodes Drying is usually carried out following the manufacturer's recommendations and requirements will be determined by the type of electrode. IMPORTANT – Thermostatic Protection (Duty Cycle) This product has a rated duty cycle of 20%. The percentage represents the welding time in a 10 minute period for example 20% means that the welding time is 2 minutes with a rest time of 8 minutes in a ten minute period although the actual duty cycle will depend on the amperage used. If the Welding Power Supply is used for longer than the duty cycle or if you are welding using large welding rods you may experience a temporary current shut off. This is to protect the transformer inside the Welding Power Supply from overheating. The thicker the material being welded, the greater the current required, therefore, the hotter the machine will become and the quicker it will cut out. When the windings reach performance temperature the cut out switch will operate illuminating the overheat indicator on the front panel. After a few minutes the cut out switch will reset and the welder will be ready for use. 37 MMA TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY Excessive spatter (beads of metal scattered around the weld area) Amperage too high for the selected electrode Reduce amperage or utilise larger diameter electrode Voltage too high or arc length too long Reduce arc length or voltage Uneven and erratic weld bead and direction Weld bead is inconsistent and misses joint due to operator Operator training required Lack of penetration - The weld bead fails to create complete fusion between material to be welded, often surface appears okay but weld depth is shallow Poor joint preparation Joint design must allow for full access to the root of the weld Insufficient heat input Material too thick Increase the amperage or increase the electrode size and amperage Poor weld technique Reduce travel speed Ensure the arc is on the leading edge of the weld puddle Work piece dirty Remove all contaminant from the material i.e. oil, grease, rust, moisture prior to welding Electrode is damp Replace or dry the electrode Arc length is excessive Reduce the arc length Excessive penetration The weld metal is below the surface level of the material and hangs below Heat input too high Reduce the amperage or use a smaller electrode and lower amperage Poor weld technique Use correct welding travel speed Burning through - Holes within the material where no weld exists Heat input too high Use lower amperage or smaller electrode Porosity - Small holes or cavities on the surface or within the weld material Use correct welding travel speed Poor fusion - Failing of weld material to fuse either with the material to be welded or previous weld beads Insufficient heat level Increase the amperage or increase the electrode size and amperage Poor welding technique Joint design must allow for full access to the root of the weld Alter welding technique to ensure penetration such as weaving, arc positioning or stringer bead technique Work piece dirty Remove all contaminant from the material i.e. oil, grease, rust, moisture prior to welding 38 TIG OPERATION Operation Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the area. Turn on the cylinder gas valve and adjust the flow regulator to obtain desired flow. Set the desired amperage on the current control dial on the front panel of the welder (Fig.38). Fig 38 Plug the earth clamp lead in to the ‘+’ terminal, and secure the earth clamp to the workpiece. For good contact, the earth clamp must be attached to clean bare metal. Clean with a wire brush where necessary. Connect a regulator to a bottle of Argon gas (both not supplied) then connect the gas connection from the TIG torch to the regulator. Plug the TIG torch (not suppled) lead to the ‘-’ terminal. For a diagram on the lead installation please see page 23. Press the MIG/MMA/TIG switch to MMA mode, Fig.36. The indicator light should be illuminated next to MMA. Fig 36 Connect to the mains supply and press the On/Off switch (Fig.37) to the ON position (l) to stop the machine press the On/Off switch to the OFF position (0). Fig 37 Adjust the welding current according to the thickness of the work piece to be welded (for a guide to welding parameters, please refer to the table below. Tungsten Electrode Current Ranges Electrode diameter (mm) DC Current (A) 1.0mm 30-60 1.6mm 60-115 2.4mm 100-165 3.2mm 135-200 4.0mm 190-280 4.8mm 250-340 Warning! Always wear a full face mask, welding gloves and protective clothing. Wear goggles while chipping slag. Do not switch on the power supply until you are ready to start welding. Practice welding on a piece of scrap material. Press the trigger on the TIG torch, allowing gas to flow from the torch nozzle. Cover your face with the head shield, bring the torch to within 3-4mm of the work, and at an angle of 45°, so that the ceramic nozzle gently touches the work surface. 39 TIG OPERATION Scratch the tip of the electrode on soon as an arc develops, quickly withdraw the electrode to maintain a gap of approx. 3-4 mm, and proceed to weld. To stop welding release the TIG torch trigger. This method is referred to as ‘Scratch Arc’. Remember to turn off the gas immediately when you finish welding. using only the heat and arc force generated by the TIG arc. