Everlast Power i-MIG 315 User manual

Rev. 1 0 10531-20
1-877-755-9353 Specications and Accessories subject to change without notice.
329 Littleeld Ave. South San Francisco, CA 94080 USA
Operator’s Manual for the Power i-MIG 315
Safety, Setup and General Use Guide
SMAW
GMAW
everlastwelders.com
CC
CV
IGBT
PHASE
DV
120/240V
1

2
TABLE OF CONTENTS
CUSTOMER GREETING 3
EVERLAST CONTACT INFORMATION 4
SAFETY INSTRUCTIONS 5
PERFORMANCE/DESIGN SPECIFICATIONS 9
ELECTRICAL INPUT/OUTPUT/DUTY CYCLE 10
GENERAL PRODUCT AND USE INFORMATION 11
DUTY CYCLE AND WARNINGS 12
SUMMARY OF FEATURES 13
GENERAL MIG/FLUX-CORED/DRIVE ROLL INFORMATION 16
MIG GUN AND WIRE SPOOL INSTALLATION 17
CONNECTING GAS AND REGULATOR INFORMATION 19
GAS SELECTION AND GAS FLOW RATE 20
CABLE CONNECTIONS AND POLARITY 21
MIG CONNECTION 22
FLUX-CORED CONNECTION 23
SPOOL GUN CONNECTION 24
STICK CONNECTION 25
SETTING UP WELDING PARAMETERS 30
MIG/FLUX-CORED INFORMATION 26
STICK INFORMATION 28
FRONT PANEL VIEW AND COMPONENT ID 30
FRONT UPPER CONTROL PANEL COMPONENT ID 32
SIDE ACCESS PANEL VIEW AND COMPONENT ID 35
REAR PANEL VIEW AND COMPONENT ID 37
MIG TORCH COMPONENT VIEW AND ID 39
MIG OPERATION AND THEORY 40
STICK OPERATION AND THEORY 85
TROUBLE SHOOTING/WARNING SCREEN INFORMATION 95
BASIC TROUBLE SHOOTING 50

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 information. Your unit registration is im-
portant should any information such as product updates or recalls be issued. It is also important so that we may track your satisfac-
tion with Everlast products and services. If you are unable to register by website, contact Everlast directly through the sales depart-
ment at the main customer service number in your country. Your unit’s warranty will be registered and in full effect. Keep all infor-
mation 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 information found on the Everlast website of the division
located in or nearest to your country. This includes the terms of the purchase and warranty procedure. Print it for your records and
become familiar of its terms and conditions. Please note that Guns, accessories and torches are covered under a separate, shorter
warranty. Please be sure you visit the website and are familiar with all the warranty terms before you call for service.
Everlast offers full technical support, in several different forms. We have online support available through email, and a welding sup-
port forum designed for our customers and non-customers to interact with each other. Technical advisors are active on the forum
daily. We also divide our support into two divisions: technical and welding performance. Should you have an issue or question
concerning your unit, please contact performance/technical support available through the main company headquarters available in
your country. This support is free to all Everlast customers. For best service call the appropriate support line and follow up with an
email, especially during weekends, holidays or any off 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 holidays. Also, for
quick answers to your basic questions, join the company owned forum available through the website. You’ll nd knowledgeable
staff available to answer your questions. You also may nd a topic that already addresses your question at http://
www.everlastgenerators.com/forums/. Should you need to call or write, always know your model name, purchase date and welder
manufacturing inspection date. This will assure the quick and accurate customer service. REMEMBER: Be as specic and informed
as possible. Technical and performance advisors rely upon you to carefully describe the conditions and circumstances of your
problem or question. Take notes of any issues as best you can. You may be asked many questions by the advisors to clarify prob-
lems or issues that may seem very basic. However, diagnosis procedures MUST be followed to begin the warranty process. Advi-
sors can’t assume anything (even with experienced users) and must cover all aspects to properly diagnose the problem. Depend-
ing upon your issue, it is advisable to have basic tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive test
meter with volt/ohm functions before you call.
Let us know how we may be of service to you should you have any questions.
Sincerely,
Everlast Customer Service

4
Serial number: ____________________________
Model number: ____________________________
Date of Purchase___________________________
Everlast USA:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [email protected]
Everlast Welding Support: [email protected] Everlast Support
Forum: http://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
FAX: [phone]
Everlast Canada:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [email protected]
Telephone: [phone]am-4:30pm EST M-F
Everlast Australia:
Port Macquarie 4/18
Acacia Ave.
Port Macquarie NSW 2444
(02) 6581 23888
After Hours Support
0431 016 416
Sales: [email protected]
Support: [email protected]
NOTICE:
Product Specications and features are subject to change without notice. While every attempt has been
made to provide the most accurate and current information possible at the time of publication, this manual is
intended to be a general guide and not intended to be exhaustive in its content regarding safety, welding, or
the operation/maintenance of this unit. Everlast Power Equipment INC. does not guarantee the accuracy,
completeness, authority or authenticity of the information contained within this manual. The owner of this
product assumes all liability for its use and maintenance. Everlast Power Equipment INC. does not warrant
this product or this document for tness for any particular purpose, for performance/accuracy or for suitabil-
ity of application. Furthermore, Everlast Power Equipment INC. does not accept liability for injury or damag-
es, consequential or incidental, resulting from the use of this product or resulting from the content found in
this document or accept claims by a third party of such liability.

