EC DECLARATION OF CONFORMITY
The manufacturer of the product covered by this Declaration is.
NAP Brands Ltd.
Napier House, Unit 7, Corunna Court,
Warwick, United Kingdom CV34 5HQ
The manufacturer hereby declares that the machine as detailed in this declaration fulfils all the
relevant provisions of the Machinery Directive and other appropriate directives as detailed below.
The manufacture further declares that the machine as detailed in this declaration, where applicable,
fulfils the relevant provisions of the essential health and safety requirements.
The Directives covered by this Declaration are as detailed below
Product Details:
Description: Mig Welder
Model No: IM-MIG150
Brand Name: Impax
Name and address of technical documentation holder.
The technical documentation required to demonstrate that the product meets the requirements of
directive has been compiled and is available for inspection by the relevant enforcement authorities.
Signed: Print: Mark Shannon
Senior Quality Control Manager.
NAP Brands Ltd.
Napier House, Unit 7, Corunna Court, Warwick, United Kingdom CV34 5HQ
Date:.30.08.2013
98/37/EEC The Machinery Directive.
2006/95/EC. Low Voltage Equipment Directive.
2004/108/EC. Electromagnetic Compatibility Directive,
93/68/EC. The CE Marking Directive.
2002/95/EC. The Restriction of the Use of certain Hazardous Substances in Electrical Equipment
(RoHS) Directive
2002/96/EC as amended by 2003/108/EC The Waste Electrical and Electronic Equipment (WEEE)
Directive.
After sales support: Tel: 0844 264 2485 Website: www.impaxpowertools.com
??
And is in conformity with the applicable requirements of the following documents
??
Always Read Instruction Manual
Retain for Future Reference
IM-MIG150
150A MIG WELDER
2
CERTIFICATE OF GUARANTEE
This product is guaranteed for a period of 1Year, 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
Thankyou 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 – 5:30pm.
Telephone Number 0844 264 2485
3
SAFETY INFORMATION
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.
Important
Warning! If you have no welding experience, we
recommend you seek training from an
experienced person.
Caution: The pages of this manual are restricted
to the basic safe use of an MIG/MAG (Metal
Inert Gas / Metal Active Gas) welding power
supply and very basic welding technique. 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.
The wire electrodes used in an MIG/MAG (Metal
Inert Gas / Metal Active Gas) 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.
THE QUALITY OF ANY WELDED JOINT IS
DEPENDANT ONTHE PREPARATION OF THE
JOINT THE SELECTION OF THE CORRECT
WIRE ELECTRODE ANDTHE SKILL AND
EXPERIENCE OF THE WELDER.
General Welding Safety
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.
Avoid using your welder in the vicinity of:
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;
c) computer and other control equipment;
d) safety critical equipment, e.g. guarding of
industrial equipment;
e) pacemakers and hearing aids etc.;
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;
It may be possible to avoid the above by
changing the time of day that welding or other
activities are to be carried out.
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.
Electrical Safety
As one of the principal dangers from welding
operations is an electric shock, from the live
parts of the welding circuit (the wire electrode
torch and the work piece), the following
practices are recommended.
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.
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.
SAFETY INFORMATION
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.
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.
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.
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.
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.
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.
Changing Wire Electrodes
When replacing a reel of wire, always switch off
the welding set (welding power source plus
wire-feed unit) and isolate it from the mains
supply.
To avoid eye injury, never look down the end of
the welding torch to check that the wire is
feeding through the conduit satisfactorily. With
the welding torch held in a safe position, wait
until the wire emerges from the contact tip.
Never leave the work-area with the welding set
turned on and the welding torch carelessly laid
on the bench or work piece. The trigger of the
welding torch can easily become pressed,
causing wire to feed continuously. If this
happens, a reel of wire may be discharged and
wasted. Or, a loop of wire may be discharged
and then contact the work piece or bench, at
which point, rapid resistance heating of the wire
loop takes place to create a dangerous ignition
source which can easily start a fire. When not in
use, the welding torch should be stowed
correctly.
4
5
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
Warning! Keep hands and body clear of the
front of the welding torch. When the automatic
feed is operated the wire electrode can easily
penetrate gloves, clothing and skin causing
injury.
