PowerPro 256D
EVERLAST
POWERPRO 256D
TIG/Stick/Plasma Digital IGBt inverter welder/cutter
CC
GTAW-P
SMAW
PAC
IGBT
1
~
PHASE
AC/DC
Operator’s Manual for the PowerPro 256D
Safety, Setup and General Use Guide
Rev.1 0 010520-15
everlastwelders.com
1-877-755-9353
Specifications and Accessories subject to change without notice.
329 Littlefield Ave. South San Francisco, CA 94080 USA
Table of contents
Section……………………………………………………………..Page
Letter to the Customer ………………...…………………. 3
Everlast Contact Information……………………………. 4
Safety Precautions………………………………………….... 5
Introduction and Specifications…………………….….. 9
Unit Specifications……………………….…………………… 10
General Overview…………….…..………………………….. 11
General Use and Care………...…………………………….. 11
Quick Setup Guide, TIG Torch/Cooler Connection 12
Quick Setup Guide, Plasma Connection.…..……….. 13
Quick Setup Guide, Stick Polarity and Connection 14
Quick Setup Guide, Rear Connection for Plasma… 15
Quick Setup Guide, Rear Connection for TIG..……. 16
Front Panel Features and Controls…………………….. 17
Rear Panel Features and Controls……………………... 22
Welder Function Summary and Explanations……. 25
Tungsten Preparation………………………………………... 31
High Frequency Start TIG Operation…………………… 32
Stick Operation……………………………………………………33
Plasma Cutting Function and Operation……………...34
Recommendations for Polarity/Amps/Tungsten…. 38
Expanded View of TIG torch……….…….……….…….… 39
PowerPro 256d Plasma Torch iPT 60………….………..40
7 Pin Connector Pin-out for Pedal or Amptrol…..…41
Basic Troubleshooting….………………………………….... 42
Plasma Troubleshooting……………………………………...43
Trouble Codes……………………………………………………..40
Customer notes…………………………………………………..41
NOTE: Product Specifications and features are subject to change without notice. While every attempt has
been made to provide the most accurate and current information possible at the time of publication, 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 with the terms and conditions of the warranty.
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 during off hours, or in the event 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 can’t assume anything, even with experienced users, and
must cover all aspects to properly diagnose the problem. Depending upon your issue, it is advisable to have basic tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive
test meter with volt/ohm 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____________________________
Contact Information
Everlast US:
Everlast consumer satisfaction email: sales@everlastwelders.com
Everlast Website: www.everlastwelders.com
Everlast Technical Support: support@everlastwelders.com
Everlast Support Forum: www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
11am-4pm PST Sat. (Seasonal)
Tech Support: EXT 207
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: 905-637-1637 9am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: 1-905-639-2817
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
(02) 9999 2949
Port Macquarie: 2B Pandorea Place Port Macquarie
(02) 8209 3389
After hours support: 0413 447 492
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. That is
the reason we offer technical support to assist you with your needs should an occasion arise.
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 in the safe operation and maintenance of
your Everlast product. It is not exhaustive however. This manual is provided to assist the operator with the information needed to be able to enjoy the best and safest operating experience.
Overall, welding and cutting require experience and common sense to obtain the best results in
the safest manner. As thorough as this welding manual may be, it is no substitute for either.
Welding takes time, patience and training to perfect. This manual is not a substitute for professional training or experience. Exercise extreme caution and care in all activities related to welding and cutting. Your safety, health and even life depends upon it. If you are in doubt of your
skills or capability, don’t attempt to use this unit. Stop and consult a welding professional.
Please carefully read this manual before you operate your Everlast unit. This manual is not
written only for the use of the unit, but to assist you in obtaining the best performance out of
your unit. Do not operate this welder 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 on this unit
or do not understand how a feature of function operates, please contact Everlast Support.
The warranty does not cover improper use, maintenance or consumables. Torches and accessories are covered under a separate warranty. Do not attempt to alter or defeat or otherwise render any piece or part of your unit unserviceable, 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 a
licensed electrician if disturbance is noted. Sometimes, improper wire routing or poor shielding may be the cause. Keep in mind HF interference is not easily predictable or identifiable.
HF can interfere with pacemakers and other medical devices. 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, 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
Introduction and Specifications
PowerPRO 256D
256D: Water-Cooled 20 series 12 ft.
(Style and series subject to change)
iPT 60 Plasma Torch
12 ft.
Argon Regulator
Work Clamp
Consumable Kit
(Does not include Tungsten)
Foot Pedal Assembly
Stick Electrode Holder
NOTE: Accessory appearance and quantities are subject to change without notice.
9
Section 1
Introduction and Specifications
PowerPro 256D Specifications
PowerPro 256D
Specification
Processes
AC/DC GTAW-P/DC SMAW/PAC
Inverter Type
Digitally controlled IGBT
Minimum/Maximum Rated Output TIG
DC: 3A/10.1V –250A/20 V
AC: 5A/10.2V-250A/20V
Minimum/Maximum Rated Output Stick
5 A/20.2 V - 200 A/28 V
Minimum/Maximum Rated Output Plasma
20A/88V-60A/104V
Start Type
TIG: HF Solid State, Plasma: Blow-back type
TIG Duty Cycle @ Rated Amps/Volts
60% @ 250A/ 20 .0V
100% @ 200A/ 18 .0V
Stick Duty Cycle @ Rated Amps/Volts
60% @ 200A/ 28.0V
100% @ 160A/ 26.4V
Plasma Duty Cycle @ Rated Amps/Volts
60% @ 60A /104V
100% @ 50A /100V
OCV (U0)
70V
Voltage Input (U1)
220/ 240V; 50/60Hz 1 Ph
Maximum Inrush Amps (I1MAX)
42A @ 220V
Maximum Operating Amps (I1EFF) (Rated effective)
35A @ 220V
Gas Pre-Flow /Post Flow Time
0-25Seconds/ 0-50 Seconds
Start Amps/End Amps
DC: 3-250A AC: 5-250A
Up/Down Slope
0-25 Seconds/0-25 Seconds
AC Frequency Control
20-250 Hz
AC Balance Control
10-90% of Electrode Positive (EP)
AC Wave Form
Advanced Square, Soft Square, Triangular, Sine
Std. Pulse Frequency Hz (Pulses Per Second)
DC: .1-500 Hz
AC: Adv. Sq. 1-250Hz, 0ther wave forms: .1-10Hz
Advanced Pulse Frequency (For AC use only)
.1-10Hz (All wave forms)
Pulse Amps (Ratio) (Std. and Advanced)
1-100%
Pulse Time On (Balance) (Std. and Advanced)
10-90%
Stick Arc Force Control
0-100%
Stick Hot Start Time
0-2 Seconds
Stick Hot Start Intensity
0-100% over welding amps
Minimum Water Ingress Protection Standard
IP21S
Efficiency
>80%
Cooling Method
Full Time High Velocity Fan
Dimensions (approximate)
18” H X 10” W X 25” L
Weight (Bare Unit)
65 lbs
10
Introduction and Specifications
Section 1
General overview: The Everlast PowerPro 256D is intended to
IMPORTANT: Before opening the unit for any reason,
be a reliable digitally controlled TIG/Stick/Plasma welding/cutting make sure the unit has been unplugged for at least 10
unit ideal for portable repair service, and for general prototyping/ minutes to allow time for the capacitors to fully disone-off fabrication duties. This unit includes the following key
charge. Severe shock and/or death can occur.
features:
A. Digitally controlled IGBT components improve reliability. The modular design of the main internal component are an improvement over the older analog series.
B. Full bridge rectifier design features soft switching technology which further extends IGBT component life and
its performance capabilities.
C. Improved HF design offers more reliable arc starts,
even at lower amperages.
D. Features automatic over-voltage, over current, duty
cycle (over-heat) and low air pressure protection.