5
Safety Precautions
Everlast is committed to providing you with the best possible equipment and service to meet the demanding
job requirements that you may have. We want to go beyond delivering a satisfactory product to you. That is
the reason we offer free technical and basic welding support to assist you with your needs, should an occa-
sion occur where it is needed. With proper use and care your product should deliver years of trouble free
service. Everlast products are designed and intended for use by professionals and knowledgeable individu-
als, who have a basic skill set and an elementary knowledge of basic welding and safe welding practices.
Untrained users can create unsafe conditions that not only endanger lives, but that also endanger property
and the equipment. Keep a printed copy of this manual available and easily accessible for all users and do
not let a user operate this equipment without fully reading and studying this manual.
Safe operation and proper maintenance is your responsibility.
We have compiled this operator’s manual, to instruct you in basic safety, operation and maintenance of
your Everlast product to give you the best possible operator/owner experience. Welding and related cut-
ting operations require basic experience and common sense. Exercise extreme caution and care in all ac-
tivities related to welding or cutting. Your safety, health and even life depends upon it.
While accidents are never planned, preventing an accident requires careful planning. Stay alert!
Please carefully read this manual before you operate your Everlast unit. This manual, if read in full, can as-
sist the user in obtaining helpful information concerning the safe operation of this unit. Do not operate the
unit until you have read this manual and you are thoroughly familiar with the safe operation of the unit. If
you feel you need more information please contact Everlast Support. The content of this manual is not meant
to be an exhaustive primer on welding. It is written to an audience that, if not professional, will have at least
a basic skill set in welding which includes basic knowledge of welding terms and best practices.
The 5 year warranty does not cover improper use, maintenance, accessories or consumables. Accessories
are covered by a separate warranty (length varies), which is also listed on our website along with the full
terms of the welder warranty. Consumables have no warranty.
Do not attempt to alter or defeat any piece or part of your unit, particularly any safety device. Keep all
shields and covers in place during unit operation should an unlikely failure of internal components result in
the possible presence of sparks and explosions. If a failure occurs, discontinue further use until malfunc-
tioning parts or accessories have been repaired or replaced by qualied personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves. These waves may dis-
turb sensitive electronic equipment such as televisions, radios, computers, cell phones, and related equip-
ment. High Frequency may also interfere with fluorescent lights. Consult with a licensed electrician if dis-
turbance is noted. Sometimes, improper wire routing or poor shielding may be the cause.
WARNING! HF can interfere with pacemakers. See EMF warnings in following safety section for fur-
ther information. Always consult your physician before entering an area known to have welding or
cutting equipment if you have a pacemaker.

6
Safety Precautions
These safety precautions are for protection of safety and health. Failure to follow these
guidelines may result in serious injury or death. Be careful to read and follow all cautions
and warnings. Protect yourself and others.
Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can cause
severe skin burn and damage. There are other potential hazards involved with welding such as
severe burns and respiratory related illnesses. Therefore observe the following to minimize
potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even under
welding helmets to protect your eyes from flying sparks and debris. When chipping slag or
grinding, goggles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct shade of
lter installed. Always use a welding helmet in good condition. Discard any broken or cracked
lters or helmets. Using broken or cracked lters or helmets can cause severe eye injury and
burn. Filter shades of no less than shade 5 for cutting and no less than shade 9 for welding are
highly recommended. Shades greater than 9 may be required for high amperage welds. Keep
lter lenses clean and clear for maximum visibility. It is also advisable to consult with your eye
doctor should you wear contacts for corrective vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless fully
protected by a lter screen, protective curtains or equivalent protective equipment. If no
protection is available, exclude them from the work area. Even brief exposure to the rays
from the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy. Ear pro-
tection is necessary to prevent hearing loss. Even prolonged low levels of noise has been
known to create long term hearing damage. Hearing protection also further protects against hot
sparks and debris from entering the ear canal and doing harm.
Always wear personal protective clothing. Flame proof clothing is required at all times. Sparks
and hot metal can lodge in pockets, hems and cuffs. Make sure loose clothing is tucked in
neatly. Leather aprons and jackets are recommended. Suitable welding jackets and coats may
be purchased made from re proof material from welding supply stores. Discard any burned or
frayed clothing. Keep clothing away from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for adequate foot
protection. Canvas, polyester and other man made materials often found in shoes will either
burn or melt. Rubber or other non conductive soles are necessary to help protect from electri-
cal shock.
Flame proof and insulated gauntlet or cuffed type gloves are required whether welding or cut-
ting or handling metal. Simple work gloves for the garden or chore work are not sufcient.
Gauntlet type welding gloves are available from your local welding supply store.
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 attempt to defeat any safety feature. Always operate unit with guard in place on the wire
feeder.

7
WARNING! Persons with pacemakers should not weld, cut or be in the welding area until they
consult with their physician. Some pacemakers are sensitive to EMF radiation and could severely
malfunction while welding or while being in the vicinity of someone welding. Serious injury or death
may occur!
Welding and plasma cutting processes generate electro-magnetic elds and radiation. While the
effects of EMF radiation are not known, it is suspected that there may be some harm from long
term exposure to electromagnetic elds. Therefore, certain precautions should be taken to mini-
mize exposure:
•Lay welding leads and lines neatly away from the body.
•Never coil cables around the body or limbs.
•Secure cables with tape if necessary to keep from the body.
•Keep all cables and leads on the same side the body.
•Never stand between cables or leads.
•Keep as far away from the power source (welder) as possible while welding.
•Never stand between the ground clamp and the torch.
•Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any guidelines
from your chosen consumable and electrode suppliers regarding possible need for respiratory
equipment while welding or cutting. Always weld with adequate ventilation. Never weld in
closed rooms or conned spaces. Fumes and gases released while welding or cutting may be
poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
Stop immediately and relocate work if necessary until adequate ventilation is obtained.
Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, copper, cadmium,
lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product can expose you to chemicals such as lead, which is known to the State of
California to cause birth defects, reproductive harm and cancer. Proposition 65 Warning. For more
information visit: www.P65Warnings.ca.gov
DANGER! Do not weld or cut around Chlorinated solvents or degreasing areas. Release of Phos-
gene gas can be deadly. Consider all chemicals to have potential deadly results if welded on or
near metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain regulations 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 recommendations. The regulatory
changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and closed. Store
chained so that overturn is not likely. Transporting cylinders incorrectly can lead to an explosion.
Do not attempt to adapt regulators to t cylinders. Do not use faulty regulators. Do not allow cylin-
ders to come into contact with work piece or work. Do not weld or strike arcs on cylinders. Keep
cylinders away from direct heat, flame and sparks.
Safety Precautions

