Everlast Power MTS 160 User manual

1
Rev. 1 0 0701-11
EVERLAST
POWER MTS 160 and 200S
Operator’s Manual for the Power MTS 160/200
Safety, Setup and General Use Guide
CC/CV MULTI-PROCESS WELDER
GMAW/GTAW/SMAW

2
Table of contents
Section……………………………………………….Page
Letter to the Customer …………………....…………
Everlast Contact Information…………….………….
Safety Precautions……………………………………
Introduction and Specifications…..…………………
Specifications MTS 160……...……………………
Specifications MTS 200S………...………………..
Main Component and Performance Information..
General Description………………………………..
Recommendations and Settings.……….………...
Front Panel Overview……………………...…..…..
Rear Panel Overview…………...………….………
Side Panel Overview……………………………….
Wire Roll Installation………………………...……..
Front Panel Detail Description…………………….
Rear Panel Detail Description…………………….
Side Panel Detail Description…………..…..…….
MIG Drive Components, Expanded View……..…
MIG Torch Assembly………………………………
TIG Torch Assembly……………………………….
Synergic MIG /Manual MIG Operation…………..
Lift Start Tig Operation……………………………..
Stick Operation……………………………………..
Trouble Shooting……………………………………..
Appendix A: Schematic………………………………
Notes…………………………………………………..
3
4
5
9
9
10
11
12
13
14
15
16
16
17
18
24
20
21
22
23
24
25
26
27
28

3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast. We appreciate you
as a 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 infor-
maon. Your unit registraon is important should any informaon such as product updates or re-
calls 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 website, contact Everlast directly through the sales
department through the main customer service number in your country. Your unit will be regis-
tered and warranty will be issued and in full eect. Keep all informaon regarding your purchase.
In the event of a problem you must contact technical support before your welder can be a candi-
date for warranty service and returned.
Please review the current online warranty statement and informaon found on the web-
site of the Everlast division located in or nearest to your country. Print it for your records
and become familiar of its terms and condions.
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 customers and noncustomer interacon.
Technical 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. For best service call the appropriate support line and follow up with an
email, parcularly if o hours, or you cannot reach a live person. In the event you do not reach a
live person, parcularly during heavy call volume mes, holidays, and o hours, leave a message
and your call will normally be returned within 24 hours. Also for quick answers to your basic ques-
ons, join the company owned forum available through the website. You’ll nd knowledgeable,
helpful people and sta available to answer your quesons, and perhaps 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 manu-
facturing 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 prob-
lems 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 advisa-
ble to have basic tools handy such as screwdrivers, 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___________________________
EVERLAST
Contact Information
Everlast US:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [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 Austrailia:
Sydney: 5A Karloo Parade Newport NSW 2106
( 0 2 ) 9999 2949
Port Macquarie: 2B Pandorea Place Port Macquarie
( 0 2 ) 6584 2037
After hours support: 0410 661 334
Everlast Technical Support: [email protected]

5
Everlast is dedicated to providing you with the best possible equipment and
service to meet the demanding jobs that you have. We want to go beyond deliv-
ering a satisfactory product to you. That is the reason we offer technical sup-
port 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 operation and proper maintenance is your responsibility.
We have compiled this operator’s manual, to instruct you in basic safety, oper-
ation and maintenance of your Everlast product to give you the best possible
experience. Much of welding and cutting is based upon experience and com-
mon sense. As thorough as this welding manual may be, it is no substitute for
either. Exercise extreme caution and care in all activities 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.
Please carefully read this manual before you operate your Everlast unit. This
manual is not only for the use of the machine, but to assist in obtaining the
best performance out of your 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 warranty does not cover improper use, maintenance or consumables. 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 mal-
functioning parts or accessories have been repaired or replaced by qualified
personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves.
These waves may disturb sensitive electronic equipment such as televisions,
radios, computers, cell phones, and related equipment. High Frequency may
also interfere with fluorescent lights. Consult with an electrician if disturb-
ance is noted. Sometimes, improper wire routing or poor shielding may be the
cause.
HF can interfere with pacemakers. See EMF warnings in following safety sec-
tion for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.
Safety Precautions

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 ob-
serve 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 chip-
ping 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 filter installed. Always use a welding helmet in good condition. Discard any
broken or cracked filters or helmets. Using broken or cracked filters 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 filter lenses clean and clear for maxi-
mum 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 filter screen, protective curtains or equivalent protective equip-
ment. If no protection is available, exclude them from the work area. Even brief expo-
sure to the rays from the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy.
Ear protection 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 fire 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 ade-
quate 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 electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient.
Gauntlet type welding gloves are available from your local welding supply companies.
Never attempt 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 cutter or welder, instant and serious burns will occur. Proper hand
protection is required at all times when working with welding or cutting machines!

