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
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10
11
12
12
16
15
17
18
19
27
28
29
30
32
40
50
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60
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61
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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.