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AC/DC MP200i WELDER

ASSEMBLY AND OPERATING INSTRUCTIONS

Item #65375

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Summary of Contents for MP200i

Page 1: ...AC DC MP200i WELDER ASSEMBLY AND OPERATING INSTRUCTIONS Item 65375 ...

Page 2: ...d 80 Gal 7 5 HP Compressor Eastwood 80 Gal 5 HP Compressor Eastwood 60 Gal 4 7 HP Compressor Eastwood 60 Gal 3 7 HP Compressor Eastwood Panoramic Welding Helmet Eastwood 30 Gal 1 9 HP Compressor Eastwood XL View Welding Helmet Eastwood Lg View Welding Helmet Eastwood Auto Darkening Helmet Concours 2 HVLP Paint Gun Items not covered under this warranty Consumables unless deemed defective are not co...

Page 3: ...ATION 15 MIG MODE USER INTERFACE OPERATION 15 MIG SHIELDING GAS FLOW ADJUSTMENT 16 MIG WELDING 16 MIG WELDING TECHNIQUES 17 SPOOL GUN SET UP AND OPERATION Spool Gun Available Separately 19 SPOOL GUN WELDING 21 TIG WELDING SET UP 22 TIG WELDING OPERATION 24 DC TIG MODE USER INTERFACE OPERATION 24 AC TIG MODE USER INTERFACE OPERATION 25 TIG WELDING 26 STICK WELDING SET UP 27 STICK WELDING OPERATION ...

Page 4: ...32 Gas Lens Collet Body 8 Gas Lens Style Gas Cup 3 32 Collet Long Back Cap Collet Body Installed J 1 Foot Pedal 16 4 85m Cable K 2 Cable Hose Hangers L 2 Gas Flowmeter CO2 Argon M 1 Adapter Cord 24 0 6m N HARDWARE ACCESSORIES BOX B 15 M5 x 12mm Screws aa 3 M5 Nuts bb 6 M5 Flat Washers cc 3 M5 Lock Washers dd 2 Gas Cylinder Chains 36 0 9m ee 1 0 030 0 8mm MIG Gun Contact Tip ff 1 0 035 0 9mm MIG Gu...

Page 5: ...0 8V 120A 24 8V Rated Duty Cycle MIG 40 200A 60 170A 100 130A 60 80A 100 60A Rated Duty Cycle TIG 50 200A 60 180A 100 140A 60 100A 100 80A Rated Duty Cycle STICK 40 200A 60 170A 100 130A 60 60A 100 50A Starting Method TIG Lift Start DC Only or High Frequency Power Factor 0 73 Efficiency 80 Wire Feed Speed MIG 39 590 in min Post Flow Time TIG 0 0 30 0 s Welding Wire Diameter MIG 0 023 0 035 Cooling...

Page 6: ...nsiderable distances at high velocity igniting flammable or exploding vapors and materials DO NOT operate electric arc Welder in areas where flammable or explosive vapors are present DO NOT use near combustible surfaces Remove all flammable items from the work area where welding sparks can reach minimum of 35 feet Always keep a fire extinguisher nearby while welding Use welding blankets to protect...

Page 7: ...jure the lungs and other organs Use enough ventilation and or exhaust at the arc to keep fumes and gases from your breathing area Use an OSHA approved respirator when welding in confined spaces or where there is inadequate ventilation Never weld coated materials including but not limited to cadmium plated galvanized lead based paints powder coat BUILDUP OF GAS CAN INJURE OR KILL Shut off gas suppl...

Page 8: ...ounting points which can allow the Welder to fall causing severe injury DO NOT exceed the rated 450 lbs 205kg weight capacity DO NOT use as a seat DO NOT stand or step on the Welder Use on a flat and level surface only DO NOT use on sloped surfaces DO NOT LIFT WELDER WITH CYLINDERS INSTALLED Lifting the Welder by the top handle with welding gas cylinders installed could result in failure at the mo...

