Impax IM-MIG120 Instruction Manual
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Impax IM-MIG120 Instruction Manual

120a mig welder
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DECLARATION OF CONFORMITY
1.
Product model: IM-MIG120
2.
Name and address of the manufacturer or his authorised representative:
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
NAP BRANDS LTD. Office 20, Fleming Court Business Centre,
Leigh Road, Eastleigh, Hampshire SO50 9YN
Tel: +44 (0)23 8064 9650. Email: sales@napbrands.co.uk
22

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  • Page 1 DECLARATION OF CONFORMITY Product model: IM-MIG120 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: sales@napbrands.co.uk This declaration of conformity is issued under the sole responsibility of the manufacturer.
  • Page 2 120A MIG WELDER IM-MIG120 Always Read Instruction Manual Retain for Future Reference...

  • Page 3: Certificate Of Guarantee

    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.

  • Page 4: Safety Information

    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”...
  • Page 5 SAFETY INFORMATION General Welding Safety installed or improperly grounded equipment is a hazard. The Workshop Environment Housekeeping is extremely important to avoid 1. Do not touch live electrical parts. injury from slips, trips and falls, damage to 2. Wear dry, hole-free insulating gloves and equipment and fire.
  • Page 6 SAFETY INFORMATION Shock Prevention Electrode Holders Exposed live conductors or other bare metal in Fully insulated electrode holders should be the welding circuit, or in unearthed, electrically- used. Do NOT use holders with protruding LIVE equipment can fatally shock a person screws or with any form of damage.
  • Page 7 SAFETY INFORMATION Changing Electrodes produced in the arc, such as ozone or oxides of The electrode holder should be isolated when nitrogen, and decomposition products from any changing the electrode, where a work piece is paint or coating which was on the metal earthed.
  • Page 8 SAFETY INFORMATION 5. Work in a confined space only if it is well Avoid paint spray rooms, dip tanks, storage ventilated, or while wearing an air-supplied areas, ventilators. If the work cannot be moved, respirator. move combustibles at least 10M, away out of reach of sparks and heat;...
  • Page 9 SAFETY INFORMATION Cylinders Can Explode If Damaged through small cracks and openings to Shielding gas cylinders contain gas under adjacent areas. high pressure. If damaged, a cylinder can 5. Watch for fire, and keep a fire extinguisher explode. Since gas cylinders are normally nearby.
  • Page 10 SAFETY INFORMATION Sparks Can Cause Battery Gases To Explode Falling Unit Can Cause Injury SPARKS can cause BATTERY 1. Lift unit with handle on top of GASES TO EXPLODE; BATTERY case. ACID can burn eyes and skin. 2. Use handcart or similar device of Batteries contain acid and adequate capacity.
  • Page 11 SAFETY INFORMATION...
  • Page 12 SAFETY INFORMATION H.F. Radiation Can Cause Interference Do not place your body between the 1. High-frequency (H.F.) can electrode and work cables. If the electrode interfere with radio navigation, cable is on your right side, the work cable safety services, computers, should also be on your right side.
  • Page 13 SAFETY INFORMATION Specific Safety Instructions Do not weld on containers or pipes that hold or Use the welding power supply as indicated in have held flammable liquid or gases (danger of the instruction manual. Improper use of this explosion) or on materials cleaned with welding power supply can be dangerous for chlorinated solvents or on varnished surfaces persons, animals or objects.
  • Page 14 If you have a problem with the machine Power disconnect switch must be available contact your local IMPAX dealer. near the welding power source. 10. NEVER use or store in a wet/damp 25. Fully insulated electrode holders should be environment.
  • Page 15 SAFETY INFORMATION The following types of welding operation c) Keep children and bystanders away while must be performed by a qualified coded operating a power tool. Distractions can welder and approved by a qualified welding cause you to lose control. inspector.
  • Page 16 SAFETY INFORMATION c) Avoid accidental starting. Ensure the Power tools are dangerous in the hands of switch is in the off position before untrained users. plugging in. Carrying power tools with your e) Maintain power tools. Check for finger on the switch or plugging in power misalignment or binding of moving parts, tools that have the switch on invites breakage of parts and any other condition...

  • Page 17: Installation

    INSTALLATION Environment Read the section on electromagnetic These units are designed for use in compatibility in this manual. environments with increased hazard of electric • Do not operate in areas with an ambient shock. temperature greater than 40°C. A. Examples of environments with increased Tilting hazard of electric shock are: Place the machine directly on a secure, level...
  • Page 18 Do not touch members radiating antennas. electrically live parts 6. Keep all panels securely in place. The IM-MIG120 Welder requires a 230V 50Hz All electrical conductors within 50 ft (15.2m) supply. of the welder should be enclosed in Connect wires according to national coding.

