EVERLAST POWER i-MIG 200E MIG/GMAW WELDER CV GMAW IGBT DC Operator’s Manual for the Power i-MIG 200E MIG Welder General Use and Setup Guide Rev. 1 everlastwelders.com 0 100041419 Specifications and Accessories subject to change without notice. 1-877-755-9353 380 Swift Ave.
Table of Contents Section……………………………………………….Page Letter to the Customer …………………....………… Everlast Contact Information…………….…………. Safety Precautions…………………………………… Introduction 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 …...……………………....………..
Dear Customer, THANKS! You had a choice, and you bought an Everlast Product. tomer and hope that you will enjoy years of use from your welder. We appreciate you as a cus- Please go directly to the Everlast website to register your unit and download your warranty information. Your unit registration is important should any information such as product updates or recalls be issued. It is also important so that we may track your satisfaction with Everlast products and services.
Serial number: ____________________________ Model number: ____________________________ Date of Purchase:__________________________ Contact Information Everlast US: Everlast consumer satisfaction email: sales@everlastwelders.com Everlast Website: everlastwelders.com Everlast Technical Support: tech@everlastwelders.com Everlast Welding Support: performance@everlastwelders.com Everlast Support Forum: http://www.everlastgenerators.com/forums/index.
Safety Precautions Everlast is dedicated to providing you with the best possible equipment and service to meet the daily demands of welding. We want to go beyond delivering a satisfactory product to you. That is the reason we offer technical support to assist you with your needs should an occasion occur. With proper use and care your product should deliver years of trouble free service. Safe operation and proper maintenance is your responsibility.
Safety Precautions These safety precautions are for protection of safety and health. Failure to follow these guidelines may result in serious injury or death. Be careful to read and follow all cautions and warnings. Protect yourself and others. Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can cause severe skin burn and damage. There are other potential hazards involved with welding such as severe burns and respiratory related illnesses.
Safety Precautions WARNING! Persons with pacemakers should not weld, cut or be in the welding area until they consult with their physician. Some pacemakers are sensitive to EMF radiation and could severely malfunction while welding or while being in the vicinity of someone welding. Serious injury or death may occur! Welding and plasma cutting processes generate electro-magnetic fields and radiation.
SAFETY PRECAUTIONS WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground clamp. Do not stand in water or damp areas while welding or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain or in extremely humid conditions. Use dry rubber soled shoes and dry gloves when welding or cutting to insulate against electrical shock.
Section 1 Introduction and Specifications Overview of Parameters and Features Power i-MIG 200E Power i-MIG 200E Specification Construction Type IGBT Inverter Dimensions 17.5”L x 13.5”H x 8.5”W Weight (Unit Only) 25 lbs. Input Voltage/Phase/Hertz 120/240V 1 Phase/ 50/60Hz Maximum Input Amps (I1MAX) 120/240V 28.7A/28.2A Rated Input Amps (I1EFF) 15A/15A Duty Cycle at Rated Output 25% @ 115A/19.75V; 25% @ 180A/23V Output Range (Amps; Volts): 120/240V 120V: 30-115A; 15.5-19.75V / 30-200A; 15.
Section 1 Introduction and Specifications 1.1 General Description, Purpose and Features. The Power i-MIG 200E is a portable MIG (GMAW) welder designed for light repair and fabrication. The unit operates on 120V or 240V V single phase input and comes equipped with a standard 120V NEMA 6-50P plug for convenient use in almost any standard 240V outlet. The unit includes a 240V to 120V pigtail adapter.
Section 1 Introduction and Specifications welder will stop welding. If this happens, allow the welder to continue to idle and cool for 15 minutes. After giving the unit time to cool, cycle the power switch off and back on to reset the welder and resume welding. Lowering the welder output will increase the duty cycle duty cycle. This welder has a rating of 25% @ 180 amps when operating 240V and 25% @ 115A when operating on 120V.