Page 9: ...Lift and support the rear end of Welder A Use nine M5 x 12 Screws aa and Washers cc five at the underside FIG 2 four at the rear FIG 3 to attach the Rear Wheel Tray Assembly C to the underside and rear of the cabinet GAS CYLINDER BRACKETS With flanges facing downward attach the two Gas Cylinder Brackets D to the rear of the cabinet with three M5 x 12 mm Screws aa for each support FIG 4 FIG 1 FIG 1...

Page 10: ...djustments This is particularly helpful when making a large change in settings 3 Menu Button Pressing the menu button will allow the Knob to change alternate parameters Long presses meaning the press is held for approximately three seconds will open the user menu where in depth process specific changes can be made 4 Foot Pedal Indicator Illuminates when the Foot Pedal is connected in TIG mode 5 VR...

Page 11: ...ng welding gas bottles larger than 125CF If a larger bottle is being used it must be secured separately Use proper equipment procedures and have adequate help when moving or lifting cylinders Shielding Gas Bottles are NOT INCLUDED with the Eastwood Elite AC DC MP200i but are necessary to MIG and TIG welding They can be bought at most local Welding Supply Stores The Eastwood Elite AC DC MP200i is c...

Page 12: ... MIG The Welder must also be set to MIG mode by pressing the MODE SELECTION BUTTON 6 and configured for solid wire welding This is detailed further in MIG MODE USER INTERFACE OPERATION CHANGING THE POLARITY FOR FLUX CORED MIG DCEN WELDING Setup the Welder as described above The Welder will automatically swap polarity when set to FLUX mode This is detailed further in MIG MODE USER INTERFACE OPERATI...

Page 13: ...wire at this point SETTING THE WIRE TENSION ADJUSTER To set the tension on the wire incrementally tighten the Spool Retaining Wingnut at the center of the Spindle until there is a slight resistance to spinning the wire spool on the Spindle If the tension is set too loose the wire spool will freely spin on the shaft and unspool all the wire If the tension is too tight the Drive Roller will have dif...

Page 14: ... Thread the welding wire feeding from the underside of the spool and forward through the Guide Tube then over the wire Drive Roller and into the Wire Feed Hole FIG 15 Replace the Tension Arm and re latch the Wire Tensioner back into place FIG 15 Connect the Welder to a power supply and turn the ON OFF Switch h on the Rear Panel to the ON position Set the process via the Mode Selection Button on th...

Page 15: ...d wire welding profile for use with 100 CO2 gas MIG welding It is designed to compensate for the hotter welding with this gas FLUX For gasless welding utilizing flux cored wire Automatically swaps polarity to DCEN ALUM Spool Gun mode for MIG welding aluminum with a 20172 Spool Gun WIRE DIAM Select the wire diameter in inches you are utilizing INDU The inductance setting controls the rate of curren...

Page 16: ...clamp to the workpieces that are to be welded Make sure the ground clamp contacts are placed on a clean piece of metal free of paint grease rust oils etc It is recommended to place your ground clamp as close to the welding area as possible Assess the general work area and make sure the welding area is also cleaned of any paint grease rust oils etc Plug in the Welder and move switch to the ON posit...

Page 17: ...lt in a lower bead height which will require minimal finishing Consult the Suggested Settings Chart on the inside of the Side Panel Door and set the Voltage and Wire Speed appropriately Get some pieces of scrap metal of the same thickness and verify that the settings will work for the specific weld you will be making Once the settings have been fine tuned tack weld the final pieces in place and re...

Page 18: ...joint between two pieces where the edges re being joined TEE WELD is a joint between two pieces where one is perpendicular to the other CORNER WELD is a joint between two pieces that meet at or near perpendicular at their edges LAP WELD is a joint between two overlapping pieces PLUG WELD is a joint which joins two overlapping pieces by filling in a hole punched in the top piece ...

