PowerPro and Power Ultra Welder Plasma Canada

8/2/2019 PowerPro and Power Ultra Welder Plasma Canada

1/28

1

EVERLASTPOWER SERIES

MULTIPROCESS TIG//SMAW/PLASMA CUTTER UNITS

Operator s ManualIncludes AC/DC PowerPro and DC PowerUltra Units

Safety, Setup and General Use GuideRev. 1 0609-09

Pro256


2/28

Thank you for purchasing an Everlast product. We appreciateyour patronage and hope that you will enjoy years of use from

our product.

Please go directly to the Everlast website to register your unitand receive your warranty information. Your unit registration

is important should any information such as product updates orrecalls be issued. It is also important so that we may track

your satisfaction with Everlast products and services. If youare unable to register by website, contact Everlast directly

through the consumer department at the main number. Yourunit will be registered and warranty will be issued and in full

effect.

2

Serial number: __________________________Model number: __________________________Date of Purchase __________________________

EVERLAST

Contact InformationEverlast consumer satisfaction email: [email protected] Website: everlastwelders.caEverlast Technical Support: [email protected] phone number: 905-630-8246 9am4pm EST M-F

10am-2pm EST Sat.

FAX: 905-639-2817

NOTES:


3/28

TABLE OF CONTENTS

Section.Page

General ...Safety Precautions...Introduction and SpecificationsKnow Your Machine..2.1 Panel Face and Functions2.2 Lower Panel and Functions....2.3 Rear Panel ..Getting Started..3.1 General Guidelines3.2 Shielding Gas Selection3.3 Regulator/Flow meter Selection3.4 Regulator Connection...3.5 Regulator Adjustment..3.6 Machine Setup.3.7 Tungsten Selection3.8 TIG Torch..3.9 TIG Welding Principles and Guide3.13 MMA (Stick Welding)3.16 Plasma Torch 3.17 Plasma Cutting Principles.

4.0 Trouble Shooting.

5691313151617171717171818192020222424

27

3


4/28

4

Everlast is dedicated to providing you with the best possible equipment andservice to meet the demanding jobs that you have. We want to go beyond deliv-ering a satisfactory product to you. That is the reason we offer technical sup-

port to assist you with your needs should an occasion occur. With proper useand care your product should deliver years of trouble free service.

Safe operation and proper maintenance is your responsibility.

We have compiled this operators manual, to instruct you in basic safety, op-

eration and maintenance of your Everlast product to give you the best possibleexperience. Much of welding and cutting is based upon experience and com-mon sense. As thorough as this welding manual may be, it is no substitute foreither. Exercise extreme caution and care in all activities related to welding orcutting. Your safety, health and even life depends upon it. While accidents arenever planned, preventing an accident requires careful planning.Please carefully read this manual before you operate your Everlast unit. Thismanual is not only for the use of the machine, but to assist in obtaining thebest performance out of your unit. Do not operate the unit until you have readthis 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. Donot attempt to alter or defeat any piece or part of your unit, particularly anysafety device. Keep all shields and covers in place during unit operation shouldan unlikely failure of internal components result in the possible presence ofsparks and explosions. If a failure occurs, discontinue further use until mal-functioning parts or accessories have been repaired or replaced by qualifiedpersonnel.

Note on High Frequen cy 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 mayalso interfere with fluorescent lights. Consult with an electrician if distur-bance is noted. Sometimes, improper wire routing or poor shielding may bethe cause.

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

GENERAL


5/28

SAFETY PRECAUTIONS

These safety precautions are for protection of safety and health. Failure tofollow these guidelines may result in serious injury or death. Be careful toread and follow all cautions and warnings. Protect yourself and others.

5

Welding and cutting processes produce high levels of ultraviolet (UV) radiation thatcan cause severe skin burn and damage. There are other potential hazards involvedwith welding such as severe burns and respiratory related illnesses. Therefore ob-serve the following to minimize potential accidents and injury:

Use appropriate safety glasses with wrap around shields while in the work area, evenunder welding helmets to protect your eyes from flying sparks and debris. When chip-ping slag or grinding, goggles and face shields may be required.

When welding or cutting, always use an approved shielding device, with the correctshade of filter installed. Always use a welding helmet in good condition. Discard anybroken or cracked filters or helmets. Using broken or cracked filters or helmets cancause 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 9may be required for high amperage welds. Keep filter lenses clean and clear for maxi-mum visibility. It is also advisable to consult with your eye doctor should you wearcontacts for corrective vision before you wear them while welding.

Do not allow personnel to watch or observe the welding or cutting operation unlessfully protected by a filter screen, protective curtains or equivalent protective equip-ment. If no protection is available, exclude them from the work area. Even brief expo-sure 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 ofnoise 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 doingharm.

Always wear personal protective clothing. Flame proof clothing is required at alltimes. Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure looseclothing is tucked in neatly. Leather aprons and jackets are recommended. Suitablewelding jackets and coats may be purchased made from fire proof material fromwelding 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 ade-quate foot protection. Canvas, polyester and other man made materials often foundin 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 orhandling 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 seriousburns and electrical shock. If your hand or body parts comes into contact with thearc of a plasma cutter or welder, instant and serious burns will occur. Proper handprotection is required at all times when working with welding or cutting machines!


6/28

SAFETY PRECAUTIONS

continued

6

WARNING! Persons with pacemakers should not weld, cut or be in the welding areauntil 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 someonewelding. 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 besome harm from long term exposure to electromagnetic fields. Therefore, certain pre-cautions 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 anyguidelines from your chosen consumable and electrode suppliers regarding possibleneed for respiratory equipment while welding or cutting. Always weld with adequateventilation. Never weld in closed rooms or confined spaces. Fumes and gases re-leased 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 andgases which contains chemicals known to the State of California to cause birth de-fects 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 Phosgene gas can be deadly. Consider all chemicals to have potentialdeadly 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. Certainregulations regarding high pressure cylinders can be obtained from OSHA or localregulatory 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 andclosed. Store chained so that overturn is not likely. Transporting cylinders incorrectlycan lead to an explosion. Do not attempt to adapt regulators to fit cylinders. Do notuse faulty regulators. Do not allow cylinders to come into contact with work piece orwork. Do not weld or strike arcs on cylinders. Keep cylinders away from direct heat,

flame and sparks.


7/28

SAFETY PRECAUTIONS

continued

7

WARNING! Electrical shock can kill. Make sure all electrical equipment is properlygrounded. 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 weld-ing or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rainor in extremely humid conditions. Use dry rubber soled shoes and dry gloves whenwelding or cutting to insulate against electrical shock. Turn machine on or off onlywith 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 ne-cessitates standing or resting on work piece, insulate with dry boards and rubbermats designed to insulate the body from direct contact.

All work cables, leads, and hoses pose trip hazards. Be aware of their location andmake sure all personnel in area are advised of their location. Taping or securing ca-bles with appropriate restraints can help reduce trips and falls.

