Everlast POWER i-MIG 253DP User manual

EVERLAST
POWER i-MIG 253DPi
Rev. 1 0 10613-18
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 253DPi
Safety, Setup and General Use Guide
A Digitally-Controlled Synergic Pulse MIG with Stick Function
PULSE
DC
CC
CV
GMAW
IGBT
SMAW

2
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………………………….
General Polarity and Amp Recommendations….
Installing The Wire Spool………………………….
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…..…………………………..
Pulse MIG Operation………………………………
MIG Control Features……………………………...
Background Settings……………………………….
Pulse MIG Work Sheets…………………………..
Stick Operation……………………………………..
General Notes Concerning Operation……………
24 Series MIG Torch……………………………….
36 Series MIG Torch………..……………………..
Trouble Shooting……………………………………..
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4
5
9
9
10
11
12
12
16
15
17
18
19
27
28
29
30
32
40
50
49
51
60
53
61
62
64

3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast product. We appreciate you as a valued 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 non-customers to interact with each other. Tech-
nical advisors are acve on the forum daily. We also divide our support into two divisions: technical and welding
performance. Should you have an issue or queson 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, especially dur-
ing 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

4
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] or [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
11am-4pm PST Sat.
FAX: [phone]
Everlast Canada:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
After hours support: 0410 661 334
Everlast Technical Support: [e-mail]
OTHER (Please record here for your records):

5
Everlast is dedicated to providing you with the best possible equipment and service to meet the de-
mands of the welding applicaons that you have. We want to go beyond delivering a sasfactory prod-
uct to you. That is the reason we oer free North American based 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 maintenance of
your Everlast product to give you the best possible experience. Overall, welding requires experience
and common sense to obtain the best results in the safest manner. As thorough 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 infor-
ma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 covered under a sepa-
rate warranty. Do not aempt to alter or defeat any piece or part of your unit, 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 person-
nel.
Please read and review all of the following safety informaon and warnings be-
fore use! Some informaon is unique to your unit and may not carry over be-
tween brands or types of welders. This is for your health and well-being.
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, im-
proper 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 informaon. Always
consult your physician before entering an area known to have welding or cung equipment if you have a pace-
maker.
Safety Precautions

6
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 cre-
ate 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 occur.
Proper hand protecon is required at all mes when working with welding or cung machines!
This welder contains moving parts that can result in injury. Keep hands, ngers, hair, and loose
clothing away from the wire feeding mechanisms and fans while unit is switched on and in use. Do
not aempt to defeat any safety feature. Always operate unit with guard in place on the wire feeder.
Safety Precautions

7
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
away from direct heat, ame and sparks.
Safety Precautions

8
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nguish-
ers close by and addionally a water hose or bucket of sand. Periodically check work area for smol-
dering 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.
Safety Precautions

9
Section 1 Introduction and Specifications
Overview of Parameters and Features*
Power i-MIG 253DPi
Amp Adjustment Range 10-250 Amps
Volt Adjustment Range 14-28 Volts in standard mode (Volt value becomes Oset/Trim value –5 to +5 in Synergic Pulse/
Double Pulse Modes)
Wire Feed Speed 60 to 600 IPM (.5-15 m/min) Includes “Wire Jog” mode for loading or changing wire without hav-
ing to dispense and waste gas.
Input Voltage 220-240V Single phase (208V permissible)
Welder Type Digitally controlled, IGBT inverter type with Pulse CV GMAW (MIG) and CC Sck funcons. Fea-
tures CV Spool Gun or CV Push-Pull gun capability (Spool/Push-Pull Gun oponal).
Wire Roll Size and Diameter .030”-.045” wire diameter assortment. including select U groove (aluminum/bronze) and V groove
(steel/stainless) drive rolls. Other oponal sizes and types available. Equipped with 12” diameter
roll capacity (30-44lb). An 8” adapter is available for use with 10-12 lb. rolls. 4” rolls not support-
ed. (Weights referenced are for commonly sold packages of steel wire for wire diameter)
MIG Operaon and Type Synergic standard MIG and Synergic Pulse/Pulse on Pulse MIG funcon.
Includes V Groove drive rolls for:
.030” to .045” (.8mm to 1.2mm in diameter for Steel, Stainless Steel use.**
Includes U groove drive rolls for:
.040” to .045” (1.0mm to 1.2mm) for Aluminum, and Bronze (brazing) use. **
Addional Drive Rolls may be ordered direct from Everlast ( 2 pc kit). Size and type stamped on
side of the drive roll next to the related groove for easy idencaon. Synergic Pulse sengs for
Mild Steel, Stainless Steel, 40XX series Aluminum, 50XX series Aluminum, and Bronze wires.
Burn Back Timer Control .01-.5 seconds
Inductance 1-10 in whole number increments.
Pulse Frequency Single: Synergically Controlled Double (Pulse on Pulse): .1 to 9.9 Hz
Peak Pulse Amps/Volts Single: Synergically Controlled Voltage/Oset (Trim). Amps adjusted to suit thickness.
Double: Synergically Controlled Voltage/Oset (Trim). Amps adjusted for each half cycle of pulse
to create “stacking eect” of weld bead. Range 10-250V
Pulse Time On Single: Synergically Controlled Double (Pulse on Pulse): 10-90% of Peak Pulse seng
Memory Save and recall up to 10 programs (0-9)
MIG Burn Back Duraon/Voltage .01-.5 Seconds 5-20V (-5 to +5 Volt oset/trim value in Synergic Pulse/Double Pulse)
Hot Start 0-200
End Amps/Volts 10-250A /14-28V (-5 to 5 oset)
Torch Trigger Funcons/latch 2T, 4T, 4T Special
Sck E6010 Capability No, 6011 only
Power Cable Length 9.5 . (3m)
Accessories** 24 Series MIG torch 9.5 . (3m), Work clamp with cable 9.5 . (3m)
300 A Sck Torch, with cable (3m) Floang ball type regulator.
*See next page for complete electrical and technical data.
**Specicaons and packaged accessories subject to change without noce.