8
Safety Precautions
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do not use frayed, cut
or otherwise damaged cables and leads. Do not stand, lean or rest on ground clamp. Do not stand in water or damp
areas while welding or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain or in extremely
humid conditions. Use dry rubber soled shoes and dry gloves when welding or cutting to insulate against electrical
shock. Turn machine on or off only with gloved hand. Keep all parts of the body insulated from work, and work tables.
Keep away from direct contact with skin against work. If tight or close quarters necessitates standing or resting on
work piece, insulate with dry boards and rubber mats designed to insulate the body from direct contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their location and make sure all personnel in area are
advised of their location. Taping or securing cables with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep re extinguishers close by and
additionally a water hose or bucket of sand. Periodically check work area for smoldering embers or smoke. It is a good
idea to have someone help watch for possible res while you are welding. Sparks and hot metal may travel a long dis-
tance. They may go into cracks in walls and floors and start a re that would not be immediately visible. Here are
some things you can do to reduce the possibility of re or explosion:
•Keep all combustible materials including rags and spare clothing away from area.
•Keep all flammable fuels and liquids stored separately from work area.
•Visually inspect work area when job is completed for the slightest traces of smoke or embers.
•If welding or cutting outside, make sure you are in a cleared off area, free from dry tender and debris that might start
a forest or grass re.
•Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held flammable liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling hot pieces of metal. Remember to
place hot metal on re-proof surfaces after handling. Serious burns and injury can result if material is improperly han-
dled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper maintenance is your responsibil-
ity. Make sure all equipment is properly maintained and serviced by qualied personnel. Do not abuse or misuse
equipment. Remove any faulty cords, plugs or electrical equipment from service or access.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding parts. Touching uncovered parts
inside machine can cause discharge of high amounts of electricity. Do not allow employees to operate poorly serviced
equipment. Always check condition of equipment thoroughly before start up.
Disconnect unit from power source before any service attempt is made and for long term storage or electrical storms.
If operating on a generator: Always switch off and disconnect the unit before shutting the unit down. Never start the
generator with the unit switched on or connected. Failure to do so may result in damage to the unit. This damage is
not covered under warranty. Make sure that any required generator grounding is performed properly and to the manu-
facturer’s recommendations.
Further information can be obtained from The American Welding Society (AWS) that relates directly to safe welding
and plasma cutting. Additionally, your local welding supply company may have additional pamphlets available con-
cerning their products. Do not operate machinery until your are comfortable with proper operation and are able to
assume inherent risks of cutting or welding.

9
General Performance Specications
Power i-MIG 315
MIG/Stick Amp Range MIG 30-315A / DC Stick: 10-200A
OCV 70V
MIG Output Type Standard, non-pulse, with Flux-Cored Capability. Spool gun ready. (Spool gun is optional)
Volt Adjustment Range MIG 15.5-30V (±3V)
MIG Wire Feed Speed 60 to 600 IPM (.5-15 m/min) (No load max 700 IPM)
Input Voltage 240V Single phase (208V is permissible but no lower than 205V)
Welder Type Digitally controlled, IGBT inverter type with MIG/Flux-Cored, Stick function and Spool Gun capability.
Wire Roll Size and Diameter .035-.045” (.9mm to 1.2mm) standard. Other wire diameters possible with optional drive rolls. Purchase
optional drive rolls for extended wire sizes and types..
Pre/Post Flow Control MIG Auto
MIG Burn Back Timer Control 0-2 seconds
Inductance/Arc Force Control 0-100%
MIG/Stick Output Type DC CV/CC
MIG Burn Back Timer 0-2 Seconds
Stick Hot Start Timer Auto
Stick Hot Start Intensity Control Auto
Stick E6010 Capability No, 6011 capable
Power Cable Length 6 ft. (2m)
Accessories 36 Series MIG torch 9.5 ft. (3m), Work clamp with cable 9.5 ft. (3m). 300 A Stick torch with cable (3m), Float-
ing ball type regulator.
Weight 66 lbs. / 30Kg
Dimensions 26”L x 11”W x 16”H(19” with handle) / 660mm L x 280mm W x 407mm H (483mm with handle)
Recommended Generator Minimum 17500W Surge with Clean power output (See detailed information page 11.)
Efciency ≥80%
Section 1 Introduction and Specifications

10
Section 1 Introduction and Specifications
MODEL: Power i-MIG 315 Serial No.
EN/ IEC60974.1
240V; DC: 30-315A; 15.5-29.8V
X35% 60% 100%
U0 V
70V
I2 315A 250A 200A
U2 29.8V 26.5V 24V
DC: 10-200A; 20.4– 28V
X35% 60% 100%
U0 V
70V
I2 200A 160A
U2 28V 26.4V
1~ 50/60 Hz
U1
240V 240V I1MAX: 63A I1EFF 38A
PROTECTION
CLASS
IP21S
COOLING METHOD:
FULL-TIME FANS INSULATION: F
f1f2
1~
S
S
Power i-MIG 315
EVERLAST
IMPORTANT!
Keep this welder at least 18 inches away from all objects for proper cooling. This unit uses multiple fans at different spots within the machine for
cooling. For this reason, proper spacing is imperative from all sides. Do not exceed 40° C in environment or duty cycle will be reduced. Regu-
larly inspect and clean the welder and circuitry on a monthly basis with dry compressed air. Remove the covers only after the unit has been
turned off and unplugged for 30 minutes to discharge the capacitors and to prevent the possibility of electrocution. Do not grind or direct sparks
near the welder to prevent damage to the panel face and internal components. Check fan blades for build up and metal scale/dust and remove
carefully. Failures or damages to the unit due to accumulation of dirt and debris on circuit boards or fan blades are not covered under warranty.
Opening your unit up to clean or adjust the unit does not void your warranty, and in fact ensures your unit will perform correctly and will uphold
your warranty.
NOTICE:
This welder conforms to North American electrical standards for 240V single phase welders, including plug type (NEMA 6-50P)and wire gauge.
These standards take into consideration duty cycle, Maximum Inrush Amperage and Rated Amperage. When wiring a new electrical service or
modifying an existing electrical service for use with this welder, always consult with a local licensed electrician. This unit is intended for use with
commercial input power, and ground service. Although this unit may be used in non commercial applications, the user should be aware that the
Welder wiring standards are different that typical household and non-commercial wiring standards. Refer to Article 630 of the NEC and to the
I1MAX (Inrush Current) and the I1EFF (Effective rated current) listed above when selecting breaker size and the wire gauge to ensure that your instal-
lation will conform to national and local electrical codes for welding equipment. Wiring codes for welders differ from wiring codes for household
electrical equipment for both plug type, breaker and wire sizing. Do not attempt to rewire this welder, or make similar unapproved modications
to this welder. To do so will void the warranty. Due to the possible EMF/HF that can be generated with this unit, interference with and disrup-
tion of electronics, and electrical equipment may occur if not properly wired and grounded. If interference is caused, have a certied and li-
censed electrician come out and ground all metal items, directly to earth, including metal wall panels, tables etc, and install a ground rod every
50 ft. The ground bolt on the back of the unit should be used in conjunction to help resolve interference issues. Install an insulated 12 gauge or
larger wire connected directly to a separate copper grounding rod driven into the earth and connect it to the grounding bolt on the rear of the
unit. Keep Ground paths a short as possible
Electrical and Performance Specications