E. The adjustable wave form design allows the user to
customize the welding arc properties for welding aluminum in different applications.
F. Arc force control, hot start time and hot start intensity
helps improve Stick welding performance.
G. New, improved design offers more intuitive adjustments, and provides better panel protection.
H. Advanced AC pulse mode is an exclusive feature which
helps to improve capability on thin aluminum and extends the top capability while welding while welding in
AC. Standard Pulse may be used in either AC or DC
modes.
Do not restrict air flow or movement of air around the
welder. Allow a buffer distance of 18” from all sides if
possible. Do not operate the welder immediately in the
weld area or the force of the fan will cause welding issues
such as unstable arc, or porosity. Do not mount in areas
that are prone to severe shock or vibration. Lift and carry
the welder by the handle.
Do not direct metallic dust or any dirt intentionally toward the machine, particularly in grinding and welding
operations. Make sure the control panel is protected
from damage during welding and cutting operations by
flipping down the clear protective cover.
Duty Cycle. The duty cycle rating of the PowerPro 256D
is rated at 60% for TIG, Stick and Plasma cutting @ 40° C.
This means that the unit can be operated continuously at
the maximum amps for the 60% percent of time out of 10
minutes (in this case 6 out of 10 minutes) without a cool
down break. For the remainder of the 10 minute time
period, the welder should rest to achieve proper cooling.
If the unit overheats and surpasses the duty cycle threshold temperature, the unit will cease welding/cutting and
the overheat indicator will light up. If this happens, leave
the unit powered on to cool down while the fan continBasic Inverter design
ues to run. Welding in dirty, humid, or hot conditions can
General Use and Care: The Digital PowerPro 256D weldaffect negatively duty cycle. Do not shut down the welder
er/plasma cutter is uniquely designed for routine use peruntil it has safely cooled for at least 15 minutes. Once the
forming on-the-spot repairs or in other similar non producwelder has sufficiently cooled, turn the power switch off
tion tasks. It provides function and convenience in these
and then back on to clear the code and reset the unit.
situations. This unit is not designed, however, for use in
production welding or cutting operations or similar indusHF Start. The welder uses High Frequency to start the
trial applications. Care should be taken to keep the unit
TIG arc. A slight buzz, or hiss may be heard immediately
out of direct contact with water spray. This unit is water
upon start as the HF energizes. A bright blue light may be
ingress rated for IP21S, which rates it for light dripping
emitted from the front or side panel as the HF spark
contact with water. It is a good idea to remove the welder
attempts to energize the arc. This is completely normal.
from the vicinity of any water, heavy, condensing fog or
other type of moisture source to reduce the possibility of
This manual has been compiled to give an overview of
electrocution or shock. Never operate in standing water.
operation and is designed to offer information centered
around safe, practical use of the welder. Welding is inEvery 1-2 months, the welder should be unplugged,
herently dangerous. Ultimately, only the operator of this
opened up and carefully cleaned with dry, compressed air.
welder can ensure that safe operating practices are being
Regular maintenance will extend the life of the unit. Failfollowed, through the exercise of common sense practices
ure to keep the unit clean internally will damage and shortand training. Do not operate this machine until the manuen lifespan of the components. Remove the rear cover
al has been thoroughly read and understood. If you do
and then the metal cover to open. Do not remove the
not have the skill or knowledge to safely operate this mafront plastic cover. Opening the case to clean the welder
chine, do not use it until further training is received.
will not void the warranty. Do not operate with the main
cover off. Isolate the unit from vibration and impacts.
11
Section 2
QUICK SETUP AND USE GUIDE
QUICK SETUP GUIDE: TIG CONNECTIONS
TORCH (-)
WORK (+)
GAS
CONTROL
35 SERIES CONNECTOR
35 SERIES CONNECTOR
AIR-COOLED TORCH
GAS (Ar)
9/17 SERIES TORCH
CONTROL
CONTROL
26 SERIES TORCH
FOOT PEDAL
35 SERIES CONNECTOR
GAS (Ar)
NOTE: Torch switch and foot pedal control
cannot be connected at the same time.
CONTROL
WATER-COOLED TORCH
18/20 SERIES TORCH
COOLANT IN FROM TORCH (RED COUPLER)
WATER COOLER
INPUT
!
WA
OUTPUT
COOLANT OUT FROM COOOLER (BLUE COUPLER)
12
THE ARGON GAS LINE SHOULD BE TAGGED AS “Ar”. IF NOT, TAKE DRY COMPRESSED AIR
AND GENTLY BLOW THROUGH THE LINES TO DISCOVER WHICH LINE EXHAUSTS
THROUGH THE TORCH AND WHICH EXHAUSTS THROUGH THE RETURN LINE. ON SOME
BRANDS OF TORCHES, THE WATER LINES ARE COLOR CODED: BLUE FOR COOL WATER
SUPPLY AND RED FOR HOT WATER RETURN. COOLER FITTINGS SHOULD BE COLOR
CODED BLUE AND RED AS WELL.
CAUTION: EVERLAST TORCHES ARE EQUIPPED WITH A DIFFERENT COLOR ARRANGEMENT. IF THE TORCH DOES NOT HAVE RED AND BLUE LINE, THEN THE COLOR CODE
DOES NOT APPLY. FOLLOW THE HOSE DIAGRAM ABOVE, AND TEST THE TORCH BY
BLOWING AIR THROUGH AS DESCRIBED ABOVE IF YOU ARE IN DOUBT. IF WATER
BEGINS TO EXHAUST FROM THE TORCH AFTER CONNECTING THE UNIT, STOP IMMEDIATELY AND CHECK THAT THE LINES ARE CONNECTED TO THE CORRECT FITTING. DO NOT
OPERATE WATER COOLED TORCHES WITHOUT WATER FOR ANY REASON.
Section 2
QUICK SETUP AND USE GUIDE
QUICK SETUP GUIDE: PLASMA CONNECTIONS
iPT 60 TORCH
WORK (+)
TORCH (-)
GAS
CONTROL
35 SERIES CONNECTOR
35 SERIES CONNECTOR
AIR
NOTES:
1)
2)
3)
4)
5)
6)
7)
8)
For safest operation, be sure 2T is selected. Do not attempt to use the foot pedal to control the amps.
Do not attempt to use the plasma torch in any other mode or test in any other mode with torch connected.
Attempt to operate only with sufficient air pressure. If pressure is too low, the unit will cease output and the unit will code
“806” to indicate the air pressure is too low.
See torch manual included in this manual for best pressure settings and parts identification.
Do not exceed 90 psi air supply pressure from compressor or failure or leakage of internal line components may result.
Do not use with an oiler or with an air line that has had oil run through the line.
Adjust torch operation pressure to 72 psi (5 bar) for best results while post flow is flowing.
When using lower amperage levels, the nozzles will need to be changed out for ones with a smaller diameter orifice. Everlast is an OEM supplier of the torch but not the torch manufacturer. Smaller diameter nozzles are available through authorized distributors of the Tecmo/Innotec PT/iPT60 torches or contact Everlast to purchase direct. (Not all parts or consumables listed may be sold or serviced individually by Everlast.)
STOP: Do not fire the torch continuously without attempting to make a cut. Doing so will keep the pilot arc
engaged and will drastically shorten the life of the consumables. The Pilot arc should only be used to initiate the arc
to start a cut. Always make sure the work clamp is directly connected to a deoxidized, unpainted location on the part
being cut. Use a grinder to ensure proper contact is being made between the work clamp and the metal if necessary.
WARNING: Plasma cutting uses a high voltage, high temperature arc. Do not touch any part of the consumable while cutting or with the torch energized even if the arc is not present! Always switch the unit off while
changing consumables. Do not disable the yellow safety cover over the torch switch.
CAUTION: Never attempt to use the torch while hooked up to the positive (+) connector or damage may occur
to the consumables and/or the torch. Always verify correct torch polarity before each use. Do not change processes
while the Plasma torch is connected or severe damage may result to the machine and torch.