Never point the welding torch towards your face
as accidental operation of the wire electrode
feed can cause serious injury to the eyes and
face.
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,
wire electrode torch, coupling devices, wire feed
operation and gas containers) 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. Any
damaged or defective parts must be replaced
before continuing the welding operation.
Fumes
Metals and metal coatings can contain substances
which generate toxic fumes during welding. These
can cause severe discomfort, illness or, in extreme
cases, death as a result of inhalation. For example,
when welding galvanised steel, the use of local
exhaust ventilation (LEV) is very important to reduce
the risk of a condition called 'metal-fume fever'.
This produces flu-like symptoms which begin
several hours after exposure with a thirst, cough,
headache, sweat, pain in the limbs and fever.
Recovery usually occurs within 1 to 2 days of
removal from exposure.
To minimise the generation of toxic fumes, anticorrosion plating, paint, other coatings and
surface contamination in the weld region should
be removed, with due regard to health & safety
issues, before welding.
It is extremely important that the effects of
welding fume and the method of reducing the
welder's exposure to fume are carefully
considered before welding. Welding fume must
be taken seriously.
The welding process vaporises 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 shielding gases and gases
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.
Warning!
Some fumes are harmful to health, for instance
stainless steel fumes contain chromium, and
welding galvanised steel produces zinc fumes
and should be avoided.
Effects can vary from a bout of 'metal fume
fever' to longer term, more serious problems if
suitable fume removal is not carried out.
Noise
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.
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.
SAFETY INFORMATION
SAFETY INFORMATION
6
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.
Hand Held and Head Shields
For most operations a hand-held or head shield
constructed of lightweight insulating and nonreflecting material is used which conforms to
EN175. The shield is fitted with a protective filter
glass, sufficiently dark in colour and capable of
absorbing the harmful infrared and ultraviolet
rays. The filter glasses conform to the strict
requirements of EN169 and are graded
according to a shade number which specifies
the amount of visible light allowed to pass
through - the lower the number, the lighter the
filter. The correct shade number for MMA
welding must be used according to the welding
current level, for example:
Recommended shade number of filter for
MIG/MAG welding:
Note: The current ranges are different for other
processes.
Welders assistants also need protective clothing
and eye protection. Passers-by should be
protected by placing opaque or properly filtered
screens around the work area.
Burns and Mechanical Hazards
Exposure to the radiation from an arc causes
burns to the skin, For this reason, welders need
to wear clothing to protect their bodies and
arms, regardless of the weather conditions.
Welders need good quality gloves, preferably
leather gauntlets, safety boots or shoes and
good quality cap and overalls. A leather apron
may also be needed. Welding produces
quantities of molten droplets of metal which are
scattered in all directions. It is essential that the
welder wears clothing which will not burn or
melt, and which is stout enough to provide
adequate protection.
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.
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.
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.
If combustibles are in area, do NOT weld or cut.
Move the work if practicable, to an area free of
combustibles.
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.
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:
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.
Shade Welding current A
number
MIG Heavy MIG Light MAG
metal metal
10 under 100 under 100 under 80
11 100 - 175 100 - 175 80 - 125
12 175 - 300 175 - 250 125 - 175
13 300 - 500 250 - 350 175 - 300
14 over 500 350 - 500 300 - 500
15 over 500 over 450
7
SAFETY INFORMATION
d) combustibles adjacent to walls, ceilings, roofs
or metal partitions can be ignited by radiant
or conducted heat.
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.
Water filling just below working level may
substitute for inerting.
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.
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.
Safe Handling of Shielding Gas Cylinders and
Regulators
Compressed gas cylinders should be handled
carefully and should be adequately secured
when in use. Knocks, falls, or rough handling
may damage cylinders or valves and may cause
leakage or an accident.
The following should be observed when setting
up and using cylinders of shielding gas:
store gas cylinders outside in a covered, well
ventilated
Properly secure the cylinder.
Before connecting a regulator to the cylinder
valve, the valve should be momentarily opened
and closed immediately to clear the valve of
dust or dirt that otherwise might enter the
regulator. The operator should stand to one side
of the cylinder valve, never in front of it.
After the regulator is attached, the adjusting
screw should be released by turning it anticlockwise. The cylinder valve should then be
opened slowly to prevent a surge of high
pressure gas into the regulator.
