Everlast POWER i-MIG 200 User manual

Brand: Everlast

Model: POWER i-MIG 200

Category: Welding System

Type: User manual

EVERLAST

POWER i-MIG 200

Rev. 2 0 1020101-15

everlastwelders.com

1-877-755-9353

Specicaons and Accessories subject to change without noce.

329 Lileeld Ave. South San Francisco, CA 94080 USA

Operator’s Manual for the Power i-MIG 200

Safety, Setup and General Use Guide

CC/CV mig/stick WELDER

GMAW/smaw

SMAW

IGBT

GMAW

120/240V

Table of contents

Section……………………………………………….Page

Letter to the Customer …………………....…………

Everlast Contact Information…………….………….

Safety Precautions……………………………………

Introduction and Specifications…..…………………

Overview of Parameters and Specifications…….

Technical Parameters……………………………...

General Description, Purpose and Features…….

Set Up Guide and Component Identification….…...

Suggested Settings…….…………………...……..

Connections and Polarity………………………….

Installing MIG Wire ……..………...……………….

Front View Main Panel……………………….……

Front Panel Item Description and Explanation….

Side View …………………………………..……....

Side View Item Description and Explanation..…..

Rear View Back Panel……………………………..

Rear Panel Item Description and Explanation…..

Basic MIG Operation…..…………………………..

Stick Operation……………………………………..

General Notes Concerning Operation……………

Expanded View of MIG Torch……………………..

Trouble Shooting……………………………………..

NOTE: Environment, Maintenance and Safety: Keep this welder at least 12 inches away from all objects for proper cooling.

Do not exceed 40° C in environment or duty cycle will be reduced. Regularly inspect and clean the welder and circuitry on a

quarterly basis with dry compressed air. Remove the covers only aer the unit has been turned o and unplugged for 30

minutes to discharge the capacitors and to prevent the possibility of electrocuon. Do not grind or throw sparks near to the

welder to prevent damage to the panel face and internal components. Damage of this nature is not covered by the warranty.

Dear Customer,

THANKS! You had a choice, and you bought an Everlast Product. We appreciate you as a customer and hope

that you will enjoy years of use from your welder.

Please go directly to the Everlast website to register your unit and receive your warranty informaon. Your unit

registraon is important should any informaon such as product updates or recalls be issued. It is also important

so that we may track your sasfacon with Everlast products and services. If you are unable to register by web-

site, contact Everlast directly through the sales department at the main customer service number in your country.

Your unit’s warranty will be registered and in full eect. Keep all informaon regarding your purchase, including

date of purchase and receipt. In the event of a problem with your unit or other issue you must contact technical

support before your welder can be a candidate for warranty service and returned. An over-the-phone review/

diagnosis must be performed BEFORE a RMA will be issued or before the unit can be sent in for service.

Please read the warranty statement published online and other important informaon found on the Everlast

website of the division located in or nearest to your country. This includes the terms of the purchase and war-

ranty procedure. Print it for your records and become familiar of its terms and condions. Please note that

Guns, accessories and torches are covered under a separate, shorter warranty. Please be sure you visit the web-

site and are familiar with all the warranty terms before you call for service.

Everlast oers full technical support, in several dierent forms. We have online support available through email,

and a welding support forum designed for our customers and noncustomers to interact with each other. Technical

advisors are acve on the forum daily. We also divide our support into two divisions: technical and welding per-

formance. Should you have an issue or queson concerning your unit, please contact performance/technical sup-

port available through the main company headquarters available in your country. This support is free to all Ever-

last customers. For best service call the appropriate support line and follow up with an email, especially during

weekends, holidays or any o hours when you cannot reach a live person. In the event you do not reach a live

person, leave a message and your call will normally be returned within 24 hours, except for weekends and holi-

days. Also for quick answers to your basic quesons, join the company owned forum available through the web-

site. You’ll nd knowledgeable sta available to answer your quesons. You also may nd a topic that already

addresses your queson at hp://www.everlastgenerators.com/forums/. Should you need to call or write, always

know your model name, purchase date and welder manufacturing inspecon date. This will assure the quick and

accurate customer service. REMEMBER: Be as specic and informed as possible. Technical and performance

advisors rely upon you to carefully describe the condions and circumstances of your problem or queson.

Take notes of any issues as best you can. You may be asked many quesons by the advisors to clarify problems

or issues that may seem very basic. However, diagnosis procedures MUST be followed to begin the warranty

process. Advisors can’t assume anything (even with experienced users) and must cover all aspects to properly

diagnose the problem. Depending upon your issue, it is advisable to have basic tools handy such as screwdriv-

ers, wrenches, pliers, and even an inexpensive test meter with volt/ohm funcons before you call.

Let us know how we may be of service to you should you have any quesons.

Sincerely,

Everlast Customer Service

Serial number: _____________________________

Model number: _____________________________

Date of Purchase:___________________________

Contact Information

Everlast US:

Everlast consumer satisfaction email: [email protected]m

Everlast Website: everlastwelders.com

Everlast Technical Support: support@everlastwelders.com

Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php

Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F

11am-4pm PST Sat.