13
Section 2
QUICK SETUP AND USE GUIDE
QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS
GAS
CONTROL
TORCH (+)
WORK (-)
NOTE:
Most electrodes require that the torch be connected to positive terminal as depicted above. This is considered
“Electrode Positive” or “Reverse” polarity. A few electrodes are rated for both positive and negative polarity (also
referred to as “Straight” polarity). The rating may vary from manufacturer to manufacturer and is dependent upon
the specific formulation of the electrode chemistry. Negative polarity is rarely used but can be useful in some circumstances to control burn through and speed up metal deposition. To determine the electrodes’ polarity capability be sure to consult the manufacturer’s information, which is usually found on or in the container with the rods or
on the manufacturer’s website. If no polarity information is found, assume it is rated for electrode positive only.
14
Section 2
QUICK SETUP AND USE GUIDE
QUICK SETUP GUIDE: REAR CONNECTIONS FOR PLASMA OPERATION
Compressor and Dryer Diagram
Caution: Do not exceed 90 psi from air compressor!
Use with compressors capable of a minimum of 5.3 cfm
at 90 psi and with at least 25 gallon tank or larger.
Compressor and Air hose w fittings
(Customer Supplied)
Regulator Assembly with builtin water trap
and dirt filter (Included)
CLAMP
1/4” Automotive Universal style
quick connector (Included)
1~220 VAC
Air Dryer/Oil Filter
(Customer Supplied)
GAS
INLET
3
1
5
1~220 V
2
4
NOTE: WHEN ASSEMBLING AIR REGULATOR NOTICE THE MARKING S THAT ARE
STAMPED ON TOP OF THE REGULATOR HOUSING FOR AIR FLOW DIRECTION. AIR
FLOW DIRECTION WILL BE NOTED AS IN/OUT OR BE STAMPED WITH A SMALL ARROW
FOR AIR FLOW DIRECTION. THE QUICK CONNECT 1/4” MALE AUTOMOTIVE COUPLING
SHOULD BE MOUNTED ON THE SIDE OF THE REGULATOR WITH “IN” OR THE ARROW
POINTING TO THE MIDDLE OF THE REGULATOR. IF PRESENT, REMOVE BRASS PLUG IN
CENTER AND INSTALL THE PRESSURE GAUGE. USE A LIGHT WRAPPING OF THREAD
TAPE TO PREVENT LEAKING AROUND THE PRESSURE GAUGE THREADS IF NECESSARY. USE THREAD TAPE SPARINGLY TO PREVENT SOLENOID LEAKS ANDCLOGGING.
NOTE: A SEPARATE AIR DRYER BETWEEN THE AIR COMPRESSOR AND REGULATOR ASSEMBLY MUST BE INSTALLED. IT SHOULD BE INSTALLED AS
CLOSE TO THE WELDER AS PRACTICAL. THIS IS A CUSTOMER SUPPLIED ITEM. THIS WILL REDUCE CUTTING ISSUES SUCH AS SPITTING, POPPING AND
RAPID CONSUMABLE WEAR. THE REGULATOR/FILTER THAT IS INCLUDED IS NOT SUFFICIENT TO REMOVE ALL MOISTURE. IT SERVES ONLY AS A WATER TRAP AND FINE SEDIMENT FILTER. ANY AIR COMPRESSOR SYSTEM WILL PRODUCE AT LEAST SOME MOISTURE REGARDLESS OF HUMIDITY LEVELS AND ENVIRONMENT. DAILY DRAINING OF THE AIR COMPRESSOR SUPPLYING AIR TO THE PLASMA CUTTER IS RECOMMENDED . THE AIR SUPPLIED TO THE PLASMA CUTTER SHOULD BE OF SIMILAR QUALITY USED FOR AUTOMOTIVE PAINTING. DIFFERENT STYLES OF DRYERS ARE AVAILABLE.
THE MOST INEXPENSIVE AND COMMONLY AVAILABLE IS THE REPLACEABLE DESSICANT TYPE USED FOR AUTOMOTIVE PAINTING. DAMAGE DONE TO
THE TORCH AND THE PLASMA CUTTER (INCLUDING BUT NOT LIMITED TO: SHORTING, CORROSION, AND DETERIORATION OF INTERNAL LINES AND
COMPONENTS) AS A RESULT OF EXCESS MOISTURE OR IS NOT COVERED UNDER THE WARRANTY. ADDITIONALLY, A FILTER SHOULD BE INSTALLED IN
-LINE OR AT THE COMPRESSOR THAT WILL FILTER ANY EXCESS OIL OR OIL BLOW-BY FROM THE LINE IF NECESSARY. DO NOT USE WITH OILING SYSTEMS DESIGNED TO AUTOMATICALLY LUBRICATE AIR TOOLS. OIL WILL DAMAGE THE TORCH AND CONSUMABLES AS WELL. DAMAGE DONE TO THE
CUTTER OR THE TORCH BY OIL IS NOT COVERED UNDER THE WARRANTY EITHER. IT IS ADVISABLE TO USE THE PLASMA CUTTER WITH A NEW AIR
HOSE/LINE THAT IS FRESH WITHOUT MOISTURE OR LUBE CONTAMINATIONAND DEDICATE IT FOR PLASMA USE ONLY. IF THERE IS AN AIR PRESSURE
DROP GREATER THAN 5-10PSI FROM THE COMPRESSOR, OR AIR FLOW IS SUSPECTED TO BE INSUFFICENT, INCREASE TO A LARGER SIZE EXTERNAL
DRYER/FILTER. FAILURE TO USE A DRYER/FILTER IS A LEADING CAUSE OF PLASMA CUTTING AND CONSUMABLE WEAR ISSUES.
15
Section 2
QUICK SETUP AND USE GUIDE
QUICK SETUP GUIDE: REAR CONNECTIONS FOR TIG / WIRING
(US/Canada)
SUPPLIED PLUG IS A NEMA 6-50P, THE STANDARD PLUG FOR MOST 1 PHASE 240 V WELDERS IN THE US AND CANADA.
220 V WATER COOLER RECEPTACLE. Do not connect any other device!
GREEN GROUND (220/240V 1
1~220 VAC
L2,WHITE; HOT
L1,BLACK; HOT
NEMA 6-50P
SWAP TUBING!
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE
RE-WIRING YOUR WELDER OR ATTEMPTING TO MAKE ANY ELECTRICAL CONNECTION.
GAS
INLET
CLAMP
NOTE : The PowerPro 256D shares the same connection/input point
for the TIG shielding gas and for the Plasma air input. This requires
swapping the TIG and Air input hoses at the lower connection point
when changing processes. Do not run argon the argon line through
the air regulator. A manifold system may be made from either a T
configuration of two ball valves or a Y valve( both customer supplied)
to switch between the plasma air input and TIG shielding gas as
needed without disconnecting and reconnecting the gas/air lines
every time the process is changed. If no switching valve or manifold
system is used, then you must manually change the input supply
tubing every time you change over to another process.
NOTE: LITERS/MINUTE (lpm)
CO2
HF
EVERLAST
NOTE: Use Ar or Ar/He only. Do not use more than 25% He in the Ar/He gas mix.
Fe, Cu
NOTE: TO PREVENT STRAY HIGH FREQUENCY INTERFERENCE, THIS UNIT PROVIDES AN ADDITIONAL GROUNDING POINT AT THE REAR OF THE UNIT. IT SHOULD BE
DIRECTLY GROUNDED THROUGH A SEPARATE WIRE TO AN OUTSIDE METAL ROD DRIVEN IN THE GROUND. THIS HELPS PREVENT BLEEDBACK OF HF INTO THE POWER GRID, AND HELPS MUTE HF INTERFERENCE. ADDITIONALLY, ALL SURROUNDING METAL OBJECTS SHOULD BE GROUNDED INCLUDING THE TABLE, PIPES, WALLS
ETC. TO PREVENT ELECTRICAL INTERFERENCE WITH OTHER CIRCUITS. DO NOT COUPLE THIS WIRE TO THE GROUND PROVIDED IN THE ELECTRICAL CIRCUIT.