11
NOTICE:
This manual has been compiled to give an overview of operation and is designed to offer information centered around
safe, practical use of the welder and its functions. Welding operations are inherently dangerous. Only the operator of
this welder can ultimately ensure that safe operating practices are being followed, through the exercise of common
sense practices and training. Do not operate this machine until you have fully read the manual, including the safety
section. If you do not have the skill or knowledge to safely operate this unit and its related functions, do not use this
welder until formal training is received. Always be aware of your surroundings and operating environment and who
and what is in that environment. Be on the lookout for res, and smoldering materials while and after welding!
Section 1 Introduction and Specifications
General Product and Use Information
GENERAL PRODUCT INFORMATION:
The inverter-based Power i-MIG 315 is a MIG/Stick unit with production welding capability designed for commercial/
industrial use and applications. (Residential or home shop use is ok as long as wiring codes are followed per Article
630 of the NEC) The unit is intentionally basic, for those users who require simplied setup and for use by multiple
operators or with operator’s with limited experience with MIG or stick welding. It features a self-contained undercar-
riage and a rear cylinder holder so that gas can be transported with the unit. It has a four roll wire feeder that features
four gear driven drive wheels. It can use either 8” or 12” spools of wire. (Adapter required for use with 8” spools).
Other than the standard Volt/Amp adjustments, this unit has burn-back control, inductance control, and a spot/stitch
timer. Burn-Back is designed to help reduce the need for wire trimming before restarts by providing a momentary arc
after the unit stops feeding wire. Typically the lowest setting of .1 to .2 seconds is recommended. The Inductance
feature controls puddle wet-in, arc width, and spatter. For steel applications, a typical setting would be between 6.5 to
7.5. For stainless, inductance levels would typically be between 8.5 to 9.5. Aluminum settings of Inductance should
be balanced at 4.5-5.5. Gas type or mix type will vary the settings required for best weld characteristics. The Spot
timer allows the user to create regular, consistent sized spot, seam or plug welds automatically by timing the arc on
time when the trigger is pulled. The stitch feature provides a repeating On/Off cycle of the spot weld function. The arc
will continue to cycle on and off as long as the trigger is held. This helps in creating consistent length or size of welds
along a seam, if forward travel speed is consistent. The Spot Timer can be used without the stitch timer, providing
only a single On/Off cycle. The Stitch Timer cannot be used without the Spot timer. The unit also features an auto-
matic Pre and Post flow time control for the gas. This improves weld quality, allowing a small bit of gas to flow before
the wire begins to feed, and for gas to flow for a short time after the weld nishes. This promotes better gas coverage
and reduces porosity at the beginning and end of the weld.
GENERATOR REQUIREMENTS AND OPERATION
Although this unit is intended to be primarily used in a shop, and not designed for portability, this unit may be used
with generators rated for 17,500 Watts with a Clean Power Output rating. Clean power is dened as 5% or less Total
Harmonic Distortion (THD). The manufacturer of the generator must specify that the generator is “clean power” or rate
THD to be equal to or less than 5%. Otherwise, any operation with other types of generators not rated to be “Clean
Power Output” will void the warranty. This is the equivalent quality of power provided by the electric company. This
unit should not be used with bank power supplies. The generator should be properly grounded, according to the gen-
erator manufacturer instructions or damage to the machine or injury or death of the operator may occur.
Never leave the unit on or connected while starting the generator. Never stop the generator while the unit is on or
connected. Severe damage will occur. This includes running the generator low on or out of fuel. This damage is not
covered under warranty, even if the unit is rated as “clean powered”. Always allow the generator to warm up before
plugging the unit in and using it. A cold engine may not develop or maintain proper RPM needed to provide stable,
clean power even if the unit is rated to be “clean power”. Never use economy idle (ECO mode), or auto idle modes.
with this unit. Use high idle whenever connected to the welder.
WARNING!
• Do not use the welder in damp or wet areas. Perspiration and other forms of water in contact with the body can increase the
risk of electrocution.
• Do not use the welder in corrosive environments.
• Always secure the cylinder to the welder with provided chains so that accidental overturn is not likely.

