Everlast POWER MTS 200, POWER MTS 250S Operator's Manual

EVERLAST

POWER

MTS

200/250S

CC/CV MULTI-PROCESS WELDER

GMAW/GTAW/SMAW

CC

CV

GMAW

GTAW

SMAW

IGBT

DC

Operator’s Manual for the Power MTS 200/250S

Safety, Setup and General Use Guide

Rev. 3 0 101009-13

everlastwelders.com

329 Lileeld Ave. South San Francisco, CA 94080 USA

1-877-755-9353

Specicaons and Accessories subject to change without noce.

Table of contents

Section……………………………………………….Page

Letter to the Customer …………………....…………

Everlast Contact Information…………….………….
Safety Precautions……………………………………
Introduction and Specifications…..…………………
Overview of Specifications MTS 200……...……..
Overview of Specifications MTS 250S………...…
Technical Parameters of MTS 200……………….
Technical Parameters of MTS 250S..….……..….
General Description, Purpose and Features…….
Set Up Guide and Component Identification….…...
Suggested Settings…….…………………...……..
Connections and Polarity………………………….
Installing MIG Wire ……..………...……………….
Front View Power MTS 200………………….……
Front View Power MTS 250S…………………..…
Front Panel Item Description and Function…..….
Side View (MTS 200 and 250S)……….………….

Side View Item Description and Function……....

Rear Panel View (MTS 200 and 250S)...………..
Rear Panel Item Desciption and Function……….
Synergic and Basic MIG Operation…..…………..
Lift Start TIG Operation……………………………
Stick Operation……………………………………..

Expanded View of Major MIG Drive Components
Expanded View of MIG Torch……………………..

Expanded View of TIG Torch……………………..
Trouble Shooting…………………………………...
Appendix A: Control Plug Schematic…………….
Notes………………………………………………...

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4
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22
23
24
26
28
29
30
31
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33
34

2

Dear Customer,
THANKS! You had a choice, and you bought an Everlast Product. We appreciate you as a cus-

tomer 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 website, contact Everlast directly through the sales
department at the main customer service number in your country. Your unit will be registered 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 candidate for
warranty service and returned. An over-the-phone review/diagnosis must be performed BE­FORE a RMA is 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. Print
it for your records and become familiar of its terms and condions. Guns, accessories and
torches are covered under a separate, shorter warranty. Please be sure you visit the web­site 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 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. This support is free to all Everlast customers. 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, leave a message and your call will nor­mally be returned within 24 hours, except for weekends and holidays. Also for quick answers to
your basic quesons, join the company owned forum available through the website. 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 in-

formed 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 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

3

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
[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):

4

Safety Precautions

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 deliv­ering a satisfactory product to you. That is the reason we offer 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 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 com­mon 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 mal­functioning 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 disturb­ance is noted. Sometimes, improper wire routing or poor shielding may be the
cause.

HF can interfere with pacemakers. See EMF warnings in following safety sec­tion for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.

5

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 ob­serve 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 chip­ping 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 maxi­mum 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 equip­ment. If no protection is available, exclude them from the work area. Even brief expo­sure 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 ade­quate 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!

6

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 pre­cautions 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 re­leased 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

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.

7

et seq

.)

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 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 ne­cessitates 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 ca­bles 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. Periodi­cally 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 han­dling. 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.

8

Section 1

Introduction and Specifications

Overview of Parameters and Features

Power MTS 200 MIG TIG STICK Welder

PROCESS: GMAW/SMAW/DC GTAW(LIFT START) MIG OUTPUT: 30- 200 A/15.5-24 V DUTY CYCLE @ RATED AMPS: 35%
INPUT: 240V 1 phase 50/60 Hz 34 A TIG OUTPUT: 10-200 A WIRE SIZE: .023”-.045”/8” SPOOL
OCV: 60 V STICK OUTPUT: 10-175 A PRE-FLOW TIME: 0-5 SECONDS
TIG UP/DOWN SLOPE TIME: 0-5 SECONDS POSTFLOW TIME: 1-10 S EFFICIENCY >85%

Power MTS 250S MIG TIG STICK Welder with

Synergic Function MIG

PROCESS: GMAW/SMAW/DC GTAW(LIFT START) MIG OUTPUT: 30- 250 A/15.5-26.5V DUTY CYCLE @ RATED AMPS: 35%
INPUT: 240V 1 phase 50/60 Hz 40 A TIG OUTPUT: 10-250 A WIRE SIZE: .023”-.045”/8” SPOOL

OCV: 60 V STICK OUTPUT: 10-200 A PRE-FLOW TIME: 0-5 SECONDS
TIG UP/DOWN SLOPE TIME: 0-5 SECONDS POSTFLOW TIME: 1-10 S EFFICIENCY: >85%

9

Section 1

Power MTS 200 Technical Parameters*

Introduction and Specifications

EVERLAST

MIG/TIG/STICK INVERTER

MODEL: PowerMTS 200 No.

1~

f1

f2

DC: 30-200 A 15.5-24 V

EN/ IEC60974.1

35% 60% 100%

X

U0 V

S

DC: 10-200 A ; 10.4-18V

60

I2 200 A 160 A 130 A

U2 24V 22 V 20.5 V

X 35% 60% 100%

U0 V

S

60

I2 200 A 160 A 130 A

U2 18 V 16.4 V 15.2 V

L: 560mm/22”

DC: 10-175 A ; 15.5-24 V

U0 V

S

1~ 50/60 Hz

PROTECTION:

IP21S

X 35% 60% 100%

I2 175 A 130 A 100 A

60

U1

220-240V

COOLING METHOD:

H: 420 mm/16.5”

U2 27 V 25.2 V 24 V

FAN

220 V I1MAX: 36A I1EFF22 A
230 V I1MAX: 35 A I1EFF21 A
240 V I1MAX: 34 A I1EFF20 A

INSULATION:

F

Weight: 22 Kg/ 49 lbs

W: 220mm/ 8.6”

10

Section 1

Introduction and Specifications

Power MTS 250S Technical Parameters*

EVERLAST

MIG/TIG/STICK INVERTER

MODEL: PowerMTS 250S No.

1~

f1

f2

EN/ IEC60974.1

DC: 30-250 A ; 15.5-26.5 V

U0 V

S

60

DC: 10-250 A ; 10.4-20 V

35% 60% 100%

X

I2 250 A 200 A 160 A

U2 26.5 24 V 22 V

X 35% 60% 100%

U0 V

S

DC: 10-200 A ; 20.4– 28V

60

I2 250 A 200 A 160 A

U2 20 V 18 V 16.4V

X 35% 60% 100%

U0 V

S

60

I2 200 A 160 A 130 A

U2 28 V 26 V 25.2

L: 560 mm/22”

1~ 50/60 Hz

INSULATION

IP21S

W: 220mm/ 8.6”

U1

220-240V

COOLING METHOD:

H: 420 mm/16.5”

220 V I1MAX: 40 A I1EFF 32 A
230 V I1MAX: 38 A I1EFF 31 A
240 V I1MAX: 36 A I 1EFF 30 A

FAN

11

INSULATION:

F

Weight: 22 Kg/ 49 lbs