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Section 1
cycle to 60%. Lowering it further to 70 amps increases
duty cycle to 100%. Keep in mind a 100% duty cycle
rating is not a continuous, infinite rating. It is rated
100% only out of a consecutive 10 minute period of
time. Certain factors like ambient temperature, humidi-
ty, particle/dust buildup inside of the welder, poor
quality power input etc, all can affect duty cycle. The
duty cycle interrupt cycle is governed by a temperature
sensor rather than a timer. This is a more effective and
practical way of determining duty cycle limit. Inter-
mittent welding and many practices involved in fabrica-
tion and repair makes it hard to track usage so a tem-
perature limit is the best way to protect the welder if it
is overworked. Intentionally and consistently reaching
the duty cycle limit so the welding is regularly interrupt-
ed rapidly ages components and may cause premature
failure of the welder. The duty cycle interrupt feature is
not a fail safe against abuse and any heat related dam-
age. Never turn the unit off until it has time to cool.
NOTE: If you are welding and the unit begins to feed
wire only without an arc when the trigger is pressed,
check the status of the duty-cycle light or the overcur-
rent light. When either an overcurrent or duty cycle
event has occurred, the unit will keep feeding wire but
not produce an arc when the trigger is held down.
1.5 Overcurrent. The unit is also equipped with an
overcurrent limiter. This feature detects when there is
either an over/under voltage or excessive amp draw.
If the overcurrent light is triggered, the unit will also
interrupt welding. When this is experienced, first pow-
er the unit off. Then check to make sure the unit is
plugged into an appropriately rated outlet and that it is
being used with a correct sized extension cord rated for
a minimum of 20 amps. Do not use with undersized
extension cords or overheating, fire or damage may
result. Check outlet voltage for a minimum of 110V and
not more than 125V. Cycle the power switch off and
back on to reset the unit. If the Overcurrent light does
not clear, then it is likely the power supply is poor or the
unit has developed an internal fault. Contact Everlast if
the overcurrent cannot be cleared or reoccurs repeat-
edly as the unit may have sustained internal damage.
NOTE: When using large diameter welding wire (.035"
or greater) at or near the maximum output of the ma-
chine, the welder may occasionally experience an
overcurrent. This can happen if the wire is not
trimmed to an appropriate length and the gun is
touched held too far away when starting the arc. Rem-
edy all other causes first before assuming this is the
Introduction and Specifications
issue. This may also occur if the contact tip is touched
to the metal when starting the arc. It can occur if the
gun nozzle has excess slag bridging inside of the nozzle
to the contact tip and the nozzle is subsequently
touched to the metal when starting the arc. This cre-
ates a dead short and can trigger an overcurrent.
1.6 General operation and setup.
1) Wire Tension. Always check wire tension before
use. Use no more wire tension than is necessary.
(See page 15 for adjustment.)
2) Work Clamp. MIG welders require good work
clamp (ground) contact. Routinely inspect work
clamp and cable and make sure they are in good
condition and that the cables are held tight in the
connectors and are free of corrosion. Always
grind a small clean spot where the work clamp is
to be attached. Always connect the work clamp
directly to the metal being welded if possible.
Hard starting or "machine gunning" at the start of
the weld may be a result of a poor ground.
3) MIG gun use and maintenance. Before use make
sure that collar on the Euro quick connect has been
fully tightened by hand. Do not use tools. Grip the
gun firmly when starting the arc to prevent push-
off and spattering/popping at the start of the weld.
Trim the wire to 1/2" or less and hold the gun just
as close to the metal to start the weld. Use nozzle
dip or a anti spatter spray to help keep the MIG
gun nozzle from becoming plugged with slag. Reg-
ularly check and clean the nozzle. Nozzle dip and
anti spatter can be bought at almost any welding
supply store. It is an economical way to prevent
harmful accumulation of slag in and on the nozzle
and can be used in the weld area to prevent
spatter from sticking to the work-piece. Do not
apply too much to the nozzle or directly to the
weld area or porosity may occur. Only apply when
the protective qualities begin to dissipate. Nozzle
dip and anti spatter also provide some lubricity to
the contact tip and increases the lifespan and ease
of feeding. Make sure to change contact tip size
when changing the wire size. Using too large of a
contact tip can cause erratic arc behavior. Using
too small of a contact tip can cause jamming.
When welding with aluminum, use a special alumi-
num contact tip or at least one size larger regular
contact tip to accommodate the wire as it expands
due to the heat. Over time, the gun liner may be-
come gradually fouled with dirt, metal filings from
the coating and other possible contaminants. To
11
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