FAX: 1-650-588-8817

Everlast Canada:

Everlast consumer satisfaction email: [email protected]

Everlast Website: everlastwelders.ca

Everlast Technical Support: sales@everlastwelders.ca

Telephone: 905-630-8246 9am-4:30pm EST M-F

10am-1pm EST Sat.

FAX: 1-905-639-2817

Everlast Australia:

Sydney: 5A Karloo Parade Newport NSW 2106

(02) 9999 2949

Port Macquarie: 2B Pandorea Place Port Macquarie

(02) 6584 2037

After hours support: 0410 661 334

Everlast Technical Support: [email protected]

OTHER (Please record here for your records):

Everlast is dedicated to providing you with the best possible equipment and service to meet the

demanding jobs that you have. We want to go beyond delivering a sasfactory product to you.

That is the reason we oer 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 operaon and proper maintenance is your responsibility.

We have compiled this operator’s manual to instruct you in basic safety, operaon and mainte-

nance of your Everlast product to give you the best possible experience. Overall, welding re-

quires experience and common sense to obtain the best results in the safest manner. As thor-

ough as this welding manual may be, it cannot substute for the me, instrucon and

knowledge level required to learn how to weld. Exercise extreme cauon and care in all acvi-

es related to welding or cung. Your safety, health and even life depends upon it. While an

accident is never planned, prevenng an accident requires careful planning.

Please read this manual carefully before you operate your Everlast unit. Do not operate this

welder unl you are thoroughly familiar with its safe and proper operaon. If you feel you

need more informaon please contact Everlast.

The warranty does not cover improper use, maintenance or consumables. Accessories such as

guns, torches regulators, foot pedals etc. are not covered in the unit warranty. They are cov-

ered under a separate warranty. Do not aempt to alter or defeat or otherwise render any

piece or part of your unit unserviceable, parcularly any safety device. Keep all shields and

covers in place during unit operaon should an unlikely failure of internal components result in

the possible presence of sparks and explosions. If a failure occurs, disconnue further use unl

malfunconing parts or accessories have been repaired or replaced by qualied personnel.

Note on High Frequency electromagnec disturbances:

Certain welding and cung processes generate High Frequency (HF) waves. These waves may

disturb sensive electronic equipment such as televisions, radios, computers, cell phones, and

related equipment. High Frequency may also interfere with uorescent lights. Consult with

an electrician if disturbance is noted. Somemes, improper wire roung or poor shielding may

be the cause.

HF can interfere with pacemakers. See EMF warnings in following safety secon for further in-

formaon. Always consult your physician before entering an area known to have welding or

cung equipment if you have a pacemaker.

Safety Precautions

SAFETY PRECAUTIONS

These safety precauons are for protecon of safety and health. Failure to follow

these guidelines may result in serious injury or death. Be careful to read and follow all

cauons and warnings. Protect yourself and others.

Welding and cung processes produce high levels of ultraviolet (UV) radiaon that can cause se-

vere skin burn and damage. There are other potenal hazards involved with welding such as severe

burns and respiratory related illnesses. Therefore observe the following to minimize potenal acci-

dents and injury:

Use appropriate safety glasses with wrap around shields while in the work area, even under weld-

ing helmets to protect your eyes from ying sparks and debris. When chipping slag or grinding, gog-

gles and face shields may be required.

When welding or cung, always use an approved shielding device, with the correct shade of lter

installed. Always use a welding helmet in good condion. Discard any broken or cracked lters or

helmets. Using broken or cracked lters or helmets can cause severe eye injury and burn. Filter

shades of no less than shade 5 for cung and no less than shade 9 for welding are highly recommend-

ed. Shades greater than 9 may be required for high amperage welds. Keep lter lenses clean and

clear for maximum visibility. It is also advisable to consult with your eye doctor should you wear con-

tacts for correcve vision before you wear them while welding.

Do not allow personnel to watch or observe the welding or cung operaon unless fully protected

by a lter screen, protecve curtains or equivalent protecve equipment. If no protecon is availa-

ble, exclude them from the work area. Even brief exposure to the rays from the welding arc can

damage unprotected eyes.

Always wear hearing protecon because welding and cung can be extremely noisy. Ear protec-

on is necessary to prevent hearing loss. Even prolonged low levels of noise has been known to

create long term hearing damage. Hearing protecon also further protects against hot sparks and

debris from entering the ear canal and doing harm.

Always wear personal protecve clothing. Flame proof clothing is required at all mes. Sparks and

hot metal can lodge in pockets, hems and cus. Make sure loose clothing is tucked in neatly. Leather

aprons and jackets are recommended. Suitable welding jackets and coats may be purchased made

from re proof material from welding supply stores. Discard any burned or frayed clothing. Keep

clothing away from oil, grease and ammable liquids.