WARNING! Fire and explosions are real risks while welding or cutting. Always keepfire extinguishers close by and additionally a water hose or bucket of sand. Periodi-cally check work area for smoldering embers or smoke. It is a good idea to havesomeone help watch for possible fires while you are welding. Sparks and hot metalmay travel a long distance. They may go into cracks in walls and floors and start a firethat would not be immediately visible. Here are some things you can do to reduce thepossibility 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 smokeor embers.

If welding or cutting outside, make sure you are in a cleared off area, free fromdry tender and debris that might start a forest or grass fire.

Do not weld on tanks, drums or barrels that are closed, pressurized or anythingthat held flammable liquid or material.

Metal is hot after welding or cutting! Always use gloves and or tongs when handlinghot pieces of metal. Remember to place hot metal on fire-proof surfaces after han-dling. Serious burns and injury can result if material is improperly handled.

WARNING! Faulty or poorly maintained equipment can cause injury or death.Proper maintenance is your responsibility. Make sure all equipment is properly main-tained 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 explodingparts. Touching uncovered parts inside machine can cause discharge of highamounts 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 orelectrical storms.

Further information can be obtained from The American Welding Society (AWS) thatrelates directly to safe welding and plasma cutting. Additionally, your local weldingsupply company may have additional pamphlets available concerning their products.Do not operate machinery until your are comfortable with proper operation and areable to assume inherent risks of cutting or welding.


8/28

INTRODUCTION AND SPECIFICATIONSSECTION 1

PowerPro 205, 256 and PowerUltra Models

PowerPro 256

PowerUltra 205

PowerPro 205

8

PowerPro 205 with Optional Cart

and Water cooler

EverlastPowerPro205

PowerPro256


9/28


Power Series TIG(GTAW) WP 18/28 Torch

Power Series TIG (GTAW)

Foot Pedal Assembly

Power Series Deluxe Stick (SMAW, MMA)Electrode Holder And Work Clamp

Power Series TIG (GTAW)Torch Accessory Pack

EverlastEverlast

Power Series Plasma

Torches

P-series, S Series

9


10/28

10

1.1 This manual has been compiled to givean overview of operation and is designed tooffer information centered around safe,practical use of the machine. It is not in-tended to teach welding technique. Allsuggestions and techniques given are ap-proximations and should be used as a gen-eral guide only.

1.2 To ensure that your Everlast product isin top condition, carefully inspect unit fordamage upon opening the box, looking fordamage on the surface of the unit and tothe machine itself and all its accessories.Do this immediately upon receipt of prod-uct. Any damage issues must be resolved

right away. It is further recommended thatthe product be tested at the same time forproper operation, even if it is to be stored

for a while. Check to make sure all pas-sages, connections and fittings are clear ofany packing material or other obstruction.Record the serial number on the page pro-vided in this manual. Include purchase date

for warranty reference. Serial numbers arelocated on the rear of the machine.

1.3 The Power Series multi-process unitsare used in industrial settings performingday to day fabrication and repair activities.The exceptional arc characteristics areprovided by the inverter based technologythat employs the use of reliable IGBT tran-sistor technology from Germany. Light-weight inverters allow a machine to be

finely tuned for precise arc characteristics,while consuming less power than the lar-ger transformer based machines. Al-though it varies upon the model, precisecontrol of the welding arc cycle is managedthrough the adjustments available on thepanel face. The independent controls al-low for a virtually limitless number of con-

figurations to suit every type metal andweld condition encountered. The use ofHigh Frequency arc starting in the TIGmode, greatly simplifies the TIG(GTAW)process. The incorporation of the ad-vanced Pilot Arc in the Plasma Mode elimi-nates the need for touch starts and greatlyimproves consumable life.

1.4 Be careful to observe dutycycles of the machine posted inthis manual and on the machineitself. A duty cycle is a rating ofpercentage of time out of 10 minutes themachine can be used at the rated powersetting . Overheating may occur if the dutycycle is exceeded. On multi-voltage, multi-phased machines, note that the rated dutycycle will change. For example, the dutycycle of the PowerPro 256 is 35% at 250amps which continuous operation is al-lowed for 3.5 out of 10 minutes before acooling period of 4 minutes is needed.SMAW operation on all units is restricted to35% at maximum amperage.

1.5 The unit should be stored in a dryplace for long term storage. Humid/wetconditions can contribute to the eventualdecay of the circuitry in the machine. Forsafety reasons, do not use this machinedirectly in the rain or with soaked clothingor protective gear.

1.6 Use only the provided handles to lift theunit. Do not suspend by cables or chainsor use fork trucks to lift the units. If neces-sary, use two people to carry the unit.

1.7 Make sure that the units cooling fanand exhaust vents are kept free of obstruc-tion. Before every operation, inspect theunit for unexpected obstructions such asinsect and rat nests. From time to time, acleaning of the machine with low pressureair and a small plastic bristle brush is nec-essary to ensure long life. On these occa-sions only, unplug unit and remove coverto access interior. Concentrate efforts onaluminum heat sinks and panel vents toremove dust and dirt.

1.8 Refer to the following pages to locateyour particular unit and its specifications.Note that product specifications are sub-

ject to change without notice due to prod-uct improvements. If any additional infor-mation is needed contact Everlast. Simplewiring diagrams may be obtained for basicdiagnosis and may be obtained from tech-nical support.



11/28


Everlast PowerPro and Pow-

erUltra Features PPro205 PPro256Over current Warning Yes Yes

Start Type (plasma) Blowback HF

Start Type (Tig) HF HF

AC Square Wave (aluminum) Yes Yes

AC Frequency 2-250 Hz 20-250Hz

AC Balance 30-70% 10-90%

Pulse Frequency .5-25 Hz .2-500 Hz

Pulse Amps (background) 5-200 A 5-95%

Pulse Time ON (width) 10-90% 10-90%

Arc Force Control (dig) Yes Yes

2T/4T remote Yes Yes

Pre-Gas Flow Timer No 0-10 S

Post-Gas Flow Timer 0-25 S 0-25 S

Start Amps None 0-100

End Amps None 0-100

Up Slope Timer 0-5 0-10 S

Down Slope Timer 0-5 0-10 S

Voltage(OCV 60-80V)

220/240 1phase

220/2401 phase

Duty Cycle TIG @ Max Ratedamps

60% at 200 35% @250

Duty Cycle Stick @ MaxRated Amps

35% @ 160 Amps 35%@ 200Amps

Duty Cycle Plasma @ MaxRated Amps

60% @ 50 A 35% @ 60 A

Water Protection Class IP21S IP21S

PU205

Yes

Blowback

HF

No (DC only)

None

None

None

None

None

No

Panel/Remoteonly

No

0-60

None

None

None

None

110/220/2401 phase

60% @ 200

35%@ 160Amps

60% @ 50 A

IP21S

11


12/28

SECTION 2 KNOW YOUR MACHINE

3

12

2.1 Panel Face. The following is a unit panelface from the PPRO 256 and PU 205 series unit.Depending upon your unit, the panel face mayvary with regard to quantity and location of

controls and features. Use the appropriate ref-erenced number to refer to equivalent featureson your unit. Some numbers are omitted oneach panel because the function does not ap-ply to that unit.