10
W: 286mm/ 11.25”
H: 457 mm/18”
L: 660mm/26”
Bare Weight: 31kg/68 lbs.
Section 1 Introduction and Specifications
MODEL: POWER i-MIG 253DPi SERIAL NO.
EN/ IEC60974.1
DC: 40-250 A; 16-30V
X35% 60% 100%
U0 V
80 V
I2250 A 195 A
U226.5 V 23.8 V
DC: 10-200 A; 20.4-28 V
X35% 60% 100%
U0 V
80 V
I2250 A 200 A
U230V 28V
U1
240V
1~ 50/60 Hz
I1MAX: 45.5A I1EFF: 36A
PROTECTION:
IP21S
COOLING METHOD:
FULL TIME, DUAL FAN
INSULATION: F
WIRE SPEED FEED RATE*: 60-600 INCHES PER MINUTE
EFFICIENCY: ≥ 85% POWERFACTOR: 83%
f1f2
1~
S
S
EVERLAST
POWER i-MIG 253DPi
*60 IPM is based on minimum useable feed rate.
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
monthly 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 the
welder to prevent damage to the panel face and internal components. Damage of this nature is not covered by the warranty.

11
General Descripon, Purpose and Features. The Power
i-MIG 253DPi features a Synergic Pulse and Double
Pulse design to help customers meet their needs re-
garding new industrial and specialty MIG welding re-
quirements in the auto and marine industries where
new alloys and welding techniques are being employed.
The low prole Power i-MIG 253DPi features faithful
IGBT power components and an intuive design. The
design includes dual fan cooling which yields a heavy
duty, industrial level 60% duty cycle performance at 250
amps maximum output not only in the MIG modes, but
also in the addional Sck mode.
The Pulse MIG capability of the Power i-MIG 253DPi is
designed to help the user maintain maximum control
over heat and fusion. The Power i-MIG 253DPi employs
a synergic single pulse and double pulse (somemes
referred to as Pulse-on-Pulse) GMAW type design that
features opmized synergic control over the pulse pa-
rameters. Synergic control most simply dened, means
that complicated parameters such as pulse width, fre-
quency, pulse volts and amps are automacally con-
trolled by pre-programmed algorithmic sengs. These
sengs are programmed and tested by trained welding
engineers at the factory for best performance. In prac-
cal terms, the synergic design needs some basic input
parameters from the user to ensure proper operaon.
These are simple things such as wire type (alloy type/
AWS classicaon), and wire diameter. Aer that,
Amps (which is the same as adjusng wire speed) are
input by the operator to match metal thickness. The arc
length can be ne tuned if needed to match welding
condion requirements. If adjustments are made to arc
length, the pulse automacally adapts operaon param-
eters to work well with the new adjustments. This
makes it ideal for use with 40XX and 50XX series Alumi-
num, and most weldable Stainless Steels where heat
and arc control is crical and out-of-posion welding is
regularly encountered. The synergic pulse also lends
itself well to applicaons such as auto-body repair
where the employment of high- strength, high carbon
steel requires MIG brazing to meet new cercaon
requirements and heat control restricons mandated by
auto manufacturers. To provide the best results while
MIG welding aluminum, or while MIG brazing high
strength steel, the unit can be equipped with the op-
onal 300 Amp Parker® SGP-360A push-pull gun or the
Parker® DSP-360A spool-gun. Both oponal gun ar-
rangements can be operated in either standard mode,
or synergic modes. These addional guns are available
directly from Everlast and oer the best choice for
welding aluminum.
For the budget minded operaon, the unit does include
a special low-resistance polymer liner designed for use
in the standard gun if Aluminum welding or brazing
must be done with out the use of either a push-pull or
spool gun. The original factory installed MIG gun liner
is designed for Steel and Stainless Steel welding and
must be removed and replaced with the polymer liner
before welding with Aluminum and Bronze wires. This
set-up is also useful in ght or compact areas where
access is restricted. If this gun arrangement is used,
the MIG gun cable must be used with the gun cable
running fairly straight without coiling or looping. Op-
eraon with oponal gun lengths longer than the facto-
ry supplied standard gun with Aluminum or Bronze
wires, will create wire feeding issues. If gun cable
lengths longer than what is supplied with the welder is
required to weld aluminum or bronze, a push-pull gun
or a spool gun is going to be necessary. For Steel and
Stainless Steel welding applicaons, longer gun lengths
up to 17 feet may be used without any issue. Longer
gun lengths may be used for larger diameter wires but
smaller wire diameters (i.e. .023”/.6 mm) may bind or
bird’s nest in the feeder or in the gun liner.
In addion to the synergic Pulse-MIG funcons, the
Power i-MIG 253DPi features a non-pulse synergic MIG
mode for basic MIG operaon, as well as an independ-
ent, manual control MIG mode. The added capability
for SMAW (sck welding), makes it an excellent candi-
date for use in commercial fabricaon shops.
This welder is designed for full-size rolls of MIG wire,
12” in diameter (up to 44 lbs. typically). A wire spool
adapter is available which will allow the unit to accept
8” spools. Although aer-market 4” spool adapters can
be purchased from many suppliers, Everlast does not
make or supply a 4” adapter for the machine. If 4”
rolls are typically the way you weld Aluminum or other
metals, consider purchasing the spool gun which is ide-