Leather boots or steel toed leather boots with rubber booms are required for adequate foot pro-

tecon. Canvas, polyester and other man made materials oen found in shoes will either burn or

melt. Rubber or other non conducve soles are necessary to help protect from electrical shock.

Flame proof and insulated gauntlet gloves are required whether welding or cung or handling met-

al. Simple work gloves for the garden or chore work are not sucient. Gauntlet type welding

gloves are available from your local welding supply companies. Never aempt to weld with out

gloves. Welding with out gloves can result in serious burns and electrical shock. If your hand or body

parts comes into contact with the arc of a plasma cuer or welder, instant and serious burns will oc-

cur. Proper hand protecon is required at all mes when working with welding or cung machines!

SAFETY PRECAUTIONS

WARNING! Persons with pacemakers should not weld, cut or be in the welding area unl they

consult with their physician. Some pacemakers are sensive to EMF radiaon and could severely

malfuncon while welding or while being in the vicinity of someone welding. Serious injury or death

may occur!

Welding and plasma cung processes generate electro-magnec elds and radiaon. While the

eects of EMF radiaon are not known, it is suspected that there may be some harm from long term

exposure to electromagnec elds. Therefore, certain precauons should be taken to minimize expo-

sure:

 Lay welding leads and lines neatly away from the body.

 Never coil cables around the body.

 Secure cables with tape if necessary to keep from the body.

 Keep all cables and leads on the same side the body.

 Never stand between cables or leads.

 Keep as far away from the power source (welder) as possible while welding.

 Never stand between the ground clamp and the torch.

 Keep the ground clamp grounded as close to the weld or cut as possible.

Welding and cung processes pose certain inhalaon risks. Be sure to follow any guidelines from

your chosen consumable and electrode suppliers regarding possible need for respiratory equipment

while welding or cung. Always weld with adequate venlaon. Never weld in closed rooms or con-

ned spaces. Fumes and gases released while welding or cung may be poisonous. Take precauons

at all mes.

Any burning of the eyes, nose or throat are signs that you need to increase venlaon.

 Stop immediately and relocate work if necessary unl adequate venlaon is obtained.

 Stop work completely and seek medical help if irritaon and discomfort persists.

WARNING! Do not weld on galvanized steel, stainless steel, beryllium, tanium, copper, cadmium,

lead or zinc without proper respiratory equipment and or venlaon.

WARNING! This product when used for welding or cung produces fumes and gases which con-

tains chemicals known to the State of California to cause birth defects and in some cases cancer.

(California Safety and Health Code §25249.5 et seq.)

WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas. Release of Phos-

gene gas can be deadly. Consider all chemicals to have potenal deadly results if welded on or near

metal containing residual amounts of chemicals.

Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain regulaons re-

garding high pressure cylinders can be obtained from OSHA or local regulatory agency. Consult also

with your welding supply company in your area for further recommendaons. The regulatory changes

are frequent so keep informed.

All cylinders are a potenal explosion hazard. When not in use, keep capped and closed. Store

chained so that overturn is not likely. Transporng cylinders incorrectly can lead to an explosion. Do

not aempt to adapt regulators to t cylinders. Do not use faulty regulators. Do not allow cylinders to

come into contact with work piece or work. Do not weld or strike arcs on cylinders. Keep cylinders

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 cung. Keep work surface dry. Do not

use welder or plasma cuer in the rain or in extremely humid condions. Use dry rubber soled shoes

and dry gloves when welding or cung to insulate against electrical shock. Turn machine on or o

only with gloved hand. Keep all parts of the body insulated from work, and work tables. Keep away

from direct contact with skin against work. If ght or close quarters necessitates standing or resng

on work piece, insulate with dry boards and rubber mats designed to insulate the body from direct

contact.

All work cables, leads, and hoses pose trip hazards. Be aware of their locaon and make sure all

personnel in area are advised of their locaon. Taping or securing cables with appropriate restraints

can help reduce trips and falls.

WARNING! Fire and explosions are real risks while welding or cung. Always keep re exn-

guishers close by and addionally a water hose or bucket of sand. Periodically check work area for

smoldering embers or smoke. It is a good idea to have someone help watch for possible res while

you are welding. Sparks and hot metal may travel a long distance. They may go into cracks in walls

and oors and start a re that would not be immediately visible. Here are some things you can do to

reduce the possibility of re or explosion:

 Keep all combusble materials including rags and spare clothing away from area.

 Keep all ammable fuels and liquids stored separately from work area.

 Visually inspect work area when job is completed for the slightest traces of smoke or embers.

 If welding or cung outside, make sure you are in a cleared o area, free from dry tender and

debris that might start a forest or grass re.

 Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held amma-

ble liquid or material.

Metal is hot aer welding or cung! Always use gloves and or tongs when handling hot pieces of

metal. Remember to place hot metal on re-proof surfaces aer handling. Serious burns and injury

can result if material is improperly handled.

WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper mainte-

nance is your responsibility. Make sure all equipment is properly maintained and serviced by qualied

personnel. Do not abuse or misuse equipment.