1. Power lamp. This light illuminates while theunit is powered on.

2. Over Current/Overheat lamp. This lampilluminates when the duty cycle has been ex-

ceeded or the machine has overheated due toimproper ventilation. Discontinue use until

lamp goes out. Allow the fan to continue to run.Once lamp goes out, you may resume using theunit and reset the breaker switch if necessary.If frequent or continuous overheating is en-countered, contact Everlast.

3. Digital Display. The display posts the ap-proximate welding amps within 3 amps. Dis-play will change to reflect actual welding amps.Pulse cycle amps will be displayed while weld-

ing, although when the machine is rapidly puls-ing the meter may not catch up to the actual hiand low amperage when it is sampling the am-perage.

4. Pulse Power Control. This 3 position rockerswitch allows for use of the built in pulse. Youmay select: Off, Low (L), or High (H). This fea-ture pulses (cycles) the amperage betweenbase and peak amps to maintain fine control ofwelding on thin materials or on out-of-positionwelds. Noticeable fluctuation of the arc inten-sity occurs when the pulsing mechanism is onat low frequency levels. PowerUltra units donot have pulse control. On PowerPro 205 units,there is no switch to turn off pulse. Manipula-tion of the pulse amps (6) knob to match the

welding amps will eliminate the pulse. Also us-ing the Pulse Time ON switch will control thecycle length of the pulse should more regulationbe needed.

5. Pulse Frequency. The pulse frequency con-trols the number of pulse cycles per second(Hz). Where applicable, when the pulse is se-lected for Low, the inner numbers are read. (.2-20 cycles per second). When the pulse is se-lected for High, read the outer numbers. (5-500)(PowerPro 205 has only one scale of numbersand a lower pulse rate of 25 Hz.)

6. Pulse Amps. This gives proportional controlof the Pulse Amps. Example: If the Amperage isset for 100 amps, and the Pulse Amps controlknob is set for 95% (.9), then the low (base) am-perage cycle of the pulse will be approximately95 (90) amps. Regardless of nomenclature, thebasic function of the control is the same. ThePowerPro 205 uses a direct method of control-ling pulse amps and no ratio control. For the PM205, Pulse Amps may be adjusted from 5 to 200amps.

7. Pulse Time ON. This controls the ratio ofthe relative amount of time that the pulsespends on during a defined cycle . For example:A setting of 50% will result in a balanced andequally shared amount of time between thePulse current and the base current. A setting of95% will result in the favoring of the Pulse stageof the cycle with only 5% of the time spent in thebase stage (low) of the Pulse cycle.

Note: This does not control the overall

1

1

2

2 3

3

17

4 5 6 7

8 9 10 11 12 13 14

1413

21

15 16 17 18 19 20

8

PowerPro 256


13/28

Figure 2.1.10 Effects of AC Frequency on welding arc properties

13

length of the pulse. The pulse frequencysetting sets the cycle length, thereby pre-determining the maximum possible length

of each leg of the cycle. But within eachcycle length, there is a definable length(ratio) of time that the pulse spends in thebase (low) amperage stage of the cycleand in the peak (high) amperage stage ofthe cycle. As the cycle frequency (Hz) in-creases, overall cycle length is shortened,thereby compressing the exact amount oftime that the cycle spends in each stage.The Pulse Time on functions within thiscompressible period of time.

8. Main Amperage Control. Some models:Welding Amps . Locations may vary. Thiscontrol knob allows for precise controlover the welding current. This controlknob also is used in the pulse mode to se-lect maximum amps of the Pulse Time Oncycle. In Plasma mode the outer scale isread for plasma amp adjustment.

9. Arc Force Control. It determines howforceful the arc penetrates when it is heldshort. It does so by automatically boostingamps in a short arc situation. This operatesin SMAW/Stick operation. The force of the

arc helps stiffen the arc to hold the moltenmetal in place in out of position welds sof-ten the arc to easily wet in the toes of theweld. The settings are matter of operatorpreference, style and skill. Rotating theknob clockwise increases arc force Thereare no recommended settings regardingthis feature. Experiment with this featureto find optimum the setting for you.

10. AC Frequency Control. This controlfocuses the welding arc and helps to con-trol penetration, and bead contour.

200Hz (AC) 20 Hz (AC)

11. AC Balance. This control determinesthe amount of time the AC cycle spends inDCEN (-) or DCEP (+). More DCEP is pre-

ferred for cleaning oxidation, particularlyin aluminum. More DCEN is preferred for

for better penetration. A 30% DCEP setting


continued(+)is customarily preferred. Try this setting

first as a starting point for adjustment.

12. AC/DC Rocker Switch. This switch se-lects the use of either AC or DC current.AC current is used primarily when TIG weld-ing aluminum. Certain stick electrodescan be welded in this mode to prevent arcblow and increase penetration.

13. 4T/2T Rocker Switch, Panel/ Remote.This switch selects for control of the TIGweld via torch trigger or foot pedal. For thePower Ultra, simply press and hold torchswitch while in panel mode to operate. InPedal mode, connect foot pedal to operatetorch. For the PowerPro series, in the 2Tmode, simply touch and hold the trigger tostart the arc and continue holding whilewelding. The machine will cycle automati-cally according to the settings selected onthe machine. Release the trigger to finish.

2t

4t

4T operation allows full control of the weld-ing cycle. By touching and releasing thetrigger once, the pre-flow, start current and

up slope are initiated. By touching and re-leasing again, the down slope, end current,and post-flow are initiated. Only a momen-tary pause between touching and releasingis necessary to activate the up or down cy-cle. *Note: The use of the foot pedal over-rides the upslope/downslope/start/end func-tions. Place the switch in the 2T positionto use the foot pedal. The foot pedal is usedto manually control the cycle.

Figure 2.1.13 Graphic of 4t/2t operation


14/28


continued

14

14. TIG/Stick rocker switch. This switch al-lows you to select the use of either High Fre-quency TIG, Cut(Plasma) or the conventional

SMAW (stick) welding features.

15. Pre Gas Flow. This timer allows the appro-priate amount of shielding gas to flow topurge the gas lines and to provide adequateshielding gas coverage over the weld beforethe weld arc initiates. The gas flow rate is af-

fected by the torch cup size and welding con-ditions.

16. Post Gas Flow. This timer controls theflow of shielding gas after the weld arc is ter-minated. Too little post flow time can cause

weld contamination or torch overheating.

17. Up Slope. This controls the time that themachine takes to ramp up the current fromthe start current to the normal welding cur-rent. This provides for excellent control overthe welding puddle after it is developed andallows the operator to adjust manipulationtechniques as the puddle warms up.

