Colton Weldtek iMIG 400S User manual

iMIG 400S
SYNERGIC MIG WELDING MACHINE
SAFETY DEPENDS ON YOU
Colton arc welding equipments are designed and built with safety in mind. However proper
installation and operation on your part can increase your overall safety. DO NOT INSTALL,
OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS OPERATING MANUAL
AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
OPERATOR’S MANUAL
COLTON WELDTEK PVT LTD
BANGALORE

Safety precautions
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE
SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD
CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
BE SURE THAT ONLY QUALIFIED INDIVIDUALS PERFORM ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES
For Engine Powered equipments
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work
requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine
and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine
parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands,
hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting,
operating or repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to perform required maintenance.
Remove guards only when necessary and replace them when the maintenance requiring their
removal is complete. Always use the greatest care when working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by
pushing on the throttle control rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator
during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as
appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. 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.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult
their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects, which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from
the welding circuit:
2.d.1. Route the electrode and work cables together secure them with tape when possible.
2.d.2. Never coil electrode lead around your body.
2.d.3. Do not place your body between your electrode and work cables. If the electrode cable is on
your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the work piece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
ELECTRIC SHOCK can kill
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch
these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large
enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically
hazardous conditions (in damp locations or wearing wet clothing; on metal structures such as floors,
gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high
risk of unavoidable or accidental contact with the work piece or ground) use the following
equipment:

Semiautomatic DC Constant Voltage (Wire) Welder
DC Manual (Stick) Welder
AC Welder with Reduced voltage control
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or
semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded.
The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe
operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders
because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of
the arc when welding or observing open arc welding. Head shield and filter lens should conform to
ANSI Z87.I standard.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of
your helpers from the arc rays.
4.c. protect other nearby personnel with suitable, non-flammable screening and/or warn them not to
watch the arc nor expose themselves to the arc rays or to hot spatter or material.

FUMES AND GASES can be dangerous
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and
gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at
the arc to keep fumes and gases away from the breathing zone. When welding with electrodes
which require special ventilation such as stainless or hard facing (see instructions on container or
MSDS) or on lead or cadmium and plated steel and other materials or coatings which produce
highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using
local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are also required when welding on galvanized
steel.
5.b. The operation of welding fume control equipment is affected by various factors including proper use
and positioning of the equipment, maintenance of the equipment and the specific welding procedure
and application involved. Worker exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or
spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a
highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough
ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this equipment and the consumables to be
used, including the material safety data sheet (MSDS) and follow your employer’s safety practices.
MSDS forms are available from your welding distributor pr from the manufacturer.
5.f. Also see item 1.b.

WELDING AND CUTTING SPARKS can cause fire or explosion.
6.a. Remove fire hazardous from the welding area. If this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding sparks and hot materials from welding
can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to
prevent hazardous situations. Refer to “Safety in Welding & Cutting” (ANSI Standard Z59.1) and the
operating information for the equipment being used.
6.c. 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.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure
that such procedures will not cause flammable or toxic vapors from substances inside. They can
cause an explosion even though they have been “cleaned”. For information, purchase
“Recommended Safe Practices for the Preparations for Welding and Cutting of Containers and
Piping That Have Hazardous Substances”, AWS F4.1 from the American Welding Society (see
address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as
leather gloves, heavy shirt, high shoes and a cap over your hair. Wear earplugs when welding out
of position or in confined places. Always wear safety glasses with side shields when in a welding
area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables
connected to the building framework or other locations away from the welding area increase the
possibility of the welding current passing through lifting chains, crane cables or other alternate
circuits. This can create fire hazards or overheat lifting chains or cable until they fail.
6.h. Also see item 1.c.
6.i. Do not use a welding power source for pipe thawing.

CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and
properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should
be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
Away from areas where they may be struck or subjected to physical damage
A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should be always be in place and hand tight expect when the cylinder is in use
or connected for use.
FOR ELECTRICALLY powered equipment
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with all local cedes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s
recommendations.

.
Principle & Technical data
iMIG series welding machine Block diagram
Block diagram of principle
This series welding machines applies IGBT soft switch inverter technology. 3- phase power supply is
rectified, inverted into high frequency AC using soft switch technology, transformed into low voltage
using HF transformer, rectified and filtered by fast recovery diodes & choke and suitable for welding. in
this process, the power source dynamic response has been greatly increased, so the size and weight
are reduced noticeably. Power source provides high-quality performance even during input/output
fluctuations
Volt/Ampere curve
Power supply
Rectifier
HF
inverter
Main
transformer
Rectifier
&Filter
Control
circuit
+
-
U(V)
-
80
-
60
-
40
-
20
-
0
U2=14+0.05I2
I(A)

