PowerARC 300
EVERLAST
POWERARC 300
Analog dc Stick/DC TIG inverter welder
CC
SMAW
IGBT
1&3
PHASE
DC
Operator’s Manual for the PowerARC 300
Safety, Setup and General Use Guide
Rev. 2
everlastwelders.com
1 00703-14
Specifications and accessories subject to change without notice.
1-877-755-9353
329 Littlefield Ave. South San Francisco, CA 94080 USA
Table of contents
Section…………………………………………………….Page
Letter to the Customer ………………...……………….
Everlast Contact Information………………………….
Safety Precautions………………………………………
Section 1: Specifications…….…………………………
Section 2: General Setup and Operation……………
General Description, Purpose and Features……….
Front Panel..…………………………………….………...
Rear Panel …….………………………………………….
Wiring……………………………………………………….
Stick E6010 Configuration………..……………………
Stick Configuration……….……………………………..
Stick Operation Technique/Information……………..
Trouble Shooting………………………………………...
Kit Contents…..…………………………………………..
Notes………………………………………………………..
3
4
5
9
10
10
12
13
14
15
16
17
18
19
20
NOTE: Product Specifications and features are subject to change without notice. Every attempt has been
made to ensure this manual’s contents is accurate at time of publication. However, certain descriptions, quantities, appearance and specifications of the product in this manual are subject to change without notice or update of this manual. This manual is intended to be a general guide and not intended to be exhaustive in its
content regarding safety, welding, or the operation/maintenance of this unit. Everlast Power Equipment INC.
does not guarantee the accuracy, completeness, authority or authenticity of the information contained within
this manual. The owner of this product assumes all liability for its use and maintenance. Everlast Power
Equipment INC. does not warrant this product or this document for fitness for any particular purpose, for performance/accuracy or for suitability of application. Furthermore, Everlast Power Equipment INC. does not
accept liability for injury or damages, consequential or incidental, resulting from the use of this product or resulting from the content found in this document or accept claims by a third party of such liability .
2
Dear Customer,
THANKS! You had a choice, and you bought an Everlast. We appreciate you
as a customer 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 information. Your unit registration is important should any information such as product updates or recalls be issued. It is also important so that we may track your satisfaction with Everlast products
and services. If you are unable to register by website, contact Everlast directly through the sales
department through the main customer service number in your country. Your unit will be registered and warranty will be issued and in full effect. Keep all information 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.
Please review the current online warranty statement and information found on the website of the Everlast division located in or nearest to your country. Print it for your records
and become familiar of its terms and conditions.
Everlast offers full technical support, in several different forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interaction.
Technical advisors are active on the forum daily. We also divide our support into two divisions:
technical and welding performance. Should you have an issue or question concerning your unit,
please contact performance/technical support available through the main company headquarters
available in your country. For best service call the appropriate support line and follow up with an
email, particularly if off hours, or you cannot reach a live person. In the event you do not reach a
live person, particularly during heavy call volume times, holidays, and off hours, leave a message
and your call will normally be returned within 24 hours. Also for quick answers to your basic questions, join the company owned forum available through the website. You’ll find knowledgeable,
helpful people and staff available to answer your questions, and perhaps find a topic that already
addresses your question at http://www.everlastgenerators.com/forums/.
Should you need to call or write, always know your model name, purchase date and welder manufacturing inspection date. This will assure the quick and accurate customer service. REMEMBER:
Be as specific and informed as possible. Technical and performance advisors rely upon you to
carefully describe the conditions and circumstances of your problem or question. Take notes of
any issues as best you can. You may be asked many questions 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 cannot 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 functions before you call.
Let us know how we may be of service to you should you have any questions.
Sincerely,
Everlast Customer Service
3
Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________
EVERLAST
Contact Information
Everlast US:
Everlast consumer satisfaction email: sales@everlastwelders.com
Everlast Website: everlastwelders.com
Everlast Technical Support: support@everlastwelders.com
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: 1-650-588-8817
Everlast Canada:
Everlast consumer satisfaction email: sales@everlastwelders.ca
Everlast Website: everlastwelders.ca
Everlast Technical Support: sales@everlastwelders.ca
Telephone: 905-630-8246
9am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: 1-905-639-2817
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
( 0 2 ) 9999 2949
Port Macquarie: 2B Pandorea Place Port Macquarie
( 0 2 ) 6584 2037
After hours support: 0410 661 334
Everlast Technical Support: support@pickproducts.com
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, operation 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 obtained.
 Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, copper, cadmium, lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product when used for welding or cutting produces fumes and gases 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 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 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
SAFETY PRECAUTIONS
continued
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. Proper 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
specifications
PERFORMANCE AND FEATURE COMPARISON
IMPORTANT: The PowerARC 300 is DC output only.
Specification:
PowerARC 300
INVERTER TYPE
ANALOG CONTROLLED IGBT
INPUT VOLTAGE ±10%;PHASE/FREQUENCY
220V; 1 Phase and 3 Phase /50-60Hz
MAXIMUM INPUT AMPS (I₁max)
60A 220V 1 phase/ 45A 220V 3 phase
MAXIMUM INPUT RUNNING AMPS (I₁eff)
46.8A @ 220V 1 phase / 31A 220V 3 phase
DUTY CYCLE % @ AMPS
60% @ 300A/32V
100% @ 240A/ 29.2V
OUTPUT
20-300A, 20.8-32V
OPEN CIRCUIT VOLTAGE
70 V
TIG PACKAGE
OPTIONAL (Gas valve torch and regulator for scratch start DC use only)
CONSTANT CURRENT (CC) OUTPUT TYPE
DC (±)
CELLULOSE ROD CAPABLE 6010,6011
YES
INCLUDES
WELDER, WORK CLAMP WITH CABLE (10 FT),STICK TORCH WITH CABLE (10FT)
DINSE CONNECTOR TYPE
35/70mm² (DINSE 50 STYLE)
HOT START (SURGE CURRENT)
Adjustable
ARC FORCE CONTROL
Adjustable
MAXIMUM SUGGESTED ROD DIAMETER
1/4” (6-7mm)
PROTECTION CLASS
IP21S
INSULATION GRADE
F
Need longer welding cables or an extension cord? The welding cables are held into the DINSE style
connectors by set screws located under the connector cover and can be accessed by aggressively
twisting the rubber cover back and forth while pulling at the same time. A little effort may be required
the first time the connector cover is removed. If necessary, very lightly clamp the end of the connector
pin in a vise or with a pair of pliers while working the cover back until the cover pops off. The torch has
a small set screw that holds the cover in place. It acts as a wedge to hold the cover in place. It should be
loosened (not removed) and the cover slid back to access the set screw holding the cable in place.
When adding welding cable or using an extension cord make sure that the respective voltage/current
carrying capacity is sufficiently rated for carrying the maximum current of the welder over the distance of the cable. Also, whether running long or short lengths, make sure the welder is strapped
down so any “whipping” movement of the cable will not overturn the welder or jerk it out of place.
9
Section 2
GENERAL SETUP AND OPERATION
2.1 General Description, Purpose and Features.
for hot start usually range from 3 to 7 (30-70%) on the
knob’s scale.
NOTE: The hot start can blow through the metal if
the setting is too high for the given thickness of the
metal. On thin metals use a lightly penetrating rod
such as an E6013 and a low hot start setting.
PowerARC 300:
The PowerARC 300 is a compact commercial welder
that incorporates professional features such as adjustable hot start and arc force control. The arc is spatterfree and stable due to heavy duty IGBT components
and advanced inverter design.
Arc Force:
The arc force control can be adjusted to improve arc
performance and allow you to use less amperage overall and maintain penetration. It is also a useful tool
when welding out of position. The arc force control
reacts to the length of the arc. Typically when the arc
length is shortened (rod held closer to the metal), arc
voltage is lowered due to the characteristic of Constant Current design. In a transformer, this would typically reduce heat but can lead to the arc snuffing out
or even a stuck rod. With the PowerARC 300, as the
voltage drops below approximately 20V, the amps are
automatically increased in reaction to the reduced arc
length. This prevents the arc from snuffing and the
rod from sticking. Although the function of voltage is
significant in the welding process, welding is also concerned with overall wattage (VxA). The arc force function is also referred to as “dig” or “inductance” in the
industry. Pushing the electrode into the puddle will
increase the heat and penetration without the arc
going out if the arc force is adjusted correctly. If converting from welding with a transformer based welder
to an inverter welder this function will require some
practice and may feel different. Some users who have
been trained on transformers may find it counterintuitive initially, but quickly begin to appreciate the
advantage this offers. Arc force requirements vary by
electrode and even by manufacturer. Arc force is set
by feel and experience rather than a given number
and can vary by personal preference and technique.