16
Section 2
QUICK SETUP AND USE GUIDE
FRONT PANEL FEATURES AND CONTROLS POWERPRO 256D
1. PROTECTIVE COVER
2. MAIN CONTROL PANEL
GAS OUTLET
CONTROL
3. POSITIVE (35 SERIES)
6. NEGATIVE (35 SERIES)
4. GAS QUICK CONNECT (9mm)
5. TORCH/PEDAL CONTROL
17
Section 2
QUICK SETUP AND USE GUIDE
FRONT PANEL FEATURES AND CONTROLS POWERPRO 256D
POWERPRO 256D
PARAMETERS
PURPOSE
1. Protective Cover
N/A
Clear hinged cover protects panel from damage. Keep closed during welding operations.
2. Main Control Panel
Digital
The main control features digital adjustment. It offers features that include Easy
Start Up, Pulse, Advanced AC pulse, Stick welding feature, VRD Stick welding
feature, Stick Hot Start, Arc force control, Lift start Tig, HF start TIG, Plasma Cutting, 2T/4T/Pedal/Amptrol Control, and error code diagnosis.
3. Positive Connector
DINSE 3570mm²
Location of the positive terminal. This is a standard 35 series connector. For Stick:
Torch Connection (most electrodes). For TIG: Work Clamp Connection. For Plasma Cutting: Work Clamp connection
4. Gas Outlet Quick Connect
9mm
Connects the gas to the TIG torch and Plasma torch To connect: Push the torch
fitting into the connector until the collar slides forward with a click. To Release:
Slide the outer collar back and remove the fitting.
5. Control Connector
7 Pin
(Panasonic
type)
Connect the foot pedal , amptrol or torch switch to this socket to control the welder. Only one control connector can be plugged in at one time. If the torch has a
torch switch feature or hand amptrol feature, tie the loose connector back or leave
it hanging while using the pedal.
7. Negative Connector
DINSE 3570mm²
Location of the negative terminal. This is a standard 35 series connector.
Stick: Work clamp Connection. TIG: Torch connection. Plasma: Torch connection
18
Section 2
QUICK SETUP AND USE GUIDE
FRONT PANEL FEATURES AND CONTROLS POWERPRO 256D
23
24
1
23a
22
2
21
6
12
5
3
7
11
8
4
13
14
10
9
18
15a
19
16
15b
17
20
15c
POWERPRO 256D
PARAMETERS
PURPOSE
1. Memory Function
1-9
This unit has 9 programs which allow the operator to select parameters then save the settings
to the selected program channel. To operate, use the selector button to select the desired
program number where the program is to be stored. The red select light will be lit, indicating
that the welder is in the programming mode. Enter the desired program parameters. After all
parameter changes have been made, press the selector button and hold for 3 seconds and
release. The green save button will light, indicating the function has been saved. After releasing the button, it will take approximately 2 seconds for the save light will go out. The unit will
then default back to the red select light.
NOTE: Any additional adjustments made after pressing “ Save” will need to be resaved by
pressing and holding the save button again. Remember this before turning the unit off as last
unsaved settings will be erased. The unit has no default settings other than “Easy Start”.
2. Easy Start Up Menu
Normal, AC,DC
In TIG mode the welder features two Easy Start Up modes, one for AC and one for DC. The
Easy Start Up features for AC and DC have been pre-programmed with parameters that are
generally usable in most situations. Most parameter adjustments are blocked and are non
adjustable in these modes. Amperage, and control functions are adjustable. Select Normal to
allow standard setup. This feature is intended for quick welds, repairs or novice use.
3. Pre-Flow
0-25 Seconds
Pre-Flow sets the gas flow time before the arc starts after the trigger or pedal is pressed. This is
used to purge the torch and flood the weld area with shielding gas so the arc start is stable and
weld is free from porosity. Use enough time so that the first “blast” of argon has time to settle.
(about .3-.5 seconds) Pre-flow delays the arc start by the amount of time selected.
4. Start Amps
5-250 A (AC/DC)
Serves as the 2T/4T beginning arc start amp value while using the torch switch, pedal or
amptrol. Allows the arc to be started at a different value than the selected maximum or minimum welding amps while using the torch switch, foot pedal or hand amptrol. Typically used to
start the weld puddle more quickly/slowly. This feature is usually turned to the minimum amp
setting (5 amps) while the foot pedal is in use. However, It can be used to create a “hot” TIG
start with the pedal, or used to improve arc starting.
19
Section 2
QUICK SETUP AND USE GUIDE
FRONT PANEL FEATURES AND CONTROLS POWERPRO 256D
POWERPRO 256D
PARAMETERS
PURPOSE
5. Upslope*
0-25 Seconds
Upslope ramps up the amps from the start amp value to the welding amp value while
starting the weld puddle. For best operation, value should be set to 0 with foot pedal in
use. If used with an hand amptrol, without a separate switch to control slope in 2T/4T
mode, then the upslope should be also be set to 0. If slope is set while in use with the foot
pedal, delayed or sluggish amp acceleration after the arc is struck will result.
6. Welding Amps
AC: 5-250 Amps
DC: 3-250 Amps
Welding amps define the top limit of amps at which the machine has been programmed to
operate. Used with the foot pedal and amptrol, this is the maximum limiting value at the
upper limit of the range of travel. With the torch switch this is the destination, or maximum
current reached after up slope has occurred. When used with pulse, Welding Amps represents the high amp stage of the pulse cycle. When used with Advanced AC Pulse, this
represents the AC, high amp stage of the pulse.
7. Pulse Time On (Balance)
5-95% of Welding
Amp (Peak) Time
Defines the duty cycle (balance) of the pulse, by dividing or skewing the amount of time the
pulse stays in the lower or upper stage of the pulse. The pulse consists of two stages: Welding amps (upper /Peak) and Pulse amps (lower/background current). This is represented by
a % of total time the pulse spends in the welding amp stage of the cycle during one full
pulse cycle. The feature can be used to increase or decrease pulse amp time relative to the
welding amp time of the cycle to help manage heat input. This functions the same in both
Standard and Advanced AC pulse modes.
8. Pulse Amps (%)
1-100% of
Welding amps
Governs the lower( base or background current) amp value during the pulse cycle as a percent of welding amps. In Advanced AC Pulse mode this also represents the DC-(negative)
low amp portion of the pulse cycle.
9. Pulse Frequency , Hertz
(Pulses per second )
DC:
.1-500 Hz
AC Advanced Square.:
.1-250Hz
AC Soft Square:
.1-10 Hz
AC Triangular:
.1-10 Hz
AC Sine:
.1-10 Hz
Advanced AC Pulse:
.1-10 Hz
Represented by Hertz (Hz), the pulse frequency defines the actual number of times each
second the pulse makes one complete cycle between welding amps (peak/high amp value)
and pulse amps (background/low amp value). This is also commonly referred to as Pulses
Per Second (PPS). Low pulse frequencies are ideal for timing the point at which filler metal
is added. This is useful for improving appearance and uniformity during manual welding
activities while controlling heat. Higher pulse frequencies are useful for welding seams and
edges of thin material. Also it is useful for overall heat input control for thicker metals.
Higher pulse frequencies are highly useful for automated welding processes.
WARNING: WELDING AT HIGH PULSE FREQUENCIES INCREASES THE DECIBEL /NOISE LEVEL
OF THE ARC. HEARING PROTECTION IS HIGHLY RECOMMENDED!
In Advanced AC mode, the function of the frequency is essentially the same, and represents
the number of times per second that the welder cycles completely between AC (assigned
as Welding Amps, the Peak current) and DC- ( assigned as Pulse amps, the base current).