Keep all covers in place. A faulty machine may shoot sparks or may have exploding parts. Touching

uncovered parts inside machine can cause discharge of high amounts of electricity. Do not allow em-

ployees to operate poorly serviced equipment. Always check condion of equipment thoroughly

before start up. Disconnect unit from power source before any service aempt is made and for long

term storage or electrical storms.

Further informaon can be obtained from The American Welding Society (AWS) that relates directly

to safe welding and plasma cung. Addionally, your local welding supply company may have addi-

onal pamphlets available concerning their products. Do not operate machinery unl your are com-

fortable with proper operaon and are able to assume inherent risks of cung or welding.

Section 1

Introduction and Specifications

Overview of Parameters and Features*

Power i-MIG 200**

Amp Range (MIG) 110V/120V: 30-125 Amps 220V/240V: 30-200 Amps

Volt Range (MIG) 110/120V: 15.5-20.3V 220V/240V: 15.5-26 Volts

Duty Cycle at Max Rated Amps MIG: 35% @ 200 Amps Sck 35% @ 160 Amps

Wire Feed Speed Up to 600 IPM

Input Voltage 120/240V

Welder Type IGBT inverter type with CC/CV MIG Sck funcons

Wire roll size and diameter .023”-.045” (with oponal drive rolls and contact ps)

Spools up to 8” in diameter (10-12 lbs)

Addional Features Burn back control, Auto Pre-ow Post-ow, Arc Force

control, Analog input with Digital Micro-controller, Spool

gun ready. Euro Quick connector, Sck Funcon.

Accessories 15 Series MIG torch 10 . (3m), Work clamp 10 . (3m)

300 A Sck Torch, Regulator , 240/120V adapter

*See next page for complete technical specicaons and data.

**Specicaons subject to change without noce. Quanty and appearance of the accessories are also subject to change without noce.

W: 235mm/ 9.25”

H: 420 mm/16.5”

L: 560mm/22”

Weight: 25 Kg/ 55 lbs

Section 1

Introduction and Specifications

MODEL: Power i-MIG 200

SERIAL NO.

EN/ IEC60974.1

110V: 30-125A; 15.5-20.3V 220V: 30-200 A; 15.5-26 V

35% 60% 100%

U0 V

I2 (220V) 200 A 160 A 130 A

U2 (220V) 24V 22V 20.5V

I2 (110V) 125A 100A 75A

U2 (110V) 20.3V 19V 17V

110V: 10-100A; 20.4V-24V 220V: 10-160 A; 20.4-24 V

X 35% 60% 100%

U0 V

I2 (220V) 160 A 130 A 100 A

U2 (220V) 26.4 V 25.2 V 24 V

I2 (110V) 100A 80A 60A

U2 (110V) 24V 23.2V 22.4V

1~ 50/60 Hz

110-220V

110 V I1MAX: 33A I1EFF20 A

220 V I1MAX: 36 A I1EFF22 A

240 V I1MAX: 34 A I1EFF20 A

PROTECTION:

IP21S

COOLING METHOD: FULL TIME FAN INSULATION: F

WIRE SPEED FEED RATE*: 60-600 INCHES PER MINUTE

EVERLAST

MIG/STICK INVERTER

*Wire speed feed rate at minimum setting will be 0. 60 IPM is based on useable minimum feed rate.

1.1 General Descripon, Purpose and Features. The

Power i-MIG 200 is a versale and compact MIG/Sck

welder capable of delivering professional quality welds.

Operang on an input of 120V or 240V 50/60Hz (1

phase), the CC/CV IGBT inverter welder is perfectly suit-

ed for many MIG and Sck welding tasks anywhere

power is available. The Power i-MIG 200 can be used

with .023”-.045” wire and features an 8” diameter spool

capacity. (Requires addional drive rollers.) The welder

is equipped with these standard features:

1) GMAW Process (MIG). The digitally controlled

MIG components precisely control arc funcons

and give real-me feed back about the welding

output parameters. The welder is also spool gun

ready for economical welding of Stainless and Alu-

minum wires if needed. (Spool gun is oponal.) It

also may be used with ux core wire when

equipped with the oponal ux core drive wheel.

2) SMAW (Sck). In sck mode the welder delivers a

smooth DC low spaer arc. Professional, high-

quality welds are obtainable with ER 7018, 7014,

309L, 316, 6011 and many specialty rods that are

designed for use with any sck welder.

3) Arc Force Control. Used with both MIG and Sck

funcons, the arc force control adjusts the quality

of the arc. In MIG mode, the arc force control is

used to adjust the current rise me. This deter-

mines how wet or s the arc feels and the pinch

point of the wiring as it feeds into the puddle. In

Sck mode, the arc force is used to adjust the amp

reacon by adjusng how much the amps are

boosted when the arc is held close and voltage

drops below 20 Volts. This helps prevent rod sck-

ing. Just as in MIG mode, in Sck mode, the Arc

force helps change the way the arc feels and re-

acts. This feature is somemes referred to as “dig”.