18. Down Slope. This controls the end cycleof the weld by slowly ramping down the weld-ing current. As the end of the weld is reached,the down slope helps prevent weld crackingand hole formation in the crater by allowingtime to fill the weld crater with extra filler be-

fore the puddle cools completely.

19. Start Amps. This selects the initial start-ing current value used to develop a properweld puddle before upslope is signaled to be-gin.

20. End Amps. This selects the destinationcurrent of the down slope cycle. This is theresidual current value required for the opera-tor to properly fill the weld crater to prevent

cracking and holes at the end of the weld.

21. Pressure Gauge. On the PowerPro series,the gauge is screwed into the pressure regu-lator on the rear of the machine. Optimumpressure is 60-70 psi.

2.2 Lower Panel. The lower front panel is de-picted below. Each terminal or lug should bekept free of dirt or obstructions. Actual layoutof items may vary depending on the unit.

Figure 2.2.1 Lower Front Panel1. Positive(+) lug. For TIG, connect thework clamp (ground) to the positiveside. For Plasma, connect the same.For Stick welding, connect electrodeholder torch to this side for most op-erations depending upon the typewelding rods used. Consult weldingrod manufacturers recommendation.

2. Quick-Connect Gas Outlet. To se-cure the TIG Argon or plasma air line

from the torch to the outlet, slide col-lar back on female fitting, mate maletorch fitting and hold the fitting in andrelease the female collar. Make surecollar returns flush with the front edgeof the female fitting. Pull the collar

forward manually if necessary. Op-

eration is the same for any type ofcommon quick connect air fitting.Check for leaks.

3. Torch Control. Plug either the footpedal or the torch trigger lead directlyinto this plug. Finger tighten the collarto secure the plug onto the machine.Both the torch and the foot pedal can-not be connected at the same time.For Plasma , the torch switch must beused. Do not use the foot pedal forplasma torch operation.

4. Pilot Arc. The single plasma torchwire with the ring is attached to this tooperate the pilot arc. Finger tighten.

5. Negative (-) lug. For TIG operation,connect the TIG torch to the negative.For Plasma torch operation, connectthe torch to the negative. For mostMMA/Stick welding situations, con-nect the work clamp to the negative.

1 23

4

5


15/28


continued

15

2.3 Rear Panel. Reference the following im-age for guidance on rear panel setup and

function. Some panels vary slightly.

1. Air regulator/filter/water trap. To adjustair pressure, pull up slightly on the controlknob on the top of the regulator until a click isheard. Twist clockwise to increase pressureor counter clockwise to decrease pressure.Note: Do not exceed 80 psi. When installingobserve directional arrow for air flow. A stepdown regulator at the tank is highly recom-mended as well as an additional air dryer atthe tank. A tank side air filter/dryer will in-crease consumable life and help keep mois-ture out of air lines. On the PowerPro series,be sure to install air pressure gauge in the

middle plug on the regulator housing.

2. Gas Inlet. This port is a dual purpose portto provide the unit with either Argon or com-pressed air. As configured in the picture, itis set up for compressed air. To use Argon,you must remove air line (5) from port (2)and install the line from the argon regulator.Alternately, you may install a T-fitting withtwo shut off valves at the inlet to eliminate the

need to change out the plumbing whenswitching functions. Do not attempt to oper-ate the plasma cutter with argon connectedand do not operate TIG with air pressure con-nected unless a suitable shut-off mechanismis in place and the lines have been sufficiently

purged. Also, quick disconnect fittings maybe used, but care must be taken not to intro-duce moisture to the system that collects onthe couplings during change out.

3. High Frequency Ground. This unit pro-vides a separate grounding point for the high

frequency to help control interference thathigh frequency may cause. This ground mustbe connected to a separate wire that isgrounded to a metal rod driven into theground. It is strongly recommended that youconnect this to a separate ground as pre-

scribed. This will assist in draining the HFand help prevent interference with electronicproducts. Do not ground to cart, table orground to the ground wire in the power sup-ply circuit. Ground only to separate groundrod. Do not ground back to panel box!

4. Specifications and Serial number. Thesespecifications override any other publishedspecifications, as changes may occur fromtime to time. Register your units serial num-ber online and record it here in the manual.

5. Switch. Flip switch up to turn the unit on.If the switch needs to be reset, due to overcurrent or overheating, flip the switch fullydown then back up to resume normal opera-tion.

6. Fan Area. Keep area from being blocked..Air flow must be free and unobstructed. Al-low 12 inches of clearance behind fan area.

7. Power cord. The power cord must not beplaced in a strain or the unit pulled by thecord at any time. To wire, use a standardNEMA 6-50 P male plug. Most plugs have

wire color coding included in the instructionmanual or printed on the plug itself. How-ever, the white is typically wired to thesmaller blade and the black wire to the larger

flat blade. The green wire is for ground only(middle post). Other types of plugs may beused, but it is suggested to use the 6-50 se-ries plugs as it meets most codes. Crow

foot plugs and other types may be used, butlocal codes must be observed at all times.

1

23

4

5

6

7


16/28

16

SECTION 3 GETTING STARTED

3.1 These are general guidelines for useand maintenance for your Power Seriesunit. Take into account all safety rules andrecommendations first before operationand service. Do not let untrained person-nel operate or service equipment in anyway.

3.2 Shielding gas selection.Do not attempt to operate the TIG func-

tion with out the proper shielding gas!

Proper shielding gas selection is crucial tosatisfactory operation of your TIG machine.Shielding gas is a special gas or mixture ofgases designed to cover and protect your

weld from contamination from the atmos-phere while welding and as it cools. Oxy-gen and other gases from the atmospherecan infiltrate the weld and make it unserv-iceable. Do not be fooled by the welds ap-pearance, because many defects are con-tained inside the weld without the use ofproper shielding gas. The most economi-cal and available gas is 100% Argon. He-lium and Argon/Helium mixes are alsoavailable. Helium offers faster weld rateswhile Argon offers a more focused coneand better cleaning action. Do not attemptto use common shielding gases designedfor MIG welders. These will melt the tung-sten and contaminate the weld. If you havenever developed a working relationshipwith your local welding supplier, then it istime to make a visit to purchase or lease atank of shielding gas. Many sizes of tanksare available. Choose the size that best fitsyour long term needs.

3.3 Regulator/ flow meter selection. Youwill need a flow meter/ regulator designedto be fitted onto your shielding gas tank. Itcontrols the flow rate of shielding gas into

your Power Series. There are two stylesgenerally available. The first has twogauges, one for pressure the other for

flow. The best regulator has a pressuregauge and a flow meter with a ball that

floats when gas flows. Certain flow meterscan regulate Helium, Argon or Helium/Argon mixes equally well. However, oth-ers cannot. It is advisable that a flow meterbe selected that can regulate both.

Always be sure to select the correctflow meter for the type of shielding

gas that is in use. Never substitute oxygen

or acetylene regulators!