10. AC Frequency
20-250 Hz
Governs the number of times per second that the current alternates from polarity in AC
mode. To achieve greater arc focus (constriction) and increase puddle agitation while welding in AC mode, increase AC frequency. This allows pinpoint use on thin materials, and
helps penetration on thicker materials. Ideal adjustment range is usually between 100-150
Hertz. For comparison most transformer welders in the US operate on 60 Hz. Greater arc
control and stability can be achieved through the higher frequency range offered by this
welder. Lower Frequencies will widen and soften the arc and reduce the level of control.
WARNING: INCREASING THE AC FREQUENCY ALSO INCREASES THE DECIBEL/NOISE LEVEL
OF THE AC WELDING ARC. HEARING PROTECTION SHOULD BE WORN!
11. AC Balance
10-90% of EP
Defines the percent of Electrode Positive (EP) used during AC welding to provide cleaning
action. This divides the time that the AC cycle spends in Electrode Positive or Electrode
Negative during one full AC cycle. It controls the amount of cleaning and penetration via a
ratio to achieve the best balance while welding on AC. Too much cleaning action will result
in tungsten balling or splitting. Too little cleaning can result in dirty, sooty welds and even a
dull weld appearance. Simply put, as the percent increases, greater cleaning will occur, but
less penetration will be achieved. NOTE: This is expressed as a percent of full Electrode
Positive polarity. This unit uses 100% Electrode Positive as the reference, which is opposite
(a reciprocal value) from some brands of TIG welders with this adjustment. Using the welder in excess of 50% EP can ball and vaporize the tungsten. For most welds, no more than
45% cleaning is needed. Ideally, start with 30% EP for a reference point, and fine tune the
cleaning by adjustment this point in increments of 5%.
*NOTE: Your program version may not allow the slope features to be adjusted while the foot pedal is plugged in and in pedal mode. In this case
you will still be able to select and highlight slope and a the parameter can be adjusted while in pedal mode but it will default and automatically re-zero
immediately after an adjustment is made. This is normal. To adjust slope with a torch mounted amp control, select either the 2T Pedal or 4T Pedal
setting where both pedal and 2T(or 4T) are lit.
20
Section 2
QUICK SETUP AND USE GUIDE
FRONT PANEL FEATURES AND CONTROLS POWERPRO 256D
POWERPRO 256D
PARAMETERS
PURPOSE
12. Down Slope*
0-25 Seconds
Down Slope ramps the amperage down from the welding amp value to the end amp value to
allow time to fill the crater left at the end of the weld bead. For best operation, the set the
value to 0 with the foot pedal in use. If used with a hand amptrol, without a separate switch
to control slope in 2T/4T mode, then the upslope should be set to 0 as well. When using the
foot pedal or amptrol without a separate control switch, the arc may flare at the end of the
weld after the weld has been lowered to the minimum amp level if the value has not been
set to 0. Can also be used in the 4T mode to help with heat control by briefly tapping the
switch to cool off the weld before tapping it again to restart the up slope sequence before
the arc reaches the end amp stage.
13. End Amps
AC: 5-250 Amps
DC: 3-250 Amps
Sets the final or minimum current before the arc is terminated. Used for filling craters at the
ends of the weld and crack prevention. When using the foot pedal, this should be set to the
lowest amp value (3 for DC; 5 for AC) or arc may suddenly get hot at the end of the weld.
14. Post Flow
0-50 Seconds
Controls the amount of time in seconds that the argon flows after the arc has terminated.
Provides proper shielding during cooling to prevent rapid oxidation of the weld which results
in porosity. Use approximately 1-2 seconds post flow time for every 10 amps.
15a. HF TIG/ Lift TIG/Stick/
VRD/Plasma (Cut) Selector
N/A
This selects TIG, Stick mode or Plasma (CUT) modes. It also selects the type of TIG start. The
Process selector offers the choice of Lift Tig (for DC only) which requires contact with the
metal to initiate the arc and High Frequency Start which allows non contact starting of the arc
(for AC and DC). When in HF mode, the unit relies upon a gapless solid state HF module to
start the arc. The lift start function provides a cold electrode for safety, and prevents accidental starts. This requires that the pedal or torch switch must be pressed to energize the
torch. HF refers to the start type only. The inverter design of the welder eliminates the need
for a constant HF overlay in AC.
15b. Stick/VRD Stick Selector
N/A
This selects the stick process or the VRD stick process. A Voltage Reduction Devices (VRD) is
required in some situations to reduce the risk of electrocution. The VRD reduces the Open
Circuit Voltage (OCV) below 20 volts (±3V) for safer operation until the arc is struck and low
resistance is sensed. The VRD can make starting more difficult in some situations, and requires a brief contact with the metal to start the weld. Rusty metals, or painted surfaces may
make starting more difficult by offering too high of a resistance value for the unit to sense an
arc strike attempt. When using the VRD Stick mode, a slight delay in arc starting may be
noticed. A firm scratching action may be necessary.
15c. Plasma (Cut) Selector
N/A
This selects the Plasma process. WARNING: Before the plasma torch is connected, select Cut
and do not switch modes and fire torch or damage to the torch and to the unit may result.
16. Parameter Selector
N/A
The push button selector is used to scroll left to right through different panel settings.
17. Parameter Adjuster
N/A
The control knob is used increase or decrease parameter values. To increase adjustment
speed, push in on the knob while turning.
18. Arc Force Control (DIG)
0-100%
Controls the arc response when an arc is held short and voltage begins to drop. Arc force
automatically compensates by modifying the volt/amp curve to maintain the energy needed
to weld. Represented as a percent of available arc force amperage.
19. Hot Start Time
(Surge Amp Time)
0-2 Seconds
Sets the length of time that the Hot Start is active while starting the arc. Used to reduce
sticking of the electrode during the arc strike phase.
20. Hot Start Amps %
0-100%
Controls the “hot” start amperage during the initial contact of the electrode. It makes arc
starting easier by sending a surge of amps briefly while arc is struck to prevent sticking. The
% represents the percent of additional hot start amps available.
21. TIG Pulse Mode Selector
Pulse OFF
Standard Pulse
Advanced AC Pulse
The unit features two pulse modes. The standard mode is available in AC and DC modes. The
Advanced AC mode, works only in AC. Pulse is used to control heat input on metals by pulsing amperage between a high (Peak) and low (Base or background) amp value. The high amp
stage is represented as Welding Amps. The low amp stage is represented as Pulse Amps. The
Advanced AC pulse pulses between AC and DC– polarity to control heat input on thin aluminum. In advanced mode, AC is assigned to the welding amps stage of the pulse, and DC– is
assigned to the pulse amps stage of the pulse. Both the standard and Advanced pulse modes
have the same features of pulse time on, pulse frequency and pulse amps. Other than
changing the polarity in Advanced AC pulse mode, the two pulses are similar in adjustment.
*NOTE: Your program version may not allow the slope features to be adjusted while the foot pedal is plugged in and in pedal mode. You will be able to select down slope and
make a temporary adjustment while in pedal mode but it will re-zero automatically after an adjustment is made This is normal. To adjust slope with a torch mounted amp
control, select either the “2T Pedal “ or “4T Pedal” setting where both pedal and 2T (or 4T)are lit.
21
Section 2
QUICK SETUP AND USE GUIDE
FRONT PANEL FEATURES AND CONTROLS POWERPRO 256D
POWERPRO 256D
22. 2T/4T/ Pedal/Amptrol
Selector*
PARAMETERS
2T, 4T, Pedal,
Pedal with 2T,
Pedal with 4T
PURPOSE
This selects the operation of the torch switch, pedal, or hand amptrol.
