HTP MIG 200i User manual

MIG 200i
Owner’s Manual
180 Joey Drive
Elk Grove Village, IL 60007-1304
Ph: [phone] · Fax: [phone]
Web: www.usaweld.com

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MANUFACTURER’S WARRANTY
It is expressly agreed that there are no warranties, expressed or implied, made by either the Salesman, Dealer, or HTP
America, Inc. on products or parts furnished hereunder, except the Manufacturer’s Warranty against defective
materials or workmanship as follows:
HTP America, Inc. warrants each new welding machine to be free from defects in material and workmanship under
normal use and service for Three (3) Years after delivery to the original purchaser. HTP America, Inc. will repair and
replace, at its factory, any part or parts thereof. Products should be returned to HTP America, Inc., with transportation
charges prepaid, and which its examination shall disclose to its satisfaction to have been thus defective. This warranty
being in lieu of all other warranties, expressed or implied, and all other obligations or liabilities on its part and it
neither assumes nor authorizes any person to assume for it any liability in connection with the sale of its machines.
This warranty shall not apply to any welding machine which has been repaired or altered by unauthorized service
departments in any way so as, in the judgment of HTP America, Inc., to affect its stability and reliability, nor which
has been subjected to misuse, negligence, or accident.
HTP America, Inc. shall not be liable in any event, unless HTP America, Inc. receives notice of alleged breach of
warranty, actual or constructed, specifying the claimed defect within not more than Thirty (30) Days after discovery.
HTP America, Inc. has reserved the right to make changes in design or add any improvements to its products, at any
time, without incurring any obligation to install the same on equipment.
This warranty is void unless the warranty card is sent to HTP America, Inc. within Fifteen (15) Business Days from
the date of purchase.
Exclusions to Warranty:
1. The MIG Welding Gun/Torch is warranted for a period of Ninety (90) Days against defects in material and
workmanship.
2. The contact tips, tip holders, gas diffusers, gas nozzles, and liners are consumable items, WHICH CARRY NO
WARRANTY.
SAFETY SUGGESTIONS
It is forbidden for people with PACEMAKERS to use or come near the machine.
Electric arc welding produces ultra-violet rays, which are harmful to skin and eyes. Ultra-violet radiation can
penetrate lightweight clothing, reflect from light colored surfaces, and burn the skin and eyes.
 Wear a heavy, pocket-less, long-sleeved shirt, cuff-less trousers, and high-topped work shoes.
 Wear a full-faced welding helmet with a number ten or darker lens and a cap.
Electric arc welding produces flying sparks and hot material, which can cause fire.
 To avoid fire, do not weld on wood, plastic tile, or carpeted floors. Concrete or masonry floors are safest.
 Do not weld on pressurized containers.
 Do not weld on drums, barrels, tanks, or other containers until they have been cleared and cleaned as described in
AWS Standard A6.01.
 Do not wear flammable materials.
 Wear non-oily/non-greasy, flameproof welding gloves; the oil or grease on the gloves may ignite.
 Avoid having any type of fuel, such as cigarette lighters or matches, on your person as you weld.
 Ensure that there is a fire extinguisher in the welding area.
Noise can damage your hearing. Pr otect yourself suitably to avoid hear ing damage.
The welding arc can cause burns. Keep the tip of the welding gun/tor ch far from your body and fr om other
persons.