al for this type of applicaon. When price per pound is
considered, full size 12” rolls are the most economical
way of welding. When using an 8” or 12” diameter roll
of Aluminum or Bronze wire, a push-pull gun is recom-
mended. The standard gun may also be ed with the
supplied polymer liner in lieu of the oponal push-pull
gun although more problems with wire feeding may be
encountered.
For easy set-up and recall of the most commonly used
sengs this welder is capable of storing up to 10 pro-
grams. This is useful when mulple operators are us-
Introduction and Specifications
Section 1

12
ing the same welder or when dierent thicknesses and
metal types are changed on a frequent basis. When
needing to save parameters, parcularly with mulple
operators, we recommend that you keep a laminated,
“quick” reference list of saved program numbers associ-
ated with specic welding applicaons near the welder.
Usually, the best place to store this is the inside of the
door of the welder. To help with this, at the end of the
manual we have created a list of quick reference charts
that you can ll out for dierent applicaons that can
be stored in a sleeve pasted on the inside door or that
can be kept in a reference note book near the welder.
The unit also features a heavy-duty wire feeding mecha-
nism with 4 driven drive rolls for maximum wire feeding
capability. The 4 roll drive system reduces the chance
of irregular feeding and helps reduce the “cork screw-
ing” eect of the wire into the puddle. “Corks crewing”
or Helixing (due to the cast of the wire) of the wire as it
comes out of the gun can result in an unstable arc and
even improper placement of the weld bead in extreme
condions. When you couple proper drive roller ten-
sion and correct drive roll selecon, unintended slipping
and irregular feeding can be virtually eliminated without
troublesome bird’s nesng and stuering of the wire (at
start) However, if too much tension is applied to any
wire feeder, bird’s nesng and even breakage of the
wire (parcularly the smallest wire diameters) will result
if the wire encounters excessive resistance such as cold
stubbing into the puddle or a contact p burn back oc-
curs. If you suspect either have occurred, stop welding
immediately and check your drive feeder for tangled or
broken wire.
See below for addional summary of 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. Both Single Pulse and Double Pulse
modes are synergically based and make welding in
pulse modes as simple as selecng the correct am-
perage to match the thickness of the weld. Arc
length can be “trimmed” to the desired length with
the voltage oset feature. As already menoned,
the Power i-MIG 253DPi is also spool gun and push-
pull gun (oponal) ready for Aluminum welding or
and brazing if needed. Both the spool gun and the
push-pull gun unit will funcon in all MIG modes
and with all synergic Pulse sengs. The welder can
also be used with the ux-core wire (FCAW) when
equipped with oponal serrated drive rolls. How-
ever, if Flux-Core is used in synergic mode and syn-
ergic Pulse modes, the welder will not operate cor-
rectly. Even with signicant adjustment of trim
and inductance sengs, problems achieving desir-
able welds may be encountered. When aempng
to use Flux-Core or Dual-Shielded wires, the stand-
ard mode (without the synergic funcon enabled)
should be used for the most reliable operaon.
2) SMAW (Sck). In sck mode the Power i-MIG
253DPi delivers a smooth DC low spaer arc. Pro-
fessional, high-quality welds are obtainable with
E7018, 7014, 309L, 316, 6011 and many specialty
rods that are designed for use with any sck weld-
er. NOTE: This unit is not designed for E6010 use.
The Sck mode also features adjustable Hot Start
intensity control which is designed to help reduce
scking during arc starts. It will also simultaneous-
ly help reduce porosity or inclusions during arc
iniaon. The sck arc force control adjusts the
quality and feel of the welding arc. The arc force is
used to adjust the amp reacon when the arc gap
is shortened and voltage drops. This helps to pre-
vent scking of the welding rod and helps maintain
the arc going as arc voltage falls. This acon also
boosts penetraon and controls overall “feel” of
the arc.
3) Burn-Back Control. The Burn-back feature is used
to control the length of the wire sck-out aer the
trigger is released. It helps to prevent the welding
wire from scking in the coalescing weld puddle
aer the arc is terminated. It also saves the user
from having to trim the wire before restarng the
arc. Burn-Back control consists of two sengs:
Burn-Back me and Burn-Back Volts. Typically
Burn back me is set long enough to prevent wire
scking in the weld puddle. The wire should melt
back to the point where trimming is not required
to restart the arc and no wire scking is observed.
Burn back me is usually adjusted to less than .1
seconds, but more me can be added as needed.
Thicker wires will need longer burn back mes. For
a starng point in Synergic pulse modes, Burn-Back
Volts (now displayed as trim/Volt oset value)
should be set for a lower value than the trim/Volt
oset value used for regular welding.
4) Synergic MIG Operaon. The synergic welding
modes are designed to simplify welder setup and
adjustment. Synergic MIG welding allows the cus-
tomer to input basic parameters of wire type and
wire diameter and the machine will automacally
Introduction and Specifications
Section 1

