Everlast PowerMTS 251Si User manual

EVERLAST
POWER MTS 251Si
Rev. 1 0 11114-16
everlastwelders.com
1-877-755-9353
Specicaons and Accessories subject to change without noce.
329 Lileeld Ave. South San Francisco, CA 94080 USA
Operator’s Manual for the PowerMTS 251Si
Safety, Setup and General Use Guide
A Digitally-Controlled, Multi-Process MIG/TIG/Stick Welder
SMAW
PULSE
DC
GMAW
CC
CV
IGBT
GTAW

2
Table of Contents
Section……………………………………………….Page
Letter to the Customer …………………....…………
Everlast Contact Information…………….………….
Safety Precautions……………………………………
Introduction and Specifications…..…………………
Overview of Parameters and Specifications…….
Technical Parameters……………………………...
General Description, Purpose and Features…….
Set Up Guide and Component Identification….…...
Suggested Settings…….…………………...……..
Connections and Polarity………………………….
General Polarity and Amp Recommendations….
Installing The Wire Spool………………………….
Front View Main Panel……………………….……
Front Panel Item Description and Explanation….
Side View …………………………………..……....
Side View Item Description and Explanation..…..
Rear View Back Panel……………………………..
Rear Panel Item Description and Explanation…..
Basic Theory and Function………………………….
Basic MIG Operation…..…………………………..
Pulse MIG Operation………………………………
Pulse MIG Work Sheets…………………………..
Stick Operation……………………………………..
Special Notes Concerning Operation………….…
Basic TIG Operation……………………………….
TIG Arc Starting…………………………………….
Tungsten Preparation……………………………..
Pulse TIG Operation……………………………….
TIG Work Sheets…………………………………...
25 Series MIG Torch………………………………
25 Series Consumables…………………………..
24 Series MIG Torch………………………………
24 Series Consumables…………………………..
26 Series TIG Torch……………………………….
Trouble Shooting Guide……………………………...
Error Codes…………………………………………
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3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast product. We appreciate you as a valued customer and
hope that you will enjoy years of use from your welder.
Please go directly to the Everlast website to register your unit and receive your warranty informaon. Your unit
registraon is important should any informaon such as product updates or recalls be issued. It is also important
so that we may track your sasfacon with Everlast products and services. If you are unable to register by web-
site, contact Everlast directly through the sales department at the main customer service number in your country.
Your unit’s warranty will be registered and in full eect. Keep all informaon regarding your purchase, including
date of purchase and receipt. In the event of a problem with your unit or other issue you must contact technical
support before your welder can be a candidate for warranty service and returned. An over-the-phone review/
diagnosis must be performed BEFORE a RMA will be issued or before the unit can be sent in for service.
Please read the warranty statement published online and other important informaon found on the Everlast
website of the division located in or nearest to your country. This includes the terms of the purchase and war-
ranty procedure. Print it for your records and become familiar of its terms and condions. Please note that
Guns, accessories and torches are covered under a separate, shorter warranty. Please be sure you visit the web-
site and are familiar with all the warranty terms before you call for service.
Everlast oers full technical support, in several dierent forms. We have online support available through email,
and a welding support forum designed for our customers and non-customers to interact with each other. Tech-
nical advisors are acve on the forum daily. We also divide our support into two divisions: technical and welding
performance. Should you have an issue or queson concerning your unit, please contact performance/technical
support available through the main company headquarters available in your country. This support is free to all
Everlast customers. For best service call the appropriate support line and follow up with an email, especially dur-
ing weekends, holidays or any o hours when you cannot reach a live person. In the event you do not reach a live
person, leave a message and your call will normally be returned within 24 hours, except for weekends and holi-
days. Also, for quick answers to your basic quesons, join the company owned forum available through the web-
site. You’ll nd knowledgeable sta available to answer your quesons. You also may nd a topic that already
addresses your queson at hp://www.everlastgenerators.com/forums/. Should you need to call or write, always
know your model name, purchase date and welder manufacturing inspecon date. This will assure the quick and
accurate customer service. REMEMBER: Be as specic and informed as possible. Technical and performance
advisors rely upon you to carefully describe the condions and circumstances of your problem or queson.
Take notes of any issues as best you can. You may be asked many quesons by the advisors to clarify problems
or issues that may seem very basic. However, diagnosis procedures MUST be followed to begin the warranty
process. Advisors can’t assume anything (even with experienced users) and must cover all aspects to properly
diagnose the problem. Depending upon your issue, it is advisable to have basic tools handy such as screwdriv-
ers, wrenches, pliers, and even an inexpensive test meter with volt/ohm funcons before you call.
Let us know how we may be of service to you should you have any quesons.
Sincerely,
Everlast Customer Service

4
Serial number: _____________________________
Model number: _____________________________
Date of Purchase:___________________________
Contact Information
Everlast US:
Everlast consumer satisfaction email: sale[email protected]m
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: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
Telephone: [phone]am-4:30pm EST M-F
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
After hours support: 0410 661 334
Everlast Technical Support: [e-mail]
OTHER (Please record here for your records):