  • Page 19: Electrical Information

    ELECTRICAL INFORMATION WARNING! THIS APPLIANCE MUST BE Models Fitted Without Plug EARTHED 230V Supply Models Fitted With 13A Plug Connect the mains lead to a suitably fused 230 Welders fitted with a standard 13 amp BS 1363 Volt (50Hz) electrical supply. The fuse rating plug, should be connected to a to a 230 volt should correspond to that shown on the (50Hz) domestic electrical supply and we...
  • Page 20 COMPONENTS Component List 1. Earth clamp 13. Welding power lead 2. Face mask 14. Negative ‘-’ output terminal 3. Carry handle 15. Positive ‘+’ output terminal 4. Power cable 16. MIG torch 5. On/Off switch 17. Mig accessories: 6. Gas inlet 1 x wrench 2 x contact tips (0.8/0.9) 8.
  • Page 21 UNPACKING Caution! This packaging contains sharp objects. be returned together in their original packaging Take care when unpacking. Remove the to the retailer. machine, together with the accessories Do not throw the packaging away, keep it safe supplied, from the packaging. Check carefully to throughout the guarantee period, then recycle if ensure that the machine is in good condition possible, otherwise dispose of it by the proper...
  • Page 22 MIG ASSEMBLY (WITH GAS) MIG Welding with GAS Connect the welding power lead to the “+” Insert the cable plug with the earth clamp into socket on the front panel of the welding the “-” socket on the front panel of the welding machine, and tighten it clockwise.
  • Page 23 MIG ASSEMBLY (NO GAS) MIG Welding (No Gas) Connect the welding power lead to the “-” Insert the cable plug with the earth clamp into socket on the front panel of the welding the “+” socket on the front panel of the welding machine, and tighten it clockwise, Fig.3.
  • Page 24 TIG ASSEMBLY TIG Welding Connect the gas hose to the regulator / Insert the cable plug with the earth clamp into flowmeter located on the shield gas cylinder and the “+” socket on the front panel of the welding connect the other end to the machine (Fig.4). machine, and tighten it clockwise.
  • Page 25 MIG ASSEMBLY Assembly Unscrew and remove the plastic knob (A), Note: Before carrying out any assembly or followed by the spring (B) and collar (C) from the disassembly of the unit please ensure that the hub, Fig.8. Fig 8 unit is not connected to the electrical supply. Assembling the Face Mask To assemble the mask bend in the top and side flaps (Fig.5) and clip into place then attach the...

  • Page 26: Mig Operation

    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).
  • Page 27 MIG ASSEMBLY Set the amperage using the current control Attaching A Gas Bottle & Regulator knob, Fig.15, based on the material thickness. Fit a suitable regulator and gas supply tube onto Fig 15 your gas bottle (Please note; regulator, gas bottle &...
  • Page 28 MIG ASSEMBLY Fig 18 Fig 21 Holding the torch straight out from the welder Set the amperage using the current control press the trigger on the torch (Fig.19). The wire knob, Fig.22, based on the material thickness. Fig 22 feed roller will operate feeding the welding wire through the torch.
  • Page 29 MIG OPERATION MIG Operation If you choose to do Gasless MIG welding, set up The operation method is the same as the above the welder as detailed on page 22. MIG operation except there are no gas options If you choose to do MIG welding with gas, set and the output polarity is reversed (see pg 22).
  • Page 30 MIG OPERATION piece of material with the same characteristics Fig 24 as that of your workpiece until you are satisfied with the result, and you have fine tuned your welder to produce a satisfactory weld. One of the problems experienced with novice welders, is the welding wire sticking to the contact tip.
  • Page 31 MIG OPERATION Tips shooting tips to determine if you are using a Try to maintain the tip of the nozzle at an angle correct electrode. of approx. 45º and at a constant distance of 1. When proper rod is used: approx 5-7mm from the workpiece.

  • Page 32: Mig Troubleshooting

    MIG TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY Porosity (within or outside Poor material Check the material is clean the bead) 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...
  • Page 33 MIG TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY Burning through – Holes Heat input too high. Use lower amperage or smaller electrode. within the material where no weld exists. Use correct welding travel speed Insufficient heat level Increase the amperage or increase Poor fusion –...
  • Page 34 MMA ASSEMBLY Description The earth clamp must only be connected to the Your Welding Power Supply features a single work piece. The area to be welded must be phase transformer suitable for welding with an clean and free from dirt, rust, paint, grease and alternating current using stick electrodes with oil.
  • Page 35 MMA ASSEMBLY & OPERATION Set the amperage using the current control the end of the electrode and the workpiece of knob, Fig.30, until the desired setting is reached. approximately 2mm (Fig.31). Fig 30 Fig 31 The chart below is an indicator of the electrode diameter and the corresponding welding Maintain this distance as constantly as possible current.