13
set the unit up to operate based o fully tested
algorithmic sengs chosen by factory welding engi-
neers. The user only needs to adjust welding Amps
to match the thickness of the metal being welded.
Then unit’s programming automacally sets the
balance of the relevant parameters. The unit’s
programming allows ne tuning of the arc length
and wire sck out with the use of the Voltage/Trim
adjustment and Inductance control. The machine
can be operated synergically in standard MIG
mode, and Single Pulse Mode. For Double Pulse
Mode, the half cycles are synergically adjusted (see
full explanaon found later in this manual in the
detailed Pulse MIG explanaon found later in this
manual)
5) Pulse MIG operaon. See full details in “Pulse MIG
secon”.
6) Adjustable Pre/Post Flow Control. The Pre and
Post-Flow control feature is designed to improve
weld quality at the beginning and end of the weld
where porosity and oxidaon is likely to occur. Pre
and post ow me is manually adjusted up or down
based o of desired shielding eect to prevent po-
rosity. Of course, the ow mes can be shortened
to conserve gas if pre and post weld shielding of
the gas is not a concern. A short Pre-Flow me of
about .3 to .5 seconds and a Post-Flow me of
about 2 to 3 seconds is a reasonable starng point
when employing these features. Keep in mind that
a long Pre-Flow me will delay the arc start and
wire will not feed the wire unl the Pre-Flow me is
sased. Add more ow me if porosity or oxida-
on or excessive discoloraon is noced at the be-
ginning and end of welds. Hold the gun in place
over the cooling weld unl post ow has terminat-
ed or the eect will be lost and gas will be wasted.
7) Slow Run-in of Wire. This feature improves arc
striking quality in MIG modes by helping prevent
arc stuering (machine gunning) and push-o dur-
ing arc iniaon by slowing the wire speed unl the
arc is established. Once the arc is established, the
wire feed speed automacally begins to rapidly
ramp up to weld at the desired wire speed/Amps.
Note: The slow run-in feature prevents the opera-
tor from taking accurate measurements of wire
feed speed manually as the wire will feed slower
unl the arc is struck and maintained. This is not
an adjustable feature and cannot be deacvated.
8) Spool Gun and Push-Pull Gun Modes. The Power i-
MIG 253DPi is well equipped to handle the alumi-
num welding needs of most customers by being
both spool gun and push-pull gun ready. The unit
can handle several dierent Everlast spool gun
models, but the most capable is the 300 amp, Par-
ker® DSP 360A spool gun. However, for profes-
sional fabricang and repair needs, the Parker®
SGP 360A Push-Pull Gun is an excellent choice to
handle welding dues that require serious or fre-
quent aluminum welding capability. The pull motor
on the push-pull gun is synchronized with the main
wire feeder in the welder cabinet to weld seam-
lessly with larger rolls of aluminum wire. When
coupled with a push-pull gun, the pulse feature of
the Power i-MIG 253DPi can greatly increase the
quality and speed of out-of-posion welds com-
mon in producon welding applicaons of alumi-
num. NOTE: Operaon of the welder with the
Push-Pull gun may require the purchase of addi-
onal Push-Pull drive rolls to match the wire di-
ameter used. Also make sure that if welding alu-
minum or bronze with the push-pull gun, or the
standard MIG gun, the main feeder drive rolls are
changed to the U groove type and that the
grooves match the diameter of the wire used.
The U-shaped groove prevents deformaon of
the so aluminum and bronze wire as the wire is
fed. This prevents feeding problems in both the
long and short terms.
Basic Welder Design and Construcon. The Power i-
MIG 253DPi features an intuive control panel and cou-
ples it with digitally controlled IGBT inverter design that
produces a stable arc while conserving energy. Everlast
ulizes quality components from US, European, and
Asian based companies to ensure reliability and parts
commonality. Major control components are a plug-
and-play design which allows rapid diagnosis and a
quick repair of the welder. Welding parameters can be
innitely and connuously adjusted throughout the
range, oering instant welding response for maximum
welding control.
Installaon. The Power i-MIG 253DPi is built with both
durability and convenience in mind. It is considered
ideal for circumstances where portability is needed.
Crical components are protected by conformal
coangs to make the welder environmentally resistant
and has a water ingress rang of IP21S, (the standard in
the welding industry to protect from vercally dripping
water). However, some common sense care should be
exercised to make sure that the welder oers the safest
and best performance. Please note the following items
regarding safe and proper welder operaon to ensure
Introduction and Specifications
Section 1

