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Everlast POWER i-MIG 200E, Operator'S Manual

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EVERLAST

 

POWER i

-

MIG 200E

 

MIG/GMAW WELDER

 

Rev. 1       0 100041419

 

everlastwelders.com                                        

 

1

-

877

-

755

-

9353

 

Specifications and Accessories subject to change without notice.

 

380 Swift Ave. Unit 12 South San Francisco, CA    94080  USA

 

Operator

’

s Manual  for the

 

Power i

-

MIG 200E MIG Welder

 

General Use and Setup Guide

 

IGBT

 

DC

 

GMAW

 

CV

 

Summary of Contents for POWER i-MIG 200E

Page 1: ...1419 everlastwelders com 1 877 755 9353 Specifications and Accessories subject to change without notice 380 Swift Ave Unit 12 South San Francisco CA 94080 USA Operator s Manual for the Power i MIG 200E MIG Welder General Use and Setup Guide IGBT DC GMAW CV ...

Page 2: ...duction and Specifications General Description Purpose and Features Set Up Guide and Component Identification Suggested Settings Installation of Filler Wire and Machine Setup Front Panel View Side View Rear Panel View Expanded View of MIG Torch Trouble Shooting General Notes 3 4 5 9 9 9 14 15 16 18 20 22 23 24 ...

Page 3: ...on the forum daily We also divide our support into two divisions technical and welding performance Should you have an issue or question concerning your unit please contact performance technical support available through the main company headquarters available in your country This support is free to all Everlast customers For best service call the appropriate support line and follow up with an emai...

Page 4: ...om forums index php Main toll free number 1 877 755 WELD 9353 9am 5pm PST M F Technical Support Extension 207 9am 5PM EST M F FAX 1 650 588 8817 Everlast Canada Everlast consumer satisfaction email sales everlastwelders ca Everlast Website everlastwelders ca Everlast Technical Support mike everlastwelders ca Telephone 905 637 1637 9am 4pm EST M Th 9am 12pm EST Fri FAX 1 905 639 2817 Everlast Austr...

Page 5: ...have read this manual and you are thoroughly familiar with its safe operation If you feel you need more information please contact Everlast Support Do not operate this welder unless you are fully aware of proper welding procedures and are ready to assume the responsibility of safe operation and the consequences of failing to do so The warranty does not cover improper use maintenance or consumables...

Page 6: ... equipment If no protection is available exclude them from the work area Even brief exposure to the rays from the welding arc can damage unprotected eyes Always wear hearing protection because welding and cutting can be extremely noisy Ear protection is necessary to prevent hearing loss Even prolonged low levels of noise has been known to create long term hearing damage Hearing protection also fur...

Page 7: ...ny burning of the eyes nose or throat are signs that you need to increase ventilation Stop immediately and relocate work if necessary until adequate ventilation is obtained Stop work completely and seek medical help if irritation and discomfort persists WARNING Do not weld on galvanized steel stainless steel beryllium titanium copper cadmium lead or zinc without proper respiratory equipment and or...

Page 8: ...Keep all combustible materials including rags and spare clothing away from area Keep all flammable fuels and liquids stored separately from work area Visually inspect work area when job is completed for the slightest traces of smoke or em bers If welding or cutting outside make sure you are in a cleared off area free from dry tender and debris that might start a forest or grass fire Do not weld on...

Page 9: ...ameter V groove for hard wire Solid Wire 023 030 6 8mm standard 035 9mm optional Flux Core Optional recommend diameter is 035 9mm OCV 70V Fan Continuous Insulation F Water Ingress Protection Standard IP21S NOTE Environment Maintenance and Safety Keep the welder at least 10 12 inches away from all objects for proper cooling Exceeding 40 C in the operating envi ronment will reduce the rated duty cyc...

Page 10: ...he Everlast SM 3035 gun Use 035 diameter wire for best results Stainless can be welded with either the spool gun or the standard gun Using a spool gun may be a more practical choice if welding smaller projects with stainless or aluminum since both stainless and aluminum wires are expensive Either coated copper or other coatings or uncoated steel wire may be used for welding steel as long as it rem...

Page 11: ...ay occasionally experi ence an overcurrent This can happen if the wire is not trimmed to an appropriate length and the gun is touched held too far away when starting the arc Rem edy all other causes first before assuming this is the issue This may also occur if the contact tip is touched to the metal when starting the arc It can oc cur if the gun nozzle has excess slag bridging inside of the nozzl...