The cylinder valve should be shut off if it is to be
left unattended.
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.
The user of the welding power supply is
responsible for their own safety and the safety
of others. It is important to read and understand
this instruction manual.
Repair and maintenance must be carried out by
qualified persons.
Maintain the welding power supply in good
condition (keep clean and dry etc).
During welding do not locate the welding power
supply 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
welding power supply.
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 MIG/MAG (Metal Inert Gas /
Metal Active Gas) electrode, the electrode
holder should be isolated.
When welding stops for a short time, the
MIG/MAG (Metal Inert Gas / Metal Active Gas)
wire electrode torch should NOT be put on the
face shield or flammable material as it may still
hot enough to cause damage.
SAFETY INFORMATION
MIG/MAG (Metal Inert Gas / Metal Active Gas)
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.
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).
Ensure there is adequate and suitable fire
fighting equipment close by.
Do not use the welding power supply in damp
or wet places or weld in the rain.
Always protect your eyes with an approved
facemask with the appropriate filter.
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.
Environments with Increased Hazard of
Electric Shock
These are as follows:
locations where the welder has restricted
freedom of movement, working in a cramped
position (kneeling or sitting) or in contact with
conductive parts.
Areas which are fully or partially restricted by
conductive elements with which the welder is
likely to make accidental contact.
Welding in wet, damp or humid conditions which
reduces the skin resistance of the body and
insulating properties of accessories.
Where electrically conductive parts have been
insulated close to the welder, there is no
increased shock hazard.
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.
Note: Tubular / Flux Cored wire produces its
own shielding gas and does not require the use
of external shielding gas
The MIG/MAG (Metal Inert Gas / Metal Active
Gas) welding is a versatile technique suitable for
both thin sheet and thick section components in
most metallic materials. In the process, an arc is
struck between the end of a wire electrode and
the work piece, melting both to form a weld
pool. The wire serves as the source of heat (via
the arc at the wire tip) and filler metal for the
joint. The wire is fed through a copper contact
tube (also called a contact tip) which conducts
welding current into the wire. The weld pool is
protected from the surrounding atmosphere by a
shielding gas fed through a nozzle surrounding
the wire. Shielding gas selection depends on the
material being welded and the application. The
wire is fed from a reel by a motor drive, and the
welder moves the welding gun or torch along
the joint line. The process offers high
productivity and is economical because the
consumable wire is continuously fed.
Introduction
This MIG/MAG process uses semiautomatic,
equipment. In semiautomatic welding, the wire
feed rate and arc length are controlled
automatically, but the travel speed and wire
position are under manual control.
Most metallic materials can be welded using the
MIG/MAG welding process. The main
considerations when selecting consumables for
MIG/MAG welding (i.e. filler wire and shielding
gas composition) are:
• Composition to suit parent material
• Mechanical properties required
• Deposition rate
• Welding position
• Bead appearance and penetration profile
8
9
Both wire and shielding gas composition are
essential variables in MIG/MAG welding and will,
therefore, influence the process performance.
Note: Tubular / Flux Cored wire produces its
own shielding gas and does not require the use
of external shielding gas
Key Characteristics:
Wires are available in a wide range of
compositions to suit different metallic materials,
e.g. steels, stainless steels, aluminium alloys,
nickel alloys, titanium alloys
MIG/MAG wires are normally specified by
composition.
Wires are typically supplied with diameters in
the range 0.8mm to 2.4mm
Wires are normally available on 15kg reels,
The wire is often layer wound to ensure smooth
feeding
The flux core produces its own shielding gas
and does not require the use of external
shielding gas
Wire Composition
Selection of the appropriate composition of the
wire electrode can be a difficult task
The selection of consumables should be
confirmed by welding trials
The main sources of information are:
• Electrode manufacturer's handbook
• Electrode manufacturer's technical department
• Parent material manufacturer
• Previous experience.
Carbon and Low Alloy Steels
AWS A5.20: Specification for carbon steel
electrodes for flux cored arc welding.
AWS A5.29: Specification for low alloy steel
electrodes for flux cored arc welding.
Stainless Steels
AWS A5.22: Specification for stainless steel
electrodes for flux cored arc welding and
stainless steel flux cored rods for gas tungsten
arc welding.