12
DUTY CYCLE AND ERROR CODES
This MIG/Stick welder features a self-diagnosing feature, which will display an Duty Cycle or Over Current
light if a problem occurs. Do not attempt to defeat or ignore any errors that arise.
This unit has a duty cycle rating of 35% @ 315 Amps while welding in MIG. The duty cycle rating for stick is
60% @ 200 Amps. The duty cycle rating is the amount of time (expressed as a percentage) out of 10
minutes the unit can weld without a rest while operating at a temperature of 40 C. Increases or decreases in
temperature, humidity and air flow around the unit can change the stated duty cycle. If temperature is low-
ered, duty cycle generally increases.
In MIG mode, the unit is capable of welding 3.5 minutes out of every 10 minutes at the maximum output of
315 Amps. For the balance of the 10 minute period, the unit should be allowed to rest and cool while run-
ning. Stick is also rated for a 6 out of 10 minute welding period but at the maximum of 200 Amps output. If
the unit’s duty cycle has been exceeded, the “Over Temperature” LED will light and welding output will cease.
If the unit has over heated and triggered the duty-cycle “Over Temperature” warning, allow the unit to run
and cool for 15 minutes. After 15 minutes of cooling while the unit is kept running, cycle the power switch
to reset the unit if it has not already reset automatically.
In the event of an Over Current, the welding output will cease the “Over Current” LED will light. In duty cy-
cle and overcurrent events, the wire may continue to feed without welding output. Overcurrent events can be
caused by too low of supply voltage, running on undersized extension cords, too large of wire diameter, or
internal or external electrical fault. When an overcurrent has occurred, turn the machine off immediately,
then check and remedy the fault before cycling the welder back on. If the error does not clear after cycling
the switch, immediately cease operation and call Everlast Technical Support. When the “Overcurrent Warn-
ing” LED lights and will not clear, the overcurrent has likely caused an internal fault. This is usually a result of
a poor power supply, a long extension cable, or from running off of a generator that is malfunctioning or not
rated for clean power use.
Section 1 Introduction and Specifications
General Product and Use Information
HELPFUL HINT:
Keep the clear protective cover lowered during operation to prevent damage to the panel and controls from
sparks and dust. Replace the cover when it becomes scratched or dirty.

13
Section 1 Introduction and Specifications
Discussion of Welder Features and Operation
SUMMARY OF FEATURES
GMAW Process (MIG) and F-CAW (Flux-Cored)
The digitally controlled components of this welder precisely control wire feeding and arc quality. It also gives real-time feed back about the weld-
ing output parameters. The welder is also spool gun (gun optional) ready for economical welding of Stainless and Aluminum wires if needed. It
can also be used to weld with Flux Cored and Dual Shield wire (when equipped with optional flux core drive wheels). However, since there is no
Dual Shield Power-Set feature, Dual-Shield can only be done in standard MIG mode. The unit is equipped with a heavy duty 36 series MIG gun.
NOTICE: This unit does not support a Push-Pull gun. It does not have a Pulse-MIG mode. Additional drive rolls are optional.
SMAW (Stick) Process
In stick mode the welder delivers a smooth DC low spatter arc. Professional, high-quality welds are obtainable with E7018, 7014, 309L, 316L,
6011 and many other similar rods that are designed for use with any DC stick welder. This setting also works well with the easier-welding
E6011, but is not designed for E6010 use. The Stick mode also features adjustable hot start time and hot start intensity controls which are de-
signed to help reduce sticking during arc starts while simultaneously reducing porosity or inclusions during arc initiation. NOTICE: This unit
does not provide AC operation in stick mode.
Burn Back Control (MIG/Flux-Cored)
Burn back control is used to control the length of the wire stick-out after the trigger is released. It helps to prevent the welding wire from sticking
in the coalescing weld puddle after the arc is terminated and saves the user from having to trim the wire before restarting the arc. The burn back
keeps the arc energized for the time specied by the user after the wire feeder stops feeding. This allows the wire to be trimmed back. For most
welding applications, this should be kept between .1 and .5 seconds. To achieve maximum effect, keep the gun held over the weld for a second
after welding has stopped.
Pre and Post Flow Control
The auto Pre and Post flow control features are designed to improve weld quality at the beginning and end of the weld where porosity from oxi-
dation can be a problem. This is accomplished by providing additional flow of shielding gas before and after the weld. This control is automatic
and is optimized for the amperage used. It cannot be turned off. When using Flux-Core the gas solenoid will continue to cycle and may cause a
slight delay in arc starting. This is normal and is not considered a defect or unit problem. If using dual shield, this is not an issue.
MIG Inductance
The MIG inductance control allows the user to customer tailor the arc to suit the position, wire type, and user preference. The Inductance is con-
trolled through the control named “Arc Force”. (This control is also used for the stick mode.) This control has been referred to by a number of
different names, such as slope and choke. This control adjusts the current rise time once the arc has short circuited against the metal. This
determines how fast the wire heats up and burns back until it pinches off a small droplet of metal to be released back into the puddle. The pinch-
ing off of the wire happens many times a second. The current rise time is only measured in fractions of a second, but can make a big difference
in the arc spatter, puddle fluidity, puddle width and even sound of the weld. For steel, start with a setting of 6.5 to 7.5 for thicker gauges and
plate, and 4.5 to 6.5 for thinner gauges. Higher or lower settings may be used depending upon operator preference, but setting the unit too low
will result in a narrow, ridged bead, resulting in excess spatter that resembles a stuttering, or improper wire feed. In reality, the burning back is
happening too slow and the wire is stubbing into the metal. This is why a high ridge in the center of the weld is observed when Inductance is too
low. The sound of the weld will be a high pitched whine. Too much inductance will result in a wide, very wet puddle. This is not a problem as
long as burn through doesn’t happen, or the tip doesn’t over heat. The sound will be lower, and can be quite coarse. Spatter will also once again
increase. With that said, try to refrain from using a “5” setting, or a one-size-ts-all setting. Inductance can be used to help smooth out the weld
with pure CO2. It is a valuable tool that should be used to improve weld quality and arc performance.
Stick Arc Force
The Arc Force function over time has been identied by a number of names such as “dig” or “arc control”. This function serves several purposes.
The primary function is to help maintain welding “wattage”. Keep in mind that welding involves the use of both Amps and Volts. When multiplied
together, you get total wattage (VXA=W). Wattage is really what dictates how the puddle flows and is maintained, and even how the electrode
burns. When welding, the height of the electrode and the arc gap created between the end of the electrode control voltage. There is no inde-
pendent control of this. Amperage can be preset, and controlled with a knob, but voltage is controlled primarily through the length of the arc.
This means that the arc length is under constant change, and that “burn-off” of the electrode naturally causes the Voltage to change. The closer
the rod is held and the shorter the arc gap that exists, the lower the voltage falls. The fall off of voltage results in a cooler puddle and a slower
burn off rate of the electrode. This means that the electrode has a high probability of sticking. With the use of Arc Force, as the voltage falls
below the preset threshold of approximately 20V, the unit senses this fall off and automatically compensates by kicking in extra amperage to the
weld to help maintain a steady melting of the electrode and a proper puddle. The Arc Force Control allows the user to set how much extra am-
perage is automatically delivered to the weld puddle when the voltage falls below the 20V threshold. The settings are numbered 0-10, but in
reality can be considered 0-100% over the actual amount of set amperage that the machine automatically increases the amperage when voltage
falls. Beyond, maintaining a consistently burning rod and puddle, it can be used to help burn in root welds, or burn out defects by simply push-
ing in on the rod engaging the arc force and automatically increasing the amperage. In the past, with most transformer type stick welders, to
increase heat while welding, or to prevent outage of the arc, the operator would purposefully increase the arc length, raising the voltage. This
creates issues with porosity by allowing the arc to break or trap air in the puddle. And of course, this will not allow a proper weld “wattage” to be
established. Despite protocols calling for certain “amp” settings, this can be somewhat futile as arc length is the “unknown” factor in the eld with
multiple operators and different skill levels. For those welders used to running machines not equipped with arc force control, some rethinking
and retraining of muscle memory may be required to create a proper weld. When more heat is needed, push the rod into the puddle. When less
heat is needed, increase the arc length slightly. This also changes the whipping motion used with some rods into a “stepping motion.”