14
best service and results while welding:
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 shock or electro-
cu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.
If the work clamp becomes corroded or damaged,
be sure to replace it with a heavy-duty work clamp
rated for at least 300 amps. If your work clamp
appears to become extremely hot while welding,
and all connecons are clean and secure, replace
the work clamp.
3) Store the welder covered with a moisture and re
resistant material.
4) If used on a mobile cart, strap or x the welder to
the cart so that accidental overturn is not likely.
Duty Cycle/Overcurrent/Under Voltage/Overvoltage
Warnings. Thanks to a dual cooling fan design, the
Power i-MIG 253DPi has a duty cycle rang of 60% at
250 Amps while welding in MIG mode and a rang of
60% @ 250 Amps while welding in sck mode. The duty
cycle rang is the amount of me (expressed as a per-
centage) out of 10 minutes the unit can weld without a
rest. For MIG, the unit is capable of welding 6 minutes
out of every 10 minutes at the maximum output of 250
Amps. For the balance of the 10 minute period, the unit
should be allowed to rest and cool while running. This
Note: If a generator is going to be used with this unit,
please make sure that it is cered by its manufactur-
er to be “clean power,” which is normally stated as
less than 5% THD ( Total Harmonic Distoron). For
proper operaon with a generator, make sure you
have at least a minimum 12,000 was of surge capabil-
ity and 8,500 was of connuous rated output capabil-
ity.
Introduction and Specifications
Section 1

15
EVERLAST
EVERLAST
Setup Guide and component Identification
Section 2
CONNECTIONS AND POLARITY
MIG* SPOOL GUN**
*For Flux-Core, install the work clamp in the
positive terminal and then change the wire feed-
er’s polarity (located under the access cover).
GUN +WORK -
CONNECT TO 5/8” CGA GAS FITTING AT REAR
CONTROL
SPOOL GUN +
STICK
PUSH-PULL GUN**
CONTROL
MOTOR
WORK -
PUSH/PULL GUN +
WORK -
WORK -TORCH +
** Push Pull gun and Spool gun are optional items
that may be purchased separately from Everlast.

16
Setup Guide and component Identification
Section 2
PROCESS TORCH POLARITY WORK POLARITY
MIG (GMAW) +-
FLUX CORE (FCAW) - +
STICK (SMAW) +-
Table 1
GENERAL POLARITY RECOMMENDATIONS*
*Consult the manufacturer of the ller material recommendaons concerning polarity .
PROCESS GAS
MIG (GMAW) STEEL For best operaon in Synergic Pulse Spray:
90/10 (opmum), 95/5 (maximum), 82/18, or 80/20 (minimum) Ar/CO2
For best operaon Short Circuit MIG: 75/25 Ar/CO2 or 100% CO2
MIG (GMAW) STAINLESS STEEL
(INOX)
For Synergic Pulse Spray: 98/2 Ar/O2, 98/2 Ar/CO2
For Short Circuit: Tri-Mix or 98/2 Ar/CO2
MIG (GMAW) ALUMINUM For Synergic Pulse Spray: 100% Ar
For Standard Spray: 100% Ar
Table 2 GAS SELECTION GUIDE
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

