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
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everlastwelders.com
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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