14
MIG/FLUX-CORED WIRE, DRIVE ROLL AND GUN INFORMATION
This unit is designed for multiple types and sizes of MIG and Flux-Cored wire. Recommended wire sizes range
from .023” to .045” (.6 to 1.2mm), with the standard equipped 36 series MIG gun. Stock V groove drive roll size sup-
ports. 035” and .045” solid/hard wire. Keep in mind that you may need to purchase optional drive rolls and/or anoth-
er gun or gun liner to fully utilize and weld with all wire types.
NOTICE: No one gun can be used for every combination of wire diameter and type. MIG and Flux-Cored drive rolls
must be sized for the diameter of wire. Each drive roll typically supports two wire diameter sizes.
NOTICE: Small diameter (.023”-.030”/.6-8mm) wires and all Aluminum wires should use a short gun which is no long-
er than 10 ft. (3m) in length, or the wire can jam or feed irregularly. For smaller diameter wires, a smaller gun is rec-
ommended. The included gun, will need an optional liner to support .023” and .030” for best feeding and to reduce
the chance of “bird’s nesting” .035” and .045” wires can be fed in longer length guns.
For small wire diameter sizes, Everlast recommends purchasing either the 15 or 24 series gun to handle the smaller
wire and to give greater flexibility when welding more delicate items. See the information below for more information
regarding gun and drive roll selection. Additional drive rolls to match the wire diameter and type are optional items that
may be required. If so, they may be purchased from Everlast.
• Flux-Cored/Dual Shield Wire: Although the standard gun can be used to weld Flux-Cored wire, it’s recommended
to use an optional flux-cored gun if much flux-cored welding is to be done to prevent nozzle plugging. If using
Dual-Shield, the standard gun is sufcient. You must use serrated-groove drive rolls if using Flux-Cored or Dual
Shield Wire. Its recommended to only use .035” or greater diameter Flux-Cored wires.
• Stainless (INOX) Wire: Standard Gun and V– groove drive rolls should be used. However, using small diameter
(i.e. .023”/.6mm) wires will result in problematic feeding without a Polymer liner.
• Steel Wire: Standard Gun and V-groove drive rolls should be used
• Aluminum Wire: There are two options available to weld Aluminum with this welder. The rst option: If using the
standard gun, an optional polymer liner can be used to smoothly to feed 50XX series Aluminum wire in guns up
to 10 ft. in length. (This means the steel liner must be removed and the new polymer liner reinserted in its place.)
U-Groove drive rolls must be used to prevent damage to the wire and the gun liner. The gun cable should be kept
relatively straight, without coiling or sharp angles to prevent feeding problems. The minimum wire size recom-
mended for this type of feeding is .035” (.9mm) with up to .062” (1.6mm) possible. 40XX series wire is usually
too soft for this type of feeding. The advantage of this method is that larger spools of aluminum wire may be
used. Never attempt to feed .023” or .030” Aluminum wire in this fashion. The second option: A spool gun can
be used to feed .035” to .045” diameter wire. This limits the spool size to 4”, which is typically 1 lb. of Aluminum
wire. This is a more expensive, but better option if a longer reach or more convenience is required. Either 40XX
or 50XX series Aluminum wire may be fed in this manner. In either case, .023” or .030” Aluminum wire should
not be used with this welder or feeding problems will result. For Spool Gun welding, purchase the optional Parker
DSP360 Spool gun from Everlast.
Section 2 Setup Guide
General Product and Use Information