17
Setup Guide and component Identification
Section 2
INSTALLING THE WIRE SPOOL
To thread the wire from the spool properly through the wire feeder into the gun:
1.Install the MIG gun as instructed in “To install the MIG gun (torch)” above. Loosen the top idler roller tensioner, rotating the black tensioner knob counter-clockwise.
2.Flip the tensioner down, toward you, releasing the carrier arm that holds the top drive rolls.
3.Raise the carrier arm up. Inspect the drive rolls to make sure that each roller’s groove size matches the wire diameter. Also make sure correct type of drive rollers are used. i.e. Flux
-Core drive rolls use special serrated rolls. (Top driven rollers do not have grooves and are not to be removed).
4.Reversal of the lower drive rollers to select the right size drive groove may be necessary. To reverse the lower drive rolls: Remove the slotted screws securing each lower drive
roll. Pull each retaining spacer. Remove the outer ring of the drive roll and flip the drive roll over. The drive roll is actually made of two pieces. Hold the inner assembly of the
drive roll on with one finger (to prevent it from slipping off the shaft), while slipping the outer “rim” of the drive roll off with the other hand. NOTE: Both inner and outer parts of
the assembly have locating keys. To reinstall: Line up the outer rim of the driver rolls keyway with the locating key. Reassemble and tighten each roller. Make sure both
rollers are matched in size. Also make sure the locating keys are in place and have not pushed or slipped out of their grooves during assembly. Lightly coat the inner mating
surfaces with light lube if necessary to prevent future seizure. Do not lubricate the surfaces of the drive rolls or wire slipping and erratic feeding may result.
5.Follow instructions above: “To Load Spool of Wire.” Make sure the spool of wire is loaded correctly so that the wire unrolls from the bottom of the spool (counter-clockwise).
Thread the wire into the coiled guide and over the grooves in lower drive rolls. Thread the wire fully through until it threads into the gun section 4”-6”. Lower the upper drive rolls
into contact with the lower drive rolls, keeping the wire securely fixed in the grooves of the lower feed rollers. If needed, use a screwdriver with a fine blade or small pick to keep
wire from moving out of the grooves until step 6 is completed. Make sure one last time that the correct groove has been selected.
6.Raise drive roll tensioner back into place. Tighten it slightly so the wire will feed. Notice markings on tensioner for future reference.
7.Remove the contact tip from the torch. (Not Shown). Hold the torch cable and gun as straight as possible, in direct line with the unit so feeding of the wire through the gun liner is
smooth and easy.. Press the gun trigger to feed wire until the wire exits the end of the torch. Reinstall the contact tip over the wire over the wire and tighten it.
8.To prevent bird nesting or slipping of the wire, adjust the tensioner clockwise until the drive rolls will not slip when the wire comes into contact with a hard surface. The wire will curl
up on end while feeding under power. If you over-tension the wire, you will increase the chances of bird nesting of the wire (balling up of the wire or curling of the wire around
the drive rolls), so it is best to tighten just until wire stops slipping and is able to curl up. Extra tension can deform wire and prematurely wear the drive rolls. Slowing of the
feeder may result as well. Remember not to test on any metal attached to the work clamp to prevent the wire from arcing while performing this test.
C
-
4
5
1
2
3
4
5
6
To install the MIG gun (torch).
A.Align pins on the torch connector with the feeder receptacle.
B.Fully engage the connector into the receptacle on the welder.
C.By hand, twist the plastic hand nut on the connector r clockwise until
it is snug. Tighten by hand only or damage may result.
A
B
C
To load the spool of wire:
1. Loosen and remove the hand nut on the spool carrier 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. Adjust de-spooling tension by turning tensioner located under the hand
nut on the spool carrier.
5. Lightly spin the spool. If it free-wheels more than 1/4 turn, tighten hex
screw a little at a time until it doesn’t. If it does not free-wheel at all,
loosen tensioner until it free wheels 1/4 turn.
6. Reinstall the hand nut so the spool is retained securely.
7. Locate the end of the 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 de- spool. Proceed to
instructions listed below: “To thread wire from the spool properly
through the wire feeder into the gun.”
NOTE: An adapter/spacer will be needed to use 8” spools. Contact
Everlast to purchase one if you do not have an adapter.
8
Bottom Drive Roll Sizing
(See side for stamped size)
.6mm=.023”-.025”
.8mm=.030”
.9mm=.035”
1.0mm=.040”
1.2mm= .045”
1.6mm=.062”(1/16”)
To change the polarity of the MIG gun: Unscrew the screw from the (+) terminal. Remove
screw and cable. Move the cable to the hole in the (— ) terminal. Reinstall the removed screw
into the ( — ) terminal. Tighten screw but do not overtighten.
NOTE: Be sure to use special serrated drive rollers while using
Flux-Cored wire and dual shielded wires. The serrated rollers
are available as an option. Contact Everlast to purchase Flux-
core drive rolls. Also, don’t forget to change gun polarity to (-)
for flux core use..