To maintain strict control of the heat, use the lower
end of the amp range of the recommended by the
electrode manufacturer. Then, increase the arc force
setting enough to maintain the arc while using a short
arc length. This will maintain/increase penetration,
but confine the arc and heat to a smaller area. Too
much arc force may create random pops or spatter.
The welder is designed to weld with any common category of welding rod and works well with electrodes
such as E7018, E6013, E7014, E7024, 309L, and others.
It is suitable for welding in any position recommended by the electrode manufacturer.
Equipped with a dedicated reactor circuit and additional negative polarity port (labeled as E6010), the
PowerARC 300 offers improved performance and penetration with all cellulosic welding rods compared to
standard inverter designs. This feature makes the
PowerARC 300 a perfect choice for professional use
where E6010/E7010 is commonly used. The E6010
port is also recommended for use with E6011.
The unit is capable of functioning on 1 or 3 phase
standard 208-240V current, 50-60Hz. Measured current below 208V at the receptacle is not recommended. This unit should not be operated on long extension cords with undersized conductors.
Note: To operate in 6010 mode, the work clamp is
moved from the negative terminal connector to the
connector labeled “6010”. Reverse polarity (DCEP ) is
maintained. There is no need to change the electrode holder position, unless straight polarity (DCEN)
is desired for special operations with E6010 or similar
rods. If DCEN (-) is desired, then the positions of the
electrode holder and the work clamp should be
swapped. Check with the manufacturer of the electrodes for polarity recommendations for each rod.
Hot Start:
The adjustable hot start reduces rod sticking and porosity that is created while striking an arc by providing
a controlled surge of amps until the arc is firmly established. After the arc is established, the hot start terminates and the welder resumes welding with the selected amp level. The intensity of the hot start contains
more adjustability than is typically required to make
good starts. The numbered scale represents a percentage of total available Hot start amperage over and
above the main welding amperage. Useful settings
Note: Some welding techniques that are maintained
with transformer welders may not be sustainable
with the PowerARC 300 or other inverter welders. In
order to control the maximum input amps, the inverter is designed to terminate the arc (shut down output) if voltage increases over a predetermined arc
voltage at any given amp level. While this prevents
10
Section 2
GENERAL SETUP AND OPERATION
over-currents internally and limits amp draw from the
power source, it also helps to improve arc termination. When converting over from a transformer a
welder with a habit of stretching the arc too far may
find the arc will stop suddenly. Constant Current
Inverters operate on somewhat different principles
than Constant Curent transformers so some retraining
and even rethinking may be necessary by welders
who have developed an exaggerated motion using a
transformer welder. A practical example is during
the whipping motion required when welding E6010.
If the welder is accustomed to exaggerating the whipping motion required, then the arc may go out. This
usually happens when the tip of the rod is flipped too
far up vertically at the end of the “whip” and raises
the tip up further than necessary. This can be simply
avoided if the rod is stepped out further in front of
the puddle with less flipping up to draw out the arc.
cally at a nearby welding supply store.
2.3 Handling and general maintenance.
Duty Cycle and Overcurrent:
Be careful to observe the duty cycle of the welder.
Overheating may occur if the duty cycle is exceeded.
Overheating will cause the unit safety cutout to engage, subsequently interrupting output. Allow the unit
to rest while remaining switched on for 10 –15 minutes
if the safety cut out has triggered. After that, reset the
unit by cycling the main power switch on the rear.