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size. Once the weld pool is established tilt the torch at about a 75° angle and move smoothly and evenly along the joint while fusing the materials together, Fig 39. Fig 39 Note: To avoid a visible strike mark on the surface of the workpiece, it is advisable to strike the arc in the joint, where the mark will be concealed by the weld. Note: Thin sheet and stainless steel may be welded with or without filler, similar to gas welding. Note: The filler is fed in at the edge of the pool. The rod must not touch the tip of the electrode or enter the arc. The end of the rod must always be shielded by the argon atmosphere to prevent as far as possible the formation of oxides of its surface. When welding stainless steel and copper, it is often possible to feed in the filler continuously at the edge of the pool. Note: The arc length generally varies between 3 and 6mm depending on the type of joint, type and thickness of material, and so on. Note: The torch is advanced in the direction of welding, without lateral movement, maintaining the torch angle of 45º to the workpiece. TIG Welding Fusion Techniques Manual TIG welding is often considered the most difficult of all the welding processes. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the workpiece. Similar to Oxygen Acetylene torch welding, Tig welding normally requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the welding torch in the other. However, some welds combining thin materials can be accomplished without filler metal like edge, corner, and butt joints. This is known as Fusion welding where the edges of the metal pieces are melted together 40 TIG OPERATION TIG Welding with Filler Wire Technique Fig 40 It is necessary in many situations with TIG welding to add a filler wire into the weld pool to build up weld reinforcement and create a strong weld. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size. Once the weld pool is established tilt the torch at about a 75° angle and move smoothly and evenly along the joint. The filler metal is introduced to the leading edge of the weld pool. The filler wire is usually held at about a 15° angle and fed into the leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly and evenly forward. It is important during the welding to keep the molten end of the filler wire inside the gas shield as this protects the end of the wire from being oxidized and contaminating the weld pool. Fig 40. TIG (GTAW) Basic Welding Guide Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (nonconsumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based. A filler metal may also be added manually in some circumstances depending on the welding application. DC TIG Welding The TIG (Tungsten lnert Gas) welding process is based on the presence of an electric arc between a non-consumable electrode (pure or alloyed tungsten with an approximate melting temperature of 3370°C) and the workpiece. An inert gas (typically argon) atmosphere protects the weld pool. 41 TIG OPERATION Guide for Selecting Filler Wire Diameter Filler Wire Diameter DC Current Range (Amps) 1.6mm 20-90 2.4mm 65-115 3.2mm 100-165 4.8mm 200-350 To avoid inclusions of tungsten in the joint, the electrode should not contact the workpiece. For this reason the arc is started through a Hi. Freq. generator. For situations requiring no Hi. Freq., Touch Start Tig reduces the short-circuit current to keep tungsten inclusions to the minimum. To improve weld bead quality at the end of the weld it is important to carefully control the downslope of current and ensure proper gas coverage over the weld. Welding Polarity DC Electrode Negative Polarity (Direct Current Straight Polarity) While Welding, there is a continuous flow of electrons from the electrode to the workpiece. This is the most used polarity, ensuring limited wear of the electrode, since the majority of the heat concentrates on the anode (workpiece). Narrow and deep welds are obtained with high travel speeds. Most materials, with the exception of aluminum and magnesium, are welded with this polarity (Fig.41). Fig 41 DC Electrode Positive Polarity. (Direct Current Reverse Polarity) In this case, there is a continuous flow of electrons from the workpiece to the electrode. The reverse polarity is used for welding alloys covered with a layer of refractory oxide. With this polarity the electrode functions as anode and is subjected to a high degree of heat; the workpiece is bombarded by positive ions sent from the electrode which break the surface oxide. In Electrode Positive Polarity, high currents cannot be used, since they would cause an excessive wear of the electrode. Steel TIG Welding The TIG process is very effective for welding both carbon steel and alloy steel, especially in applications requiring precision results. DC Electrode Negative Polarity is required. Since this process does not include the removal of impurities, proper cleaning and preparation of the edges is required. Filler material: The filler rods must deposit welds with mechanical characteristics appropriate for the application. Copper TIG Welding Since the TIG welding is a process