Everlast POWER i-MIG 253DP Operator's Manual page 32

Section 2
To convert welding requirements that may mention
wire speed (IPM) into approximate Amps, or to find
the Amp value equivalent of wire speed that you
may be used to, use the following conversion formu-
la:
.023": IPM ÷ 3.5 = Amps
.025": IPM ÷ 3.1 = Amps
.030": IPM ÷ 2 = Amps
.035": IPM ÷ 1.6 = Amps
.045": IPM ÷ 1 = Amps
Keep in mind these are approximate conversions
and do fall off in accuracy as Amps are increased into
the upper current limits for the given wire diameter.
Even though you will find general recommendations
about setting the Amps, Volts and even shielding gas
through a variety of free downloadable apps and
online calculators, every filler metal manufacturer
has its own specific parameters for Volt and Amp
settings for each wire diameter and AWS alloy class
of wire. Note that wire speed isn't usually men-
tioned in wire manufacturer specifications, just
volts and amps. The range of Volt and Amp parame-
ters generally varies somewhat from brand to brand,
so be sure to read the packaging and/or manufactur-
er literature to determine what range of settings are
recommended. The wire diameter also limits the
practical maximum thickness of what can be reason-
ably welded. The issue with following charts, graphs
and calculator recommendations is that most people
find them either too hot or too cold. For some peo-
ple, it may not even close. However, nothing can
substitute for watching the arc and listening to the
sound of the arc. In the short circuit transfer meth-
od of MIG welding, a crisp, steady sound, frequently
referred to as a "Bacon frying sound" should be
heard. The actual frying sound can vary somewhat
and may have somewhat of a high pitch whine to it
somewhere between the sound of a flying bee and a
mosquito. If these sounds are present, look at the
arc to see if it is steady, and producing low amounts
of spatter. If large amounts of spatter are present,
the puddle seems fluid (appears wet) and the wire
speed is within the targeted range, decrease volts a
little at a time to reduce the spatter. If this does not
correct the problem, change the torch angle and
Setup Guide and component Identification
BASIC MIG OPERATION
torch height. Hold the torch more vertical, with less
than a 15 degree deviation from vertical and reduce
stick-out of wire to 3/8" or less. If this still does not
help, reduce the wire speed. Some spatter is nor-
mal, though it should be minimal overall.
The wire can also pop and spatter if the voltage is
too low for the Amps (wire feed speed) and/or wire
diameter. This is mostly observed as flying bits of
red-hot but un-melted wire, along with popping as
the wire inconsistently stubs into the puddle. This is
followed by the wire pushing back against your hand
pressure while the wire visibly turns white/red hot
before burning off. Too low of voltage will also pro-
duce a high piled bead with the toes (edges) of the
weld not properly wetting in resulting in poor fusion.
Inductance Control.
The third important variable in setting up the Power
i-MIG 253DPi is the adjustable Inductance control.
This setting isn't found on most basic welders. This
isn't because basic welders don't have inductance,
it's just because it is fixed by the welder's design.
Regardless of whether it is fixed or adjustable, the
amount of Inductance determines the feel of the arc
at any given Volt and Amp setting. It is used to bal-
ance the stiffness of the arc against the wetness of
the arc. It does so by adjusting the pinch point of
the wire, and regulating how fast the droplets of
molten metal are deposited in the weld.
Some professionals refer to the "buttery-ness" of
the arc. "Buttery-ness" is arguably somewhat a sub-
jective term. However, it generally refers to how
smooth and fluid the arc feels and looks. In fact, if
adjustable, as is the case with this welder, the in-
ductance alone can affect how much Amps or Volt-
age is needed in any given application. It does not
typically require an altering of Volts or Wire Speed
settings. However the Inductance control can ex-
pose poorly selected Volt/Wire Speed parameters by
magnifying the effects.
While Everlast uses the term "inductance" on this
model, it is known by many different terms. On
some units it is referred to as "arc force". Often it is
referred to as choke or slope and even dig. Simply
put, the Inductance adjustment controls how long it
takes the current to recover and rise to the estab-
lished welding current to melt the wire after the
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