High heat and humid conditions will also affect the
duty cycle of the welder. If the unit overheats or an
overcurrent condition is experienced, the duty cycle
light will light as well. Welding will resume once the
duty cycle light is cleared after resting and cycling the
power switch. An over current or under current condition is usually caused by dirty power conditions, over/
under voltage power supply or an internal fault. If the
overcurrent light is lit, turn the machine off and check
for wiring faults, then turn the unit back on to see if
the light has cleared. If it does not clear, contact Everlast technical support for further instruction.
2.2 Basic Overview and operation.
Package:
The PowerARC 300 includes a stick electrode holder
with cable, and a work clamp with cable. Cables are
approximately 10 ft. in length. Longer cables can be
added to electrode holder, work clamp and connectors.
The unit should be stored in a dry place for long term
storage. Humid/wet conditions can contribute to the
eventual decay of the circuitry in the machine. For
safety reasons, do not use this machine directly in the
rain or with soaked clothing or damp protective gear.
The service rating for this unit is IP21S, and is not designed for wet environment use.
Stick:
The stick function is fairly simple and straight forward.
Arc striking can be done quite easily with practice and
the hot start reduces sticking. As with any type of
welding, this takes practice. Be sure to double check
that the electrode holder cable is located in the positive terminal, and the work clamp is located in one of
the negative terminals. See page 17 for arc striking
technique and general rod size selection. Using too
much hot start or arc force control can result in burn
through. Using too little will result in poor arc performance and rod sticking.
Make sure that the unit’s cooling fan and exhaust
vents are kept free of obstruction. Before every operation, inspect unit for unexpected obstructions such as
insect and vermin nests. Once a month, or as needed,
clean the machine thoroughly inside and out with compressed air. Before removing the covers however, unplug the welder for 30 minutes to allow the internal
capacitors to discharge to prevent shock, injury and
even death. Afterwards, open the units by removing
the rear plastic cover and the metal cover only. Do not
remove the front cover. Do not remove circuit boards
unless authorized. Check all plugs and connections for
tightness before replacing the covers. Do not pinch
any wires when reinstalling the covers. Wear safety
glasses/goggles to prevent eye injury from flying particles that may get dislodged while cleaning with compressed air. Do not concentrate compressed air on the
skin or serious injury may occur.
TIG:
Although the PA 300 is sold as a DC Stick welder, the
unit can be used as a scratch start DC TIG welder. The
unit though does not provide a lift start or HF circuit
for starting the arc, so a scratch start method must be
used to strike the arc. When using for scratch start TIG,
be sure to turn the arc force and hot start controls to
the minimum setting. Contact Everlast for an optional
scratch start TIG package if desired, or source one lo-
11
Section 2
GENERAL SETUP AND OPERATION
PowerARC 300
Front Panel View
ON INDICATOR
DIGITAL AMP METER
DUTY CYCLE INDICATOR
AMP/CURRENT CONTROL
OVER CURRENT INDICATOR
ARC FORCE CONTROL
HOT START CONTROL
NEGATIVE (-) STANDARD CONNECTOR
6010
POSITIVE (+) CONNECTOR
NEGATIVE (-) 6010 CONNECTOR
Note: The unit cannot strike an arc if both the electrode holder and the work clamp are engaged in the two
negative (left and middle) ports. To work, either the electrode holder connector or the work clamp connector must
be engaged in the far right positive (+) connector with the other engaged in one of the two negative ports. Most
electrodes require reverse polarity. To maintain reverse polarity (also known as positive polarity or DCEP+) the
work clamp should be engaged in one of the two negative (-) ports, and the electrode holder should always be in
the positive port. When required, negative polarity may be used, and the electrode holder should then be engaged in one of the two negative ports and work clamp will be moved to the positive port. Consult electrode manufacturer data and/or instructions for polarity recommendations and specific amp requirements. Electrode instructions are usually found attached to electrode container or box. If not, consult the electrode manufacturer’s online
resources and specifications for more specific information.
12
Section 2
GENERAL SETUP AND OPERATION
PowerARC 300
Rear Panel View
MAIN POWER SWITCH/BREAKER
1~220 V
OR
3~220v
GROUND BOLT
POWER CORD
Even though the unit is grounded by the main ground wire to the chassis, an additional bonded ground
may be necessary in some locations to comply with code. Consult a locally licensed electrician concerning the any requirement of this connection and its proper use and application.