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Electric arc welding produces toxic fumes.
 Provide adequate ventilation in the welding area at all times.
 Do not weld on galvanized zinc, cadmium, or lead beryllium materials unless you are POSITIVE that sufficient
ventilation is provided. These materials produce toxic fumes.
 Do not weld in areas close to degreasing or spraying operations. Chlorinated hydrocarbon vapors may react with
the ultra-violet rays and form highly toxic phosphate gas.
 If you develop momentary eye, nose, or throat irritation during welding, stop welding immediately. This is an
indication that ventilation is not adequate. Do not continue to weld until ventilation is improved.
ELECTRIC SHOCK CAN KILL.
Exposed, electrically hot conductors, other bare metal in the welding circuit, or ungrounded, electrically hot
equipment can fatally shock a person whose body becomes a conductor. Do not stand, sit, lie, lean on, or touch a wet
surface when welding.
 Disconnect the power supply before working on the welding machine.
 Do not work with deteriorated or damaged cables.
 Frequently inspect cables for wear, cracks, and damage. Replace those with excessively worn insulation to avoid
a possible lethal shock from bared cable.
 Do not touch bare electrical parts.
 Ensure that all of the panels covering the welding machine are firmly secured in place when the machine is
connected to the power supply.
 Insulate yourself from the workbench and from the floor (ground); use insulating footwear and gloves.
 Keep gloves, footwear, clothes, the work area, and the welding equipment clean and dry.
 Check the machine power cable frequently; the power cable must be free from damage to the insulation. BARE
CABLES ARE DANGEROUS. Do not use the machine if the power cable is damaged; a damaged power cable
must be replaced immediately.
 If it is necessary to open the machine, first disconnect the power supply. Wait Five (5) Minutes to allow the
capacitors to discharge. Failure to take this precaution may expose you to the dangerous risk of electric shock.
For more information, refer to the following standards and comply as applicable.
 ANSI Standard Z49.1 SAFETY IN WELDING AND CUTTING, obtainable from the American National
Standards Institute, 1430 Broadway, New York, NY 10018.
 ANSI Standard Z87.1 SAFE PRACTICE FOR OCCUPATIONAL AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY
10018.
 AWS Standard A6.0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES,
obtainable from the American Welding Society, 2051 NW 7th St., Miami, FL 33125.
 NFPA Standard 51 OXYGEN-FUEL GAS SYSTEMS FOR WELDING AND CUTTING, obtainable from the
National Fire Protection Association, 470 Atlantic Ave., Boston, MA 02210.
 NFPA Standard 51B CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, 470 Atlantic Ave., Boston, MA 02210.
 CGA Pamphlet P-1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 500 Fifth Ave., New York, NY 10036.
 OSHA Standard 29 CFR, Part 1910, Subpart Q WELDING, CUTTING, AND BRAZING.

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Fig. 1

5
GENERAL CHARACTERISTICS
The MIG 200i features an incredible arc dynamic, which makes the MIG 200i suitable for any kind of wire and for
any material thickness from 26 gauge up to 1/4”. With the MIG 200i, you can weld in manual mode or in synergic
mode with Easy Set™ technology. The Easy Set feature makes set up a breeze by automatically setting your welder,
in a couple of simple steps, to the correct parameters. A simple polarity reversal allows you to weld with gas (solid
wire) or without gas (flux-cored wire). The MIG 200i also features manual wire feed, manual gas purge, and start
speed adjustment.
The HTP MIG 200i, which features electronic adjustments controlled by a microprocessor, allows you to achieve
excellent welding quality thanks to the advanced technologies applied. The microprocessor circuit controls and
optimizes arc transfer irrespective of the load variation and of the impedance of the welding cables. The inverter
technology used in the HTP MIG 200i, as well as other welding machines in our product line, enabled us to obtain the
following:
 Machines with extremely low weight and compact dimensions.
 Reduced energy consumption.
 Excellent dynamic response.
 Very high power factor and yields.
 Better welding characteristics.
The sensitive electronic components are cooled with forced air by fans with low noise production, and the MIG 200i
features sophisticated, electronic overheat protection to prevent damage to your machine.
NOTE: The HTP MIG 200i is not suitable for thawing pipes.
The MIG 200i package includes:
 HTP MIG 200i Power Source
 10’ MIG Welding Gun
 10’ Ground Cable and Clamp Assembly
 Flow Meter
 6’ Gas Hose
 Owner’s Manual
NOTE: A 12’ or 15’ MIG welding gun may be purchased in place of, or in addition to, the 10’ MIG welding
gun.
Check that all of the material listed above is included in the package. Inform HTP America, Inc. if anything is
missing. Check that the machine has not been damaged in transit. If you see any sign(s) of damage, consult the
COMPLAINTS section for instr uctions. Befor e working with the machine, please r ead the entir e Owner ’s
Manual.
COMPLAINTS
Complaints for damage during transit: If your equipment is damaged dur ing transit, you must pr esent a claim
to the carrier.
Complaints for faulty goods: All equipment shipped by HTP Amer ica, Inc. is subjected to strict quality control.
However, if your equipment does not work properly, consult technical support at HTP America, Inc. as soon as
possible.

