Everlast POWER i-MIG 200E Operator's Manual

EVERLAST

POWER i-MIG 200E

MIG/GMAW WELDER

Rev. 1 0 100041419

everlastwelders.com

1-877-755-9353

Specicaons and Accessories subject to change without noce.

380 Swi 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

2

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 …...……………………....………..

Expanded View of MIG Torch……………………….
Trouble Shooting…...………………………………...
General Notes………………………………………...

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Dear Customer,
THANKS! You had a choice, and you bought an Everlast Product. We appreciate you as a cus-

tomer and hope that you will enjoy years of use from your welder.

Please go directly to the Everlast website to register your unit and download your warranty infor-

mation. 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. If you are unable to register by website, contact Everlast directly through the sales depart­ment at the main customer service number in your country. Your unit will be registered and warran­ty will be issued and in full effect. Keep all information regarding your purchase. In the event of a

problem you must contact technical support before your welder can be a candidate for warranty

service and returned. An over-the-phone review and diagnosis of the issue must be performed

BEFORE a RMA is issued or before the unit can be sent in for service.

Please read the warranty statement published online and other important information
found on the Everlast website of the division located in or nearest to your country. Print it
for your records and become familiar of its terms and conditions. Guns, torches and ac­cessories are covered under a separate warranty of 6 months. Please be sure you visit the
website and are familiar with all the warranty terms before you call for service.

Everlast offers full technical support, in several different forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interaction.
Technical advisors are active 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 email, particularly if off hours, or you cannot reach a
live person. In the event you do not reacha live person, leave a message and your call will normally
be returned within 24 hours, except for weekends and holidays. Also for quick answers to your basic
questions, join the company owned forum available through the website. You’ll nd knowledgeable
staff available to answer your questions. You also may nd a topic that already addresses your
question at http://www.everlastgenerators.com/forums/. Should you need to call or write, always
know your model name, purchase date and welder manufacturing inspection 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 conditions and circum­stances of your problem or question. Take notes of any issues as best you can. You may be asked
many questions 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 prob-

lem. Depending upon your issue, it is advisable to have basic tools handy such as screwdrivers,

wrenches, pliers, and even an inexpensive test meter with volt/ohm functions before you call.

Let us know how we may be of service to you should you have any questions.

Sincerely,

Everlast Customer Service

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Serial number: ____________________________
Model number: ____________________________
Date of Purchase:__________________________

Contact Information

Everlast US:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]

Everlast Welding Support: [e-mail]

Everlast Support Forum: http://www.everlastgenerators.com/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: [phone]

Everlast Canada:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
Telephone: [phone]am-4pm EST M-Th; 9am-12pm EST Fri

FAX: [phone]

Everlast Australia:
4/18 Acacia Ave. Port Macquarie NSW2444
[phone]
After hours support: 0410 661 334

Everlast Technical Support: [e-mail].

OTHER (Please record your local distributor’s information here for your records)

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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. This unit and manual
is designed for operators with basic knowledge and understanding of welding.
While this operator’s manual has been compiled to instruct the user in basic safe­ty, operation and maintenance of this Everlast welder, much of welding and cutting

is based upon experience and common sense. As thorough as this welding manu-

al may be, it is no substitute for either. Exercise extreme caution and care in all
activities related to welding or cutting. Your safety, health and even life depends
upon it. While accidents are never planned, preventing and avoiding an accident
requires careful planning. Please carefully read all of this manual before you op-
erate this welder. This manual is not only to help instruct in the proper use of the

welder, but to assist in obtaining the best performance out of it. Do not operate

the unit until you 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. Do not

attempt to alter or defeat any piece or part of your unit, particularly any safety
device. Keep all shields and covers in place during unit operation should an un-

likely failure of internal components result in the possible presence of sparks and

explosions. If a failure occurs, discontinue further use until malfunctioning parts

or accessories have been repaired or replaced by qualied personnel.

Note on High Frequency electromagnetic disturbances:

Certain welding and cutting processes generate High Frequency (HF) waves.
These waves may disturb sensitive electronic equipment such as televisions, radi­os, computers, cell phones, and related equipment. High Frequency may also in­terfere with fluorescent lights. Consult with an electrician if disturbance is noted.
Sometimes, improper wire routing or poor shielding may be the cause.

