Impax IM-MIG120 Instruction Manual

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