5
Everlast is dedicated to providing you with the best possible equipment and service to meet the
demands of the welding applicaons that you have. We want to go beyond delivering a sas-
factory product to you. That is the reason we oer technical support to assist you with your
needs should an occasion occur. With proper use and care your product should deliver years of
trouble free service.
Safe operaon and proper maintenance is your responsibility.
We have compiled this operator’s manual to instruct you in basic safety, operaon and mainte-
nance of your Everlast product to give you the best possible experience. Overall, welding re-
quires experience and common sense to obtain the best results in the safest manner. As thor-
ough as this welding manual may be, it cannot substute for the me, instrucon and
knowledge level required to learn how to weld. Exercise extreme cauon and care in all acvi-
es related to welding or cung. Your safety, health and even life depends upon it. While an
accident is never planned, prevenng an accident requires careful planning.
Please read this manual carefully before you operate your Everlast unit. Do not operate this
welder unl you are thoroughly familiar with its safe and proper operaon. If you feel you
need more informaon please contact Everlast.
The warranty does not cover improper use, maintenance or consumables. Accessories such as
guns, torches regulators, foot pedals etc. are not covered in the unit warranty. They are cov-
ered under a separate warranty. Do not aempt to alter or defeat any piece or part of your
unit, parcularly any safety device. Keep all shields and covers in place during unit operaon
should an unlikely failure of internal components result in the possible presence of sparks and
explosions. If a failure occurs, disconnue further use unl malfunconing parts or accessories
have been repaired or replaced by qualied personnel.
Note on High Frequency electromagnec disturbances:
Certain welding and cung processes generate High Frequency (HF) waves. These waves may
disturb sensive electronic equipment such as televisions, radios, computers, cell phones, and
related equipment. High Frequency may also interfere with uorescent lights. Consult with
an electrician if disturbance is noted. Somemes, improper wire roung or poor shielding may
be the cause.
HF can interfere with pacemakers. See EMF warnings in following safety secon for further in-
formaon. Always consult your physician before entering an area known to have welding or
cung equipment if you have a pacemaker.
Safety Precautions

6
Safety Precautions
These safety precautions are for protection of your 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 from danger and injury.
Welding and cung processes produce high levels of ultraviolet (UV) radiaon that can cause se-
vere skin burn and damage. There are other potenal hazards involved with welding such as severe
burns and respiratory related illnesses. Therefore observe the following to minimize potenal acci-
dents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even under weld-
ing helmets to protect your eyes from ying sparks and debris. When chipping slag or grinding, gog-
gles and face shields may be required.
When welding or cung, always use an approved shielding device, with the correct shade of lter
installed. Always use a welding helmet in good condion. Discard any broken or cracked lters or
helmets. Using broken or cracked lters or helmets can cause severe eye injury and burn. Filter
shades of no less than shade 5 for cung and no less than shade 9 for welding are highly recommend-
ed. Shades greater than 9 may be required for high amperage welds. Keep lter lenses clean and
clear for maximum visibility. It is also advisable to consult with your eye doctor should you wear con-
tacts for correcve vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cung operaon unless fully protected
by a lter screen, protecve curtains or equivalent protecve equipment. If no protecon is availa-
ble, exclude them from the work area. Even brief exposure to the rays from the welding arc can
damage unprotected eyes.
Always wear hearing protecon because welding and cung can be extremely noisy. Ear protec-
on is necessary to prevent hearing loss. Even prolonged low levels of noise has been known to
create long term hearing damage. Hearing protecon also further protects against hot sparks and
debris from entering the ear canal and doing harm.
Always wear personal protecve clothing. Flame proof clothing is required at all mes. Sparks and
hot metal can lodge in pockets, hems and cus. Make sure loose clothing is tucked in neatly. Leather
aprons and jackets are recommended. Suitable welding jackets and coats may be purchased made
from re proof material from welding supply stores. Discard any burned or frayed clothing. Keep
clothing away from oil, grease and ammable liquids.
Leather boots or steel toed leather boots with rubber booms are required for adequate foot pro-
tecon. Canvas, polyester and other man made materials oen found in shoes will either burn or
melt. Rubber or other non conducve soles are necessary to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cung or handling met-
al. Simple work gloves for the garden or chore work are not sucient. Gauntlet type welding
gloves are available from your local welding supply companies. Never aempt to weld with out
gloves. Welding with out gloves can result in serious burns and electrical shock. If your hand or body
parts comes into contact with the arc of a plasma cuer or welder, instant and serious burns will oc-
cur. Proper hand protecon is required at all mes when working with welding or cung machines!
This welder contains moving parts that can result in injury. Keep hands, ngers, hair, and loose
clothing away from the wire feeding mechanisms and fans while unit is switched on and in use. Do
not aempt to defeat any safety feature. Always operate unit with guard in place on the wire feeder.

7
Safety Precautions
WARNING! Persons with pacemakers should not weld, cut or be in the welding area unl they
consult with their physician. Some pacemakers are sensive to EMF radiaon and could severely
malfuncon while welding or while being in the vicinity of someone welding. Serious injury or death
may occur!
Welding and plasma cung processes generate electro-magnec elds and radiaon. While the
eects of EMF radiaon are not known, it is suspected that there may be some harm from long term
exposure to electromagnec elds. Therefore, certain precauons should be taken to minimize expo-
sure:
 Lay welding leads and lines neatly away from the body.
 Never coil cables around the body.
 Secure cables with tape if necessary to keep from the body.
 Keep all cables and leads on the same side the body.
 Never stand between cables or leads.
 Keep as far away from the power source (welder) as possible while welding.
 Never stand between the ground clamp and the torch.
 Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cung processes pose certain inhalaon risks. Be sure to follow any guidelines from
your chosen consumable and electrode suppliers regarding possible need for respiratory equipment
while welding or cung. Always weld with adequate venlaon. Never weld in closed rooms or con-
ned spaces. Fumes and gases released while welding or cung may be poisonous. Take precauons
at all mes.
Any burning of the eyes, nose or throat are signs that you need to increase venlaon.
 Stop immediately and relocate work if necessary unl adequate venlaon is obtained.
 Stop work completely and seek medical help if irritaon and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, tanium, copper, cadmium,
lead or zinc without proper respiratory equipment and or venlaon.
WARNING! This product when used for welding or cung produces fumes and gases which con-
tains chemicals known to the State of California to cause birth defects and in some cases cancer.
(California Safety and Health Code §25249.5 et seq.)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas. Release of Phos-
gene gas can be deadly. Consider all chemicals to have potenal deadly results if welded on or near
metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain regulaons re-
garding high pressure cylinders can be obtained from OSHA or local regulatory agency. Consult also
with your welding supply company in your area for further recommendaons. The regulatory changes
are frequent so keep informed.
All cylinders are a potenal explosion hazard. When not in use, keep capped and closed. Store
chained so that overturn is not likely. Transporng cylinders incorrectly can lead to an explosion. Do
not aempt to adapt regulators to t cylinders. Do not use faulty regulators. Do not allow cylinders to
come into contact with work piece or work. Do not weld or strike arcs on cylinders. Keep cylinders
away from direct heat, ame and sparks.