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SETUP
Installation
Correct installation ensures issue free operation of the HTP MIG 200i. Please adhere to the following procedures
before and when using the machine.
 Position the machine in such a way that air circulation is and remains unobstructed. While the machine features
an internal fan for cooling, the louvered vents must be unobstructed in order for heat to move out of the machine.
 Ensure that the fan does not suck deposits of dust into the machine.
 Avoid impacts and rubbing, as well as exposure to dripping water, excessive heat sources, or any other abnormal
situations.
Electrical Connection
Your HTP MIG 200i operates on single-phase, 230 volt power (208-240 volt). The machine draws 34 amps out of the
wall when operating at a welding output of 200 amps. If you operate the machine on a generator, it needs to be a
clean power generator with a minimum of 8500 watts (8500 watts must be the continuous rating or running watts
rating of the generator, NOT the peak rating or starting watts rating of the generator).
 Before making an electrical connection between the welding machine and the power supply, turn the power
supply off.
 Ensure that your electrical distribution panel complies with all local rules and regulations.
 When using long extension cables, the cable core diameter size is relevant to the machine requirements for
achieving optimum performance.
 The power input supply receptacle, from the main voltage supply, must have a suitable switch provided together
with a slow-burning type fuse.
 In the event of damage to the power cable, replacement or repair must be performed by a qualified technician.
Grounding
To ensure operator safety, the welding machine must be grounded correctly.
 To avoid electrical shock due to accidental contact with grounded objects, you must properly ground the power
cable to the plug by means of the yellow-green ground wire.
 The chassis (conductive) is electrically connected to the ground lead; if you improperly ground the HTP MIG
200i, you run the risk of exposure to electric shock, which can be fatal.
Lifting
Weight:
Power Source Alone: 39 Lbs.
Power Source + 11 Lb. Spool of Wire: 50 Lbs.
Power Source + 33 Lb. Spool of Wire: 72 Lbs.
Lifting by Hand: You may lift the power source with or without an 11 Lb. spool of wire installed.
ATTENTION! Do not lift the power source with a 33 Lb. spool of wire installed. Before lifting the power
source, remove the 33 Lb. spool of wire.
Securing the HTP MIG 200i
Failure to properly secure the machine may result in personal injury. Do not use or turn on the machine without
properly securing the machine first. Do not put the machine on an unlevelled surface with an angle greater than 10º.

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FRONT PANEL CONTROLS
Fig. 2
1) Synergic Mode LED for .035” Welding Wire
2) Synergic Mode LED for .030” Welding Wire/Over-Heat Alarm LED
3) Synergic Mode LED for .023”/.024”/.025” Welding Wire
4) MIG 2T LED
5) MIG 4T LED
6) Select Mode Button
7) Easy Set™ Button (Synergic Mode Button)
8) Advanced Settings “SET” Button
9) Manual Wire Feed Button
10) Manual Gas Purge Button
11) Wire Speed/Material Thickness (for Synergic Welding Mode) Knob
12) V/SET Knob
12 11
10
9
87
6
5
4
3
2
1

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FRONT PANEL CONNECTIONS
Fig. 3
TYPE CONNECTION PIN DESCRIPTION
MIG GUN 1POSITIVE *Factory Setting
MIG SPOOL GUN (Optional) 2
7-PIN (The spool gun receptacle does not come preinstalled on
your machine. If you choose to purchase the spool gun kit, you
will need to install the 7-pin receptacle and pigtail, which plugs
into the PCB.)
GROUND 3NEGATIVE *Factory Setting
1
23