13
Section 2
GENERAL SETUP AND OPERATION
PowerARC 300
Wiring
1 PHASE 220/240 V SHOWN. FOR 3-PHASE 220/240 VUSE, CONSULT LICENSED ELECTRICIAN
GREEN GROUND (220/240V 1 and 3 phase)
L1,BLACK; HOT(240V 1 or 3 phase)
L2,WHITE; HOT (240V 1or 3 phase)
GAS
INLET
NEMA 6-50P
1~220 V
OR
3~220v
L3,RED; HOT(240V 3 phase only)
3 PHASE WIRE COLORS FOR POWERARC 300
GREEN: GROUND
RED:L3
WHITE: L2
BLACK: L1
FULLY TAPE RED WIRE SO THAT IS IS OUT OF THE WAY AND COVERED FOR
SINGLE PHASE USE! RED WIRE IS FOR 3 PHASE 220/240 V USE ONLY!
HF
PLUG IS NOT INCLUDED! IT MUST BE SUPPLIED BY CUSTOMER.RECOMMENDED
PLUG IS A NEMA 6-50P FOR SINGLE PHASE USE. CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE MODIFYING EXISTING CIRCUITS OR INSTALLING THE WELDER. See page 20 for further details and explanation.
IMPORTANT:
EVERLAST IS NOT RESPONSIBLE FOR DAMAGE OR INJURY RESULTING FROM IMPROPERLY WIRED WELDERS!
Fe, Cu
Even though the unit is grounded by the main ground wire to the chassis,
an additional bonded ground may be necessary in some locations to
comply with code. Consult a locally licensed electrician concerning the
any requirement of this connection and its proper use and application.
14
Section 2
GENERAL SETUP AND OPERATION
PowerARC 300
STICK E6010 WELDING CONFIGURATION
6010
WORK 6010(-)
TORCH (+)
NOTE: Also, suitable for use with E6011 and other electrodes with cellulose based flux such as E7010.
15
Section 2
GENERAL SETUP AND OPERATION
PowerARC 300
STANDARD WELDING CONFIGURATION
6010
WORK (-)
NOTE: Use this configuration with most standard electrodes except ones with cellulose flux such as E6010/6011.
TORCH (+)
IMPORTANT: Most electrodes require DCEP (+). Always consult electrode manufacturer directions before using DCEN (-).
16
Section 2
GENERAL SETUP AND OPERATION
STICK OPERATION TECHNIQUE
STARTING METHODS
Scratch/Match Method
Tapping Method
1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program.
2. Make sure electrode holder is hooked into the positive connector and the work clamp is hooked
the negative connector. If welding with E6010 or a electrode (rod) with a cellulose based flux, connect the work clamp to the 6010 port.
3. Select the amps desired. Use the electrode diameter selection chart below to determine the approximate range of amps suitable for the rod size selected. Consult the welding electrode manufacturer’s recommendation for proper amperage range. Each manufacturer has specific recommendations for its electrodes regarding amp range, though a general range can be determined.
4. Strike the arc with either the tapping method or the match strike method. Beginners usually find
that the match strike method yields best results. Professionals tend to gravitate toward the tapping
method because of its placement accuracy, which helps prevent arc striking outside of the weld zone.
DC STICK (SMAW) OPERATION GUIDE
METAL THICKNESS
ELECTRODE SIZE
WELDING AMPS
< 1 mm/.040”
1.5 mm/ 1/16”
20-40
2 mm/.080”
2 mm/3/32”
40-90
3 mm/ 1/8”
3.2 mm/1/8”
80-150
4-5 mm/ 3/16”
3.2-4 mm/ 1/8”-3/16”
100-170
6-12 mm/ 1/4”-1/2”
4–5 mm/ 3/16”
130-250
>12mm/>1/2”
>5mm/3/16”
200-300
17
Section 3
Trouble shooting
TROUBLE:
CAUSE/SOLUTION
Machine will not turn on
Check cords and wiring in the plug. Check circuit
breaker. Contact Everlast Technical Support to
check and replace main unit fuse.