Aluminium Alloys
The main concerns when welding aluminium
alloys are the risk of solidification cracking and
porosity. Wires for
AWS A5.10/A5.10M: Specification for bare
aluminium and aluminium alloys welding
electrodes and rods.
Wire Diameter
Selection of the appropriate wire diameter is
dependent on a number of factors, chiefly:
• Mode of metal transfer
• Welding current
• Deposition rate
The electrode manufacturer usually specifies the
typical current ranges of operation for a
particular wire size. It is then a case of ensuring
that the welding current is in the mid-upper
range of current-carrying capability.
Storage of Wires
It is essential that all consumable wires are in
first-class condition. This is particularly so for
MIG/MAG welding where process stability relies
on consistency of wire feed and electrical
contact. In order that this can be achieved and
maintained, the following control measures may
be necessary -
The wire should be in a clean condition with the
minimum of grease and drawn-in dirt. Therefore,
when not in use, reels should be stored
correctly and not left on equipment for long
periods. Dust covers should be used, if
available.
If a wire has been left on the equipment for a
short period of time, it is good practice to run
off at least one layer of wire to remove the worst
of any surface oxidation or contamination that
may have occurred.
For storage, consideration should be given to
factors such as humidity, temperature and.
Reels should be stored at a temperature above
the dew point of the local area.
SAFETY INFORMATION
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.
SaveThese 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.
10
11
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.
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.
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) PowerTool 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.
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.
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.
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.
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.
SAFETY INFORMATION
ELECTRICAL INFORMATION
THIS MIG WELDER REQUIRES A SEPERATE 16AMP OUTLET
IMPORTANT! DO NOT CONNECT TO A STANDARD 13A SOCKET AS THIS WILL OVERLOAD
THE CIRCUIT AND CAUSETHE CIRCUIT BREAKER TO TRIP.
CAUTION:
Seek professional electrical advice on the installation of a 16 amp outlet supply.
12
COMPONENTS
3
10
11
2
5
Component List
1. ON/OFF switch
2. Thermal cut out indicator
3. Carry handle
4. Welding current control switch (Min/Max)
5. Welding current control switch (1/2)
6. Gas pipe attachment point
7. Spool holder spring and collar
8. Plastic knob
9. Pivoted pressure roller bracket
10. Wire liner
11. Roller groove
12. Face mask
13. Flux cored wire
14. Shroud
15. Contact tip
16. Earth clamp
17. Torch
18. Wire feed control
19. Power cable
20. Spool holder fastening knob
21. Guide tube
Technical specification
Input power: 230-240V~50Hz
Phase: 1
Rated no load voltage: 32V DC
Rated input capacity: 3.1kVA
Duty cycle: 20% @ 105A
Output current range: 30-105A
Peak current: 150A
Wire capacity: 0.6-0.9mm
Insulation grade: H
Cooling type: Fan cooled
Torch: Non live
Case protection class: IP21S
External dimensions: 42 x 24.5 x 37.5mm
Weight: 18kg
6
20
7 8 9
4
1
18
19
16
17
1415 12
21
13
13
UNPACKING AND ASSEMBLY
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.
Assembly
Note: Before carrying out any assembly or
disassembly of the unit please ensure that the
unit is not connected to the electrical supply.
Assembling the Face Mask
To assemble the mask bend in the top and side
flaps (Fig.1) and clip into place then attach the
handle and mask glass shield as shown in Fig.2.
Insert the clear glass panel first, followed by the
dark glass panel into the recess in the shield,
i.e. the clear glass MUST be on the outside of
the shield. Securing them with the plastic
screws provided.
The dark panel is a certified, specific optical
class, and should not be exchanged for any
other type.
The clear glass panel should be replaced when
it becomes badly pitted.
Warning! NEVER look at an electric arc without
eye protection as this can injure the eyes
permanently. ALWAYS use a protection mask or
welding helmet.
Installing the Welding Wire
Unscrew the shroud from the end of the torch
then unscrew the contact tip (Fig.3).
Open up the side cover of the welder. If the wire
spool is mounted on the spool holder, it needs
to be removed in order to remove the plastic
wrapper. To do this, proceed as follows:
Unscrew and remove the plastic knob (A),
followed by the spring and collar (B) from the
hub, Fig.4.