Image 3.3a Ball type flow meter

Image 3.3b Ball type flow meter

3.4 Regulator/Flow meter connection. Af-ter connecting regulator safely to tank,attach hose end to shielding gas inlet .(see 2.3.5) Firmly clamp and secure hose

end to the unit. Depending upon the flowmeter manufacturer, you may have to cutand remove the pre-crimped hose fitting toattach the hose to the shielding gas inletbarb. Open the tank valve slowly andgradually increase the regulator flow tocheck for leaks.

3.5. Regulator /Flow meter adjustment.


17/28


continued

17

Adjust the flow meter per manufacturersrecommendations. Generally, the flowshould be set around 7-10 lpm (EverlastRegulators register lpm or liters per mi-ute!!!!) or 15-25 CFH (cubic feet per hour)indoors for Argon. Helium settings are usu-ally at least twice the flow rate of Argon.You will have to increase the flow of gas ifweld porosity, sootiness, or weld discol-oration is encountered. If a draft is presentor welding is done outdoor, additional

flow may be needed. Increase flow meteroutput until symptoms disappear.

3.6. Machine set up .1. Plug installation. Due to the lackof standards concerning 220V plug con-

figurations, Everlast chooses to shipmost of our units without a plug for service.We recommend a license electricianbe consulted to connect your welder forservice to ensure all codes are followed.The following is provided as a generalguide only. Determine the plug prong pat-tern of the existing 220V outlets in yourshop or garage. Make sure both plug andreceptacle match perfectly. We recom-mend the standard 50 amp NEMA 6-50 Pwelder plug. Higher amperage units re-

quire twist lock type connections. Do notforce plugs to mate . The green wire isused as the ground and the black andwhite wires are hot 110 V wires. To makea 220V circuit work, two hot wires mustbe used from separate 110V wires from thepanel box. Do not attempt to wire the unit

from the same phase 110 V leg of thepanel. Identify your green ground wire firstand properly attach the wire to the groundprong. The remaining black and whitewires are your 110V hot wires. Attach thetwo remaining wires to the remaining two

blades. The ground bolt on the rear ofthe machine is designed to help eliminateHigh Frequency interference from the ma-chine. Ground the case bolt to a separatewire connected to a metal ground rod out-side of the facility that is in moist soil. Oc-casionally multiple ground points are re-quired. Do not ground back to the electri-cal circuit ground as harmful HF feedbackcan occur. Always consult your local, li-censed electrician for proper installation!

Do not attach HF ground directly to table,cart, electrical circuit or panel box.!Image 3.7a Painted Tips

3.7 Tungsten Electrode Se-lection (TIG)). Currentlythere are many choicesavailable for tungsten elec-trodes. Tungsten is gener-ally referred to by a colored

band painted on the end of each electrode.Each color represents a certain alloying ele-ment that is present with the tungsten thathelps to extend tungsten life. Sizes alsovary. Each size tungsten is capable of han-

dling a certain current range. Not all tung-sten electrodes are alike. Pure tungsten(Green) is NOT recommended for use in anyEverlast Power Series Multi-process ma-chine! Pure tungsten is not capable of han-dling the heat and stress placed upon it byan inverter based welder. Although pureTungsten is the most affordable, it forms alarge ball that makes the arc erratic and dif-

ficult to control in inverter based machines.Old style transformer welders are bettersuited for pure tungsten.

The most widely used tungsten isthoriated (Red). It withstands theheat of inverter based weldingquite well and retains its shapewithout over-melting. Red

(thoriated) tungsten may pose a health riskas it is slightly radioactive. Inhalation of thegrinding dust or microscopic particles ispossible. Although it is suited for weldinguse in an Everlast machine, many peoplechoose not to risk their health. Red tung-sten has been available for a long time andis the standard tungsten in the industry to-day. However, as concerns rise, more com-panies are looking for alternatives.

The most favored alternatives have are ei-ther a Ceriated (Orange) tungsten or Lan-thanated (Gold) tungsten. Both are suitable

for use in an Everlast Power Series unit.Costs for these electrodes are considerablyhigher than pure or thoriated types of tung-sten. Many welders experiment with severaltypes, eventually finding one that they favorin all situations.


18/28


continued

18

The following table supplies basic informationabout Tungsten selection and suitability.

Note: Use only recommended sizes in Tigtorches unless you purchase additional col-lets to fit the electrodes snugly. Loose fittingelectrodes quickly ruin TIG torch parts.

NOTES:

NR

NR

OK

OK

NR

Table 3.7.1

NotRecommended


19/28


continued

19

3.8 TIG Torch. Becoming fa-miliar with a TIG torch is a nec-essary step to becoming profi-cient at TIG welding. Due toconstant issues with sharpen-ing and replacement of thetungsten, frequent adjustmentand breakdown of the torchcomponents is often required.Refer to the following image

for a typical TIG torch break-down.

Image 3.8b Typical Torch Parts

1. Cap. This is also referred to as a Spur orRooster Spur. Short caps are available to pro-vide easy access to tight places.

2. Tungsten. Be sure to select the proper sizetungsten for each job. Avoid use of green tung-sten (pure) on Everlast Power Series welders.See chart on page 19.

3. Collet. A snug fitting collet must be used toprevent slippage and internal arcing.

4. Torch body. All parts connect inside or tothe outside of the torch body through threadedconnections.

5. Gas Insulator. Prevents loss of shieldinggas around cup. Replace if leaking or cracked.

6. Collet body. Holds collet.7. Cup. Focuses and directs shielding gasaround weld area. Replace if damaged.

3.9 TIG Operation and Principles.Before any welding takes place, it isnecessary to put on protective gear andfamiliarize yourself with safety precautions.

TIG welding is an elite form of welding. Notmany people learn to fully master the tech-nique due to the patience and practice this art

form requires. This manual cannot make youa good welder. Only practice and skill can dothat. Everlast provides this basic informationas a general guideline to assist the operator inlearning basic principles and techniques.Notice the basic components of the TIG proc-ess in the image below.

The shielding gas flows out from the torchhead to cool and protect the molten puddleand the tungsten as the arc continues to meltthe base metal. As the metal melts and a cir-cular puddle is formed, the Tig torch is slowlymoved forward. While the metal gently flowstogether, the filler rod is kept near the arcand in the gas cone to keep it hot and keep it

from oxidizing. As the metal begins to form akeyhole shaped puddle and penetration ofthe metal is achieved, the filler rod is gentlyadded to the molten puddle and then removed

as a molten drop of filler material is added tothe base material.

As you familiarize yourself with the above di-gest of basic TIG welding, there are a coupleof basic knowledge items that need to be ad-dressed.