Machine runs, but will not weld and/or Check for sound work clamp connection. Make
sure work/Torch cable is securely fastened to
Red LED is on.
DINSE connector. Check circuits for over/under
voltage. Dirty power from generator. Internal fault
or incorrect wiring. (LED does not have to be lit if it
is incorrectly wired). Check wiring in plug/
receptacle if unit switches on but produces light
spark or no spark.
Reset main power switch if overcurrent light is on
after cool down period. Contact Technical Support if
if light is still on after checking/correcting the issue.
Arc has difficulty establishing, welding rod sticking
Wet welding rods. Too low of amperage. Too high
of amperage. Use fresh rods. Adjust amps. Wrong
polarity. Hot start/Arc force too low.
Welding rod is rapidly consumed.
Too small of welding rod. Too high of amperage
setting. Wrong polarity.
Porosity of the Weld. Discolored
weld color. Too much spatter.
Too much arc force control. Too long of arc length.
Too high of amps.
Weld quality is poor, Cold lapped
weld, unstable arc.
Clean paint/rust from weld. Make sure work clamp
has good contact. Too low of amps
LED illuminates yellow/green. Machine runs, but no weld power.
Duty cycle exceeded. Allow machine to cool. Reset main power switch after full cool down period.
Make sure fan is not blocked. Cycle power switch
after 10-15 minutes of cooling.
Slight whine or squeal to arc.
Normal. Sound may vary.
Circuit breaker trips. Internal Fuse
blown.
Wiring fault. Too small of wire or circuit breaker.
Welder internal short. Contact Everlast Technical
Support before resuming use.
18
Section 4
Kit contents
PowerARC 300 Box Contents
Qty.
Description
1
Tong style Stick electrode holder, 10ft cable with DINSE 50 style connector
1
Steel work clamp, 10ft cable with DINSE 50 style connector
1
PowerARC 300 DC Stick Inverter welder
1
Manual
NOTE: Kit contents, appearance, size and quantity are subject to change without notice.
19
Remember that these important terms refer to the same thing and are generally interchangeable:
Shielded Metal Arc Welding = SMAW= Stick Welding= MMA = Manual Metal Arc Welding
DCEP = Direct current, electrode positive = Reverse polarity = Positive polarity(+) = Torch in Positive
DCEN = Direct current, electrode negative (-) = Straight polarity = Negative polarity (-) = Torch in Negative
Stinger = Electrode holder = Stick Holder = Torch
Welding rod = Electrode = Stick
Arc force = Dig = Inductance = Arc response
Why doesn’t the PowerARC 300 come with a power plug? The PowerARC 300 is both a single phase and three
phase machine. This means it can work in home shops and industrial factories with different power supplies. Single
phase welders in North America use only three wires for 240V operation with two 120V lines arranged out of phase
(measuring 240V between the hot legs and 120V to ground) with a third wire serving as a ground. No neutral is
needed. This differs from a range or dryer cord where a return path is needed for a 120V circuit that may be also
used in a range or dryer circuit. Wire colors used for a dryer or range connection do not match up to the standard
wire colors used in wiring a welder. In three phase, 4 wires are used, with 3 hot wires (again, out of phase with each
other) are used. These should measure a nominal 240V between any twp hot legs, though to ground measurements
on a hot leg will be less. Once again, only one wire is used for a ground. No neutral exists in a 3 phase circuit for a
welder either. Welding equipment that can operate on both single and three phase voltage do not have a
“standard” plug that can be used for both single and three phase operation, so the unit must be wired specifically
for each phase. Therefore, when wiring for single phase, one wire will not be used. If using it for permanent single
phase operation, a separate, dedicated welder circuit is suggested. Wiring into existing range or dryer connections
is not recommended as these utilize a neutral wire and confusion over wire colors and numbers can be created
causing the welder to malfunction. The possible issues with wire confusion and mismatch require professional
oversight so always be sure to consult/hire a licensed electrician to comply with local codes and for wiring safety.
Do not connect unit to 460/480V 3 phase unless unit is special ordered for 460/480V use!
NOTES:
20
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