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 cung. Keep work surface dry. Do not
use welder or plasma cuer in the rain or in extremely humid condions. Use dry rubber soled shoes
and dry gloves when welding or cung to insulate against electrical shock. Turn machine on or o
only with gloved hand. Keep all parts of the body insulated from work, and work tables. Keep away
from direct contact with skin against work. If ght or close quarters necessitates standing or resng
on work piece, insulate with dry boards and rubber mats designed to insulate the body from direct
contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their locaon and make sure all
personnel in area are advised of their locaon. Taping or securing cables with appropriate restraints
can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cung. Always keep re exn-
guishers close by and addionally 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 distance. They may go into cracks in walls
and oors and start a re that would not be immediately visible. Here are some things you can do to
reduce the possibility of re or explosion:
 Keep all combusble materials including rags and spare clothing away from area.
 Keep all ammable fuels and liquids stored separately from work area.
 Visually inspect work area when job is completed for the slightest traces of smoke or embers.
 If welding or cung outside, make sure you are in a cleared o area, free from dry tender and
debris that might start a forest or grass re.
 Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held amma-
ble liquid or material.
Metal is hot aer welding or cung! Always use gloves and or tongs when handling hot pieces of
metal. Remember to place hot metal on re-proof surfaces aer handling. Serious burns and injury
can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper mainte-
nance is your responsibility. Make sure all equipment is properly maintained and serviced by qualied
personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding parts. Touching
uncovered parts inside machine can cause discharge of high amounts of electricity. Do not allow em-
ployees to operate poorly serviced equipment. Always check condion of equipment thoroughly
before start up. Disconnect unit from power source before any service aempt is made and for long
term storage or electrical storms.
Further informaon can be obtained from The American Welding Society (AWS) that relates directly
to safe welding and plasma cung. Addionally, your local welding supply company may have addi-
onal pamphlets available concerning their products. Do not operate machinery unl your are com-
fortable with proper operaon and are able to assume inherent risks of cung or welding.

9
Section 1 Introduction and Specifications
Overview of Parameters and Features*
Power i-MIG 251Si**
MIG/TIG/Sck Amp Range 120V: MIG 30-150A/ TIG 10-150A/ Sck 10-120A
240V: MIG 30-250A/ TIG 10-250A/ Sck 10-200A
Volt Adjustment Range MIG 120V: 15.5-22V 240V: 15.5-30V
MIG Wire Feed Speed 120V: 60-400 (5-10 m/min) 240V: 60 to 600 IPM (.5-15 m/min)
Input Voltage 120-240V Single phase (208V permissible)
Welder Type Digitally controlled, IGBT inverter type with CV Pulse MIG , Pulse TIG, CC Sck funcons.
Wire Roll Size and Diameter .023”-.062” wire diameters possible with oponal drive rolls.
12” diameter roll (Up to 44 lbs.); 8” adapter available (10-12 lbs.); 4” Diameter NOT SUPPPORTED
Pre/Post Flow Control MIG/TIG MIG: (Pre) 0-10 Seconds/ (Post) 0-10 Seconds; TIG (Pre) 0-10 Seconds/ (Post) 0-10 Seconds
Up/Down Slope of MIG Volts/ TIG Amps MIG: 0-1 Second; TIG: 0-10 Seconds
Synergic MIG Synergic MIG funcon for wires from .023” to .045” in diameter, with mild steel, stainless and Alumi-
num sengs. Synergic feature operates via speed control on MTS version of Spool gun as well.
MIG Burn Back Timer Control 0-2 seconds
Inductance/Arc Force Control 0-100%
MIG/TIG Pulse Frequency MIG: 10-250 Hz; TIG: .5-500Hz
Base MIG Volts/Pulse TIG Amps MIG: 10-100% of Peak Volts; TIG: 3-95% of Peak Amps
Pulse MIG/TIG Time On/Balance MIG 10-90%; TIG 5-95%
Memory Saves up to 9 programs.
MIG Spot and Stch Timer 0-15 Seconds
MIG Burn Back Timer 0-2 Seconds
Sck Hot Start Timer 0-2 Seconds
Sck Hot Start Intensity Control 0-100% over set amperage
Sck E6010 Capability Not recommended, however E6011 may provide a more stable arc.
Power Cable Length 9.5 . (3m)
Accessories 24 Series MIG torch ( some units, 25 Series) torch 9.5 . (3m), Work clamp with cable 9.5 . (3m)
300 A Sck Torch with cable (3m), Floang ball type regulator.
*See next page for complete electrical and technical data.
**Specicaons subject to change without noce.