7
SAFETY PRECAUTIONS
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 fields 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 fields. Therefore, certain pre-
cautions should be taken to minimize exposure:
 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 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 confined spaces. Fumes and gases re-
leased 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 ob-
tained.
 Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, cop-
per, cadmium, lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product when used for welding or cutting produces fumes and gas-
es which contains 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 Phosgene 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 regarding 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 fit 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,
flame and sparks.

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 weld-
ing 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 ne-
cessitates 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 ca-
bles with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodi-
cally check work area for smoldering embers or smoke. It is a good idea to have
someone help watch for possible fires while you are welding. Sparks and hot metal
may travel a long distance. They may go into cracks in walls and floors and start a fire
that would not be immediately visible. Here are some things you can do to reduce the
possibility of fire 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 fire.
 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 fire-proof surfaces after han-
dling. Serious burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Prop-
er maintenance is your responsibility. Make sure all equipment is properly maintained
and serviced by qualified 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 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.
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 concerning 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
W: 210mm/ 8.25”
H: 380mm/15”
L: 470mm/18.5” Weight: 11.5Kg/ 25.3lbs
Power MTS 160 Technical Parameters*
Section 1 Introduction and Specifications
88
P
++
+
E
+
-
EVERLAST
MIG/TIG/STICK INVERTER
f1
f2
1~
S
MODEL: PowerMTS 160 No.
EN/ IEC60974.1
DC: 25-160 A
X30% 60% 100%
U0 V
58
I2160 A 115 A 90 A
U2
DC: 10-160 A
X30% 60% 100%
U0 V
58
I2160 A 115 A 90 A
U2
DC: 10-160 A
X30% 60% 100%
U0 V
58
I2160 A 115 A 90 A
U2
1~ 50/60 Hz
U1
220-240V
±10%
I1MAX:
MIG 27 A TIG 22 A
SMAW 31.6
PROTECTION:
IP23S
COOLING METHOD:
FAN
INSULATION:
F
S
S

10
W: 210mm/ 8.25”
H: 380mm/15”
L: 470mm/18.5” Weight: 11.5Kg/ 25.3lbs
Power MTS 200S Technical Parameters*
Section 1 Introduction and Specifications
88
P
++
+
E
+
-
EVERLAST
MIG/TIG/STICK INVERTER
f1
f2
1~
S
MODEL: PowerMTS 200S No.
EN/ IEC60974.1
DC: 25-200 A
X25% 60% 100%
U0 V
58
I2200 A 115 A 90 A
U2
DC: 10-200 A
X25% 60% 100%
U0 V
58
I2160 A 115 A 90 A
U2
DC: 10-170 A
X30% 60% 100%
U0 V
58
I2170 A 115 A 90 A
U2
1~ 50/60 Hz
U1
220-240V
±10%
I1MAX:
MIG 37 A TIG 29A
SMAW 33
INSULATION
IP23S
COOLING METHOD:
FAN
INSULATION:
F
S
S

11
Rectifier Inverter Transformer Rectifier Hall
Current
Feedback
control
Single-phase AC DC AC DC
220V 50Hz
AC DC
Welding current
regulate
(Wire feed speed)
Wire feeder
motor
PWM signal
CPU control
Voltage
Feedback
control
44
14
0600 Io（A）
Uo（V）
Working point
Volt-ampere characteristic The relation between the rated loading
voltage and welding current
I（A）
0
100％
60％
90
X
The relation between duty cycle and welding
current for MIG160
115 160
Volt/Amp Characterisc
Work Point
Volt/Amp Formula: U2=14+0.05I2(V)
Working Relaonship Between
Volts and Amps Rated Load
Duty Cycle/Amp Performance Curve
Section 1 Introduction and Specifications
30%
200
MIG Volt/Amp Performance
Main Component/Circuit Flow Diagram
MTS 160
MTS 200s
regulator