4) Burn Back Control. Burn back control is used to

control the length of the wire sck out aer the

trigger is released. It helps prevent scking of the

wire to the weld and saves the user from having to

trim the wire before restarng.

1.2 Basic Design and Construcon. The Power i-MIG 20

uses analog input and then couples it with a digitally

controlled IGBT inverter to produce a stable arc while

consuming less power than equivalent transformer

based welders. Everlast ulizes quality components

from US, European, and Asian based companies for

trusted reliability and parts commonality. Welding pa-

rameters can be innitely and connuously adjusted

while the unit is in operaon, oering instant welding

response for maximum control. The unit also features

spool gun compability to economically expand it’s

capability for welding aluminum and other expensive

metals that lend themselves well to smaller and less

costly spools of wire. It can also be ed with oponal

ux-core drive rollers for applicaons where solid MIG

wire is not the best soluon.

1.3 Installaon. The basic construcon of the Power i

-MIG is rugged and durable, and is considered ideal for

circumstances where portability is of concern. Crical

components are protected by coangs to make the

welder environmentally resistant and has a water in-

gress rang of IP21S, (the standard in the welding in-

dustry to protect from vercally dripping water). How-

ever, some care and common sense should be taken to

make sure that the welder oers the safest and best

performance. Please note the following items regard-

ing safe operaon:

1) Do not use the welder in damp or wet areas. Per-

spiraon and other forms of water in contact with

the body can increase the risk of electrocuon.

2) Do not use the welder in extremely corrosive envi-

ronments. To maintain opmum power transfer,

check main connecons, clamps and cables fre-

quently to ensure that components are not corrod-

ed. Excessive dirt, corrosion and oxidaon can re-

sult in an unstable arc and excessive heat build-up.

1.4 Duty Cycle/Overcurrent. The Power i-MIG 200 has

a duty cycle rang of 35% at 200 Amps while welding in

MIG mode and a rang of 35% @ 160 Amps while weld-

ing in sck mode. The duty cycle rang is the amount

of me (expressed as a percentage) out of 10 minutes

the unit can weld without a rest. For MIG, the unit is

capable of welding 3.5 minutes out of every 10 minutes

at the maximum output of 200 Amps. For the balance

of the 10 minute period, the unit should be allowed to

rest and cool while running. This rang is based o a

40° C maximum temperature. If the unit’s duty cycle

has been exceeded. the temperature light (idened by

the thermometer icon) will come on and unit will cease

welding output. If a duty cycle event has occurred, al-

low the unit to run and cool for 15 minutes. Aer 15

minutes cooling, cycle the power switch to reset the

unit. In the event of an overcurrent, the welding out-

put will cease and the Overcurrent light will come on.

(In duty cycle and overcurrent events, the wire will con-

nue to feed). Overcurrent events can be caused by too

low of supply voltage, running on undersized extension

cords, too large of wire diameter, too high of sengs

for wire diameter, too high of input voltage, or internal

or external electrical fault. When an overcurrent has

occurred, turn the machine o immediately, then check

and remedy the fault before switching the welder back

on.

Introduction and Specifications

Section 1

Setup Guide and component Identification

Section 2

PROCESS

TORCH POLARITY WORK POLARITY

MIG (GMAW)

+ -

FLUX CORE (FCAW)

- +

STICK (SMAW)

+ -

GENERAL POLARITY RECOMMENDATIONS*

*Consult manufacturer direcons of ller material. There are excepons!

Table 1

PROCESS GAS

MIG (GMAW) STEEL 80/20 Ar/CO2 or 75/25 Ar/CO2 for short Circuit MIG

MIG (GMAW) STAINLESS 98/2 Ar/O2 or TriMix

MIG (GMAW) ALUMINUM 100% Argon

GAS SELECTION GUIDE

Table 2

WIRE DIAMETER WELDING AMPS (A) PLATE THICKNESS GAS FLOW RATE MAX

.023” (0.6) 25-110 .040”-.063” (1.0-1.6) 15-20 CFH /7-10 lpm

.030” (0.8) 35-200 .040”-.128” (1.0-3.2) 20-25 CFH/ 10-14 lpm

.035” (0.9) 45-250 .040”-.128”.(1.0-3.2) 20-30 CFH/ 10-16 lpm

.040” (1.0) 45-250 .050”-.25”+(1.2-6.0+) 25+ CFH/ 14+ lpm

.045” (1.2) 60-250 .25”+ (6.0+) 25+ CFH/ 14+lpm

MIG (GMAW) CURRENT/WIRE/SINGLE PASSTHICKNESS GENERAL SUGGESTIONS

METAL THICKNESS ELECTRODE SIZE WELDING AMPS

< 1 mm/.040” 1.5 mm/ 1/16” 20-40

2 mm/.080” 2 mm/3/32” 40-90

3 mm/ 1/8” 3.2 mm/1/8” 90-110

4-5 mm/ 3/16” 3.2-4 mm/ 1/8”-3/16” 90-130

6-12 mm/ 1/4”-1/2” 4–5 mm/ 3/16” 130-200

DC STICK (SMAW) OPERATION GUIDE

Table 3

Table 4

TORCH + WORK -

EVERLAST

GAS TO REAR OF WELDER

SPOOL GUN (OPTIONAL)

CONTROL

Setup Guide and component Identification

Section 2

CONNECTIONS AND POLARITY

MIG

WORK -

MIG

STICK

MIG*

SPOOL GUN

* For Flux Core, install work in positive and

change polarity under the access cover. Be

sure to use the special serrated drive rollers

for Flux Core, which are available as an option.