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MIG WELDING WITH GAS
Check the position of the polarity cable. To weld with
gas, the gun must be set to Positive (+) polarity, and the
ground cable must be set to Negative (-) polarity. See
also REVERSE POLARITY.
Connect the MIG welding gun to the Euro receptacle
(Fig. 3, #1) located on the front panel of the machine,
and then connect the ground cable to the Dinse
receptacle (Fig. 3 , #3) also located on the front panel
of the machine. Next, connect one end of the gas hose
to the coupling on the rear panel of the machine and the
other end of the gas hose to the flow meter or regulator
connected to your gas bottle. After making all of the
lead connections, load the wire into the machine.
THE WELDING WIRE AND THE WIRE FEED
COMPONENTS ARE ELECTRICALLY CHARGED
FOR THE FIRST FOUR (4) SECONDS. KEEP HANDS
AWAY.
After waiting four (4) seconds, insert the wire into the
wire feeder; feed the wire into the groove on the bottom
drive roll.
NOTE: The drive roll has two grooves. To choose
the desired groove size, simply flip the drive roll.
When changing the size (diameter) of the wire, you
must also change the drive roll and the contact tip to
match the new wire size (diameter).
The contact tip is the little copper tip on the gun from
which the wire exits the MIG welding gun.
TIP: Remove the nozzle and the contact tip, and
also hold the gun as straight as possible, to more
easily feed the new wire through the gun lead/cable
assembly.
Insert the power plug into a suitable power receptacle,
close the pressure roller, switch the machine on by
turning the line switch to the ON position, and press the
Manual Wire Feed Button (Fig. 2, #9) to feed the wire
through the gun lead/cable assembly. Please keep the
side panel closed while manually feeding wire through
the MIG welding gun. Switch the machine off by
turning the line switch to the OFF position.
Reinstall the contact tip and the nozzle, and then adjust
the pressure of the wire feeder (for steel wire, set the
pressure to approximately 2 or 3).
Step by Step Instructions
 With the Select Mode Button (Fig. 2, #6), select
either MIG 2T or MIG 4T. In MIG 2T, depressing
the trigger makes the wire feed and also ignites an
arc when the wire makes contact with the work
surface. Releasing the trigger stops the wire from
feeding and also extinguishes the arc. In MIG 4T,
depressing the trigger starts pre-gas flow, releasing
the trigger makes the wire feed and the arc ignite
upon contact with the work surface, pressing the
trigger again stops the wire from feeding and
extinguishes the arc, and releasing the trigger again
starts post-gas flow.
 Press the Easy Set Button (Fig. 2, #7) repeatedly until all
of the Wire Selection LEDs turn off.
 Regulate the welding voltage using the V/SET Knob (Fig.
2, #12).
 Regulate the wire speed using the Wire Speed Knob (Fig.
2, #11).
 Begin welding.
MIG WELDING IN SYNERGIC MODE
 Press the Easy Set Button (Fig. 2, #7) to select an
appropriate wire diameter (indicated by LEDs; Fig. 2, #1
for .035” wire, Fig. 2, #2 for .030” wire, and Fig. 2, #3
for .023”/.024”/.025” wire). If all of the LEDs are turned
off, the machine is in manual mode.
 Select the thickness of the material to be welded using the
Wire Speed Knob (Fig. 2, #11; the scale of color
corresponds to the selected wire diameter: blue for .035”
wire, yellow for .030” wire, and green
for .023”/.024”/.025” wire).
 Optional Step: With the V/SET Knob (Fig. 2, #12),
adjust the output voltage (-4V, +4V; red in scale). The
default position is 0, at the center of the scale.
MIG WELDING WITHOUT GAS
To use flux-cored wire, which allows welding without
the use of gas, proceed as follows:
 Check the position of the polarity cable. To weld
with gas, the ground cable must be set to Positive
(+) polarity, and the MIG welding gun must be set
to Negative (-) polarity. See also REVERSE
POLARITY.
 Connect the MIG welding gun to the Euro
receptacle (Fig. 3, #1).
 Connect the ground cable to the Dinse receptacle
(Fig. 3, #3).
 Follow the instructions laid out in MIG WELDING
WITH GAS.

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REVERSING POLARITY
MIG Welding with Gas:
Connect the BLACK cable to the - (Ground)
Connect the RED cable to the + (MIG Welding Gun)
MIG Welding without Gas
Connect the BLACK cable to the + (Ground)
Connect the RED cable to the - (MIG Welding Gun)
Use the appropriate tool (provided inside the wire
compartment) to loosen/tighten the nuts for all polarity
reversals.
ADVANCED SETTINGS “SET”
While post-flow time is fixed at 3 seconds and start time
is fixed at 0.3 seconds, you can adjust the start speed
from 10 to 100% (the default start speed value is 35%).
You can also adjust burn back from 0 to 10. A burn
back setting of 0 provides the most stick out, while a
burn back setting of 10 provides the least stick out.
Depending on the wire type and diameter, higher burn
back settings may cause burn back into and damage of
the contact tip. To adjust the start speed or burn back
parameters, follow these instructions:
 Turn the V/SET knob (Fig. 2, #12) to the desired
position (use the white scale, numbered from 1-10).
 Hold down the buttons corresponding to the setting
you want to change (Fig. 2, #8 and #9 for burn back
and Fig. 2, #8 and #10 for start speed) until you hear
a continuous sound after three (3) shorter sounds.
At this point, the setting is stored and you can proceed
as usual.
NOTE: TO RESET THE DEFAULT VALUE OF
THE START SPEED OR BURN BACK
PARAMETERS, HOLD DOWN BUTTONS 7 AND
8 (Fig. 2) UNTIL YOU HEAR A CONTINUOUS
SOUND AFTER THREE (3) SHORTER SOUNDS.
SPOOL GUN KIT
The HTP MIG 200i also operates with an optional
spool gun. You can locate the connection
specifications for the spool gun within the optional
spool gun kit (sold separately).
To activate the Spool Gun mode, hold down the Mode
Selection key until you hear an acoustic signal. In the
Spool Gun mode, the wire speed changes and this is
indicated by a continuous blinking of the LED which
corresponds to the mode being used.
NOTE: The HTP MIG 200i does not feature a TIG
welding mode.
OVERCURRENT PROTECTION
If the welding current is more than 200 Amps, the MIG
200i automatically reduces the wire speed and the
welding parameters. In this case, the Overheat Alarm
LED (Fig. 2, #2) blinks until the operator sets the
welding parameters lower than those previously set
which caused activation of the MIG 200i’s overcurrent
protection.
Fig. 4