12
1.1 General Descripon, Purpose and Features. The
PowerMTS 160 and 200S, are compact lightweight CV/
CC welders capable of handling most jobsite dues and
portable repairs. Operang on 1 phase 220-240V
50/60Hz, the units are designed to strike an excellent
balance between versality and performance. The fol-
lowing processes are included on the PowerMTS series.
1) GMAW (MIG) oers wave form control which re-
sults in a smooth, stable arc . Digital controlled
MIG components precisely control funcons and
give real-me feed back about the welding output
parameters. The 200S also ulizes fully digital syn-
ergic technology with a manual override funcon
for standard operaon. (see below). MTS 160 has
manual funcon MIG with no synergic capability.
2) GTAW (TIG) oers advanced li start DC TIG opera-
on includes a standard gas valve torch. (Series 17
compable). Note: DC Li start is actuated by the
remote contactor built into the handle (included).
The TIG torch is not live unl the contactor switch is
depressed. The user has a choice of either 2T or 4T
operaon while welding.
3) SMAW (Sck) delivers smooth spaer free welds.
Arc force control increases performance, and im-
proves out of posion welding characteriscs.
Smooth spaer free welds are easily obtained on
ER 7018, 309L, and many specialty rods.
1.2 Basic Design and Construcon. The PowerMTS se-
ries units uses advanced Pulse Width Modulaon cou-
pled with IGBT module construcon to produce a stable
arc without consuming large amounts of power aribut-
ed to standard transformer welders. Inverter frequency
is approximately 40KHz. Welding power is generated as
follows (See page 11 for ow diagram) : Single phase
220V AC (nominal) power is fed into the welder, where
it is reced in to 350V DC. Aer it passes through an
intermediate transformer, reducing the voltage, power
is fed to the IGBT based inverter where it is converted
to converted to AC power cycling around 40Khz. Next
power and passed back through fast recovery diodes to
recfy the power back to DC while being ltered
through an inductor circuit. The circuit then uses cur-
rent/voltage feedback sensing technology through the
means of its CPU control board to maintain stable TIG/
Sck performance, ensuring stable MIG performance as
well. Welding parameters can be innitely and connu-
ously adjusted while the unit is in operaon, oering
instant welding response.
1.3 Installaon and Wiring. The basic construcon of
the PowerMTS is rugged and durable, and is considered
ideal for circumstances where mulple welders may be
required, but not available. Crical components are
protected by coangs to make the welder environmen-
tally resistant with a water ingress rang of IP23S,
among the highest in the industry. However, some
care and common sense should be taken to make sure
that the welder oers the safest and best performance.
Please note the following items regarding safe opera-
on:
1) Do not use the welder in damp or wet areas. Per-
spiraon and other forms of water in contact with
the body can increase the risk of electrocuon.
VRD technology helps to reduce the risk of electro-
cuon from high OCV, but does not necessarily
eliminate the risk, especially while welding.
2) Do not use the welder in extreme corrosive envi-
ronments. To maintain opmum power transfer,
check main connecons, clamps and cables fre-
quently to ensure that components are not corrod-
ed. Excessive corrosion and oxidaon can result in
an unstable arc and excessive heat build-up.
Match the correct colored wires located on page 15
with the wires found on your unit so that the unit can
be properly connected to the power supply. Be sure to
make a secure ground connecon to the plug and iden-
fy the correct 115 V power legs on the power input
side, commonly referred to as “hot” wires. A neutral
wire is not required, and should not be used. If a 4th
wire on the input side is found in a single phase system,
it is probably a neutral. The circuit should be rewired if
this neutral is present so that only two “hot” wires and
one ground wire is present. Everlast strongly recom-
mends using the NEMA 6-50, a three wire 50 amp plug
and receptacle, available at almost all hardware stores.
The NEMA 6-50 P/R is the industry standard plug /
receptacle for welders. Consult local codes and li-
censed electricians should any doubts or problems
arise. If doubts remain, contact Everlast for more infor-
maon. Wiring the welder incorrectly can result in fail-
ure/damage to the welder.
Introduction and Specifications
Section 1
NOTE: DC TIG is not generally considered capable
of welding Aluminum. The MTS units are DC only
and do not have AC capability.
Aluminum welding may be performed with
the MIG process, with Argon gas, and a suitable gun
liner. Recommended wire size for welding alumi-
num is .040”. 50XX series wire is also recommend-
ed. 40XX series may have diculty feeding.