1. Main technical parameters
Model
iMIG 400S
iMIG 500S
Rated input voltage (V)
Three phase
415V±10%/50Hz
Three phase
415V±10%/50Hz
Rated input power (KVA) @100%
11
17
Rated input current (A)
27
35
Rated output voltage(V)
34
39
Open circuit voltage (V)
70
80
Range of welding voltage (V)
14-45
14-50
Range of welding current (A)
60-400
60-500
Wire diameter (mm)
0.8-1.6
0.8-1.6
Rated duty cycle (%)
60%
60%
Efficiency(%)
89
89
Power factor
0.87
0.87
Wire feeder type
Wire pushing
Wire pushing
Weight (kg)
40
42
Dimension (mm3)
650 × 320 × 565
650 × 320 × 565

2. Components list
No.
Items
iMIG 400S
iMIG 500S
1
Circuit Breaker
1
1
2
Rectifier 3-phase
1
1
3
EMI Filter coil
1
1
4
PCB EMI filter
1
1
5
Capacitor DC link C1
1
1
6
IGBT module
2
2
7
Capacitor C2-C5
4
4
8
Inductor input L1
1
1
9
Capacitor snubber IGBT C6
1
1
10
Diode Fast Recovery
2
3
11
PCB IGBT protection
1
1
12
PCB Current sensor
1
1
13
Inductor switching L2
1
1
14
Capacitor C9
1
1
15
Inductor HF transformer L3
1
1
16
Main Transformer T1
1
1
17
Inductor output L4
1
1
18
Sensor output current
1
1
19
PCB output protection OPB-15
1
1
20
Terminal output
2
2
21
Connector J-1/1
1
1
22
Control transformer T2
1
1

23
PCB IGBT soft drive
1
1
24
Connectror J-2/1
1
1
25
Circuit breaker 6A
1
1
26
Fuse 2A
1
1
27
Thermostat TH-1
1
1
28
PCB iMIG control
1
1
29
PCB iMIG display
1
1
30
Fan
1
1

Features & Applications
iMIG series inverter CO2/MIG welders are high-quality performers that can be used for semi-automatic
CO2gas shield welding with solid or flux-cored wire (Ф0.8-Ф1.6mm) for welding mild steel and low alloy
steel work apart from MMAW. This series welder enjoys excellent static characteristic and sound
dynamic characteristic.
Features and benefits:
Capable of presetting welding current or wire feeding speed.
Capable of presetting wire diameter selection.
Capable of presetting shield gas selection.
Capable of presetting material selection.
Enjoying synergic function.
Optional remote control box.
Perfect functions of starting arc and reducing melting ball while end arc.
Capable of operation with extended 50M long welding cable.
Applications:
Suitable for mild steel and alloy steel welding.
Electric power, petrochemical Constructions.
Automobiles.
Metal shop.
Equipment manufacture.
Boiler Pressure vessel manufacture.
Shipyards.
Steel structure workshops.
Light and heavy industries.
This series welding machine is strictly in line with National standard IEC 60974-1.

Installation Guide
1．Pre-installation
1.1 Installation Environment
iMIG series welding machine are designed for use in adverse environments. Examples
of environments with increased adverse conditions are:
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;
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;
In wet or damp hot locations where humidity or precipitation considerably reduces the skin
resistance of the human body and the insulation properties of accessories.
Environments with adverse conditions do not include places where electrically conductive
parts, in the near vicinity of the operator, which can cause increased hazard, have been
insulated.
The gradient of ground must not be more than 10°
Ensure no wind at the welding position, or use screen to block the wind.
When using water-cooled torches, care must be taken to de-freeze.
Welding power sources with degree of protection IP23S may be stored, but are not
intended to be used outside during precipitation unless sheltered.
1.2. Installation Location
Be sure to locate the welder according to the following guidelines:
In areas, free from moisture and dust.
Ambient temperature between 0 degrees C to 40 degrees C.
In areas, free from oil, steam and corrosive gases.
In areas, not subjected to abnormal vibration or shock.
In areas, not exposed to direct sunlight or rain.
Place at a distance of 12" (304.79mm) or more from walls or similar boundaries that could

restrict natural airflow for cooling.
1.3 Power Source Connections
Warning
Thermal Arc advises that this equipment be electrically connected by a qualified
electrician.
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source; disconnect the input power employing
lockout/tagging procedures.
Lockout/tagging procedures consist of pad locking line; disconnect switch in open
position.
Removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other
disconnecting device.
1.4．Power Supplier Requirements
Input volt must be standard sine wave, effective value 400V±10%, frequency 50Hz.
Unbalance degree of 3- phase volt must be no more than 5%
Model
iMIG 400S
iMIG 500S
Power supply
415V / 3phase
415V / 3phase
Min. capacity
Power network
20KVA
25KVA
Generator
30KVA
40KVA
Input volt
protection
Fuse
30A
40A
Circuit breaker
32A
63A
Cable size
(cross-section)
Input volt
≥4mm2
≥6mm2
Output volt
50mm2
70mm2
Ground lead
≥2.5mm2
≥2.5mm2
Power supply connection
Please note: The size of fuse and breaker in the table are for reference only.
2. Installation:
This series welder is small, light and portable. It will be more convenient if place them on the trolley.