10
W: 286mm/ 11.25”
H: 457 mm/18”
L: 660mm/26”
Bare Weight: 32kg/70 lbs.
*60 IPM is based on minimum useable feed rate.
NOTE: Environment, Maintenance and Safety: Keep this welder at least 12 inches away from all objects for proper cooling.
Do not exceed 40° C in environment or duty cycle will be reduced. Regularly inspect and clean the welder and circuitry on a
monthly basis with dry compressed air. Remove the covers only aer the unit has been turned o and unplugged for 30
minutes to discharge the capacitors and to prevent the possibility of electrocuon. Do not grind or direct sparks near the
welder to prevent damage to the panel face and internal components. Damage of this nature is not covered by the warranty.
MODEL: PowerMTS 251Si Serial No.
EN/ IEC60974.1
240V; DC: 30-250A; 15.5-26.5V 120V; DC: 30-150A; 15.5-21.5V
X40% 60% 100% 40% 60% 100%
U0 V
60V
I2 250A 200A 160A 150A 120A 90A
U2 26.5V 24V 22V 21.5V 20V 18.5V
240V; DC: 10-250A; 10.4-20V 120V; DC: 10-150A; 10.4-16V
X40% 60% 100% 40% 60% 100%
U0 V
60V
I2 250A 200A 160A 150A 120A 90A
U2 20V 18V 16.4V 16V 14.8V 13.6V
240V; DC: 10-200A; 20.4– 28V 120V; DC 10-120A; 20.4V-24.8V
X40% 60% 100% 40% 60% 100%
U0 V
60V
I2 200A 160A 130A 120A 95A 70A
U2 28V 26V 25.2V 24.8V 23.8V 22.8V
1~ 50/60 Hz
U1
120-240V
120V I1MAX: 36A I1EFF 22.8A
240V I1MAX: 37A I1EFF 23.2A
PROTECTION
CLASS
IP21S
COOLING METHOD:
DUAL, FULL-TIME FAN
INSULATION: F WIRE SPEED:
240V: 60*-600 IPM
120V: 60*-400 IPM
EVERLAST
f1f2
1~
S
S
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POWERMTS 251Si
Section 1 Introduction and Specifications

11
General Descripon, Purpose and Features. The Power
MTS 251Si mul-process unit features an industry rst
Pulse MIG design for MTS-type welders. The compact
stature of the PowerMTS 251Si features faithful IGBT
power components and a simplied digitally controlled
inverter design. The welder’s Pulse MIG capability is
geared towards providing maximum control over heat
and fusion. The unit employs a single-pulse MIG design
that features full manual control over the pulse parame-
ters. This makes it ideal for use with Aluminum and
Stainless Steels in applicaons where heat and arc con-
trol are crical with the MIG process. To provide the
best results while welding aluminum, the unit can be
equipped with the new Heavy-Duty Parker 36 series,
300 amp spool gun. The PowerMTS 251Si also features
a synergic funcon designed for non-pulse MIG opera-
on, as well as full manual control. This welder does
not have the tradional bulk of an undercarriage which
is normally associated with mul-process welders of this
range of capability, making it one of the most portable
MIG/TIG/Sck welder in its class. In addion, the weld-
er can accommodate full size rolls of MIG wire up to 12”
in diameter (up to 44 lbs. typically). A wire spool adapt-
er is available which will allow the unit to accept 8”
spools. Although aer-market 4” spool adapters can be
purchased from many aer-market suppliers, Everlast
does not supply a 4” adapter for the machine. If 4”
rolls are typical of your paern of use, consider pur-
chasing a spool gun which is ideal for this type applica-
on. The welder is capable of storing up to 9 programs
for rapid setup and recall of favorite sengs. This is
helpful when storing favorite pulse programs. The unit
also features a heavy-duty wire feeding mechanism
with 4 driven drive rolls for maximum wire feeding ca-
pability. The mul-process aspect of this welder fea-
tures addional welding processes which include DC TIG
and Sck. The TIG process also features an industry rst
for MIG/TIG/Sck welders: a fully adjustable TIG Pulse
seng, which allows the unit to pulse up to 500 mes a
second between two selected amp values. The TIG pro-
cess also features High Frequency (HF) start (which is
another industry rst) to allow contactless starng of
the TIG arc. The PowerMTS 251Si is the rst unit in the
industry to feature out-the-front controls for TIG, which
also includes a solenoid controlled gas connecon. See
below for addional summary of features:
1) GMAW Process (MIG). The digitally controlled
MIG components precisely control arc funcons
and give real-me feed back about the welding
output parameters. As already menoned, the
welder is also spool gun (gun oponal) ready for
economical welding of Stainless and Aluminum
wires if needed. The spool gun will funcon in all
MIG modes and is a good soluon when consider-
ing welding aluminum with MIG. The single pulse
MIG design also further expands the capability of
the welder. The welder can also be used with the
ux core wire when equipped with oponal ux
core drive wheels. However, when used in syner-
gic mode, Flux-Core operaon will not be op-
mized, though the programmed rao can be reset
to funcon as desired and saved for future use.
2) GTAW (TIG). The TIG mode of the welder is DC
output which is suitable for welding all metals ex-
cept aluminum and magnesium. It includes a high
frequency start and a li start funcon to give the
operator maximum exibility welding in areas that
are restrict HF use. All connecons are provided
on the front of the panel. No install kits are neces-
sary to make the unit TIG ready. A gas solenoid is
used to automacally control gas ow when the
arc is started and stopped according to the me set
on the panel. A foot pedal or torch switch is used
to control the TIG funcon. The pedal controls the
amps when plugged in. Similarly, the torch switch
provided with the TIG torch can be used to control
the sequencer that is used to set gas ow, amp
and slope parameters. The unit is ready to TIG
weld (with the excepon of Tungsten and shielding
gas) when it arrives. Addional TIG consumable
kits can be purchased from Everlast which include
stubby consumables or gas lens kits with Tungsten
in the kit.
3) SMAW (Sck). In sck mode the welder delivers a
smooth DC low spaer 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 sck welder. This
unit is not specically opmized for welding E6010.
Customers considering using the unit for serious
E6010 use should consider other welder alterna-
ves for use with cellulosic rods like the E6010 rod.
The Sck mode also features adjustable hot start
me and hot start intensity controls which are de-
signed to help reduce scking during arc starts
while simultaneously reducing porosity or inclu-
sions during arc iniaon.
4) Sck Arc Force Control. The arc force control ad-
justs the quality and feel of the welding arc. It
does so by modifying the volt/amp curve. As the
voltage drops below approximately 20 volts when
the arc gap length is shortened, the unit reacts by
automacally boosng the amps over the original
Section 1 Introduction and Specifications