13
Setup Guide and component Identification
Section 2
PROCESS TORCH POLARITY WORK POLARITY
MIG (GMAW) +-
FLUX CORE (FCAW) - +
TIG (GTAW) - +
STICK (SMAW) +-
GENERAL POLARITY RECOMMENDATIONS*
*Consult manufacturer direcons of ller material. There are excepons!
Table 1
PROCESS GAS
MIG (GMAW) STEEL 80/20 Argon/CO2 (For opmum synergic operaon)
MIG (GMAW) STAINLESS 98/2 Argon/O2 (For opmum synergic operaon)
MIG (GMAW) ALUMINUM 100% Argon
DC TIG (GTAW) 100% Argon
GAS SELECTION GUIDE
Table 2
WIRE DIAMETER WELDING AMPS (A) PLATE THICKNESS GAS FLOW RATE
.023” (0.6) 25-110 .040”-.063” (1.0-1.6) 15-20 CFH /7-10 lpm
.030” (0.8) 35-160(200) .040”-.128” (1.0-3.2) 20-25 CFH/ 10-14 lpm
.035” (0.9) 45-160(200) .040”-.128”.(1.0-3.2) 20-30 CFH/ 10-16 lpm
.040” (1.0) 45-160(200) .050”-.25”+(1.2-6.0+) 25+ CFH/ 14+ lpm
MIG (GMAW) CURRENT/WIRE/THICKNESS GENERAL SUGGESTIONS
METAL THICKNESS WELDING AMPS (A) TUNGSTEN DIA. Ar FLOW RATE
1-3 mm/.040”-1/8” 40-80 1-2 mm/.040”-3/32” 8-15 CFH /4-7 lpm
3-6 mm/ 1/8”-3/16” 80-200 2-3 mm/ 3/32”-1/8” 15-25 CFH/ 7-14 lpm
DC TIG (GTAW) OPERATION GUIDE
METAL THICKNESS ELECTRODE SIZE WELDING AMPS
< 1 mm/.040” 1.5 mm/ 1/16” 20-40
2 mm/.080” 2 mm/3/32” 40-50
3 mm/ 1/8” 3.2 mm/1/8” 90-110
4-5 mm/ 3/16” 3.2-4 mm/ 1/8”-3/16” 90-130
6-12 mm/ 1/4”-1/2” 4–5 mm/ 3/16” 130-170
DC STICK (SMAW) OPERATION GUIDE
Table 3
Table 4
Table 5

14
Setup Guide and component IdentificationSection 2
888 888
PowerMTS 200S
+
+
+
+
2T
4T
Fe
Al
Ss
.023
.030
.035
.040
ALT
VOLTS
ON
TIG/STICK AMPS
MIG VOLTS
TIG DOWN SLOPE
STICK ARC FORCE
WAVE FORM
EVERLAST
MIG WIRE SPEED
1
!
2
3
456
7
8
9
10
+
-
- +
Power MTS
PORTABLE
POWER
Synergic Multi–Process
IGBT Inverter Technology
+
+
-
AMPS/SPEED
1. Clear Protective Shield
Keep closed while welding!
2. Wire Alloy Type Selector
Synergic Feature of 200S only
3. Wire Diameter Selector and
ALT Function (Manual mode)
Synergic Feature of 200S only
4. Wave Form Control (MIG):
Inductance/Current Rise Time
MTS 160 and 200S
5. Negative Connector
MIG: Work Clamp
TIG: Torch
Stick: Work Clamp
6. TIG Torch Switch Control
7. Positive Connector
MIG: Not Used
TIG: Work Clamp
Stick: Electrode Holder
8. MIG Torch Euro Connector
9. TIG Torch Gas Connector
10. Adjustment Knob
MIG: Volts
TIG: Down Slope Timer
Stick: Arc Force Control
11. Amp/Wire Speed Adjustment Knob
MIG: Wire Speed (cm/min)
TIG: Amps
Stick: Amps
12. 2T/4T Torch Switch Selector
13. MIG/TIG/STICK Process Selector
14. Amp/Wire Speed Display
MIG: Wire Speed (while static)
TIG: Amps
Stick: Amps
15. Volt Display
16. ON Indicator
17. Duty Cycle Warning Indicator
FRONT VIEW/ MAIN PANEL