To operate with the torch switch, select 2T or 4T. For 2T operation, simply press and hold the
switch. The panel program will cycle automatically. When the switch is released, the arc will
downslope and terminate with post gas flow. When in 4T mode, the switch is pressed, and
held to start the pre-flow and the start amps part of the cycle. When released, upslope begins and continues until the amps are raised to the preset welding amps. When pressed and
held again, downslope starts and ramps down to the end amp stage (crater current). When
released, the arc terminates, and post flow begins. If desired, before the downslope finishes,
the switch may be tapped again to start the up slope again.
To operate with the foot pedal, select pedal mode. The features such as start amps,
upslope, down slope, and end amps will function with the pedal. Be sure to lower these
features to the minimum values when the foot pedal is in use, unless a desired effect is
needed. The start amp feature can be particularly useful as a brief “hot start” tig setting
which provides an initial burst of amps to be to rapidly develop a puddle.
To operate with a hand amptrol, select Pedal, and then press the selector additionally to
select the 2T or 4T feature light. Both the Pedal and the 2T or 4T pedal will be lit. The
starting and ending of the arc will be the same as the standard 2T or 4T mode, except the
amps can be adjusted while welding with the amptrol. However, some amptrols have only a
a switch that is built into the amptrol mechanism, and is not controllable independently of
the amperage. When this type of amptrol is used, the unit should be placed into standard
pedal mode for proper operation.
23. AC Waveform/DC selector
Test Gas (Plasma)
DC
AC
Advanced Square
Soft Square
Triangular
Sine
The unit features AC/DC operation, with 4 standard wave forms available in AC for specialized
welding needs. The advanced square wave is the default mode and is the best all around
mode with excellent wet in, and arc controllability . Soft Square wave and Sine wave mimic
the feel and effect of the transformer welders. The Soft square wave is similar to Square
wave transformers, and have a smooth, buttery feel, but maintains good control over the arc.
The Sine wave is similar to much older sine wave transformer TIG welders. This offers the
softest arc, and affords less control than other modes. The Triangular wave is designed for
rapid wet in, and high speed travel on the metal. It also features rapid freeze of the puddle.
DC mode is the standard mode used for all metals except aluminum and magnesium. Aluminum and Magnesium should be welded in AC only.
23a.
24. Data Indicator
Test Gas
(Purge)
To purge gas or set gas flow during Plasma use, select “Test Gas”. Deselect this before
cutting so that it returns to normal operation.
Amps
Seconds
Percent
Hertz
Warning
On
The unit features a single main display. The data in the display is always accompanied by a
corresponding LED light which indicates the function being represented. This also includes a
self diagnosing function which displays an error code and a corresponding warning light. See
trouble shooting for lists of error codes. NOTE: Some error codes once displayed require
resetting of the welder by powering down the welder and turning it back on to clear and
allow the welder to return to normal function. Other codes will allow the welder to weld
once the cause of the code has been remedied without cycling the power off and on.
*NOTE: Your program version may not allow certain parameters to be adjusted while the foot pedal is plugged in and in pedal mode. You will be
able to highlight or select certain features and make a temporary adjustment while in pedal mode but the unit will automatically re-zero after
manual adjustment is made. This is normal. For adjustment of slope (if needed) with a torch mounted amp control, select the 2T Pedal or 4T Pedal
setting where both pedal and 2T(or4T) are lit.
22
Section 2
QUICK SETUP AND USE GUIDE
REAR PANEL FEATURES AND CONTROLS POWERPRO 256D
1. 220V WATER COOLER CONNECTION
2. 2-POLE POWER SWITCH
6. REGULATOR ASSY.
1~220 VAC
3. POWER CABLE 1 ~ 220/240V
GAS
INLET
1~220 V
5. HF GROUND BOLT
4. GAS INLET
23
Section 2
QUICK SETUP AND USE GUIDE
REAR PANEL FEATURES AND CONTROLS POWERPRO 256D
POWERPRO 256D
PARAMETERS
PURPOSE
1. Water Cooler Receptacle
IEC 60320-1 “C-14”
This connection supplies power to the Everlast PowerCool 300 water cooler. This is a 220 VAC
outlet. Do not use this connection to power any other device. 4 amp max. This remains live
while the unit is plugged in. The power switch on the unit does not turn the cooler outlet off.
2. 2-Pole Power switch
On/Off
The breaker switch has 2 poles. It serves as the On/Off switch for the welder. Always turn the
welder on and off by the switch first before using any disconnect. The Water cooler outlet on
the rear remains live after the switch is turned off.
3. Power Cord
220/240 V
1 phase, 50/60 Hz.
The unit is prewired with a standard NEMA 6-50 plug. This is the standard plug for welders in
the US and Canada. Other countries vary plug configuration as well as input.
4. Gas Input Connection
1/4-5/16”
This is the point where the shielding gas from the regulator connects. The unit is supplied with
tubing and clamps which connect this fitting to the regulator. The hose barb design allows
universal connection of the welder to almost any regulator or setup found throughout the
world. Make sure the tubing slides fully over the connector, then thoroughly tighten the
clamp. Use an additional clamp if necessary to prevent leaking. If you suspect leaking, test
the connection with a solution of mild soapy water. If bubbles are seen, retighten or reinstall
the tubing. While changing processes, the tubing must be swapped. Do not run the Argon gas
through the air regulator/filter. A T-fitting or Y-fitting may be placed inline at the connection to
leave both argon and air hooked up without having to swap out the lines. This is not supplied
by Everlast and is up to the customer to responsibly install if not using the standard change
over method recommended by Everlast. This can usually be purchased from online sources or
at any well equipped welding supply store.
5. HF Ground Bolt
N/A
HF energy can be devastating to surrounding electronic equipment. If the operating environment includes electronic equipment, this connection can serve as a direct path to an outdoor
grounded metal rod that is isolated from the main electrical circuit to help bleed off excess HF
circuit. All metal parts inside the building should be grounded as well, including pipes, tables,
and even metal siding. HF energy has been known to bleed back into the power grid and
disrupt electronic devices further down the line. It is recommended that a separate ground
wire (minimum 14 gauge) be attached at this point while in use.
6. Air Regulator Assembly
with pressure gauge
90 psi maximum
Supply pressure.
70-75 psi operating
pressure while
cutting
The regulator serves a multiple purposes. 1) It controls air pressure for plasma. 2) It filters
fine particulates and large drops of water. The regulator is not designed to regulate Argon
flow or have argon flowing through it. 3) It displays the operating air pressure.
NOTE: A separate air dryer must be installed inline to prevent rapid torch and consumable
wear (customer supplied). The regulator assembly is not designed to remove moisture from
the air, only large drops of water that may be created in the coupling and uncoupling process.
Everlast does not warranty damage caused to torches or consumables by moisture. Residual
moisture in the line will also contaminate the system, causing problems while TIG welding. So,
keeping the internal lines of the unit dry is of upmost importance. One of the leading issues
experienced with Plasma cutting and the cause of many different symptoms in TIG is the presence of moisture in the air line. To adjust the pressure for cutting, simply pull up slightly on the
knob until it clicks then rotate it clockwise to increase the pressure and rotate it counter clockwise to decrease the pressure. To adjust the pressure correctly, adjust the pressure while the
air is flowing in the “ Gas Test” mode. If a flow tube for the torch is provided, adjust it so the
ball floats in the window as depicted in the torch manual. Do not fire torch with the flow tube
installed on the torch. Turn Post flow to maximum, fire the torch, then install the flow meter
and make adjustments to the air pressure while it is flowing. If no flow tube is provide, adjust
the air pressure to 70-75 psi, with 73 psi being the optimum target pressure.
NOTES:
1. The gas input connection should be checked for tightness periodically, especially if the machine is moved or when changing processes.