12
Amp seng. This helps to prevent the rod from
scking and helps keep the arc going as arc voltage
falls. This acon also boots penetraon and can be
used to change the way the arc feels and acts.
5) Burn Back Control. Burn back control is used to
control the length of the wire sck-out aer the
trigger is released. It helps to prevent the welding
wire from scking in the coalescing weld puddle
aer the arc is terminated and saves the user from
having to trim the wire before restarng the arc.
6) Spot and Stch Timers. The spot mer funcon is
frequently used in fabricaon applicaons where
consistent tack welds are required. The Stch m-
er is used in conjuncon with the spot mer to cre-
ate a regular on/o cycle of the arc while the MIG
gun trigger is held to control heat input and to
make consistent seam weld during producon.
7) Synergic MIG Mode. Synergic mode may be en-
gaged to simplify welder setup and adjustment.
This mode will allow the customer to input basic
parameters and the machine will automacally set
the wire feed speed (amps) and voltage based o
of the user input. The unit’s programming is easily
overridden and the welder will remember the new
rao of voltage to wire feed seng during the ac-
ve welding session unl the process is changed, or
unl the Synergic mode is deselected. The machine
has three synergic modes, one for standard MIG
operaon, one for standard Spool gun operaon
and one for standard push-pull gun operaon.
8) Pulse MIG Mode. Pulse MIG operaon is de-
signed to help the user achieve several key goals
while welding. Most oen, the pulse MIG mode is
employed as a modicaon of the Pulse process
using a dierent blend of gas (≤10% CO2 typically,
but as high as 20% CO2), than standard 75/25 Ar/
CO2 mix used in short circuit steel. The use of Pulse
spray is helpful for welding out-of-posion
(posions other than at/down hand welding),
which is nearly impossible to do in true axial spray
mode. It is also used to weld thinner material than
typical with spray, while using a thicker wire diame-
ter. The main advantages of the Everlast version of
the single pulse MIG is that it oers control of the
heat and arc cone while maintaining good wet in
and travel speeds by pulsing voltage between two
dierent values. Due to the unique design of the
Everlast pulse MIG system, short circuit pulse is
feasible with steel and stainless alloys and can be
used successfully to weld materials as thin as .030”
in thickness when properly adjusted. When cou-
pled with either a push-pull gun, or a spool gun, the
pulse feature is an excellent tool for use in the pro-
ducon welding or repair of Aluminum alloys.
9) Pulse TIG Mode. The pulse TIG feature can be
employed to control heat, wicking of the puddle
and reduce the arc cone diameter, improving the
directability of the arc. The Pulse TIG mode allows
the seng of Pulse Amps, Pulse Frequency, and
Pulse Time-On. Each features serves to change and
shape the welding arc and puddle to control heat,
wet-in and penetraon.
10) Pre and Post Flow Control. The adjustable Pre
and Post ow control features are designed to im-
prove weld quality at the beginning and end of the
weld where porosity from oxidaon can be a prob-
lem. This is accomplished by providing adjustable
me controls for both pre ow and post ow of
shielding gas. This control is acve for both MIG
and TIG.
11) Slow Run-in of Wire. This feature improves arc
striking quality in MIG modes by helping prevent
arc stuering (machine gunning) and push-o dur-
ing arc iniaon by slowing the wire speed unl
the arc is established. Note: This feature does
prevent the user from taking accurate measure-
ments of wire feed speed manually as the wire
will feed slower unl the arc is struck and main-
tained. This is not an adjustable feature and can-
not be deacvated.
12) Spool Gun Modes. This welder is well equipped
to handle the aluminum welding needs of most
customers by being both spool gun and push-pull
gun ready. The unit can handle several dierent
Everlast spool gun models, but the most capable is
the 300 amp, Parker® DSP 360A spool gun. Also
the user may want to consider the Everlast
SM200N-MTS gun which is a 200+ Amp gun with a
24 series barrel. A spool gun is an economical
choice for light to heavy applicaons requiring a
fast deposion rate of aluminum on materials
3/16” or greater in thickness. A spool gun is lim-
ited to 4” rolls (usually holding 1 lb of aluminum
and 2 lbs of other ller metals) so numerous
spools may be needed on larger projects.
Basic Design and Construcon. This mul-process
welder features an intuive control panel and couples
it with digitally controlled IGBT inverter design that
produces a stable arc while conserving energy. Everlast
ulizes quality components from US, European, and
Asian based companies to ensure reliability and parts
commonality. Major control components are of a plug-
and-play design which allows rapid diagnosis and repair
Section 1 Introduction and Specifications