15
Setup Guide and component IdentificationSection 2
+
3. Power Input Cable
1. Gas Connector
+
2. Main Power Switch
CONSULT A LICENSED ELECTRICIAN FOR
PROPER WIRING AND LOCAL CODES.
NOTE: WELDER WIRE COLOR MAY NOT AGREE
WITH THE WIRE COLOR FOUND IN OUTLET.
REAR VIEW/BACK PANEL
WHITE 120V “HOT” LEG
GREEN 120V “HOT” LEG
GREEN /YELLOW STRIPE GROUND WIRE
L1, GREEN 120V
L2,WHITE 120V
30/50 AMP
EVERLAST
GREEN/YELLOW STRIPE
(Ground)
220/240V NEMA 6-50 PLUG SHOWN
(Customer Supplied)

16
Setup Guide and component Identification
Section 2
SIDE VIEW
+
+
+Burn Back
+
-
1. Wire Spool Holder Assy.
2. Polarity Buss Bar 3. Burn Back Control Timer
4. Wire Feeder Assy.
TO INSTALL WIRE:
1. Loosen top idler tensioner, rotating counter-clockwise
2. Flip tensioners down, releasing top drive rolls.
3. Raise top drive rolls.
4. Inspect the drive roll to make sure that the groove size matches the wire
diameter. Reversal of the lower roller may be necessary. To reverse the
roller, remove the thumb screw securing the drive roll. Pull the drive roll
off, and flip the drive roll over. Reassemble and tighten roller. If larger
roller is needed, contact Everlast.
5. Thread straightened wire over grooves in lower drive roll, fully through
until it begins to start threading into the gun section. Lower upper drive
rolls onto lower drive roll, keeping wire in the groove.
6. Raise tensioner back into place. Tighten slightly so wire will feed. Notice
markings on tensioner for future reference.
7. Hold torch straight out as possible. Press gun trigger to feed wire until the
wire exits the end of the torch.
8. Adjust tensioner clockwise until drive rolls will not slip when wire comes
into contact with surface and the wire will curl up on end. Remember to
keep wire away from metal that is attached to the work clamp clamp to
prevent the wire from arcing.

17
Front Panel:
1. Clear Protecve Cover. Prevents damage to
the control and display area. Keep closed
while welding and grinding or during long
term storage.
2. Wire Alloy Selector. This funcon applies to
only the Synergic MIG funcon of the MTS
200S. Does not apply to the standard MTS
160. Select your wire type according to the
basic categories of Fe (Steel), Ss (Stainless
Steel) or Al (Aluminum). This input must be
made to properly use the Synergic funcon to
automacally adjust the Volts needed to weld
at the selected wire speed.
3. Wire Diameter/ALT selector: This funcon
applies only to the Synergic MIG funcon of
the MTS 200S . Does not apply to the stand-
ard MTS 160. Select your wire diameter ac-
cording of the type wire you are using. Se-
lecng the correct wire diameter is crical to
opmum Synergic funcon of the welder, au-
tomacally compensang the voltage while
the wire speed is adjusted. For alternate full
manual control of the welder to funcon in
“normal” mig mode, select ALT. This will allow
for full, independent control of MIG wire
speed and voltage.
4. Wave Form Control. Varies the slope of the
current rise me between during short circuit
MIG operaon. This aects the actual point
where the current has risen suciently to burn
back the wire. The point at which it has
burned back is considered the “pinch point”.
To put it in more praccal terms, the user will
see that the wire is scking out longer or short-
er from the MIG torch before it burns away,
depending upon the exact seng. This con-
trols spaer, penetraon and bead prole. It
also will be noted that the arc is more “s”
and penetrang, or more “uid” and the wire
wets in more easily into the toes of the weld.
Bead prole changes will occur as well. A s-
er arc will produce a deep but narrow prole.
A buery/uid arc will produce a wider, shal-
lower weld, usually with an improved bead
appearance and less spaer. This is an unique
feature from Everlast and separates it other
small MIG units. Wave form control is also
known as inductance control, slope or arc
force control (MIG). By changing the wave
form, the user can achieve arc performance
that is similar to or idencal to the unit he/she
is accustomed to using as well. The arc pitch
will change as the wave form is adjusted, go-
ing from a pitched whine to a frying sizzle. All
brands with no wave form control have a xed
slope, though not all are set at the same level.
A person using the MTS unit can achieve an arc
that is very similar to what he/she is used to
and then use the control to improve the units
versality.
5. Negave Polarity Connector. Connects to
work clamp while in MIG/Sck mode. Con-
nects directly to TIG torch while in TIG mode.
6. Control. Plug the control wire from the torch
switch directly into this receptacle. This allows
the torch switch to iniate the arc through 2T
or 4T mode. (Not designed for foot pedal use.)
7. Posive Polarity Connector. Connects to Sck
torch in Sck Mode. Connects to work clamp
in TIG mode. Not used for MIG.
8. Euro Quick Connect for MIG. This style of con-
necon makes the MTS unit compable with
many aer market MIG torches/guns. Con-
nect the MIG torch by aligning pins on the gun
cable with the receptacle and pushing in.
Twist the collar on the cable connector to lock
in place. Do not use pliers or other tools to
ghten. Hand ghten only.
9. TIG Gas Connecon. The gas line from the TIG
torch should be connected to control the gas
ow while in TIG mode. This feature provides a
solenoid controlled stop/start of gas ow while
using the g torch.
10. MIG Volt/TIG Down Slope/ Sck Arc Force
Control. In each mode, the funcon of the
control changes. In the MIG mode, the control
is used to adjust the arc voltage. While in TIG
mode, the it funcons to adjust the down
slope of the arc current while the unit is used
in 4T mode. In Sck mode, the control is used
to vary the automac arc force current re-
sponse. When used for sck welding the arc
force is also known as “dig”. When welding in
sck mode, the current is increased as the
volts fall o due to a short arc length. This
helps maintain the arc by providing more wa-
age.
11. Amp/Wire Speed Control. For Sck and TIG
funcon, this adjusts the amps. For MIG opera-
on,the amps are directly ed to the wire
speed feed. Increasing the speed increases the
amps and vice versa. While the unit displays in
cm/min for MIG operaon, a change in this
Setup Guide and component Identification
Section 2