Page 19: ...ther leak or not be able to pass through the connection to the end of the Spool Gun Remove the MIG Gun Trigger plug and install the Spool Gun Trigger Plug to the MIG Gun Trigger Wire Connector b at the Front Upper Panel INSTALLING THE GROUND CABLE AND CLAMP The Ground Cable Clamp installation is the same as for the MIG Gun see INSTALLING THE GROUND CABLE AND CLAMP FOR SOLID WIRE MIG DCEP WELDING W...

Page 20: ... pressure onto the welding wire IMPORTANT NOTE If this is too tight it will deform the wire and cause feeding issues if it is too loose the Drive Roller will slip on the wire Install the Cover and fasten the threaded knob to retain it Unthread the Nozzle and using the included Contact Tip Wrench hh Remove the Contact Tip from the end of the Spool Gun Connect the Welder to a power supply and turn t...

Page 21: ... and move the Power Switch at the Rear Panel to the ON position Set the Welder to MIG mode and select the ALUM process in the User Menu for Spool Gun welding see MIG MODE USER INTERFACE OPERATION Open the valve on the Argon shielding gas bottle and adjust the flow rate if necessary Depress the Spool Gun Trigger for a few seconds pointing the welding gun away from your body and then let go of the t...

Page 22: ...rom the Front Panel Insert the Foot Pedal Plug and fasten the security lock TORCH DISASSEMBLY Make sure the Welder is turned off and unplugged Remove the Back Cap from the Torch If there is a tungsten installed in the Torch pull it out from the front of the Torch Slide the Collet out of the Torch rear Unscrew and remove the Gas Nozzle Unscrew and remove the Collet Body FIG 18 TORCH ASSEMBLY Select...

Page 23: ...ate needs to be adjusted so that the proper amount of Shielding Gas is flowing over the weld If there is too little gas flow there will be porosity in the resulting welds as well as excessive spatter If there is too much gas flow this will be wasting gas and may affect the weld quality The included Regulator has 2 indicators on it the gauge on the left is Flow Rate while the gauge on the right is ...

Page 24: ... them To save and exit automatically do not adjust anything for five seconds and it will return to the default view STRT Start allows you to switch the starting method for DC TIG welding There are two options HF High frequency start allows the torch to begin the arc without physical touching the workpiece It only needs within approximately 1 4 to start LIFT Lift start is an older method of startin...

Page 25: ...sing the Menu Button will then cycle to the following options BASE Base is setting the percentage of the set amps you wish for the low side of the pulse to be Adjustable from 5 95 PEAK Peak is setting the percentage of the set amps you wish for the high side of the pulse to be Adjustable from 5 95 USER MENU Long pressing the Menu Button holding it for three seconds will open the User Menu where th...

Page 26: ...e the Dip and Pull technique with the Filler Metal Rod and Torch Dip and Pull is the practice of forming a puddle moving the Torch while maintaining the puddle and adding filler rod metal to the puddle by dipping and pulling as you go being careful not to allow the Tungsten to contact the puddle or rod Keep in mind that you MUST let the shielding gas flow over the weld after releas ing the Trigger...

Page 27: ...wise until it is tight FIG ARC DCEP Locate the Electrode Holder with 14 8 4 5m Cable H and connect the plug on the cable end to the Electrode Holder Connector e on the Front Lower Panel of the Welder To connect the plug line up the key on the plug with the keyway on the socket of the Welder insert the plug and twist clockwise until it is tight FIG ARC DCEP ARC DCEN Utilize the Mode Selection Butto...

Page 28: ...rode is best for use with clean bare steel and is suitable for moderate penetration Electrode Amperage Chart Electrode Diameter Amperage Range IN MM 6010 6011 3 32 1 8 5 32 3 16 2 4 3 2 4 0 4 8 6013 1 16 5 54 3 32 1 8 5 32 3 16 1 5 2 0 2 4 3 2 4 0 4 8 7014 3 32 1 8 5 32 2 4 3 2 4 0 7018 3 32 1 8 5 32 2 4 3 2 4 0 7024 3 32 1 8 5 32 2 4 3 2 4 0 Ni Cl 3 32 1 8 5 32 3 16 2 4 3 2 4 0 4 8 308L 3 32 1 8 ...