The tungsten must be shaped prior to initiat-ing an arc. With inverter based TIG welders,

Image 3.8aPowerTig Torch

Assembly

12

45

6 7

3

Image 3.9a


20/28


continued

20

tungsten sharpness is important. Refer tothe following diagram to correctly sharpena Tungsten electrode. Notice the incorrectway of sharpening an electrode. Radiallysharpening an electrode will cause an un-stable, wandering arc, making it difficult tocontrol the weld puddle. Carefully rotate thetungsten as it is being ground to prevent a

flat spot or a hollow ground point. Alsonote that tapering the tungsten to 2.5 Xs ofits diameter is generally recommended

for most DC welding applications. Forhigher amperage DC welding, do not oversharpen the point, but leave a slight trunca-tion on the end of the electrode. This pre-vents the tungsten tip from breaking awayand falling into the weld. When AC welding,a small ball may form. This is normal. How-

ever, if a large globular ball begins to form,re-sharpen the tungsten and adjust the ACbalance. It is also normal for a slight dometo form on the tungsten in DC mode. How-ever, if the arc becomes erratic or the arc isdifficult to start, regrinding will be neces-

sary. If the tungsten is accidentally dippedinto the weld puddle, re-grind the tungsten,particularly on aluminum. Grind tungstenelectrodes only on a dedicated stone, freeof contamination from other metals. Handheld tungsten grinders usually grind perfectpoints. Chemical sharpeners may be used.

Once the tungsten has been sharpened,install it into the torch, with approximately1/8 of an inch of the tungsten sticking out.

3.10. Filler Rod Selection. Dependingupon the metal to be welded, filler rodselection is critical. Consult with your lo-cal welding supplier for the optimum fillerrod to properly complete the weld. In cer-tain applications, TIG welding can be per-

formed without the use of a filler rod.

3.11 Beginning the TIG weld. One of thebiggest issues for beginning welders isholding and maintaining an arc. Startingan arc with your High Frequency Everlastwelder is quite simple. Select the machine

for TIG operation. Then, select the desiredamperage. Grip the torch in a mannerthat is comfortable to you. (Many skilled

welders use an underhanded grip tosteady themselves on the metal.) Placethe torch so that the tungsten is no morethan 1/8 inch from the weld surface. De-pending upon the setup, either press the

foot pedal down or touch the torch andhold (2T setting. See section 2.13) thetrigger to initiate the high frequency arc.A small blue spark may be observed. Thisis the high frequency arc trying to start.Immediately after that, you should see astrong, stable arc flowing from the torch.As the arc begins to grow, a molten pud-

dle will appear. If it does not appear, stopwelding and increase the amperage orclean the area to be welded, includingwork clamp. Repeat the start sequence.

For the following, reference illustration3.11a on the next page.

1. To help the molten puddle form, slowlymake small circles with the torch to buildthe heat in the weld area. A bright, fluidpuddle will begin to form.

2. Once a uniform puddle is established,tilt the torch head about 75 degrees fromthe weld surface into the direction of theweld. This will direct the arc to the frontof the weld puddle.

3. Grip the filler rod at a 15 degree angleto the weld surface with the other hand.Hold the rod in the iridescent cone of gasthat surrounds the weld puddle. Do nothold it in the arc. Keep it close to the

Image 3.9b Tungsten Sharpening

For use with DC lower than 20 Amps.Sharpen point to 2.5 times the diameter.

For use with AC or DC higher than 20 Amps.

Image 3.9c


21/28

21


continuedweld. A skeleton keyhole will begin to

form in front of the weld. The keyhole isevidence that you are ready to add filler

material and move forward. Introduce thefiller rod into the key hole area underneaththe arc. Wait for a single molten drop to

fall off the tip of the rod.

4. When a molten drop falls from the rod,quickly remove the rod, keeping it insidethe gas cone. The molten drop of fillermetal should blend quickly into the puddle.

5. Move the torch forward slightly, carry-ing the keyhole with the weld. If the keyhole is lost, then forward travel was too

fast or too far. When the keyhole showsgood development, repeat the steps 3-5until you have a proper weld bead estab-lished.

3.12 Weld termination. When the weldbead has reached the desired length, add a

final drop of filler and slowly circle thetorch over the end of the weld to fill thecrater. If the weld crater is not correctly

filled, cracking and weld failure may oc-cur. This is a small but important step toproperly completing a weld. Release the

foot pedal or release the trigger to stop.

3.13 Machine operation. MMA/Stick(SMAW)Select switch for MMA/Arc operation.

1. Insert electrode into electrode holder.Position the electrode for the most com-

fortable position so that the electrode canbe held directly over the work piece with aslight angle.

2. Set Amperage to the recommended am-perage by the electrode manufacturer.Strike an arc by swiping it briskly acrossthe work piece in the same manner as one

would strike a match. Alternatively, you

may strike an arc with firm tapping motionagainst the work piece. Either method isacceptable. An arc should initiate. Con-tinue to keep the arc going by holding theelectrode off the work piece no more thanthe electrode width. Continue the arc by

feeding the electrode into the weld puddlewhile moving the electrode forward. Thiswill take some coordination, but will be

fairly easy to do after practice. Do not al-low the arc to become too long, becauseair and slag can become entrapped in themetal. The sound of a proper arc will besimilar to a gentle frying sound. A long arcwill emit a humming sound. An arc that is

too short may be extinguished and theelectrode may stick to the work piece. Ifthe electrode sticks, immediately releasethe electrode from the electrode holderand break the electrode loose by hand. Ifthe flux breaks off, simply trim off the ex-cess rod until flux and bare metal meet. Awelding rod must have flux to shield theweld from the atmosphere or the weld will

fail.

Image 3.11a

Image 3.13 a


22/28


continued

22

4. Use the Arc force and Amp adjustmentto change arc qualities. Adjust the amper-age according to the recommendations of

the electrode (welding rod) manufacturerfor the type and size of the electrode used.

The arc force will affect how crisp the arcis whether it is smooth and buttery ordeeply penetrating. Use it to suit the de-sired weld finish. Experimentation will berequired to find the optimal setting de-sired. It is an excellent tool for out of posi-tion welding.

5. Electrode selection. Electrodes areusually given performance and character-istic ratings using a system of letters andnumbers determined by the AmericanWelding Society (AWS). The rating systemincludes the minimum tensile strength ofthe finished weld, the weld position (flat,vertical, horizontal, or overhead or a com-bination of two or more positions) and the

flux type. Additional information may begiven. Each manufacturer has their indi-vidual name and terminology as well. Asthere is no general recommendation thatcan be made about a particular electrodeselection, except for practice welds, aelectrode designated by the AWS as E

6011, E 6013, E 7014, or E 7018 may beused, each having its own distinct featuresand purpose. These are among the mostcommon electrodes used in the industryand are not difficult to find. E 6011 elec-trodes are not as smooth running as someof the other electrodes, but offer the ad-vantage of being able to weld on rustymetal and contaminated surfaces. It iswidely used and requires very little skill tobegin using. This is not a particular en-dorsement of an E6011, rather a simpleexample of what may be used in develop-

ing proficient technique. It is recom-mended that a variety of electrodes beused and practiced with. Consultationwith an experienced local welding supplierwill help greatly in determining what weld-ing electrode is the best for your givensituation. Many times, samples or smallpackages of electrodes are available atrelatively low cost to determine for your-self the best electrode to use.