2. Never operate welder on a generator that is not certified by its manufacturer to be “clean” power, which is less than 10% total harmonic distortion.
less than 5% is preferred. Operating the unit on square wave output or modified sine wave generator is strictly prohibited. Contact the manufacturer of the generator for this information. Everlast does not have an “approved” list of generators. But, if the generator is not listed as clean
power by its manufacturer, then operation is prohibited. Generators that do not at least meet the operating input requirements of the welder
are also forbidden to be used with the welders. Surge amp capability of the generator should equal or exceed the maximum inrush demand of
the welder. But the surge capability should not be used as the only factor. The regular, running output of the generator should match or exceed
the running or “rated” demand of the welder. Any damage done by operating the welder on a generator not specified by its manufacturer to be
“clean”, will not be covered under warranty. This also includes all forms of questionable power sources where voltage is below 208 V and above
250 V (including wiring that is undersized for its length and rating).
24
Section 3
Basic theory and function
Welder Function Summary and Explanations.
The standard pedal mode in certain program versions
of the PowerPro 256D incorporates the same adjustability of the parameters of the sequencer. When used,
it is similar in operation to the 2T mode with the same
settings. However, all features except pre-flow and
post flow would should be programmed for the minimum allowable value so the functions do not interfere
with normal pedal operation. But if a TIG “hot start” is
needed to improve arc transfer, or develop an instant
puddle, the start amp feature can be used. Any other
feature such as down slope can be used as well, for
any special application or need . However, be sure to
remember to reset these features to the minimum
values when they are not required, or undesirable operation such as arc flares, sluggish operation may occur after releasing the foot pedal. Depending upon
the program version, for setup simplification and
improved operator experience, your unit may not
allow adjustment to some parameters in pedal the
mode even though you may be able to toggle through
each individual parameter. In this case, any adjustment made to the parameter will automatically rezero after an is adjustment has been made. This is
normal and is subject to further programming change
as Everlast seeks to continually improve the usefulness of the features and simplify setup up procedures.
1. 2T/4T/Pedal sequencer. The 2T/4T feature allows operation of the welder without a foot pedal.
In many circumstances, a foot pedal is not practical
for use. So, the 2T/4T function has been created to
allow programming of the welder to simulate the
activities of the foot pedal while providing more
accurate, programmed control. The “T” refers to
the number of travels of the remote switch installed on the torch required to operate the programming. 2T is essentially a “press and hold” operation and all programming is cycled automatically. Releasing the switch begins the final stage of
programming. 4T operates differently in the fact
that each touch activates a different stage of the
programming, allowing for greater control. Also, in
4T, while actually welding at full amps, no finger
contact with the switch is required which allows a
more relaxed grip. Follow the graphic lines below,
to visually trace and learn the activity and function
of each part of the welding cycle. In either 2T or 4T
operation the programming can be reset to
“upslope” before reaching the end amp stage by
pressing the switch once more. Setting a long
down slope improves the use of this reset function.
See the graphics below for further explanation.
The up and down arrows indicate the switch travel
direction.
NOTE: The welder features an additional combined
2T or 4T pedal mode where the pedal mode light is lit
along with either the 2T or 4T light. This is actually
designed for use with a hand amptrol with a separate
torch switch for initiating the arc and activating the 2T
or 4T sequencer cycle. This type torch amptrol should
have a momentary on/off button should mounted sep-
2T Torch Operation Effect on Weld Cycle
WELD AMPS
WELD AMPS
START AMPS
END AMPS
POST FLOW
PREFLOW
Everlast 26 series torch with hand operated amptrol and separate switch
= UP ON SWITCH
= DOWN ON SWITCH
arately to activate the arc cycle if none is provided.
Some aftermarket torch amptrols have a built-in
switch that automatically activates and initiates the
arc as the amptrol is rolled on. In this case, the
amptrol should only be used in the pedal mode, or 2T
pedal mode. Everlast offers additional torch options
with built-in amptrols that are designed for use in the
combined 2T or 4T pedal mode of the welder. Torches
with both a separate torch switch and a separate
amptrol functions just as it would with a regular 2T or
4T cycle switch, except the amperage can be adjusted
at the torch while welding once the welding cycle has
reached the normal welding stage of the cycle.
4T Torch Operation Effect on Weld Cycle
WELD AMPS
START AMPS
PREFLOW
END AMPS
POST FLOW
25
Section 3
2. Easy Start Modes (AC and DC). The unit is
equipped with a separate AC and DC “Easy Start”
mode. This mode allows the operator to quickly
start welding without having to worry about correct setup. The unit’s easy startup modes are programmed for all-around performance, handling a
broad, general purpose range of tasks requiring
either AC or DC output. The amperage is preset,
but can also be adjusted if desired. Torch switch or
pedal control can be selected, but most other features are locked into an optimized general purpose
setting. This feature is useful for novice welders
and for customers desiring a quick start up, bypassing the usual setup procedure. The easy start up
modes are not intended for advanced welding
tasks but can be useful as a default setting without
having to create and save another program to the
welder’s memory channel.
3. AC Wave Forms. The wave form control is a
useful feature for achieving a desired type of arc
performance in AC mode. There are 4 wave forms
to choose from. The default AC wave form is the
advanced square wave. This wave form is excellent
for all types of welding, and offers quick puddle
wet-in, and good arc stability. The triangular wave
form is useful in situations where a fast freezing
puddle is desired, particularly on thin aluminum.
The soft square wave offers a buttery arc, with a
smooth feel similar to the feel of a standard
square wave transformer-based welder. The sine
wave form mimics older transformer welders. This
is the softest feeling wave form, and offers less arc
definition and control than other wave forms. This
is preferred by some older more experienced welders. When using various AC wave forms, only the
Advanced Square wave offers a high pulse frequency of 250 Hz in the standard pulse mode. All other
wave forms are limited to a maximum of 10 Hz.
Advanced pulse mode limits the pulse frequency to
10 Hz on all wave forms due to practical limitations.
Basic theory and function
rectional control of the arc, and to focus the arc so
that a narrower bead profile can be achieved. Also, at
higher frequencies, the puddle agitation is greater
which improve the breakup of undesirable oxides.
Penetration can also be pinpointed and deepened as
frequency goes up. All wave forms can be adjusted
from 20-250 Hz. For obtain a more fluid puddle when
welding aluminum, lower the AC frequency. A good
starting point for AC frequency is between 100 and
120 Hz as it seems to offer good general capability.
200 Hz
60 Hz
Effects of AC frequency
5. AC Balance. The AC output is formed by rapidly
alternating a current’s polarity between electrode negative (EN) and electrode positive (EP), creating a type
of a sine wave when viewed on an oscilloscope. Usually, a standard transformer welder (both standard sine
wave and square wave welders) have little or no way
to alter the ratio of EN to EP, which results in having to
weld with a molten ball at the tip of the tungsten and
a less stable arc. In TIG, electrode negative (EN) provides the penetration part of the AC cycle due to the
direction of the electron flow. Electrode positive (EP)
creates a strong reverse flow of electricity that breaks
up weld-resistant oxidation that is present on Aluminum. However, it is poor at creating penetration because it places most of the heat on the Tungsten. In a
“balanced” wave where both EP and EN are equal in
time length (50% setting), penetration is reduced and
too much cleaning action results in wide etch lines
running parallel to the side of the weld. This is not
ideal at all as the Tungsten will tend to ball (or even
burn) and the arc will begin to “hunt” or wander. Not
all welds conditions are alike so more cleaning is reCleaning/Frosted Area of Aluminum
30% EP
Narrow bead/etching/sharp tungsten
4. AC Frequency. The AC frequency control is only
used in the AC mode. It does not have any bearing
or effect in the DC mode. Standard transformer
based welders typically have a fixed frequency of
60 Hz. This is essentially the line input frequency
supplied by the power company. However, due to
the IGBT inverter design of this welder, the capability of to make adjustments to the AC frequency is
practically limitless up to 250Hz. The capability to
adjust AC frequency is useful to help improve di-
50% EP
Wider bead/etching/rounded tungsten
65% EP
Wide bead/etching/balled tungsten
26
Section 3
Basic theory and function
quired at times than others. Similarly, more penetration will be required at times than others. Ordinarily,
about 20-35% electrode positive is considered an ideal amount (65-75% electrode negative). This means
that more heat is put into the work than on the tungsten and a sharper point can be used. Cleaning is still
sufficient at that level. Typically, good results can be
achieved with an AC balance setting of about 30% EP
NOTE:
1.