18
FRONT VIEW/ MAIN PANEL POWER i-MIG 253DPi
Setup Guide and component Identification
Section 2
PULL MOTOR CONTROL
1
15
12 2
13
11
8
14
4
7
9
3
10
5
6
16 18 19
17 20

19
Front Panel Descripon and Explanaon:
1. Protecve Cover. The unit features a protecve
hinged cover. This cover should be lowered
whenever welding is acvely taking place or
when the welder is stored for an extended peri-
od of me.
2. Volts/Funcon Display and LEDs. The Volt/
Funcon display works in conjuncon with the
LEDs directly below the display to indicate the
values of specic funcons. As the “Select Pa-
rameter” buon (#10) is pressed, the LEDs will
light up, one at a me while progressing through
the parameter menu (graph). The LED indicates
which funcon value is currently being shown in
the display. The list of funcons controlled in
this display are: Volts (V), Hertz (Hz), Seconds in
tenths/thousandths (.S), and Percentage (%).
Each one of these represents a value of a param-
eter listed in the graphical parameter represen-
taon of the welding funcons below in #6.
NOTE: Depending upon which mode is select-
ed, not all LED’s will be highlighted as you scroll
throughthe parameters. The default funcon
represented in the display is Volts. Aer ad-
jusng or selecng each funcon, the unit will
return to the Volt seng automacally within 3
seconds. While welding, this display changes
from set voltage to dynamically display actual
welding voltage output while welding.
3. Amps Display and Warning LEDs. The Amps
display is a single purpose display and is used
only to display selected Amps or dynamic Amp
output, depending on whether or not the unit is
actually welding. The actual Amp output will
vary somewhat in standard modes and will actu-
ally display a dierent Amp output in pulse
mode since the unit gures an “average value”
of the pulse Amps. During Amp selecon, in
Pulse mode, you are only selecng for the
“Welding Amps” and not the Pulse values. The
synergic funcon of the Pulse mode takes over
and gures the balance of the pulse sengs
which will create a displayed Amp output while
welding that is slightly dierent than set. How-
ever, this should not be of concern, other than a
reference of overall heat going into the weld.
Keep in mind that when you are adjusng Amp
output, you are also adjusng wire speed.
While wire speed is commonly used as a refer-
ence in lower er MIG welders, it is not the
most accurate way of adjustment and measure-
ment. Wire speed only gives you a reference of
Inches of wire delivered to the weld in one mi-
nute. However, if you are to swap the wire spool
and change wire diameter, the same wire feed
seng used with the rst roll will not produce the
same amp output in the second roll because the
wire diameters are dierent. With lower er
welders, you oen don’t have an opon to pro-
gram the wire diameter into the machine, so wire
speed is the only gure that can be used as a ref-
erenced value unl the unit starts welding and a
built-in sensor can measure and display the actual
Amps being delivered to the weld. With this unit,
even in standard mode, you are able to input the
wire diameter, from .030” to .045”. This ensures
the most precise method of regulang the weld
parameters. As a reminder: Always remember to
select the wire diameter rst so that the amps
can be correctly displayed during adjustment.
With wires larger or smaller than the listed wire
diameter calibraons included in #5, select the
nearest diameter to the size that is installed.
While this won’t be 100% accurate, it can be used
as a relave reference for setup. In this case, you,
may have to rely on sight and sound to accurately
set up the welder, as you would with a MIG with-
out a display. See conversion factors found later
in this manual for guring approximate wire
speed and amperage. The LED ON Indicator di-
rectly underneath the display should be lit any-
me the machine is turned on and the unit is re-
ceiving power. If the unit is switched on but no
ON light appears and the fans do not start, check
for a tripped breaker and check for incoming pow-
er at the receptacle. You may noce that the ON
indicator along with the displays and fan, may
remain powered up to 10 seconds aer the unit is
switched o as the capacitors discharge. This is
part of normal operaon and not a defect.
When the LED Warning Indicator lights up, the
machine power output will cease. This is due to
the fact that the duty cycle has been exceeded
and the unit has over-heated. If this occurs, al-
low the machine to run so it can connue to cool
the electronics for 15 minutes. If the machine
does not automacally reset aer this me,
switch the unit o and turn it back on. If the ma-
chine does not reset, check the fuse. If the fuse is
good, call Everlast tech support for further diag-
nosis procedures.
4. Synergic Funcon. The Synergic funcon is used
to simplify setup and improve results while weld-
ing. It eliminates the need for the operator to
Setup Guide and component Identification
Section 2
!