18
control also results in a change of amps.
12. 2T/4T Torch Trigger Selector. The torch trig-
ger funcon is designed to operate for both
MIG and TIG funcons. To operate in 2T
mode, the trigger on either the MIG or TIG
torch should be simply held down. The 4T
funcon operates as a torch “latch” in MIG
mode that locks the MIG torch on without
needing to hold the trigger. To operate 4T in
the MIG mode, simply press the torch trigger
and hold it down unl the arc starts. To lock it
on, release the trigger and weld without hold-
ing the trigger down. To stop, the trigger must
be pressed again, and then released aer 1-2
seconds. The 4T funcon in TIG mode acts sim-
ilarly, but in conjuncon with the down slope
mer. As the torch trigger is pressed for the
second me, the trigger should be held in unl
the downslope mer completes its cycle. The
the trigger may then be released to end the
arc. Releasing before the down slope is n-
ished will terminate the arc immediately.
NOTE: The unit will always default to 4T op-
eraon each me the unit is powered on.
13. Process Selector. Each icon graphically repre-
sents each process for rapid eye acquision
when changing processes. The top funcon
represents MIG. The middle funcon repre-
sents Sck. The boom funcon represents
TIG. Note: The unit will default to MIG each
me the power is cycled on.
14. Volt Display. The display displays MIG volts
that are selected either through the automac
synergic funcon (200S) or through the manual
adjustments made with the MIG Volt control
knob. The funcon of the Volts display will
change to reect actual welding volts during
welding. This may reect a slightly dierent
voltage than selected. This is normal and due
to minor variaons of arc length, power input
etc. The Volt meter also registers TIG and Sck
voltage, though the voltage is non adjustable
on these funcons.
15. Power Indicator. This L.E.D. should remain
on while the switch is on.
16. Duty Cycle/Overcurrent/Over or Under-
Voltage Warning. When the duty cycle has
been exceeded or an overcurrent, over-voltage
or under-voltage condion has occurred, the
L.E.D. will light. Allow the unit to cool while
running unl the light goes o or for 10
minutes before reseng the welder. If condi-
on persists check for loose wires or voltage
supply problems.
Rear Panel:
1. Gas Supply. Connect the Gas regulator hose
to this point via the brass ng. (Regulator is
customer supplied and not provided as stand-
ard equipment at me of publicaon.)
2. Power Switch.
3. Power Input Cable. The MTS requires a
220/240 V single phase 50/60 Hz power input.
Do not aempt to hook to any other power
conguraon. See page 13 for proper wiring
instrucons. If used on a generator, the gener-
ator must labeled as “clean power” and pro-
vide a sine wave with less than 10% variaon.
Side Panel:
1. Wire spool holder assembly. See page 21 for
the detailed view. Make note of the correct
assembly order of the rubber tension washers
and spring. The order in which they are as-
sembled is important to be able to provide
enough resistance to prevent de-spooling of
the wire. When inserng the spool , make
sure the small tab on the inside of the spool
holder is located in one of the recesses made
into the spool, if any. Tighten the outer hand
nut aer installing the wire spool so that the
wire will not connue to keep rolling aer
wire has stopped feeding. Do not over ghten
so that the drive rolls slip or the feeder strains
to pull the wire. The tensioner assembly can
accommodate either 8” or 4” spools of wire.
However, the black center adapter must be
removed to use the smaller rolls.
2. Polarity Buss Bar. Note the “+” and “-” sym-
bols located on the inside of the unit next to
the buss bar terminals. To change the polarity
of the MIG torch, simply loosen the middle
screw and remove the top and boom screws
on the terminals. By pivong the buss bar on
the center, loosened screw., swing the buss
bar into posion over the desired polarity. Re-
install the screws, lining up the holes in the
buss bar with the terminal. Tighten all buss
bar screws. Always remember to alter your
work clamp to reect the polarity change. If
the terminal buss bar is oriented to negave,
then the work clamp should be in the “+” posi-
Setup Guide and component Identification
Section 2

