Everlast POWER i-MIG 253DP Operator's Manual page 12

Section 1
ing the same welder or when different thicknesses and
metal types are changed on a frequent basis. When
needing to save parameters, particularly with multiple
operators, we recommend that you keep a laminated,
"quick" reference list of saved program numbers associ-
ated with specific welding applications near the welder.
Usually, the best place to store this is the inside of the
door of the welder. To help with this, at the end of the
manual we have created a list of quick reference charts
that you can fill out for different applications that can
be stored in a sleeve pasted on the inside door or that
can be kept in a reference note book near the welder.
The unit also features a heavy-duty wire feeding mecha-
nism with 4 driven drive rolls for maximum wire feeding
capability. The 4 roll drive system reduces the chance
of irregular feeding and helps reduce the "cork screw-
ing" effect of the wire into the puddle. "Corks crewing"
or Helixing (due to the cast of the wire) of the wire as it
comes out of the gun can result in an unstable arc and
even improper placement of the weld bead in extreme
conditions. When you couple proper drive roller ten-
sion and correct drive roll selection, unintended slipping
and irregular feeding can be virtually eliminated without
troublesome bird's nesting and stuttering of the wire (at
start) However, if too much tension is applied to any
wire feeder, bird's nesting and even breakage of the
wire (particularly the smallest wire diameters) will result
if the wire encounters excessive resistance such as cold
stubbing into the puddle or a contact tip burn back oc-
curs. If you suspect either have occurred, stop welding
immediately and check your drive feeder for tangled or
broken wire.
See below for additional summary of features:
1) GMAW Process (MIG). The digitally-controlled MIG
components precisely control arc functions and
give real-time feed back about the welding output
parameters. Both Single Pulse and Double Pulse
modes are synergically based and make welding in
pulse modes as simple as selecting the correct am-
perage to match the thickness of the weld. Arc
length can be "trimmed" to the desired length with
the voltage offset feature. As already mentioned,
the Power i-MIG 253DPi is also spool gun and push-
pull gun (optional) ready for Aluminum welding or
and brazing if needed. Both the spool gun and the
push-pull gun unit will function in all MIG modes
and with all synergic Pulse settings. The welder can
also be used with the flux-core wire (FCAW) when
Introduction and Specifications
equipped with optional serrated drive rolls. How-
ever, if Flux-Core is used in synergic mode and syn-
ergic Pulse modes, the welder will not operate cor-
rectly. Even with significant adjustment of trim
and inductance settings, problems achieving desir-
able welds may be encountered. When attempting
to use Flux-Core or Dual-Shielded wires, the stand-
ard mode (without the synergic function enabled)
should be used for the most reliable operation.
2) SMAW (Stick). In stick mode the Power i-MIG
253DPi delivers a smooth DC low spatter arc. Pro-
fessional, high-quality welds are obtainable with
E7018, 7014, 309L, 316, 6011 and many specialty
rods that are designed for use with any stick weld-
er. NOTE: This unit is not designed for E6010 use.
The Stick mode also features adjustable Hot Start
intensity control which is designed to help reduce
sticking during arc starts. It will also simultaneous-
ly help reduce porosity or inclusions during arc
initiation. The stick arc force control adjusts the
quality and feel of the welding arc. The arc force is
used to adjust the amp reaction when the arc gap
is shortened and voltage drops. This helps to pre-
vent sticking of the welding rod and helps maintain
the arc going as arc voltage falls. This action also
boosts penetration and controls overall "feel" of
the arc.
3) Burn-Back Control. The Burn-back feature is used
to control the length of the wire stick-out after the
trigger is released. It helps to prevent the welding
wire from sticking in the coalescing weld puddle
after the arc is terminated. It also saves the user
from having to trim the wire before restarting the
arc. Burn-Back control consists of two settings:
Burn-Back time and Burn-Back Volts. Typically
Burn back time is set long enough to prevent wire
sticking in the weld puddle. The wire should melt
back to the point where trimming is not required
to restart the arc and no wire sticking is observed.
Burn back time is usually adjusted to less than .1
seconds, but more time can be added as needed.
Thicker wires will need longer burn back times. For
a starting point in Synergic pulse modes, Burn-Back
Volts (now displayed as trim/Volt offset value)
should be set for a lower value than the trim/Volt
offset value used for regular welding.
4) Synergic MIG Operation. The synergic welding
modes are designed to simplify welder setup and
adjustment. Synergic MIG welding allows the cus-
tomer to input basic parameters of wire type and
wire diameter and the machine will automatically
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