characterized by high heat concentration, it is particularly suitable for welding materials with high thermal conductivity, like copper. As with steel, the DC Electrode Negative Polarity is employed, with argon as protective gas. Considering the fluidity of molten copper, the use of backup support may prove useful. Filler material: In order to avoid the oxidation of the molten material, filler materials containing phosphorus, silicon or other deoxidating materials are typically used. The mechanical properties can also be improved through the use of silver. H 42 TIG OPERATION Tungsten Electrodes Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and hightemperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius. Follow the manufacturer’s warnings, instructions, and the Material Safety Data Sheet (MSDS) for its use. Tungsten electrodes are nonconsumable and come in a variety of sizes, they are made from pure tungsten or an alloy of tungsten and other rare earth elements. Choosing the correct tungsten depends on the material being welded, the amount of amps required and whether you are using AC or DC welding current. Tungsten electrodes are colour-coded at the end for easy identification. Thoriated (Red) Thoriated tungsten electrodes contain a minimum of 97.30 percent tungsten and 1.70 to 2.20 percent thorium and are called 2 percent thoriated. They are the most commonly used electrodes today and are preferred for their longevity and ease of use. Thorium increases the electron emission qualities of the electrode, which improves arc starts and allows for a higher current-carrying capacity. This electrode operates far below its melting temperature, which results in a considerably lower rate of consumption and eliminates arc wandering for greater stability. Compared with other electrodes, thoriated electrodes deposit less tungsten into the weld puddle, so they cause less weld contamination. Ceriated (Grey) Ceriated tungsten electrodes contain a minimum of 97.30 percent tungsten and 1.80 to 2.20 percent cerium and are referred to as 2 percent ceriated. Ceriated tungstens perform best in DC welding at low current settings. They have excellent arc starts at low amperages and become popular in such applications as orbital tube welding, thin sheet metal work. They are best used to weld carbon steel, stainless steel, nickel alloys, and titanium, and in some cases it can replace 2 percent thoriated electrodes. Ceriated tungsten is best suited for lower amperages it should last longer than Thoriated tungsten higher amperage applications are best left to Thoriated tungsten. Zirconiated (White) Zirconiated tungsten electrodes contain a minimum of 99.10 percent tungsten and 0.15 to 0.40 percent zirconium. Most commonly used for AC welding Zirconiated tungsten produces a very stable arc and is resistant to tungsten spitting. It is ideal for AC welding because it retains a balled tip and has a high resistance to contamination. Its current-carrying capacity is equal to or greater than that of thoriated tungsten. Zirconiated tungsten is not recommended for DC welding. Thorium however is a low-level radioactive hazard and many users have switched to other alternatives. Regarding the radioactivity, thorium is an alpha emitter but when it is enclosed in a tungsten matrix the risks are negligible. Thus holding a stick of Thoriated tungsten in your hand should not pose a great threat unless a welder has open cuts on their skin. Thoriated tungsten should not get in contact with open cuts or wounds. The more significant danger to welders can occur when thorium oxide gets into the lungs. This can happen from the exposure to vapours during welding or from ingestion of material/dust in the grinding of the tungsten. 43 TIG OPERATION Tungsten Electrode Types Electrode Type (Ground Finish) Welding Application Features Colour Code Thoriated 2%. DC welding of mild steel, stainless steel and copper. Excellent arc starting, Long life, High current carrying capacity. Red Zirconated 1% High quality AC welding of aluminium, magnesium and their alloys. Self cleaning, Long life, Maintains balled end, High current carrying capacity. White Ceriated 2% AC & DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys Longer life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc. Grey Welding Rate Base Metal DC Current DC Current Tungsten Thickness for Mild for Stainless Electrode Steel Steel Diameter Filler Rod Argon Gas Diameter (if Flow Rate required) Litres/min Joint Type 1.0mm 35-45 40-50 20-30 25-35 1.0mm 1.6mm 5-7 Butt/Corner Lap/Fillet 1.2mm 45-55 50-60 30-45 35-50 1.0mm 1.6mm 5-7 Butt/Corner Lap/Fillet 1.6mm 60-70 70-90 40-60 50-70 1.6mm 1.6mm 7 Butt/Corner Lap/Fillet 3.2mm 80-100 90-115 65-85 90-110 1.6mm 2.4mm 7 Butt/Corner Lap/Fillet 4.8mm 115-135 140-165 100-125 125-150 2.4mm 3.2mm 10 Butt/Corner Lap/Fillet 6.4mm 160-175 170-200 135-160 160-180 3.2mm 4.0mm 10 Butt/Corner Lap/Fillet 44 TIG TROUBLESHOOTING Problem Possible Cause Remedy Excessive bead build up or poor penetration or poor fusion at edges of weld. Welding current is too low. Increase weld current and/or faulty joint preparation. Weld bead too wide and flat or undercut at edges of weld or excessive burn through. Welding current is too high. Decrease weld current. Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart. Travel speed too fast. Reduce travel speed. Weld bead too wide or excessive bead build up or excessive penetration in butt joint. Travel speed too slow. Increase travel speed. Uneven leg length in fillet joint. Wrong placement of filler rod. Re-position filler rod. Electrode melts or oxidises when an arc is struck. Torch lead connected to positive welding terminal. Connect torch lead to negative welding terminal. No gas flowing to welding region. Check the gas lines for kinks or breaks and gas cylinder contents. Torch is clogged with dust or dirt. Clean torch. Gas hose is cut. Replace gas hose. Gas passage contains impurities. Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities. Gas regulator turned off. Turn on. The electrode is too small for the welding current. Increase electrode diameter or reduce the welding current. Power source is set for MMA welding. Set Power Source to TIG mode. 45 TIG TROUBLESHOOTING Problem Possible Cause Remedy Dirty weld pool. Electrode contaminated by contact with work piece or filler rod material. Clean the electrode by grinding off the contaminates. Work piece surface has foreign material on it. Clean surface. Gas contaminated with air. Check gas lines for cuts and loose fitting or change gas cylinder. Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems. Arc start is not smooth. Tungsten electrode is too large for the welding current. Select the right size tungsten electrode. Refer to Tungsten Electrode Current Ranges on page 39. The wrong electrode is being used for the welding job. Select the right tungsten electrode type. Refer to Tungsten Electrode Types on page 44. Gas flow rate is too high. Select the right rate for the welding job. Refer to Welding Rates on page 44. Incorrect shielding gas is being used. Select the right shielding gas. Poor work clamp connection to work piece. Improve connection to work piece. Tungsten electrode is too large for the welding current. Select the right size tungsten electrode. Refer to Tungsten Electrode Current Ranges on page 39. Arc flutters during TIG welding. 46 MAINTENANCE WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. • Turn the input power off at the fuse box, disconnect supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment. • Do not touch electrically hot parts. WARNING Do not open this machine and do not introduce anything into its openings. Power supply must be disconnected from the machine before each maintenance and service. After each repair, perform proper tests to ensure safety. CAUTION The power supply must be disconnected from the machine before each maintenance and service. Always use gloves in compliance with the safety standards. Routine Maintenance The welder must be kept clean and dry at all times. Use a dry cloth to clean the welder. 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. If the supply cord requires replacing, the task must be carried out by the manufacturer, the manufacturer’s agent, or an authorised service centre to avoid a safety hazard. Welding Mask Maintenance Always maintain your welding mask in good condition. If the clear glass protection lens becomes badly pitted, sufficient to interfere with vision, or cracked, have it replaced immediately. NEVER use any dark filter lens other than that provided by IMPAX, or one with the same certified ‘Optical class’ (degree of protection). The shield should always be cleaned with a clean soft cloth after use, ensuring the lenses are clean. Remove any dust that may have accumulated and store it in a safe place where it cannot be damaged. NEVER use a shield that is not in perfect condition. Keep the electrodes clean and dry and ensure all cables are in good condition. Keep the louvre passages clean to avoid a build up of dirt and oxides inside the machine, which can reduce machine output. The nozzle will occasionally need to be cleaned of spatter from welding. Clean it with a metal brush. When the nozzle deteriorates or can no longer be cleaned, it will need to be replaced. Unscrew the nozzle and replace it with a new one. Always try to avoid getting particles of metal inside the machine since they could cause short circuits. 47 TROUBLESHOOTING DANGER Follow all safety precautions whenever diagnosing or servicing the tool. Disconnect power supply before service. Problem Possible Cause Remedy There is no display on the current meter and voltage meter after turning on the machine. The power cord is not well connected. Reconnect the power cord. The welding machine fails. Have an qualified service technician repair the machine. The fan does not work during welding. Fan blocked/dirty. Remove obstruction and clean with compressed air. Auxiliary power fails. Have the fan replaced by a qualified service technician. Welder overheated. Allow unit to cool with the fan on. Duty cycle or amps too high. Reduce duty cycle or amps. Airflow is blocked. Clean vents and fan out with compressed air. There is no response when pushing the torch trigger and the alarm indicator does not illuminate. The welding torch is not well connected with the wire feeder. Reconnect it. The torch trigger has failed. Repair or replace