Be sure to observe the manufacturer rec-ommendations regarding polarity. If theweld appears lumpy, porous or otherwise

malformed, change the polarity of theground cable and the electrode holder ca-ble. Many electrodes run with a reverse,(DCEP) setting. A few run with a straightpolarity (DCEN). Some will run either way.

3.14 Proper weld identification. The fol-lowing image is designed to help you iden-tify welding issues related to amperageand speed. These are the two major issuesthat are encountered when most peoplelearn to weld. Notice that the weld bead

contour is affected as well. Overlap and

undercutting are two main causes of weldfailure. Proper washing of the weld beadinto the sides or toes of the weld is impor-tant. Keep the welding electrode or the TIGtungsten and welding arc within the weld

joint to prevent overlap. Pausing on thesides of the welds to wait for the sides to fillreduces the chance of undercutting, evenif the current is a little too high. If it is pos-sible, with any practice weld, cut the jointdown the middle, lengthwise, or place theweldment in a vice and use a hammer tobend the metal over the weld area until it is

either broken or bent 90 degrees. This de-structive testing method will help you im-prove your skill by revealing faults and

flaws in your welds.

Image 3.14a


23/28


23

3.15 Plasma Torch. Becoming familiar with aPlasma torch is a necessary step to becoming

proficient at Plasma

Cutting. Refer to thefollowing image for atypical Plasma torchbreakdown for thePlasma 50 and 60-80torch assemblies.

1. Cup. Screws to torch body. It focus thegas in the plasma stream. Replace when ei-ther severely burned or cracked.

2. Cutting Tip. Directs the plasma flame tothe base metal. Either screws to torch or sitsinside cup, depending upon model. Check tip

frequently for wear or burn through.

3. Swirl Ring. Rapidly spins air into a tornadolike stream to create plasma. Not found on alltorch designs. If your torch (S-series in par-ticular) has a swirl ring, it must be used.

4. Electrode. This forms the arc needed tocreate the plasma head. Often when tip is

burned or worn, the plasma cutting ability ofthe unit becomes limited. Check conditionwhen changing out cutting tips. Make surethey are tight or torch failure can occur.

5. Torch Body. Keep the body of the torch ingood condition. Inspect often for cracks andburns in the torch body to prevent electrocu-tion. Make sure that the switch is functioningproperly. Do not oil or grease the switch.

3.16 Plasma Cutting Principles. Beforeany welding or cutting takes place, it is nec-essary to put on protective gear and familiar-ize yourself with safety precautions.Plasma Cutting is an efficient and simple wayto cut multiple metal types. The super sonicplasma stream, generated by ionized pressur-ized air, is capable of rapidly burning metalwithout overheating the surrounding area.This is helpful for preventing warpage andpreventing the formation of Heat AffectedZones (HAZ) in the metal.

3.17 Simple and easy steps to cutting cor-rectly with an Everlast Power Series Cutter.1. Set Amperage and Air pressure to suit theunits specifications.

Place the torch cuttingtip directly on the edgeof the metal. Alterna-tively, you may allowup to 1/8 inch of stand-off to prevent extra

wear and blow back of material.

2. Press trigger to begin cutting. Hold torchtrigger down to continuecutting in Standardmode. To cut in Auto-matic mode, press trig-ger to allow arc to startand release trigger tocontinue cutting.

3. Once Plasma stream is established andsparks exit the bottom ofthe piece of metal beingcut, slowly move thetorch forward into the cut.Depending upon torch ori-entation, you may pull,

push or move side-to-sideto make the cut. Grip thetorch only tight enough to

keep the trigger pressed. A tight grip will re-sult in uneven cutting. Glide the hand gentlyacross the metal, maintaining a drag style cutor a standoff. Use standoff wheels or ring ifnecessary on long cuts. If the torch tip sticksor fouls excessively, revert to standoff cutting.

Image 3.8aPlasma Torches

1

1

2

2

4

3 4

5

5

Image 3.8bTypical Everlast Torch Parts

Everlast

Everlast

Ev

erlast

Everla

st


24/28


continued7. Allow post/after flow cooling to occur.

Post flow will continue forup to a half a minute after

the cut is completed. If ad-ditional cooling is requiredbecause of heavy cutting orextended cutting, switchthe post flow switch to

Test to start manual cooling of the torch.After the torch is sufficiently cooled, returnthe switch to cutting mode to discontinuethe post/after flow cooling cycle.

3.8 Helpful Hints for cutting.1. Make several practice cuts first. Adjustthe amperage and air pressure throughoutthe range to see the effects it has on thecut. Each machine will have a slightly dif-

ferent range or sweet spot.

2. Use a substantial flat piece of metal tomake a long, clean cut. Attempting to cutodd objects or make short cuts cannotreally train proper technique. It will also bedifficult to ascertain the quality of the cut.

Image 3.11 Practice Cuts Using DifferentSettings.

3. Keep torch straight in the cut. Do notlean or tilt the torch excessively except atstart. The ergonomic design of Everlasttorches eases this problem. However, fa-tigue is a common cause for poor, unevencuts.

4. Keep consumables checked for wear.Tip wear can decrease cutting capacity andcut quality at an imperceptible rate until

4. Continue cutting following the desiredpath of cut. Make surethat the sparks are exiting

the piece of metal at a 10-15 degree angle. If thesparks are exiting straightdown, then the cuttingspeed is too slow. In-crease cutting speed untila change of the spark an-

gle is observed. If excessive slag is build-ing up on the bottom of the metal (morethan 1/8 inch) then either increase amper-age, travel speed or air pressure. Some-times excessive slag build up on the bottomof the cut occurs because the machine has

reached its severance limit. Occasionallyexcessive slag can be caused by rusty orcontaminated metal. Note that cuttingthicknesses posted in the specificationpage are specifically for mild carbon steelunder ideal circumstances. Stainless, Alu-minum and other metals have reduced rat-ings cut ratings. Cutting capacity of thesemetals are generally 10-20% less than mildsteel.

5. Exit the cut by pausing briefly to allowthe spark stream to catchup and to be directedstraight down. This is usu-ally the most challengingpart of the cut because thebottom of the cut needs tobe even with the top beforeexiting or the cut piece will

remain stuck to the parent piece of metal.Carefully work the plasma stream to thevery edge of the cut.

6.Release the trigger to break the arc inthe Standard mode setting.In the Automatic mode set-

ting, repress the triggerand release to discontinuethe arc.

Caution! Breaking thearc in the auto mode by lifting the arc awaywill not satisfactorily terminate the arc andwill restart the pilot arc. Precautions mustbe taken in this mode or serious injury canoccur.