11
DUTY CYCLE & OVER-HEAT PROTECTION
The HTP MIG 200i is designed for the maintenance welder. It has the ability to weld a lot of different materials and a
great variety of thicknesses. Thicker material, depending on type, temperature, etc. may require multi-pass welds.
Duty cycle ratings can be confusing, but we want to make duty cycle less confusing. An 80% duty cycle means that,
out of a 10-minute time span (duty cycle is always a 10-minute time span, per definition, and this never changes), the
machine can weld for eight (8) minutes and then needs to idle with the cooling fan running for two (2) minutes. Do
not turn off or unplug the machine during this time.
However, these numbers change with the selected welding amperage and the ambient temperature. In reality, very few
can keep track of welding time like this so we equipped the MIG 200i with very sophisticated over-heat protection.
The machine monitors the temperature of several vital internal components. Just before temperatures venture outside
the safe operating range, the cooling fan continues to run and the welding output is shut down for four (4) minutes.
This time allows the machine and internal components to cool down to a safe operating temperature. There is no harm
to the machine when the message is displayed, and it does not matter how often this happens. There is no way to
override this function.
Fig. 5

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Part# Description Part# Description
A. 15023-10 .023” Contact Tip, 10-Pack I. 13002-DLT Gas Diffuser
A. 15030-10 .030” Contact Tip, 10-Pack J. 14009 Trigger Switch
A. 15035-10 .035” Contact Tip, 10-Pack L. 15100 10’ MIG Gun
C. 15106 Spot Weld Nozzle L. 15120 12’ MIG Gun
D. 15104 Cylindrical Nozzle L. 15150 15’ MIG Gun
E. 15105B Conical Nozzle, 3-Pack M. 15040-16 16’ Steel Liner
F. 15108 Small Conical Nozzle N. 50013 Consumable Kit
G. 15058 Head Insulator f/Flex Neck O. 63160 Drive Roll f/Steel, .023”-.030”
G. 15500 Flexible Swan Neck P. 63498 Drive Roll f/Flux-Cored Wire
H. 15062B Nozzle Retaining Spring, 4-Pack Q. 15510 10’ Flex Neck MIG Gun
I. 14058 Head Insulator Q. 15512 12’ Flex Neck MIG Gun
I. 15002 Swan Neck, Standard Rigid Neck Q. 15515 15’ Flex Neck MIG Gun
HTP 15 Series MIG Welding Gun & Parts

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MIG 200i Wiring Diagram

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MIG 200i Parts Diagram

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Position Part# Description Position Part# Description
1661157 Plastic Frame 20 644240 Input Power Cable
2661062 Knob 21 660785 Cable Strain Relief
3661043 Fan Cover 22 620751 Tool
4600512 Remote Control Receptacle (Optional) 23 661034 Handle
5642740 Ground Receptacle/Socket 24 619350 Line Filter PCB
6620804 Front Panel 25 620742 Fan Support
7a 613913 V/SET Potentiometer 26 611331 Fan
7b 613915 Wire Feed Potentiometer 27 613923 Power Transformer
8613922 Front Panel PCB 28 620743 Power Transformer Support
9650897 Lem Probe 29 620741 Vertical Support
10 613653 Output Inductance 30 664860 Spool Holder
11 600513 Spool Gun Kit (Optional) 32 620744 Protection PCB
12 635880 Foot 33 666320 Hand Screw
13 613882 Inverter/Flyback/Driver PCB Group 34 642800 Socket
15 650236 Thermal Switch 35 613849 Wire Feed Assembly
15a 613883 Inverter PCB 36 664620 Euro MIG Gun Connector Flange
15b 613557 Flyback & Driver PCB 37 661322 Control Panel Label
16 620738 Cover 38 664710 Sliding Latch
17 620736 Base 39 620739 Door
18 617030 Solenoid Valve 40 664680 Hinge
19 647240 Power Switch
MIG 200i Parts List

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MIG 200i Wire Feed Assembly
Parts Diagram
MIG 200i Wire Feed Assembly Parts List
Position Part# Description
1613849 Wire Feed Motor (24V/40W)
3634690 Retaining Screw
4634990 Euro MIG Gun Adapter
5636250 Connecting Screw M12 x 1.5 x 35mm, Brass
6636260 Gas Connection Screw, Brass
8636370 Wire Guide Tube 5 x 2 x 57mm, Brass