13
of the welder. Welding parameters can be innitely and
connuously adjusted throughout the range, oering
instant welding response for maximum control.
Installaon. The basic construcon of the PowerMTS
251Si is rugged and durable. It is considered ideal for
circumstances where portability is of concern. Crical
components are protected by coangs to make the
welder environmentally resistant and has a water in-
gress rang of IP21S, (the standard in the welding indus-
try to protect from vercally dripping water). However,
some common-sense care should be exercised to make
sure that the welder oers the safest and best perfor-
mance. Please note the following items regarding safe
and proper operaons to ensure best service and re-
sults while welding:
1) Do not use the welder in damp or wet areas. Per-
spiraon and other forms of water in contact with
the body can increase the risk of electrocuon.
2) Do not use the welder in extremely corrosive envi-
ronments. To maintain opmum power transfer,
check main connecons, clamps and cables fre-
quently to ensure that components are not corrod-
ed. Excessive dirt, corrosion and oxidaon can re-
sult in an unstable arc and excessive heat build-up.
If the work clamp becomes corroded or damaged,
be sure to replace it with a heavy-duty work clamp
rated for at least 300 amps. If your work clamp
appears to become extremely hot while welding,
and all connecons are clean and secure, replace
the work clamp.
3) Store the welder covered with a moisture and re
resistant material.
4) If used on a mobile cart, strap or x the welder to
the cart so that accidental overturn is not likely.
Duty Cycle/Overcurrent/Under Voltage/Overvoltage
Warnings. Thanks to a dual cooling fan design, the
PowerMTS 251Si has a duty cycle rang of 40% at 250
Amps while welding in MIG and TIG mode and a rang
of 40% @ 200 Amps while welding in sck mode. The
duty cycle rang is the amount of me (expressed as a
percentage) out of 10 minutes the unit can weld with-
out a rest. For MIG, the unit is capable of welding 4
minutes out of every 10 minutes at the maximum out-
put of 250 Amps. For the balance of the 10 minute peri-
od, the unit should be allowed to rest and cool while
running. This rang is based o a 40° C maximum tem-
perature. If the unit’s duty cycle has been exceeded, the
Stop LED will come on and unit will cease welding out-
put. An error code of “E04”will be displayed If a duty
cycle event has occurred. Allow the unit to run and cool
for 15 minutes. Aer 15 minutes of cooling the unit
while switched on without welding, cycle the power
switch to reset the unit. In the event of an overcurrent,
the welding output will cease and the “Stop” LED will
come on and an error code of EO2 will be displayed. In
duty cycle and overcurrent events, the wire may conn-
ue to feed without output. Overcurrent events can be
caused by too low of supply voltage, running on under-
sized extension cords, too large of wire diameter, too
high of sengs for wire diameter, too high of input
voltage, or internal or external electrical fault. When
an overcurrent has occurred, turn the machine o im-
mediately, then check and remedy the fault before
switching the welder back on. Under or over voltages
will also trigger the Stop LED. The error code of E01 will
be displayed. This is likely a result of a poor power sup-
ply, a long extension cable, or from running o of a
generator that is malfunconing.
Note: If a generator is going to be used with this unit,
please make sure that it is cered by it’s manufactur-
er to be “clean power,” which is normally stated as
less than 5% THD ( Total Harmonic Distoron). For
proper operaon with a generator, make sure you
have at least a minimum 9,000 was of surge capabil-
ity and 6500 was of connuous rated output capabil-
ity.
Section 1 Introduction and Specifications

14
EVERLAST
EVERLAST
Setup Guide and Component IdentificationSection 2
CONNECTIONS AND POLARITY
MIG* SPOOL GUN**
*For Flux-Core, install the work clamp in the
positive terminal and then change the wire feed-
er’s polarity (located under the access cover).
GUN +WORK -
CONNECT TO 5/8” CGA GAS FITTING AT REAR
CONTROL
SPOOL GUN +
STICK
WORK -
WORK -TORCH +
** Push Pull gun and Spool gun are optional items
that may be purchased separately from Everlast.
TIG
WORK -TORCH -
PEDAL
GAS
SWITCH (2T/4T)
NOTE: In TIG mode, the user
must choose between pedal opera-
tion or torch switch operation. Both
cannot be in use at the same time.

15
PROCESS TORCH POLARITY WORK POLARITY
MIG (GMAW) +-
FLUX CORE (FCAW) - +
STICK (SMAW) +-
TIG (GTAW) - +
Table 1
GENERAL POLARITY RECOMMENDATIONS*
*Consult the manufacturer of the ller material recommendaons concerning polarity .
PROCESS GAS
MIG (GMAW) STEEL 80/20 Ar/CO2 or 75/25 Ar/CO2 or 100% CO2 for short Circuit MIG
80% or higher Argon content or a 90% Ar Steel trimix blend with bal-
ance of CO2 and 02. (no helium)
MIG (GMAW) STAINLESS 98/2 Ar/O2 , 98/2 Ar/CO2, or TriMix/ StainMIX with Helium
MIG DUAL SHIELDED Follow Manufacturer’s recommendaon
MIG (GMAW) ALUMINUM 100% Argon
TIG (GTAW) STEEL/STAINLESS 100% Argon
GAS SELECTION GUIDE
Table 2
WIRE DIAMETER WELDING AMPS (A) PLATE THICKNESS GAS FLOW RATE
.023” (0.6 mm) 25-110 .040”-.063” (1.0-1.6) 15-20 CFH /7-10 lpm
.030” (0.8 mm)) 35-200 .040”-.128” (1.0-3.2) 20-25 CFH/ 10-14 lpm
.035” (0.9 mm) 45-250 .040”-.128”.(1.0-3.2) 20-25CFH/ 10-14 lpm
.040” (1.0 mm) 45-250 .050”-.25”+(1.2-6.0+) 25+ CFH/ 14+ lpm
.045” (1.2 mm) 60-250+ .25”+ (6.0+) 25+ CFH/ 14+ lpm
.062” (1.6 mm) 140-250+ .375+ (9.5+) 25+ CFH/ 14+ lpm
MIG (GMAW) CURRENT/WIRE/SINGLE PASS THICKNESS GENERAL SUGGESTIONS
Table 3
IMPORTANT: Use the synergic function of the welder if you are unsure of the best volt and amp
settings to use. This feature automatically sets a generally useable volt/amp ratio for you. After this is
set, based off of the inputs you have provided for wire diameter and wire type, it is a simple matter of turn-
ing the amps up or down until the arc is stable and the sound of the arc is a crisp frying sound. If no work-
able setting is found, the volts may be adjusted up or down while in synergic mode. Adjusting the volts will
reset the volt/amp ratio and create a whole new range of adjustment capability. Changing the shielding
gas mix from the standard 75/25 in MIG mode will affect how accurate the volt/amp ratio is. The synergic
mode provides much better results in general than a chart can provide. Please note that in synergic mode,
the unit changes to read in Amps, not the actual wire feed speed(IPM) while adjusting. This is a
more accurate method since wire diameter and type is known. Many wire manufacturers provide a range
of amps for their wire type in the printed material, or in their online information. Actual suggested amp
and volt ranges may differ somewhat from brand to brand. MIG inductance settings will also affect final
settings. Before adjustment of volts and amps begins, set the inductance to approximately 65-75%, then
fine tune the inductance only after all fine tuning of volts and amps has been completed.
Setup Guide and Component IdentificationSection 2