Section 1 Introduction and Specifications until the bubbles disappears completely. Crack the twist the nozzle like a screw to install or remove as adjustment on the regulator an small additional it grips the nozzle tightly. There is a special retainamount to ensure full gas coverage. This process ing spring under the nozzle that acts as a thread. will reduce waste and help ensure you are not introThis feature allows you to position the nozzle in ducing oxygen into the weld.
Section 1 Introduction and Specifications violent and irregular. Note that point as well. Lower the voltage to a point midway between the two extremes where the arc seems to even out. After the voltage is set, gradually adjust the wire feed/amps until the sound of the arc is crisp. Listen to the arc. A steady sizzle, or whine should be present. The weld puddle should be wetting out neatly on the edges of the weld. This sound has often been referred to as a “frying” sound.
Section 2 Setup Guide and Component Identification General Reference Information for Operation and Parameters GENERAL POLARITY RECOMMENDATIONS* Table 1 *Consult manufacturer directions of filler material. There are exceptions.
Section 2 Setup Guide and Component Identification INSTALLATION OF FILLER WIRE AND MACHINE SETUP TO LOAD WIRE SPOOL: 1. 2. 3. 4. 5. 6. Loosen the oblong thumb nut (inside of cover) by turning it counter-clockwise. Remove the spring, then the outer support collar. Slide spool onto shaft. Make sure wire is unwrapping from bottom of the spool. Turn support collar so shallow side of should faces “in” for 8” spools, out for 4” spools. Reinsert spring then tighten the thumb nut clockwise.
Section 2 Setup Guide and Component Identification FRONT VIEW 1. LED Indicators: ON/TEMP/OVERCURRENT 2. VOLTAGE ADJUSTMENT 3. WIRE SPEED/AMP ADJUSTMENT 4. SPOOL GUN SWITCH 200 WIRE SPEED 5. SPOOL GUN CONTROL 6. WORK CLAMP CONNECTOR 3.
Section 2 Setup Guide and Component Identification Front Panel: 1. LED Indicators. The LED’S indicate the existing status of the machine. The On indicator is lit anytime the machine is turned on . The amber color light will be lit when the duty cycle has been exceeded. When it is lit, welding will be interrupted. (The wire will continue to feed but will not arc when the trigger is pressed.
Section 2 Setup Guide and Component Identification SIDE VIEW 2. Polarity Connection 1. Wire Spool Holder Assy. - _ + + + 4. Wire Feeder Assy. .
Section 2 Setup Guide and Component Identification Regularly monitor any metal flaking and dirt build up that may occur around the feeder. Clean it away gently with compressed air as necessary. Use proper safety attire while doing this, i.e. glasses, gloves etc. to prevent injury. Do not use cleaners or solvents. Felt wire lubricators may be bought and used to keep feeding cleanly while using steel or stainless wire. You may purchase additional drive rolls from Everlast for flux core use. Side Panel: 1.
Section 2 Setup Guide and Component Identification REAR VIEW/BACK PANEL 2. Main Power Switch 1. Gas Connector (Barb Type) . 3. Power Input Cable 4.
Section 2 Setup Guide and Component Identification Rear Panel: 1. 2. 3. 4. Gas Supply. Connect the Gas regulator hose to this point via the brass barb fitting. The hose barb connection must be tight to prevent gas leakage. Install an extra clamp if needed to prevent gas from escaping. Test for leaks with soapy water. Do not leave gas valve open on cylinder when not attended or in use. Power Switch. Turns unit on or off. Power Input Cable. The unit operates on 120V or 240V input power.
Section 2 Setup Guide and Component Identification EXPANDED VIEW OF MIG TORCH NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PARTS Diffuser D.12 14-15AK Contact Tip 0.8/M6*25 15AK Goose gun neck assy. Adapter for goose neck Plastic adapter MIG gun handle Torch switch 21.8mm Screw D.
Section 3 Trouble Shooting NO.
GENERAL NOTES: 1. While welding aluminum with the Spool gun or MIG gun you must use 100% argon. You cannot use a mix as you would with steel or stainless. 2. While welding aluminum with the Spool gun or MIG gun you must use the next size up tip or a special oversize tip for the wire because the heat will cause the aluminum wire to swell and it will either drag or seize in the tip. 3.