15
Section 2 Setup Guide
General Product and Use Information
MIG/FLUX-CORED WIRE, DRIVE ROLL AND GUN INFORMATION
For smooth wire feeding, free of jamming and slipping, the drive rolls must be sized correctly. You must select the proper type and size of drive roll for the size
and type of wire used. The size of the wire and the type of drive roll is marked on the side of each drive roll. On this welder, the groove on the same side of the
printed size is the groove that corresponds to the marked size. This means that when installed, the size of the groove will always be facing in. You may need to
remove the drive roller to verify the correct groove size is being used. Only the bottom drive rolls need to be changed. The top drive rolls hold pressure and are
flat. The top drive rolls are not removeable.
The type of wire dictates the groove type:
•Steel and Stainless (INOX) wire uses a V-shaped groove milled into the drive roll. This will be signied by a winged “V” stamped on the side of the drive roll, next
to the wire diameter marking.
•Aluminum wire uses a U-shaped groove milled into the drive roll. This will be signied by a U mark stamped on the side of the drive roll, next to the wire diame-
ter marking. This cushions the wire, and prevents scoring and damage for easy feeding when using a polymer type gun liner.
•Flux-Cored/Dual Shield wire uses a serrated groove milled into the drive roll. When viewed from the top, the appearance of the groove is similar to a closed
zipper, or saw blade. This also has a zig-zag marking on the side of the drive roll next to the wire diameter marking.
These drive rolls may be stamped in metric wire sizes, or in both metric and imperial sizes. To avoid confusion, use the following conversion to select the proper
drive roll for you wire diameter:
•.6mm=.023-.025”
•.8mm=.030”
•.9mm=.035”
•1.0mm=.040”
•1.2mm= .045”
To change or flip the drive rolls:
•Release the tensioner, by flipping the tensioner down and toward you. The upper drive roll arm should raise.
•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 or replace it, making note of its size.
•The drive roll is actually made of two pieces. Hold the inner assembly of the drive roll on with one nger (to prevent it from slipping off the shaft), while slipping
the outer “rim” of the drive roll off with the other hand. Both inner and outer parts of the assembly have locating keys. The inner assembly does not need to
be removed.
To reinstall the drive rolls:
•Line up drive roll keyway with the locating key on the inner assembly.
•Reassemble in reverse order 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 machine oil if necessary to prevent future seizure. Do not lubricate the surfaces of the drive rolls or erratic feeding
may result. Please note that the size and type of drive roll is stamped on the side of the drive roll. The size and type is always stamped on the side nearest to the
actual groove. This means that, when installed, the stamped size will be turned to the inside, and not visible to view.
Grooves
Size/Type Stamp
Screw
Retaining Spacer
Tensioner Lever
Upper Drive Roll Arm
Lower Drive Roll (x2)
Keyway

16
Section 2 Setup Guide
General Product and Use Information
MIG/FLUX-CORED WIRE, DRIVE ROLL AND GUN INFORMATION
The MIG gun has a Euro-style quick connect that is used to connect the gun to the welder. This type of connection is the most common throughout the world and
most major MIG gun manufacturers can supply any MIG gun in this type of conguration If you need to change your gun to match other guns in your shop (to
keep consumables the same), contact the manufacturer of your preferred gun for a replacement gun with this type of back-end. The Euro-style quick-connect can
be rapidly connected and disconnected from the welder without the use of any tools.
To install the MIG Gun:
•Align the pins and the wire pick-up on the torch connector with the holes on the feeder receptacle on the welder.
•Fully engage the connector into the receptacle, wiggling slightly to ensure the ttings seat home.
•Using your hand, twist the plastic hand nut on the gun connector clockwise until it is snug.
•Check for side to side play once more by wiggling it.
•Re-tighten if necessary.
The gun supplied with this unit is an air-cooled 36 Series, 340 Amp gun, design. This gun is a common Binzel®-type gun. This is a widely used gun design and
offers excellent ergonomics and dependability.
To load the spool of wire:
•Loosen and remove the hand nut on the spool carrier by turning it counter-clockwise.
•Align the locating pin with the hole on the wire spool. If using an 8” spool slide the adapter on the shaft before sliding the spool on.
•Slide the spool onto the shaft. Make sure wire is unwinding from the bottom of the spool. This means the spool turns counter-clockwise as it feeds.
•Adjust de-spooling tension by turning tensioner located under the plastic cap nut on the spool carrier.
•Lightly spin the spool. If it free-wheels more than 1/4-1/2 turn, tighten hex nut. If it does not free-wheel at all, loosen tensioner until it free wheels 1/4 -1/2 turn.
•Reinstall the plastic hand nut so the spool is retained securely.
•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 on the next page regarding feeding the wire.
-
Tension
Spring
Stud
Nut
(Viewed from the Front)
Locating Pin
Spool Carrier
Plastic Cap Nut

17
Section 2 Setup Guide
General Product and Use Information
WARNING!
The wire feeder has moving parts and has pinch points. Keep all guards in place during use or serious inju-
ry may occur. Make sure all drive rolls are tight and the wire is properly tensioned. Over tensioning can
create jamming and wrapping of the wire around the wire feeder. Keep cover closed while feeding wire.
MIG/FLUX-CORED WIRE, DRIVE ROLL AND GUN INFORMATION
1.Install the MIG gun as instructed in “To install the MIG gun (torch)” on the previous page. 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 drive roll 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.Unscrew the plastic retaining cap from the spool carrier. (See Previous page for more information.) 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 through until it threads into the gun section 4”-6”.
5.Reverse the procedure. Begin by lowering the upper drive rolls into contact with the lower drive rolls, keeping the wire securely
held down so that it stays in the inner groove of the drive roll. If needed, use a screwdriver with a ne blade or small pick to
keep wire from moving out of the grooves until step 6 is completed.
6.Raise drive roll tensioner back into place. Tighten it slightly so the wire will be held and not slip out. Notice markings on tension-
er for future reference.
7.Remove the contact tip from the torch. 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 the 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.
-
4
5
1
2
3
4
8