  • Page 36: Mma Operation

    MMA OPERATION Inspect the job carefully. With a correct Fig 35 60º combination of electrode size and current setting the area of weld should be complete >30mm fusion of the electrode and parent metal/s. Any slag which forms on the surface should be chipped away with the pick/brush supplied.
  • Page 37 MMA OPERATION Cellulosic electrodes contain a high proportion Features: of cellulose in the coating and are characterised • Low hydrogen weld metal by a deeply penetrating arc and a rapid burn-off rate giving high welding speeds. Weld deposit • Requires high welding currents/speeds can be coarse and with fluid slag, deslagging •...
  • Page 38 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...

  • Page 39: Mma Troubleshooting

    MMA TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY Excessive spatter (beads Amperage too high for the Reduce amperage or utilise larger selected electrode diameter electrode of metal scattered around the weld area) Voltage too high or arc length too Reduce arc length or voltage long Uneven and erratic weld Weld bead is inconsistent and...

  • Page 40: Tig Operation

    TIG OPERATION Operation Turn on the cylinder gas valve and adjust the Before starting any welding activity ensure flow regulator to obtain desired flow. that you have suitable eye protection and Set the desired amperage on the current control protective clothing. Also take the necessary dial on the front panel of the welder (Fig.38).
  • Page 41 TIG OPERATION Scratch the tip of the electrode on soon as an using only the heat and arc force generated by arc develops, quickly withdraw the electrode to the TIG arc. Once the arc is started the torch maintain a gap of approx. 3-4 mm, and proceed tungsten is held in place until a weld pool is to weld.
  • Page 42 TIG OPERATION TIG Welding with Filler Wire Technique It is necessary in many situations with TIG Fig 40 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.
  • Page 43 TIG OPERATION DC Electrode Positive Polarity. (Direct Guide for Selecting Filler Wire Diameter Current Reverse Polarity) In this case, there is a continuous flow of Filler Wire Diameter DC Current electrons from the workpiece to the electrode. Range (Amps) The reverse polarity is used for welding alloys 1.6mm 20-90 covered with a layer of refractory oxide.
  • Page 44 TIG OPERATION Tungsten Electrodes Follow the manufacturer’s warnings, Tungsten is a rare metallic element used for instructions, and the Material Safety Data Sheet manufacturing TIG welding electrodes. The TIG (MSDS) for its use. process relies on tungsten’s hardness and high- Ceriated (Grey) temperature resistance to carry the welding Ceriated tungsten electrodes contain a minimum...
  • Page 45 TIG OPERATION Tungsten Electrode Types Electrode Type Welding Application Features Colour Code (Ground Finish) Thoriated 2%. DC welding of mild Excellent arc starting, steel, stainless steel Long life, High current and copper. carrying capacity. Zirconated 1% High quality AC Self cleaning, Long White welding of aluminium, life, Maintains balled...

  • Page 46: Tig Troubleshooting

    TIG TROUBLESHOOTING Problem Possible Cause Remedy Welding current is too low. Increase weld current and/or faulty joint Excessive bead build up or poor penetration preparation. or poor fusion at edges of weld. Welding current is too high. Decrease weld current. Weld bead too wide and flat or undercut at edges of weld or...
  • Page 47 TIG TROUBLESHOOTING Problem Possible Cause Remedy Electrode contaminated by Clean the electrode by grinding off the Dirty weld pool. contact with work piece or filler contaminates. rod material. Work piece surface has foreign Clean surface. material on it. Gas contaminated with air. Check gas lines for cuts and loose fitting or change gas cylinder.

  • Page 48: Maintenance

    After each repair, perform proper tests to ensure safety. NEVER use any dark filter lens other than that provided by IMPAX, or one with the same certified ‘Optical class’ (degree of protection). CAUTION The shield should always be cleaned with a...

  • Page 49: Troubleshooting

    TROUBLESHOOTING Follow all safety precautions whenever diagnosing or servicing the DANGER tool. Disconnect power supply before service. Problem Possible Cause Remedy The power cord is not well Reconnect the power cord. There is no display on the current meter and connected.

  • Page 50: Environmental Protection

    TROUBLESHOOTING Problem Possible Cause Remedy Bad weld connections. Clean and tighten weld connections. Erratic or improper arc or welding output. Polarity incorrect. Connect polarity correctly. Workpiece painted or dirty. Clean workpiece thoroughly. Nozzle obstructed by welding Clean or replace nozzle. spatter.
  • Page 51 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 No load voltage …A/…V to …A/…V Range of output...
  • Page 52 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 Waste electrical products standards. should not be disposed of with household waste. Please recycle where facilities exist. Check with your Local Conforms to UK safety Authority or retailer for...

  • Page 53: Wiring Diagram

    WIRING DIAGRAM...
  • Page 54 NOTES...
  • Page 55 NOTES...

  • Page 56: Ec Declaration Of Conformity

    EC DECLARATION OF CONFORMITY Product model: IM-MIG120 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: sat@nuair.pt This declaration of conformity is issued under the sole responsibility of the manufacturer.

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