20
know complex algorithms or to have extensive
experience at seng up complex parameters
related to MIG welding, especially Pulse parame-
ters. The Synergic funcon of the Power i-MIG
253DPi applies to non-pulse, single pulse and
double pulse forms of MIG welding. In standard
non-pulse MIG mode, the synergic funcon is
oponal and can be turned on and o. However,
in all pulse MIG modes, the synergic light will
stay illuminated as a reminder of funcon and
cannot be deselected (turned-o). To select for
Synergic operaon simply press the buon to
illuminate the LED located directly over the
buon. Then, select the relevant parameters in
items #5 and #6 (see reference picture on previ-
ous page for comparison). Note: The synergic
non-pulse MIG mode is designed and intended
for steel operaon with Ar/CO2 or 100% CO2
shielding gas. The operaon, theory and dier-
ences in Synergic non-pulse MIG mode, Synergic
Single Pulse MIG mode and Synergic Double
Pulse MIG modes are discussed in more detail
later in this manual. Please see the separate
secons dealing with Basic MIG welding and
Pulse MIG welding for more informaon.
5. Wire Diameter Selector. The wire selecon
parameter is used to ensure accurate Amperage
calculaon. The selecon of wire diameter will
be required in all modes including during non-
synergic operaon. If the wire diameter selected
does not match the wire being used, the display
will not accurately reect the Amps unl welding
has started. If the size of wire you have installed
(i.e. .023” diameter) does not have a counter-
part in item #5, use the seng that is the next
closest in size. However keep in mind that the
Amp seng is only going to be able to be used as
an approximaon and is good for a reference
seng only. This statement also applies to Flux-
Core and dual-shield operaon. In these cases,
set the unit up using basic setup techniques used
to set up MIG welders without a display. Also, it
is suggested that in these cases that Synergic
Mode not be used since it may require extensive
altering of background sengs to funcon cor-
rectly. Standard Mode will also allow the Voltage
to be manually adjusted to the correct seng in
these excepons to wire diameters/types.
6. Filler Metal Type Selector. This funcon is de-
signed to be used exclusively in Synergic Pulse
Modes only. The input of ller metal type will
always be required in both types of Pulse Mode.
Setup Guide and component Identification
Section 2
In the non-pulse synergic mode, the unit defaults
to Steel operaon and does not allow selecon for
other Filler metal types since it is assumed that
Aluminum, Stainless Steel (INOX), and Bronze will
be used exclusively in the Pulse modes. In this case
no LED will be illuminated. Not every possible
ller metal category will be listed on the panel. If
the Alloy you are using is not listed, use the ller
metal opon that is most closely related to the ller
metal type you plan to use. Any dierence in
sengs can be ne tuned by the Voltage/Arc Trim
feature, or by the Inductance if needed. Addional-
ly there are background sengs that can be altered
to help correct any issues that cannot be corrected
by tuning factory sengs (though it is not normally
needed). In the case of the Aluminum Alloy that is
currently required by some manufacturers in auto
body repairs, 5554, select the 5356 Alloy opon. As
a rule of thumb, always remember that with any
4XXX ller use the 4043 Alloy opon. With any
5XXX ller use the 5356 Alloy opon. The welding
requirements are similar between them and the
voltage oset/arc trim feature can quite easily dial
the welder in if needed. These newer alloys have
been eld tested and proven to and work with the
Power i-MIG 253DPi. This includes cercaon
tesng. The inductance feature can be further
tuned for out-of-posion applicaons if needed.
7. Welding Mode Selector. The welding mode selec-
tor buon is used to select the desired welding
mode. The modes that are selectable are Sck,
Standard/Synergic MIG Steel mode (MIG/CO2),
Single Pulse, and Double Pulse modes. As the
buon is pressed each me, the LEDs will cycle and
illuminate one-at-a-me, from le to right. The
Single Pulse mode and the Double Pulse mode can
only be operated in the synergic modes. The syn-
ergic light cannot be deacvated when one of
these modes is selected. You’ll noce that the
“Setup” light is present in the series of LEDs as well,
but is skipped over while cycling through. This is
normal. This LED represents the hidden or back-
ground programmable part of the units welder.
How to access this funcon and the adjustable
background parameters that are controlled by this
funcon will be covered in greater detail separately
in the appendix of this manual. The Setup should
not be accessed unless the operator is sure that
changes are needed as it will signicantly alter the
factory programmed sengs. The Setup funcon
has a hidden feature that also allows the original