Post Flow

24


25/28


continued3.18 Gouging.Everlast Plasma cutters are able to per-

form light to medium gouging, dependingupon the type of metal with the standardcutting tip and electrode. To gouge, sim-

ply lower the air pressure until the low airpressure warning light comes on. Whenthe light illuminates, allow the air pressureto stabilize and increase the air pressure5-10 pounds above the warning lightthreshold. Lean the torch at a 30-35 de-gree angle to the work piece and begin togouge. If you experience problems, ex-periment with the air pressure to accom-plish the desired type of gouge. For cer-tain applications, a special gouging tipmay be required. For this special need,contact Everlast in advance of the ex-

pected time of need to determine avail-ability of special gouging electrodes.

3.19 Piercing.Occasionally, the need will arise to piercedirectly down into a piece of metal to initi-ate a cut with out the benefit of starting onthe edge of the material. This is known aspiercing. To pierce, simply start the torchwith a 1/8 inch stand-off at the desiredspot. If possible, lean the torch at a slightangle so that blowback does not become

a problem and will not foul the tip. Makesure that you tilt the torch away from thepiece being cut out to prevent marring.Allow the torch to slowly burn its waythrough the metal. As the torch plasmaarc burns down through the plate,straighten the torch into the cutting posi-tion. As sparks begin to exit the bottom,you may shorten the stand-off and beginyour cut. Excessive use of piercing willsignificantly reduce consumable life, par-ticularly with an inexperienced operator.Do not attempt to pierce an object that is

thicker than 50-60% of the rated cut ca-pacity to ensure long torch life.

Note: Piercing can produce a lot ofmolten metal blow back. Protective

gear is absolutely required, especiallyface shields and fire proof clothing.

25


26/28

SECTION 4 TROUBLE SHOOTING

TROUBLE: CAUSE/SOLUTIONMachine will not turn on. Check cords and plug wiring. Occasion-

ally a terminal screw will loosen after in-stallation and use. Check circuitbreaker. If no fault is found, contactEverlast Support.

Machine runs, but will not cut. Check for a good ground. Make sureground cable and plasma torch is se-curely fastened to lug and receptacle.Check that the Auto/Standard switch isin the correct position for type of use de-sired (see Auto/Standard operation).

Plasma Cutter pilot arc will not ener-gize. Engergizes erractically.

Check electrode/cup tightness. Tightenelectrode with supplied wrench or pliers.Torch switch wire disconnected insidetorch

Electrodes and tips are rapidly con-sumed.

Inadequate air flow. Water in air supply.Poor cutting technique. Return to stand-off cutting of no more than 1/8 inch.Check and tighten consumables.

Heavy slag on the underside of the cutwith complete cut through.

Travel speed too slow. Either increasecutting speed or reduce cutting amper-age to fit metal thickness. Too muchstandoff (more than 1/8 inch). Worn con-sumables.

Plasma cut is beveled on one side. Plasma cutters tend to leave a slightlybeveled side (up to 5 degrees). However,

decreasing the standoff and increasingair pressure can help reduce or eliminateproblems. Worn Consumables.

Okay air pressure light does not illumi-nate. (some models)

Internal leakage around air fittings. Con-sult with Everlast Support for repair in-structions if needed. No air supply.

Cut quality is poor or irregular. Check and adjust settings. Increase/decrease air pressure. Check for con-sumable wear.

Over current LED illuminates. Duty cycle exceeded. Allow machine tocool while running

Unstable Plasma Arc. Poorly grounded unit or worn electrode.

Surrounding lights, or electronic equip-ment malfunctions.

Use high frequency ground connected toan exterior ground rod to drain Electromagnetic frequencies. Use a shieldedwire to drain if necessary.

26


27/28


TROUBLE:(TIG/STICK) CAUSE/SOLUTIONTig arc is unstable. Check Polarity. Install TIG torch DC

(negative) polarity. Install Stick electrodeholder for DC+(positive) polarity. Contami-

nated tungsten. Grind tungsten to point 2.5xsdiameter of the Tungsten. Wrong Color Tung-sten. Do not use green tungsten (pure) underany circumstance even for AC operation.Poor work clamp location or connection.Change location or grind location area. Do notintentionally ball tungsten, use sharpened

point. Inverters do not need a balled tungsten.Tungsten is contaminated, or dipped intoweld pool.(Displayed as green arc or similaroff color arc characteristic). Regrind tungsten.

Tig tungsten balls up excessively. Check Polarity. For standard operation in al-

most all circumstances, DCEN, or straight po-larity is used. If in AC operation, for aluminum,too much DC+ (positive) is being administered.Try and reduce to 35% DCEP

TIG tungsten is rapidly consumed. Make sure of gas mix is Argon or Argon heliumonly and is not contaminated. Check torch po-larity so that torch is DCEN or reduce DCEPsetting in AC mode. Too small of tungsten. In-crease to next size or reduce current. Checkfor proper shielding gas flow and adjustment.

Foot Pedal operates and torch comeson, but little or no amperage controlor very low or high output.

Check foot pedal. Try to operate unit in 2T or4T mode without foot pedal. If it operates nor-mally, foot pedal down rod or rheostat may bebent or damaged. Contact Everlast support forsimple repair solutions.

Unit will scratch start in TIG, but notstart with HF.

HF points out of adjustment. Consult everlastsupport for proper point maintenance gaps.Possible HF ground wire disconnected or ter-minal plug disconnected internally. Check

switch position is not placed in stick mode.

While in stick mode, weld quality is

poor or the bead is piled up or ropy.

Use stick electrode holder in DC+ for most

welding situations. Only certain electrodescan be used DCEN. Increase arc force controlto improve penetration.

Weld is dull or contaminated in TIG. Hold tighter arc. Make sure argon flow is cor-rect . Start at 7lpm or 15 cfh flow rate. In-crease flow rate with larger cups. Check torchangle so that a venture effect is not created by

too much angle.

27


28/28


TROUBLE: CAUSE/SOLUTIONMachine runs, but will not weld in eithermode.

Check for good ground. Make sureground cable and TIG Torch is securelyfastened to lug and receptacle. Checkthat the switch is correctly selected for

TIG, MMA(Stick) or Plasma (Cut).

Tungsten is contaminated. Tungsten is dipping into weld. Check andadjust stick out to meet welding condi-tions and torch angle. Reduce amperageor increase tungsten size.

Porosity of the weld. Discolored weld

color. Tungsten is discolored.

Low flow rate of shielding gas. Too short

of post flow period. Wrong TIG cup size.Possible gas leaks internally or externallydue to loose fittings. Base metal is con-taminated with dirt or grease.

Weld quality is poor. Weld is dirty/oxidized.

Eliminate drafts. Check if there is suffi-cient shielding gas left in tank. Checkgas flow. Adjust for higher flow of gas.Listen for audible click of gas solenoid. Ifno click or no gas flow is heard, contactEverlast Support.

Will not operate in Stick mode Check that STICK has been selected.

Make sure cables are securely in lugs.Make sure of good work (ground) clampcontact and location.

Excessive weld spatter in Stick mode. Hold tighter arc. Push electrode closer tometal.

Burn through in TIG or Stick modes Reduce amperage.

Documents

PowerPro and Power Ultra Welder Plasma Canada