Contact Everlast to purchase additional drive

rolls. See next page for instructions on chang-

ing polarity and drive rollers.

TO INSTALL MIG GUN (TORCH):

A. Align pins on the torch connector with the feeder receptacle.

B. Fully engage the connector into the receptacle.

C. By hand, twist the knurled nut on connector clockwise until it is snug.

DO NOT OVERTIGHTEN! USE HAND PRESSURE ONLY.

TO THREAD WIRE INTO FEEDER:

1. Loosen top idler tensioner, rotating the black tensioner knob counter-clockwise

2. Flip the tensioner down, releasing the top drive roll carrier arm.

3. Raise top drive idler roller. Inspect the drive roll to make sure that the groove size

matches the wire diameter.

4. Reversal of the lower roller may be necessary. To reverse the roller, remove the

black thumb screw securing the drive roll. Pull the drive roll off, and flip the drive

roll over. Reassemble and tighten roller. If larger roller is needed, contact Everlast.

5. Thread straightened wire into coiled sheath and over grooves in lower drive roll.

Thread through until it threads into the gun section 3”-4”. Lower the upper drive roll

onto lower drive roll, keeping the wire securely fixed in the groove of the feed roller.

Make sure the correct size groove has been selected.

6. Raise tensioner back into place. Tighten slightly so wire will feed. Notice markings

on tensioner for future reference.

7. Hold torch straight out as possible. Press gun trigger to feed wire until the wire

exits the end of the torch.

8. Adjust tensioner clockwise until drive rolls will not slip when the wire comes into

contact with a hard surface and the wire will curl up on end. Remember to keep

wire away from metal that is attached to the work clamp to prevent the wire from

arcing while performing this test.

TO LOAD WIRE SPOOL:

1. Loosen and remove the hand nut by turning it counter-clockwise.

2. Align the locating pin with the hole on the wire spool (if present).

3. Slide spool onto the shaft. Make sure wire is unwinding from the bottom of the spool.

4. Use a 8mm hex wrench to adjust tension (Hex screw located under hand nut)

5. Lightly spin the spool. If it free-wheels more than 1/4 turn, tighten hex screw. If it does

not free-wheel at all, loosen hex screw until it free wheels 1/4 turn.

6. Reinstall Hand nut so the spool is retained securely.

7. Locate end of wire and clip the bent end of the wire so that it will feed through the wire

feed mechanism smoothly. Carefully hold the spool of wire with one hand so the wire

will not despool. Proceed to instructions listed below: “To thread wire into feeder”

Setup Guide and component Identification

Section 2

INSTALLING MIG WIRE

Bottom Drive Roll (See side for stamped size)

.8mm=.030”-.035” 1.0mm=.040”-.045”

.6mm=.023”-.025” .8mm= .030”-.035”

.9mm-.035” 1.2mm=.045”

FRONT VIEW/ MAIN PANEL POWER i-MIG 200

4. Amp/Wire Speed Display

MIG: Wire Speed (while static)

Stick: Amps

2. Volts Display

12. Process Selector

10. MIG Torch Euro Connector

9. Positive Connector

Flux Core: Work Clamp

Stick: Torch

8. Negative Connector

MIG: Work Clamp

Stick: Work Clamp

7. Control (Spool Gun)

Setup Guide and component Identification

Section 2

1. Protective Cover

5. LED Indicators: ON/TEMP/OVERCURRENT

6. Amp/Wire Speed Adjustment Knob

MIG: Wire Speed (in/min) Stick: Amps

3. Arc Force Control: MIG/Stick

11. Adjustment Knob:

MIG Volts

Front Panel Descripon and Explanaon:

1. Protecve Cover. The unit features a protecve

hinged cover. This cover should be down when-

ever welding is acvely taking place or when the

welder is stored for an extended period of me.

2. Volts Display. The readout displays MIG volts

and Sck volts. The unit voltage will vary as the

voltage knob is increased or decreased in MIG

mode during setup. In sck mode the volts are

not adjustable, but the unit will display the open

circuit voltage (OCV). While welding, the volts

will display dynamically and show actual output.

3. Arc Force Control. Varies the current rise me

during MIG welding. It also varies the amp re-

sponse and arc feel in Sck operaon. For MIG:

This aects the actual point where the current

potenal has risen suciently to burn back the

wire aer pinching o and deposing in the pud-

dle. The point at which it has burned back is

considered the “pinch point”. This is where the

wire will begin to once again melt and transfer.