HF can interfere with pacemakers. See EMF warnings in following safety section

for further information. Always consult your physician before entering an area

known to have welding or cutting equipment if you have a pacemaker.

Safety Precautions

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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 cau-

tions 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. Therefore observe the following to
minimize potential accidents and injury:

Use appropriate safety glasses with wrap around shields while in the work area, even under
welding helmets to protect your eyes from flying sparks and debris. When chipping slag or

grinding, goggles and face shields may be required.

When welding or cutting, always use an approved shielding device, with the correct shade
of lter installed. Always use a welding helmet in good condition. 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 cutting and no less than shade 9 for
welding are highly recommended. 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 contacts for corrective vision before you wear them
while welding.

Do not allow personnel to watch or observe the welding or cutting operation unless fully

protected by a lter screen, protective curtains or equivalent protective 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 further protects against

hot sparks and debris from entering the ear canal and doing harm.

Always wear personal protective clothing. Flame proof clothing is required at all times.
Sparks and hot metal can lodge in pockets, hems and cuffs. 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 flammable liquids.

Leather boots or steel toed leather boots with rubber bottoms are required for adequate foot
protection. Canvas, polyester and other man made materials often found in shoes will either

burn or melt. Rubber or other non conductive soles are necessary to help protect from elec­trical shock.

Flame proof and insulated gauntlet gloves are required whether welding or cutting or han-

dling metal. Simple work gloves for the garden or chore work are not sufcient. Gauntlet

type welding gloves are available from your local welding supply companies. Never attempt 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 cutter or weld­er, instant and serious burns will occur. Proper hand protection is required at all times when

working with welding or cutting machines!

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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 elds and radiation. While

the effects of EMF radiation are not known, it is suspected that there may be some harm from

long term exposure to electromagnetic elds. Therefore, certain precautions should be taken
to minimize exposure:

• 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 cutting processes pose certain inhalation risks. Be sure to follow any guidelines
from your chosen consumable and electrode suppliers regarding possible need for respiratory

equipment while welding or cutting. Always weld with adequate ventilation. Never weld in

closed rooms or conned spaces. Fumes and gases released while welding or cutting may be
poisonous. Take precautions at all times.
Any 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 ventilation.

WARNING! This product when used for welding or cutting produces fumes and gases which
contains 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

Phosgene gas can be deadly. Consider all chemicals to have potential 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 regula­tions regarding high pressure cylinders can be obtained from OSHA or local regulatory agency.
Consult also with your welding supply company in your area for further recommendations. The

regulatory changes are frequent so keep informed.

All cylinders have a potential explosion hazard. When not in use, keep capped and closed.
Store chained so that overturn is not likely. Transporting cylinders incorrectly can lead to an
explosion. Do not attempt 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 away from direct heat, flame and sparks.

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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. Turn machine on or off 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 tight

or close quarters necessitates standing or resting 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 location and make
sure all personnel in area are advised of their location. Taping or securing cables with appro­priate restraints can help reduce trips and falls.

WARNING! Fire and explosions are real risks while welding or cutting. Always keep re ex-
tinguishers close by and additionally 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 floors 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 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 re.

• Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held

flammable liquid or material.

Metal is hot after welding or cutting! Always use gloves and or tongs when handling hot piec­es of metal. Remember to place hot metal on re-proof surfaces after handling. Serious burns
and injury can result if material is improperly handled.

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

maintenance is your responsibility. Make sure all equipment is properly maintained and ser-

viced 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 employees to operate poorly serviced equipment. Always check condition of
equipment thoroughly before start up. Disconnect unit from power source before any service
attempt is made and for long term storage or electrical storms.

Further information can be obtained from The American Welding Society (AWS) that relates
directly to safe welding and plasma cutting. Additionally, your local welding supply company
may have additional pamphlets available concerning their products. Do not operate machinery
until your are comfortable with proper operation and are able to assume inherent risks of cut­ting or welding.