Ensure the welder is placed at a even location.
The outside connection of the welder is shown in figure 5:
Outside Connection Diagram
4.1 Preparation prior to operation procedure:
(1) Connect the welder’s terminal plug (-) to work piece.
(2) Connect the welder’s terminal plug (+) to wire feeder by welding cable.
(3) Connect the welder’s control cable socket to wire feeder by control cable.
(4) Connect feeder’s gas hose to CO2 regulator.
(5) Connect the regulator’s heater cable to the welder’s “gas heater power “cable socket. (on the
rear panel)
(6) Connect the welder’s 3-phase power cable to the switch board, and grounds the lead safely.
(7) Reset the air switch on the welder’s rear panel.
5. Operating procedure:
Turn on the MCB on the rear panel. Press on the “Inch feeding” button and regulate the current knob
on the controller, the feeder will begin to feed wire. Set the parameters on the front panel and
controller according the welding demand. When the torch trigger is pulled, the feeder start to feed
wire, and CO2will blow out of the nozzle, making it ready to be used for welding. Operators can select
parameters from table listed below. Be sure to turn off the gas regulator or valve of gas cylinder and

unplug the power cord while not welding.
Welding current（A）
Welding voltage（V）
Suitable wire（mm）
60-80
17-18
Ф0.8、Ф1.0
80-130
18-21
Ф1.0、Ф1.2
130-200
20-24
Ф1.0、Ф1.2
200-250
24-27
Ф1.0、Ф1.2
250-350
26-32
Ф1.2、Ф1.6
Suggested voltage and Ampere for different wire size
It is better to choose torch in accordance with EN60974-12
Please refer to appendix B for EMC suggestions for installation and use of welder.

Operating Instruction
1. Panel illustration
1.1 Quick plug socket for welding cable (-)
Connect to workpiece through output cable.
1.2 Control socket
The control socket is a 7 pin MS-style connector to communicate between the power source &
the wire feeder. Connect the control cable.
1.1 Control panel
The control panel is used for functional selection and setting some welding parameters. The panel includes
7 segment LED Display, knobs, touch keys and LED indicators.

1.3.1 Functional selection
1.3.1.1 Wire diameter selection key
Selecting wire diameter among Φ1.6, Φ1.2, Φ1.0 & 0.8mm, and the related LED will light on.
1.3.1.2 “Individual/Synergic” selection key
Select individual/synergic mode. On “Individual” mode, welding current and voltage can be adjusted
individually by regulating controller of wire feeder. On “Synergic” mode, welding voltage automatically
adjusts to welding current based on the preset selections of Material, Wire diameter & Gas. You can
adjust the welding voltage slightly by regulating “voltage” knob. When the synergic mode is activated,
the related LED will light on.
1.3.1.3 “Gas test” key
The gas flows out for about 30 seconds when pressed on and the related LED will light on. Stop gas
flowing when pressed again in 30 seconds.

1.3.1.4 “Wire Inch” key
The wire feeds when pressing on the key and the related LED will light on. Stop feeding by releasing the
key. (It has the same function as to press the inching button on the wire feeder controller)
1.3.1.5 PROCESS selection key
Selecting the different processes “MMAW/GMAW (NORMAL-SYNERGIC)/ GMAW (ROOT WELD)/
GMAW (FORCEARC)”and the related LED will light on.
1.3.1.6 Mode selection key
Selecting 2-step, 4-step, Advanced 4-step or arc spot welding and the related LED will light on.
(1) 2-step: Perform welding when push torch trigger, stop welding when release the trigger. This mode is
suitable for welding the short weld.
(2) 4-step: After successfully starting arc by push torch trigger, then you can perform welding by release
the trigger, when you pull torch trigger again, torch will turn into crater-filling condition which was preset
by stop-arc knobs on the front panel. The welder will stop welding when release the trigger. This mode is
suitable for welding long weld.

(3) Advanced 4-step: This mode provides additional features to the normal 4-step where start weld &
end weld features is incorporated.
(4)Arc spot welding: After successfully starting arc by push torch trigger, the welder will stop welding
automatically at the end of arc spot welding time. If release the trigger during arc spot welding, the
welder will stop welding immediately.
1.3.1.7 Material selection key
Select the required material to be welded and the related LED will light on.
1.3.1.8 Gas selection key
Select the required shielding gas to be welded and the related LED will light on.