To put it in more praccal terms, the user will see

that the wire is scking out longer or shorter

from the MIG torch before it burns away, de-

pending upon the exact seng. This controls

spaer, penetraon and bead prole. When the

arc force knob is rotated from one extreme to

the other, the operator will observe that the arc

is more s at one end or more uid at the other

end. Bead prole changes will occur as well. A

ser arc will produce a deep but narrow prole.

A uid arc will produce a wider, shallower weld,

usually with an improved bead appearance and

less spaer. Arc force control is also known as

inductance control, slope or wave form control

(MIG). By changing the level of inductance the

user can ne tune the arc performance so the

welder responds in a manner that the user is ac-

customed to with other brands of machines. The

arc sound will also change as the arc force is ad-

justed, going from a pitched whine to a frying

sizzle. All MIGs, regardless of brand, without an

adjustable arc force, do have some xed level of

inductance, though not all are set at the same

level. A person can either adjust the arc force to

have a familiar feel, or to improve arc behavior

whenever welding posion or condion change.

For Sck: The control is used to vary the auto-

mac arc response. While sck welding, the arc

force counter acts the drop in voltage experi-

enced when the arc length is too short and falls

below 20 volts. The amps are automacally in-

creased to oset the loss of voltage to maintain

the welding arc and prevent the rod from going

out and scking. It can also be used to help in-

crease penetraon. Too much arc force in sck

can or MIG can create a violent arc, so be careful

about seng too much. For MIG a good starng

point is around 7. For Sick start at 3. Gradually

make half increment changes up or down to ne

tune the arc. Giant swings in sengs will make

other parameters harder to dial in properly as

the arc force can greatly aect the feel of the

welder.

4. Amp/Wire Speed Display. This displays wire

speed while the unit is not welding and actual

output amps while welding in MIG mode. Wire

speed is calibrated in inches per minute (IPM).

While welding in sck, amps are displayed.

While welding, it changes funcon and reads the

acve, dynamic amp output of the machine.

5. LED Indicators. These LED’s indicate the acve

status of the machine. The On indicator is lit

anyme the machine is turned on. The Duty Cy-

cle or Overheat light (represented by a thermom-

eter symbol) will light up when the machine has

been pushed beyond its thermal limits. When

this happens, welding will be interrupted. In case

of an overheat event, allow the unit to cool while

switched on for 15 minutes minimum. Do not

shut the machine down unl it has safely cooled.

If the machine experiences an overcurrent, it will

be indicated by LED with the triangular warning

symbol. The welder will have to be cycled o and

the power circuit analyzed for malfuncon or

inadequate wiring. NOTE: In both the case of

over temperature and the overcurrent, the unit

will connue to run, but welding output will be

interrupted. The wire feeder will connue to

funcon when the trigger is pulled but the arc

will not strike. In the event of an overheat, wait

15 minutes before turning the unit o. Then

reset the welder circuit by turning the unit o,

waing 10 seconds , the turning back on. In the

event of an overcurrent, turn the machine o

immediately and invesgate the cause of the

overcurrent. If the overcurrent does not clear

when the unit is turned back on, contact Everlast

technical support.

6. Wire speed /Amp Adjustment. This control ad-

justs wire speed while in MIG mode, and adjusts

amperage in Sck mode. Since this digitally con-

trolled welder uses an analog input with a nite

range of adjustment, a slight change in wire

Setup Guide and component Identification

Section 2

speed or amps may result in what appears to be a

jump by several amps or inches per minute. This

is normal and not something that is crical to ne

tuning the machine to where it is needed. Oen a

light touch will result in the correct seng or with-

in an amp or two.

7. Control. This seven pin plug is used to control the

MIG gun while connected to the Euro Connector.

8. Negave Polarity Connector (-). Connect to the

work clamp while in MIG/Sck mode. If using Flux-

core check the required polarity. Most ux core

wires use a negave polarity. If the ux core wire

requires it, change the work clamp to the posive

and change the buss bar under the cover to the

negave posion.

9. Posive Polarity Connector (+). Connect to Sck

torch in Sck Mode. Connect to work clamp if us-

ing ux core. (See comments regarding ux core

operaon in item 11).

10. Euro Quick Connect for MIG. This style of connec-

on makes the i-MIG compable with many aer

market MIG torches/guns. Connect the MIG torch

by aligning pins on the gun cable with the recepta-

cle and pushing in. Twist the collar on the cable

connector to lock in place. Do not use pliers or

other tools to ghten. Hand ghten only.

11. MIG Volts Adjustment. In each mode, the func-

on of the control changes. In the MIG mode, the

control is used to adjust the arc voltage. In sck

mode, this control is non-funconal.

12. Process Selector. This is used to toggle back and

forth between MIG operaon and Sck operaon.