Fig 1
Fig 2
Fig 3
Fig 4
Contact tip
Shroud
A B
14
ASSEMBLY
Remove the plastic wrapper then slide the spool
back 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.
Threading the Welding Wire (Fig.5)
Loosen the plastic knob (A) by turning it
anticlockwise, (this device maintains pressure on
the wire).
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.
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.
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.6).
Reposition the pressure roller bracket (C, Fig.5)
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 side panel of the machine and plug
into a 230-240V, 50HZ outlet. Turn the welder On
using the On/Off switch (Fig.7) then holding the
torch straight out from the welder press the
trigger on the torch (Fig.8). The wire feed roller
will operate feeding the welding wire through the
torch.
Do not point the end of the torch at any part of
your body or face, the welding wire is very sharp
and can cause an injury. When the wire has
emerged from the end of the torch release the
pressure on the trigger, turn the On/Off switch to
the Off position then refit the contact tip and
shroud. Finally trim off any excess wire to 3mm
from the end of the contact tip.
Fig 5
Fig 6
Fig 7
Fig 8
A
C
D
B
B
E
D
15
ASSEMBLY
Earth Clamp
Ensure that the area of the work piece where the
earth clamp is to be connected is cleaned using
a file or a grinder to ensure a good electrical
contact. Attach the earth clamp to the work
piece. The earth clamp must only be connected
to the work piece. The area to be welded must
be clean and free from dirt, rust, grease and oil.
Electrode Polarity
The polarity of the electrode can be changed
depending on the material to be welded.
Open up the side cover of the welder and
change the polarity by swapping the position of
the electrode and earth clamp wires on the
terminal connections (Fig.9).
Converting to 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:
Welding Wire: Either Mini or 5kg wire spools, at
0.6mm or 0.8mm diameter.
Contact Tips: The appropriate tip must be used
to suit the thickness of wire being used. i.e.,
8mm wire requires a 0.8mm tip and 0.9mm wire
requires a 1.0mm tip.
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 Impax 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 metal
Attaching Gas Bottle and Regulator
Fit a suitable regulator and gas supply tube onto
your gas bottle (Please note; regulator, gas
supply tube and gas bottle not supplied). Attach
the other end of your gas supply tube onto the
gas pipe attachment point on the back of the
welder (Fig.10).
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.
Adjusting the Output (Fig.11)
Set the amperage using the current control
switch (11.1) and the wire speed control knob
(11.2) located on the front panel, switching from
one setting to another adjusts the output and
wire speed. On thin materials use a low setting
through to a higher speed for thicker materials.
Welding on thick materials will significantly
reduce the duty cycle of the welder.
Fig 9
Fig 10
Fig 11
11.2
11.1
OPERATION
16
Operation
Warning! If you have no welding experience,
we recommend you seek training from an
experienced person.
Caution: This manual is a basic guide to
welding. We recommend you purchase a good
quality welding book to be able to use the
welder to its full potential.
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.
Switching On and Off (Fig.12)
Connect to the mains supply and press the
On/Off switch to the ON position (l) to stop the
machine press the On/Off switch to the OFF
position (0).
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.
Set the correct gas flow (when required) and
amperage output for the material you are
welding.
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.
Position the tip about 6mm from the material to
be welded, hold the face mask in front of your
face then press the trigger on the torch. When
the arc strikes move the torch along the
workpiece. 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.13).
When welding material from 7mm to 30mm thick
prepare the material as shown in Fig.14 filling up
the space with several layers of weld.
When welding together material over 30mm in
thickness prepare the material as shown in
Fig.15 filling up the space with several layers of
weld.
Fig 12
Fig 13
7mm
2-3mm
17
OPERATION
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.
Notes: As MIG welding is an aquired skill, it is
strongly advised that, if you are not fully familiar
with this type of welding, you practise on a
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.
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 from
MIN to MAX, and vice versa. 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.
IMPORTANT – Thermostatic Protection
(Duty Cycle)
This product has a rated duty cycle of 60%. The
percentage represents the welding time in a 10
minute period for example 60% means that the
welding time is 6 minutes with a rest time of 4
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 indicator lamp on the front panel
(Fig.16). After a few minutes the cut out switch
will reset and the welder will be ready for use.