18
Section 2 Setup Guide
General Product and Use Information
CONNECTING THE GAS REGULATOR TO THE CYLINDER:
To safely connect the regulator to the cylinder, rst make sure the cylinder is properly chained and secured. Then,
before connecting the regulator and while standing to the side of the discharge (not in front of the discharge), briefly
crack the valve and allow a 1 to 2 second blast of gas to clear any dirt or contamination from the valve seat. Then con-
nect the regulator and screw the tting clockwise until nger tight and nish tightening with one 1 1/8” wrench. Do not
use a pair of pliers or other grip/lock devices. Use a large adjustable wrench if no other wrench is available. Make sure
the connection is tight. Slowly open the valve to check the connection for leaks with luke-warm soapy water (or ap-
proved leak detector solution) applied to the ttings at the valve.
To connect the hose to the rear of the unit, screw the 5/8” gas tting into the gas inlet on the rear of the unit, rotating
clockwise until nger tight. Then use two (2) 3/4” wrenches to complete the tightening process. One wrench should
be placed on the female gas inlet nut and should be held tightly to while the other wrench is used to nish tightening
the male tting. Always tighten the connection at the welder using one wrench to hold the welder inlet tting and an-
other wrench to tighten the regulator hose tting. Using only one wrench may result in damage to the ttings. Check
all ttings and connections for leaks once again. See illustration next page for proper connection arrangements.
Do not use thread tape or sealant on threads of the unit, regulator or cylinder. Plugging and sticking of the gas sole-
noid valves, regulator or torches may occur if thread sealants are used. The compression ttings used will tighten up
once proper pressure has been achieved. If the cylinder will not seal, the threads may be worn on the valve. If hoses
show sign of leaks, tighten the clamps with a pair of side cutters or end nippers. Gently squeeze the clamp tight until
the leak stops or add an additional clamp only if absolutely necessary. If the regulator leaks, remove it from service.
NOTICE:
The Power i-MIG 315 includes a self-contained undercarriage, which also includes a built-in carrier for the cylinder.
This carrier will hold multiple sizes of gas cylinders. However, do not use small cylinders (20 Cu. Ft. or similar sizes)
that do not rise above the cylinder yoke, that secures the cylinder with a chain. The yoke should strike the cylinder
below the bell shaped area that forms the top of the cylinder. The cylinder should be secured with the included chains
dropping through the chain slots on the yoke. It should be as tight as practical, so that play between the yoke and the
side of the cylinder is minimized. The gas inlet on the unit is a 5/8” CGA tting, which is the North American Standard
for gas ttings on MIG welders. If using pure CO2 a regulator specially made for this application must be used.
WARNING!
Never attempt to repair a damaged regulator yourself. The parts are under pressure. Serious injury or death may occur.
Do not open the cylinder valve quickly or damage can occur to the regulator.
REGULATOR ADJUSTMENT
The Ball valve will float briefly once the main cylinder valve is opened and will then settle down and stop floating after
4 to 5 seconds. Fully open the cylinder when in use to prevent valve leaks. If the valve continues to float, you have a
leak. Stop and check. To adjust the gas flow rate, the welder must be turned on. First release the tension of the drive
spools by flipping down the tension lever. Then, select MIG and squeeze and hold the gun trigger so the gas begins
to flow. Adjust the flow rate with the small knob on the down tube on the regulator. Screw the knob counter-clockwise
to increase flow. This meter will work with both Argon and Argon/CO2 mixes. (Not for use with 100% CO2) The flow
rate is calibrated in Cubic Feet per Hour (CFH). (Markets outside of North America may be calibrated in Liters per Mi-
nute (LPM)). The pressure gauge only registers the pressure inside of the gas cylinder. Use the clear plastic tube
with the floating ball to read flow rate. Use the middle of the ball to read flow rate correctly. As the cylinder looses
pressure near the end of its contents, flow rate may need to be readjusted. This is normal.

19
Section 2 Setup Guide
General Product and Use Information
Gas and Electrical Connections
FUSE
1x220V
5/8”-18 RH INERT
NEMA 6-50P 50A 240V
1 PHASE PLUG
ADJUSTMENT VALVE FLOATING BALL
NOTICE:
The unit is shipped with a regulator rated for Ar/CO2 or 100% Argon use only. If using with 100% CO2, an CO2 regula-
tor must be used. Gas Cylinders are not included, and shown only for demonstration purposes.
CYLINDER PRESSSURE
580 CGA

20
Section 2 Setup Guide
General Product and Use Information
GAS SELECTION
Gas selection for different processes and different metals can be confusing. These guides help you remember which
gases should be used. However, for MIG, they are not absolute. The suggested gases for MIG are based upon stand-
ard, short-circuit mode and do not take into account the axial spray mode. See below for the stated Gas modes and
alternate (permissible) gases that can be used.
• Stainless MIG: Recommended: 98/2 Ar/CO2 , Permissible: Tri-Mix (for short circuit only)
• Steel MIG C25: Recommended: 75/25 Ar/CO2 (for short circuit); Recommended: 90/10, 80/20, 95/5 Ar/CO2 (All
gases 80/20 and above are considered to be gases used for axial spray.)
• Steel MIG: C100: Recommended: 100% CO2 (for short circuit); Permissible: No other gas.
• Aluminum MIG: Recommended: 100% Argon; Permissible: No other gas.
WARNING!
Do not leave the regulator on when not the welder is not in use or loss of cylinder contents may occur. Loss of cylin-
der contents may result in asphyxiation since the shielding gas is heavier than air and does not dissipate quickly. Al-
ways have enough ventilation. Do not weld in tight, closed spaces for extended periods of time.
ADJUSTING GAS FLOW RATES:
The gas flow rates for MIG welding are critical for creating a good, contamination and porosity free weld. Too much
flow rate will create turbulence and introduce air to the weld. It may seem counter-intuitive, but solving issues with
gas coverage by steadily increasing gas flow can create more problems than it solves, and can actually mimic the same
issues observed by too little gas flow. In general, ideal gas flow will vary and no one gas flow rate is perfect for every
situation. Gas flow rates for MIG are usually 20 to 30% higher when used outside. However, when adjusting gas flow,
keep in mind the following variables:
• Joint Design/Type
• Nozzle Size (Larger cups require more gas flow. )
• Metal Type (Aluminum typically requires higher rates.)
• Welding Position (Flat position usually requires less gas flow.)
• Air Circulation Around the Weld Area (A shield such as a piece of plywood may need to be used outdoors)
• Gas Type
The best method for setting gas flow rates involves trial and error by welding, observing the weld and stopping to
make quick gas flow adjustments.
To properly set gas flow:
• Start by setting the gas flow rate to 20 CFH (Cubic Feet Per Hour). This will be an approximate setting.
• To obtain the best setting, lower the gas flow rate, 2 CFH at a time. Do this until bubbles and porosity, and extra
soot are noticed.
• If bubbles and porosity are present at 20CFH, proceed directly to the next step.
• Slowly raise the gas flow rate 1CFH at a time until the bubbles and porosity disappear from the weld.
• Once the porosity and gas disappear, add another 1 to 2 CFH to allow a buffer zone of gas flow. This will mini-
mize gas wasting and prevent issues caused by too much gas flow. The weld should be bright and shiny if the
metal was properly prepped, gun/torch angles were correct etc.
For Aluminum MIG welding, extra gas flow is required. Start this process around 30 CFH.