Setup Guide and component Identification

Section 2

3. Burn Back Control Timer

Setup Guide and component Identification

Section 2

SIDE VIEW POWER i-MIG 200

4. Wire Feeder Assy.

1. Wire Spool Holder Assy.

Burn Back

0 1.5

2. Polarity Buss Bar

Side Panel Descripon and Explanaon:

1. Wire Spool Carrier Assembly. Make note of

the correct assembly order if disassembled.

The order in which they are assembled is im-

portant to be able to provide enough re-

sistance to prevent de-spooling of the wire.

When inserng the spool , make sure the small

tab on the inside of the spool holder is located

in one of the recesses made into the spool, if

any. Tighten the hex head screw under the

hand nut aer installing the wire spool so that

the wire will not connue to keep rolling more

than a 1/4 turn aer wire has stopped feeding.

Do not over ghten so that the drive roller

slips or the feeder strains to pull the wire due

to excessive resistance. The tensioner assem-

bly can accommodate 8” spools of wire (10-

12 lbs.) However, a simple center adapter may

be easily fabricated from PVC pipe to accom-

modate the smaller 4” diameter roll (2lb roll).

NOTE: 4” rolls may cause excessive cast due

to the ghter coiling of the wire around a

smaller center hub. These can cause issues

with the wire corkscrewing while welding and

interfere with arc stability as the wire wanders

from side to side. It also can create feeding

issues as it can be more dicult to thread

through the drive roller causing the wire to

jump outside the groove if proper pressure is

not maintained.

2. Polarity Buss Bar. Note the “+” and “-” sym-

bols located on the inside of the unit next to

the buss bar terminals. To change the polarity

of the MIG torch, simply loosen the middle

screw and remove the other screws on the

polarity terminals. By pivong the buss bar on

the center loosened screw, swing the buss bar

into posion over the desired polarity. Rein-

stall the screws, lining up the holes in the buss

bar with the terminal. Tighten all buss bar

screws. Always remember to alter your work

clamp to reect the polarity change if using

ux core. If the buss bar is connected to nega-

ve, then the work clamp should be in the “+”

posive output terminal. Standard polarity for

MIG is “+” (DCEP) with the work clamp in the

negave.

3. Burn Back Timer Control. The burn-back con-

trol helps to prevent too much sck out when

restarng a weld, by keeping the arc energized

for a short me aer the wire feeder stops

feeding . The wire will burn back to the de-

sired length by adjusng the control. This im-

proves re-starts and keeps the user from hav-

ing to re-trim the wire between welds. NOTE:

Too much burn back me may cause the wire

to burn back to far and seize to the p.

4. Wire Feed Assembly. Note the numbers on

the side of the tensioner. These numbers are a

reference point to help properly tension the

wire so that the drive roller will not slip. Do

not over-tension the wire because it can create

a condion known as birds nesng, where the

wire will tangle up around the feeder and will

not slip if the wire burns back into p, scks

fast in the weld puddle or other resistance is

met. This will connue wrap the wire around

the drive mechanism or jam wire inside the

gun liner unl the trigger is released. Consid-

erable eort is usually needed to clear out a

bird’s nest condion. Too lile tension will

result in wire slippage and cause rapid wear on

the drive components. Do a feed test before

beginning a weld. Occasional cleaning of the

feeder mechanism is necessary to prevent

wear and damage to the feeder and to the

MIG gun liner. Regularly monitor any metal

aking and dirt build up that may occur. Clean

it away gently with compressed air. Do not use

harsh cleaners or solvents. Felt wire lubricators

may be bought and used to keep feeding

cleanly while using steel or stainless wire. You

may purchase addional drive roll sizes from

Everlast, including ux core. Each groove will

drive at least two sizes of wire. For example if

the roller has a .8 mm groove and a 1.0 mm

groove, this will allow either .030” and .035”

wire to be used in the smaller groove. The

larger groove allows .040” and .045” wire to be

used. Do not forget to change the contact p

size when changing to a another wire diame-

ter. Depending upon the size wire used, the

liner from the MIG gun may need to be

changed to work properly. Do not aempt to

feed any wire greater than .045” wire with the

welder. Most common jobs can be welded

with either .030” or . 035” wire.

Setup Guide and component Identification

Section 2

NOTE: If errac feeding is experienced, check

wire feed tensioner, Spool Tension (rolling

resistance) and for correct size groove. Also

make sure the wire is riding in the groove and

not on the shoulder of the lower drive roll.

Setup Guide and component Identification Section 2

1. Gas Connector (Barb Type)

REAR VIEW/BACK PANEL POWER i-MIG 200

4. 5 A fuse for Wire Feeder

2. Main Power Switch

3. Power Cord/NEMA 6-50 Plug

GAS

INLET

1x110/220V

FUSE

5. Fan Shroud

6. Ground (Where required)

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Everlast POWER i-MIG 200 User manual

Brand: Everlast

Model: POWER i-MIG 200

Category: Welding System

Type: User manual

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Everlast POWER i-MIG 200 User manual

Everlast POWER i-MIG 200 User manual

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