Page 29: ...e stick is moved closer to the workpiece in order to maintain the same overall power output The higher the set percentage the greater this effect is USER MENU Long pressing the Menu Button holding it for three seconds will open the User Menu where the below settings can be adjusted Pressing the Menu Button will cycle through them and scrolling the Adjustment Knob will change them To save and exit ...

Page 30: ...trode holder must be held so that the electrode is in a downward angle moving in the direction of the weld joint To stop welding simply lift the electrode away from the workpiece When finished welding remove the electrode from the holder and turn off the Welder ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH Improper use of an electric Welder can cause electric shock injury and death Read all precautions...

Page 31: ...To order parts and supplies 800 343 9353 eastwood com 31 DATA CHART ...

Page 32: ...hine and lower the outputs to prevent overloading again Digital Displays Show ERR 02 Unit Overheated and Went Into Thermal Protection Mode Allow the Welder to cool for a minimum of 15 minutes or until the error display goes out If error is still flashing after 15 minutes restart the Welder Digital Displays Show ERR 03 Wire Feeding Malfunction Contact Eastwood Technical Assistance at 800 343 9353 o...

Page 33: ...s Attached to Work Piece Check that the correct welding ground from Welder being used is attached to the work piece MIG Gun Contact Tip is Excessively Worn Replace MIG Gun Contact Tip Intermittent Welding Arc Incorrect Input Voltage Check power supply The Elite AC DC MP200i requires a properly grounded 240 Volt AC 50 Amp power supply or a properly grounded 120 Volt AC 20 Amp power supply Wrong Siz...

Page 34: ... Gun closer to the work piece to shorten the length of exposed wire Material Too Thick The Elite AC DC MP200i is rated for a maximum thickness of 3 8 Exceeding this will result in poor penetration Poor Material Preparation If welding heavy gauge metals it may be necessary to increase the welding gap between the two pieces and also bevel the edges on the weld side of the pieces Excessive Penetratio...

Page 35: ...metal making sure to remove any oil debris coatings or moisture If base metal is aluminum make sure all of the oxide is removed using either a dedicated stainless brush or flap wheel Incorrect AC Balance Decrease AC Balance to increase penetration and decrease cleaning effect Porosity in Weld Bead Poor Gas Flow Adjust the flow rate of the shielding gas Check for loose fittings where gas could be l...

Page 36: ...pearance Crater in the End of the Weld Bead Insufficient Shielding Effect Keep the torch on the base metal while the post flow shielding gas flows to protect and cool the metal and tungsten Not Enough Filler Material Reduce current with Pedal and add more filler at end of weld It may also be beneficial to back step to ensure no crater will form Weld Bead is Cracking Too Much Heat in Material Reduc...

Page 37: ...le welding keep the ignited end of the electrode closer to the weld joint Current Too High Adjust the current on the front of the Welder to a lower current setting Poor Penetration Poor Joint Preparation Clean the weld joint of any dirt grease paint of other possible contaminates If the pieces being Welder are of a heavy gauge it may be necessary to bevel the edges of the pieces Current Too Low Ad...

Page 38: ...38 Eastwood Technical Assistance 800 343 9353 tech eastwood com NOTES ...

Page 39: ...To order parts and supplies 800 343 9353 eastwood com 39 NOTES ...

Page 40: ...ns Style Gas Cup 10 Pack 20658 TIG Torch 12 Gas Lens Style Gas Cup 10 Pack 12822 1 16 Collet 12824 3 32 Collet 12825 Long Back Cap OPTIONAL ITEMS 19015 MIG Welders Pliers 55070 55071 Leather MIG Welding Gloves M L 55068 55068 Leather TIG Welding Gloves M L 12762 L XL XXL Cotton Welding Jacket 55065 L XL XXL Leather Welding Jacket 21484 XL View Auto Darkening Welding Helmet 21483 Large View Auto Da...

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