16
METAL THICKNESS WELDING AMPS
(A)
TUNGSTEN DIA. Ar FLOW RATE
1-3 mm/.040”-1/8” 40-80 (60-125) 1-2 mm/.040”-3/32” 8-15 CFH /4-7 lpm
3-6 mm/ 1/8”-1/4” 80-200 (125-200) 2-3 mm/ 3/32”-1/8” 15-25 CFH/ 7-14 lpm
6-10 mm 1/4”-3/8” 150-200 (200-250) 3-6 mm/ 1/8”-1/4” 20+ CFH/10-15 lpm.
METAL THICKNESS ELECTRODE SIZE WELDING AMPS
< 1 mm/.040”1.5 mm/ 1/16” 20-40
2 mm/.080”2 mm/3/32”40-90
3 mm/ 1/8” 3.2 mm/1/8”90-110
4-5 mm/ 3/16” 3.2-4 mm/ 1/8” 90-130
6-10 mm/ 1/4”-3/8” 4–5 mm/ 1/8”-5/32” 130-200
STICK (SMAW) OPERATION GUIDE
TIG (GTAW) OPERATION GUIDE FOR STEEL (ALUMINUM)*
*As a general rule, set amperage using 1 amp for every .001” of metal thickness for aluminum. Less is required for DC.
TUNGSTEN SELECTION GUIDE FOR AN INVERTER
TYPE PERCENT COLOR PROCESS RECOMMENDATION
Pure 100% Tungsten Green AC NOT RECOMMENDED!
Do not use in an inverter.
Thoriated
(slightly radioactive)
2% Thorium Red AC/DC YES. Great for all purpose welding. Most eco-
nomical.
Ceriated 2% Ceria Orange AC/DC YES. Good for low amp use.
Lanthanated 1.5% Lanthanum Gold AC/DC YES. Best alternative to 2% Thoriated. Tough
performer.
Lanthanated 2% Lanthanum Blue AC/DC YES. Slight advantage over 1.5% Lanthanated.
Zirconiated 1% Zirconia Brown AC NOT RECOMMENDED!
Do not use in an inverter.
Setup Guide and Component IdentificationSection 2

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

18
FRONT VIEW/ MAIN PANEL POWER i-MIG 251Si
CONTROL GAS
6
2
1
16 17
14
18
5
11
8
4
10
3
9
19
15
13
7
12
Setup Guide and Component IdentificationSection 2

19
Front Panel Descripon and Explanaon:
1. Protecve Cover. The unit features a protecve
hinged cover. This cover should be lowered
whenever welding is acvely taking place or
when the welder is stored for an extended peri-
od of me.
2. Volts/Seconds/Percent Display and LEDs. The
Volt/Funcon display works in conjuncon with
the LEDs directly beside the display. As dierent
parameters are selected, the LED’s to the right
of the display, that represent the unit of meas-
ure that is currently being represented will be lit.
The display represents Volts, seconds, and per-
cent. Aer adjustment is completed to parame-
ters other than Volts, the display will revert to
displaying Volts aer a few seconds of inacvity.
3. Amps/Wire Speed/Hz Display and LEDs. The
Amps/Wire Speed/Hz display works in the same
way as the Volts/Seconds/Hz Display and LEDs
discussed in item 2 above. This display express-
es value of the Amps, Wire Feed Speed or Hz
(PPS). As one of the Select buons (#13) are
pressed, it cycles through each LED funcon
while the display shows the corresponding se-
lected unit of measure for each funcon that the
digital display is assigned to represent. NOTE:
Depending upon which process is selected, not
all funcons will be referenced during setup.
Aer selecon/adjustment of the other display
related funcons is completed or if no adjust-
ment is made aer a few seconds, the display
will default to the wire feed speed seng, dis-
playing selected wire feed speed in Inches Per
Minute (IPM), unl welding starts. When weld-
ing begins, actual amps output will be displayed
dynamically. In the synergic modes, the wire
feed speed no longer displays IPM, but displays
in Amps. Amps is always represented as the de-
fault in synergic mode, as the LED is the same
one used to represent IPM in standard and pulse
modes. In sck mode, only Amps will be dis-
played.
4. LED ON Indicator. The On indicator should be
lit anyme the machine is turned on and the unit
is receiving power. If the unit is switched on but
no ON light appears and the fans do not start,
check for a tripped breaker and check for incom-
ing power at the receptacle. You may noce
that the ON indicator along with the displays and
fan, may remain powered up to 10 seconds aer
the unit is switched o as the capacitors dis-
charge. This is part of normal operaon and not
a defect.
5. LED Stop Indicator. This indicator will light up
anyme a machine fault or an electrical issue is
detected. When this lights up, machine output
will cease and an error code will be generated in
the display. Wire feeding may connue if the Stop
indicator is on, but welding output will cease. If
an error code is generated, look up the error code
in the troubleshoong secon of the manual.
Most error codes will require a power down and
power up cycle of the unit to clear the codes and
restore the operaon of the unit.
6. Synergic Funcon. The Synergic funcon is used
to simplify setup and improve results while weld-
ing. While similar to auto-seng features in oth-
er brands, it is dierent and more advanced as it
takes into account wire diameter and wire type
and allows ne tuning without a “one-size ts-all”
approach that would prevent you from customiz-
ing the arc to your requirements . The synergic
mode presets a rao of wire feed speed to volt-
age that is useful for operaon with the operator
selected type of wire and wire diameter. It does
not set a parcular target voltage or wire speed
however since it does not take into account mate-
rial thickness. The machine sets a minimum de-
fault voltage and wire feed speed with a dierent
programmed rao for each combinaon of
sengs. This rao voltage to wire feed speed is
coupled, or rather “locked” together, so that the
wire speed feed adjustment knob alone can con-
trol both voltage and wire speed feed simultane-
ously. Even though the machine is in the Synergic
mode and the wire feed control is designed to
control both voltage and wire speed together, the
voltage can be ne-tuned at any me by simply
using the voltage adjustment knob to change the
voltage. This will establish a new rao of volts to
amps. Once the voltage has been ne tuned to
suit the user’s preferences, this will reprogram
the machine to remember this newly established
rao of volts to amps. The user will then once
again be able to use the wire speed to control
both the wire speed and voltage together through
the wire speed adjustment knob. If further ne
tuning is needed, the voltage can be adjusted in-
dividually at anyme without aecng the wire
speed. This new rao will be remembered as long
as the unit is in the synergic mode. Once the unit
has exited the synergic mode or the unit is pow-
ered down, the newly established rao will be
cleared from memory. While in synergic mode,
Setup Guide and Component IdentificationSection 2