Page 12: ...ust decrease gas flow until the weld begins to bubble and exhibit porosity Gradually increase the gas flow until the bubbles disappears completely Crack the adjustment on the regulator an small additional amount to ensure full gas coverage This process will reduce waste and help ensure you are not intro ducing oxygen into the weld As the pressure drops within the cylinder readjustment may be neces...

Page 13: ... in this formula represents inches per amp This formula is only a guide and is only accurate in lower ranges as the function is not truly linear But it usually will be within the overall range speci fied by the manufacturer For each manufacturer the filler wire diameter amp range may differ somewhat though a general range can be established 1 7 Spool Gun The spool gun is an optional but useful too...

Page 14: ...i Mix Ar He CO2 MIG GMAW ALUMINUM 100 Argon GAS SELECTION GUIDE Table 2 WIRE DIAMETER WELDING AMPS A PLATE THICKNESS GAS FLOW RATE 023 0 6 25 120 040 125 15 20 CFH 7 10 lpm 030 0 8 35 200 040 187 20 25 CFH 10 14 lpm 035 0 9 45 250 063 250 20 30 CFH 10 16 lpm MIG GMAW CURRENT WIRE THICKNESS GENERAL SUGGESTIONS Table 3 General Reference Information for Operation and Parameters NOTES AND FAVORITE SET...

Page 15: ...o feed wire until the wire exits the end of the torch Remove contact tip if necessary to feed out wire 8 Adjust tensioner clockwise until drive rolls will not slip when the wire comes into contact with a hard surface a block of wood and the wire will curl up on end Re member to keep wire away from metal that is attached to the work clamp to pre vent the wire from accidentally arcing A B C Setup Gu...

Page 16: ...QUICK CONNECT FOR MIG SPOOL GUN 200 1 LED Indicators ON TEMP OVERCURRENT 5 SPOOL GUN CONTROL 4 SPOOL GUN SWITCH 3 WIRE SPEED AMP ADJUSTMENT 2 VOLTAGE ADJUSTMENT 6 WORK CLAMP CONNECTOR Setup Guide and Component Identification Section 2 ...

Page 17: ...le voltage results in a ropey narrow weld with poor fusion Too much voltage results in an erratic violent arc and undercutting 3 Wire Speed Amp Selector The wire speed se lector controls amperage throughout the range by varying the speed of the wire The relationship between wire feed speed and amps is a direct one Increasing one increases the other Actual amp output at the same given wire speed wi...

Page 18: ...18 SIDE VIEW _ 2 Polarity Connection 1 Wire Spool Holder Assy 4 Wire Feeder Assy Setup Guide and Component Identification Section 2 ...

Page 19: ...P with the work clamp serving as the negative output terminal Also known as reverse polarity For flux core use see the wire manufacturer s direction for polarity recommendation 3 Wire Feed Assembly Note the numbers on the side of the tensioner These numbers are a refer ence point to help properly tension the wire so that the drive roller will not slip Do not over tension the wire because it can cr...

Page 20: ...20 REAR VIEW BACK PANEL 3 Power Input Cable 1 Gas Connector Barb Type 2 Main Power Switch 4 Fan Setup Guide and Component Identification Section 2 ...

Page 21: ...nnect the pigtail adapter to this plug No rewiring or changing of polarity is required to operate on 120V The unit senses the change automatically and adjusts output accordingly 4 Fan The welder fan is designed to run continu ously while the unit is switched on It may con tinue to run for up to 5 seconds after the welder has been switched off while the capacitors dis charge This is normal and not ...

Page 22: ...omponents Tighten the contact tip and contact tip s adapter to spanner tightness The MIG torch liner may eventually become worn and will need to be replaced When welding aluminum a Teflon liner must be used necessitating a liner change A spool gun is the preferred method to weld Al To change the liner 1 Remove the securing nut of the liner 17 which exposes the end of the wire guide 2 Straighten th...

Page 23: ...amaged Check setting Check knob Replace poten tiometer Control circuit damaged Check the board Wire reel turns or tries to turn inter mittently The tensioner is loose or wire slips on rollers Increase tension The drive roller does not fit the diameter of weld wire Change roller or wire size to match Wire Spool is damaged Change out wire spool Gun liner is jammed Repair or change it clear wire from...

Page 24: ... it If you incorrectly adjust the welder while weld ing aluminum in the MIG process you will burn up contact tips almost instantly 5 If you are trying to weld Aluminum with 030 wire or smaller you may not achieve ade quate results because of the higher wire feed speeds needed Try stepping up to the next wire size and wire feed speed rate requirements will drop 6 If using with a generator use with ...

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