19
ve output terminal. Standard polarity is
“+” (DCEP) with the work clamp in the (-) neg-
ave output terminal. For ux core use see
manufacturer’s direcon for polarity recom-
mendaon. See TABLE 1 for complete recom-
mendaons
3. Burn Back Timer Control. The burn-back con-
trol helps to prevent too much sck out when
stopping and restarng a weld, by keeping the
arc energized for a short me aer the wire
feeder stops feeding and while the gas is post
owing. The wire will burn back to the length
desired by adjusng the control. This improves
re-starts and keeps the user from having to re-
trim the wire between welds. It should also be
adjusted while feeding aluminum, prevenng
the wire from burning back into the p and
seizing.
4. Wire Feed Assembly. Note the numbers on
the side of the tensioner. These numbers are a
reference point to help properly tension the
wire so that the drive roller will not slip. Do
not over tension the wire because it can create
a condion known as birds nesng, where the
wire will ball up trying to feed if too much re-
sistance is met. Too lile tension will result in
wire slipping and fast wear on the drive com-
ponents. Note that while welding aluminum,
the tension is absolutely crical. Do not de-
form the wire. Use 50XX series wire for Alumi-
num, with a diameter of .040” for best results.
Test the tension of the wire and inspect for
proper feeding before beginning a weld. Oc-
casionally cleaning of the feeder mechanism is
necessary to prevent wear and damage to the
feeder and to the MIG gun liner. Monitor any
metal aking that may occur, and dirt accumu-
laon and clean it away gently with com-
pressed air as necessary. Use proper safety
are while doing this, i.e. glasses, gloves etc to
prevent injury. Do not use cleaners or sol-
vents. Felt wire lubricators may be bought and
used to keep feeding cleanly while using steel
or stainless wire.
Setup Guide and component Identification
Section 2
NOTE: Keep welder at least 10-12 inches away
from all objects for proper cooling. Regularly
inspect and clean the welder, and its circuits on a
quarterly basis with dry compressed air. Remove
the covers only aer the unit has been turned o
and discharged for 30 minutes to help prevent
electrocuon.

20
Setup Guide and component Identification
Section 2
EXPANDED VIEW OF MAJOR MIG DRIVE COMPONENTS*
*Some non-signicant variaon may occur in component details. Not all components are individually
serviceable, and are added for detail and explanaon of assembly
7
8
9
10
1 2 34 5 6
NO. Parts Qty NO. Parts Qty
1Wire feed motor 110 Locking thumb screw 1
2Key 111 Tensioning Spring 1
3Feed roller 112 Reel Retaining cover 1
4Locking screw 113 Fricon 7 washer 1
5Machine 114 Wire guide tube 1
6Connector 115 Wire reel sha 1
7Screw thimble 116 Sha core 1
8Screw nut 117 Washer 1
9Feed strut 1
17 16 15 14 13 12 11