20
you will noce while cycling between dierent
wire types and wire thicknesses, the basic volt
and wire feed sengs do not appear to change.
This is normal. Keep in mind that the unit de-
faults to the minimum seng for each synergic
seng and only the rao changes. The wire
speed seng does not change because instead
of reading in Inches Per Minute, the machine is
programmed to recalibrate itself to read in
Amps while in the synergic mode. Amps are
directly linked and controlled by wire feed speed
in MIG welding. Due to Ampacity, dierent wire
diameters can deliver a dierent amount of amps
at the same given wire feed speed. So, this is
why the unit is calibrated to read in Amps while
in the synergic mode. It should be noted that
while acvely welding, this unit reads actual out-
put amps regardless of standard or synergic
modes. To operate, simply select the type and
size of wire being used once a synergic mode is
selected. Selectable opons for wire type in-
clude: Steel, Aluminum, and Stainless. Wire sizes
for the synergic funcon include, .023”, .030”,
.035”, and .045” wire diameters. Some exact
wire sizes may vary from what is listed. Note:
With the excepon of .062” and larger wires,
select the next wire size down if the wire size is
not listed on the panel face and the synergic
funcon is desired. If .062” or similar sized wire
is used, select the standard mode and avoid us-
ing the synergic feature. The synergic mode is
not calibrated for Flux-Core or dual shielded
wires, or every possible formulaon of ller wire,
but does oer a good starng point for most
wires. Remember, the synergic mode is designed
to assist in seng up the machine and simplies
operaon. It will not always oer every user the
best seng in all situaons. Use it as a tool, and
keep in mind that experience is the ulmate re-
source for proper machine setup. Special Note
concerning Synergic operaon with the spool
gun: Make sure if you purchase a spool gun for
operaon with this unit, that a MTS version of
the spool gun is purchased. This will oer you
excellent control of both Amps and Volts
through the speed control knob located on the
spool gun. This is something parcularly useful
and will allow you beer control than any other
brand or type of spool gun on the current mar-
ket by reducing your need to visit the panel to
make correcons to voltage while welding. You
will not be able to adjust amps/wire speed on
the panel in synergic mode since wire speed/amp
control is routed through the gun, but will sll be
able to ne tune voltage on the panel if needed.
Otherwise, the synergic spool gun mode operates
essenally the same as the Synergic MIG mode.
7. Pedal/2T/4T selector. Press the buon to select
one of the torch switch or pedal funcon modes.
Select 2T for simple press-and-hold operaon of the
torch switch. For 2T operaon with the torch
switch: 1) Press and hold the switch to start the
arc and weld. Release the switch to cease welding.
Select 4T for advanced use of the sequencer con-
trols on the panel such as pre-ow, post-ow, up
slope and down slope. To operate in 4T mode with
the torch switch/remote: 1) Press and release the
switch to start arc. 2) The current will begin to
upslope to reach normal welding current. 3) Press
and hold switch to begin downslope. 4) Release
switch to terminate the arc. In 4T mode, if the
puddle becomes too hot, it can be cooled by light-
ly tapping the switch to begin downslope and tap-
ping again to restart upslope before end current is
reached. Seng a long downslope helps improve
heat control in 4T as the torch switch is cycled be-
tween downslope and upslope before the arc is
terminated. IMPORTANT: To use the foot pedal
mode select pedal mode and adjust TIG amps to
the maximum desired seng. The pedal will then
control the amperage throughout the enre range
of amps up to the maximum selected amperage,
based o the pedal posion.] The foot pedal is for
TIG use only. The 2T 4T modes can be with TIG
mode or MIG mode.
8. Mode (Process) Selector. Select the desired pro-
cess by toggling the arrow buon. Each press of
the buon will advance and highlight the next pro-
cess to the right. Select between the following pro-
cesses: Standard MIG mode, Synergic MIG mode,
Pulse MIG mode, Standard Spool Gun mode, Syner-
gic Spool Gun mode, Pulse Spool-Gun mode, Stand-
ard TIG mode, Pulse TIG mode and sck mode. In
standard MIG or Standard Spool gun modes, volts
and amps are controlled completely independent
of each other. When Synergic MIG or Synergic
Spool gun mode is selected, the Synergic mode LED
will light above the synergic secon to remind you
that the operaon is synergic instead of manual. In
sck mode, almost all electrodes can be used ex-
cept rods with a high percentage of cellulose in the
ux. If using with cellulosic rods, such as E 6010,
less than sasfactory performance may be experi-
Setup Guide and Component IdentificationSection 2