the welding torch. When the torch trigger is pushed, there is gas output, but there is no output current, and the alarm indicator does not illuminate. The earth cable is not well connected with the workpiece. Reconnect it. The wire feeder or welding torch fails. Repair the wire feeder or welding torch. There is output current when pushing the torch trigger to feed gas, but the wire feeder does not work. The wire feeder is clogged. Unclog it. The wire feeder fails. Have an qualified service technician inspect then repair the welder. The control PCB or wire feeding power PCB inside the machine fails. Have an qualified service technician inspect then repair the welder. No weld output; high temperature light on. 48 TROUBLESHOOTING Problem Possible Cause Remedy Erratic or improper arc or welding output. Bad weld connections. Clean and tighten weld connections. Polarity incorrect. Connect polarity correctly. Workpiece painted or dirty. Clean workpiece thoroughly. Nozzle obstructed by welding spatter. Clean or replace nozzle. Circuit Breaker rating is too low. Install a circuit breaker rated for greater than 13 Amps. Main supply fuse shuts off frequently. ENVIRONMENTAL PROTECTION Information for (private householders) for the environmentally responsible disposal of Waste Electrical and Electronic Equipment (WEEE) This symbol on products and or accompanying documents indicates that used and end of life electrical and electronic equipment should not be disposed of in household waste. For the proper disposal, treatment, recovery and recycling, please take these products to designated collection points, where they will be accepted on a free of charge basis. Alternatively, in some countries you may be able to return your products to your retailer upon the purchase of an equivalent new product. Disposing of this product correctly will help to save valuable resources and prevent any potential adverse effects on human health and the environment which could otherwise arise from inappropriate waste disposal and handling. Please contact your local authority for further details of your nearest designated collection point. Penalties may be applicable for incorrect disposal of this waste in accordance with national legislation. FOR BUSINESS USERS IN THE EUROPEAN UNION. If you wish to discard electrical and electronic equipment, please contact your dealer or supplier for further information. Information on Disposal in other Countries outside the European Union. This Symbol is only valid in the European Union. If you wish to dispose of this product, please contact your local authorities or dealer and ask for the correct method of disposal. 49 SYMBOLS Symbols and Technical Data EN 60974-6:2003 European standard relating to Welding Power Supply’s for limited use IM-MIG120 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 S Standardised plug Suitable for welding in an environment with increased hazard of electric shock 50 SYMBOLS The rating plate on this product may show symbols. These represent important information about the product or instructions on its use. Conforms to European safety standards. 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 Conforms to UK safety standards. Always wear approved face mask with correct filter, gloves and apron to protect against welding operation Read the instruction manual. Product conforms to RoHs requirements Do not use this welder in damp conditions Warning! Electrical welding process uV Keep bystanders and pets clear of the welding power supply when in use. Protect operator and passer bye from the effect of uV radiation. This can cause permanent damage to the eye. Make sure the arc and resulting flash is shielded at all times. 51 WIRING DIAGRAM 52 NOTES 53 NOTES 54 EC DECLARATION OF CONFORMITY 1. Product model: IM-MIG120 2. Name and address of the manufacturer or his authorised representative: Nuair Ibérica, Lda. Rua da Zona Industrial, 560, 4520-114, Santa Maria da Feira, Portugal Tel: +351 256 580 930. Email: [email protected] 3. This declaration of conformity is issued under the sole responsibility of the manufacturer. 4. Object of the declaration: Equipment: 120A MIG Welder Brand name: IMPAX Model/type: IM-MIG120 5. The object of the declaration described above is in conformity with the relevant Union harmonisation legislation: 2006/42/EC. Machinery Directive. 2006/95/EC. Low Voltage Directive. 2004/108/EC. Electromagnetic Compatibility Directive. 93/68/EC. CE Marking Directive. 2011/65/EU. Restriction of the Use of certain Hazardous Substances in Electrical and Electronic Equipment (RoHS) Directive. 2002/96/EC as amended by 2003/108/EC. Waste Electrical and Electronic Equipment (WEEE) Directive. 6. References to the relevant harmonised standards used or references to the other technical specifications in relation to which conformity is declared: EN IEC 60974-10 BS EN IEC 60974-10 EN IEC 60974-1 BS EN IEC 60974-1 7. The person authorized to compile the technical file: Name: Sérgio Fernandes Address: Nuair Ibérica, Lda. Rua da Zona Industrial, 560, 4520-114, SMF, Portugal Signed for and on behalf of: Authorised Representative 22 Sérgio Fernandes, Technical Manager 03/03/2022 55
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