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.
Try to maintain a constant speed of movement
with the torch.
Do not weld in windy conditions or in an area
where ventilation is a problem, or where air flow
fluctuates.
ALWAYS keep the wire and nozzle clean. NEVER
use rusted wire.
Fig 14
Fig 15
>30mm
60º
2-3mm
1
2
4
3
5
6
>30mm
60º
2-3mm
Fig 16
18
MAINTENANCE
Avoid sharp bends or kinks in the welding hose.
Periodically remove the dust, using LOW
PRESSURE compressed air, within the casing.
Adequate heat dissipation is essential during the
welders operation.
Maintenance
Warning! Ensure the welder is disconnected
from the electrical mains power supply before
attempting any service or maintenance.
The welder must be kept clean and dry at all
times. Use a dry cloth to clean the welder.
Keep the shroud and contact tip clean and
ensure all cables are in good condition.
Caution: Water must never come into contact
with the welder.
Regularly check that all the fixing screws are
tight. They may vibrate loose over time.
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 the 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.
19
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE REMEDY
No weld current Blown rectifier. Replace rectifier.
(plug fuse blowing).
No weld current Poor earth clamp connection. Check and clean up connections.
Break in earth lead. Replace earth lead.
Break in torch lead. Replace torch or lead.
Feed motor not working. Defective motor or defective gears. Replace.
Roller rotates but no wire Incorrect roller adjustment. Adjust pressure arm.
feed or uneven wire feed. Deformed welding wire. Check roller tension.
Dirt in torch liner. Clean or replace.
Shroud or contact tip faulty. Replace.
Unstable arc. Incorrect settings. Check settings.
Impurities in the weld area. Clean the weld area prior to
welding.
Faulty shroud. Replace.
Weld current interrupted. Thermal trip has operated. Allow the welder to cool down.
Porous weld. Rusty or dirty joints. Clean the weld area prior to
welding.
Problem with the gas flow. Check the regulator, and gas
hoses.
Torch at wrong angle or too far Check the contact tip. Use a
from the workpiece. windbreak when welding outside.
Irregular weld cap. Torch incorrectly held. Weld with the torch at the correct
distance and angle to the
workpiece.
Wire weaving in weld pool. Check roller tension.
Narrow raised weld cap. Weld speed too fast / weld current Adjust settings. Move the torch
too low. slower.
Weld cap too wide Weld speed too slow / weld current Adjust settings. Move the torch
too high. faster.
Arc too long Move the torch closer to the
workpiece.
Poor penetration. Weld current too low. Adjust settings.
Arc too long Move the torch closer to the
workpiece.
Excessive penetration. Weld speed too slow / weld current Adjust settings.
too high.
Torch is too far from the workpiece. Weld with the torch at the correct
distance and angle to the
workpiece.
20
ENVIRONMENTAL PROTECTION & SYMBOLS
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.
The rating plate on this product may show symbols. These represent important information about the
product or instructions on its use.
Conforms to relevant safety
standards.
Read the instruction manual.
Product conforms to RoHs
requirements
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
Warning! Electrical welding
process
uV
Protect operator and passer
bye from the effect of uV
radiation. This can cause
permanant damage to the
eye. Make sure the arc and
resulting flash is shielded at
all times.
Always wear approved face
mask with correct filter,
gloves and apron to protect
against welding operation
Do not use this welder in
damp conditions
Keep bystanders and pets
clear of the welding power
supply when in use.
21
SYMBOLS
Symbols and Technical Data
European standard relating to Welding Power Supply’s for limited use
IM-MIG150 Type ID
Single phase transformer
Metal inert & active gas welding including the use of flux cored wire
50Hz Nominal mains frequency
S Suitable for welding in an environment with increased hazard of electric shock
U
0
No load voltage
…A/…V to …A/…V Range of output
X% Duty cycle
I
2
Conventional welding current
U
2
Conventional load voltage
U
1
Mains voltage
I
1
max Maximum absorbed current
I
1
eff Effective supply current
IP21S Grade of protection
Standardized plug
Suitable for welding in an environment with increased hazard of electric shock
S
EN 60974-1:
1998+A1+A2
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