EXAMPLE: AC EP (+) BALANCE
1 Hz (one full AC cycle)
EP 50%
EN 50%
50%
Standard transformer welder balance: 50% EN/EP
Balling tungsten, light penetration, wide cleaning area.
2.
EP 65%
EN 35%
50%
Extreme cleaning setting. 65% EP:
Shallow penetration, balling tungsten, excessive cleaning area.
50%
3.
EP 35%
EN 65%
Good penetration setting 35% EP:
Deeper penetration, sharper tungsten, narrow cleaning area.
4.
5.
or less. The cleaning action is still sufficient even at
these levels. Ideally, the cleaning action should be
adjusted until a small amount of frosting can be seen
no more than 1/8” distance from the edge of the
weld. If a particular piece of Aluminum is heavily oxidized or dirty, more cleaning action will be required.
If too much cleaning action is used, the tungsten will
begin to ball and will erode (burn) away. If this much
cleaning action is truly needed, then switch to a larger
sized tungsten that can handle the increased heating
level. Signs of too little cleaning action while welding
aluminum are sooty, black or dull looking welds. A
dedicated stainless brush and suitable aluminum
cleaner such as acetone should still be used before
welding any type of aluminum to help break up the
heavy oxide layer. This will require less EP so better
penetration can be achieved. Even if the aluminum
has a mirror finish to it, it still has a layer of oxide that
must be removed to achieve a properly welded joint.
High Frequency (HF) is not needed except to start the arc.
The HF TIG feature refers specifically to the initial arc start,
and is normally used in both AC and DC modes. In a standard transformer welder, the HF is used continuously to
stabilize the AC arc. However, continuous HF is not needed
in an inverter due to the rapid switching provided by the
IGBT electronics. Therefore, with this welder, HF refers only
to how the arc is started, and not to AC function. However,
to reduce tungsten contamination by the aluminum, you
should only operate the welder in the AC mode with the HF
start selected unless it is absolutely necessary due to work
place restrictions. Lift start is recommended for use only in
DC mode, or for use in AC mode when a copper scratch
block is used and the arc is transferred. Lift start would be
used in areas that are sensitive to electronic interference
such as hospitals or around computerized equipment such
as CNC.
The addition of Helium to Argon can increase the welding
capacity of the welder and alter the amount of cleaning
typically needed. Do not exceed 25% however or arc starts
will be difficult and erratic.
If arc wandering in AC is a problem, reduce cleaning percent. If it continues, reduce gas flow and then check for
drafts or for poor work clamp connection. Also check for
highly oxidized or dirty aluminum or a faulty work clamp or
connection. Try relocating work clamp directly to the metal
being welded.
AC controls only apply to AC operation, and do not affect
the settings on DC.
Too slow of travel speed will increase the etching (cleaning)
area even if the AC balance is adjusted correctly.
Parameter Notes:
27
Section 3
6. Standard Pulse. (AC and DC) The pulse creates two
amp values, a high and a low value that cycle back and
forth between each other while welding. The upper
amperage is called the “welding amps” (sometimes
called peak current) and the lower amperage is called
“pulse amps “ (sometimes called background or base
current). This creates a situation where penetration
can be achieved without overheating the metal, particularly on metals that are prone to structural deterioration or burn through. In effect you are creating an
average of amps. The PowerTIG series feature three
adjustable parameters concerning the pulse:
1. Pulse Amps. Both welding amps and pulse amps are
independently set. Adjust the welding amps with the
main control knob and the pulse amps with the pulse
amp knob. However, when you adjust the pulse
amps, you are actually defining a fixed ratio of amps.
This is expressed as a percentage of Welding Amps.
The display is not synchronized with the pulse so it
samples at a set rate that is independent of pulse
changes, which yields randomly fluctuating numbers.
As you increase amperage, the pulse will maintain the
same ratio of amps you have selected. To adjust the
pulse amps to a desired setting using an example of
100 Welding Amps, setting the pulse amps to 50%
would yield a 50 amp value for the pulse amps. The
foot pedal will control both Welding Amps and Pulse
Amps according to the %(Ratio) selected on the panel.
Basic theory and function
AMPS
EXAMPLE 1
Welding Amps: 100 amps,
PulseAmps: 50%
Pulse Time On: 50%
DC Pulse Frequency: 1 Hz
Pulse Time ON
Welding Amps
100
Pulse Amps
50
Pulse Hz
DC
1S
AMPS
2S
3S
EXAMPLE 2
Welding Amps: 100 amps
Pulse Amps: 50%
Pulse Time On : 50%
DC Pulse Frequency: 25Hz
100
50
DC
1S
2. Pulse Frequency. Pulse speed or frequency as it is
referred to is measured in the unit standard “Hertz”.
Simply, it is the number of pulses per second that occur. Pulse frequency controls the arc constriction and
also help with heat management.
AMPS
EXAMPLE 3
Welding Amps: 100 amps
Pulse Amps: 25%
Pulse Time On: 75%
DC Pulse Frequency: 3 Hz
100
3. Pulse Time On (Balance). Pulse Balance is the percentage (%) of time that the pulse stays in the welding
amp stage of the cycle. Increasing the Pulse time on
can increase the duration the welding amp stage of
the cycle to increase the overall heat input. Pulse
Balance is also commonly referred to as pulse duty
cycle. For welding purposes, the term “Pulse Time
On” is used as it deals with the sharing of on time between Peak and base amp values during one pulse
cycle.
25
DC
1S
Setting up the pulse is not a process with a fixed adjustment procedure. Changes to frequency, balance,
and time will skew the final result. A slow pulse with a
equal 50% pulse time on and somewhere around a
28
Section 3
Basic theory and function
50-75% Pulse Amp setting is typically used to help
with timing the addition of filler metal to the weld
puddle. A higher pulse frequency level with variations
in Pulse Time On and a narrow/wider ratio can be used
to prevent burn through and speed up welding on thin
materials. It can also help maintain a proper bead on a
thin edge weld or prevent burn through on extremely
thin metal. A fast pulse speed will make fine ripples in
the weld while a slow pulse speed will give a much
more coarse, but visually appealing result. There are
limitless ways to adjust the pulse. Keep in mind
though, that the basic purpose of the pulse is to average the heat input while maintaining penetration.
7. Advanced Pulse (AC only). The Advanced Pulse is a
feature not typically found on most pulse type TIG
welders. In the “advanced” mode, the unit pulses
current back and forth between AC and DC negative (-)
polarity. This is designed primarily for use with welding aluminum, and is accessible only when used in AC
mode. The purpose of Advanced Pulse mode is to create a quick freezing puddle, and offer more definition
of the puddle ripples. It is also useful for controlling
cleaning width, and for heat input control on thin
gauge aluminum. AC is assigned as the welding amps
setting (pulse peak), and the DC— is assigned as the
pulse amps % ( base value). Otherwise, the pulse frequency, and pulse time on are adjusted the same and
perform the same function as the standard pulse mode
adjustments. Occasionally during use, a slight wobble
of the arc may be seen as it pulses between AC and
DC—. This is usually observed if the frequency is set
low and the metal is highly oxidized, the arc length is
too long, or the work clamp is not connected securely.
If this happens, readjust the work clamp, re-clean the
metal and /or shorten the arc length. If pulsing slowly,
the filler should be added on the audible AC stage of
the pulse as this is the hotter stage of the pulse. Note:
The graph below has been simplified for clarity. It is
designed to show the relationship and interaction
between the AC and DC parts of the pulse and does
not depict the effect of AC frequency cycling between
— and + polarity during the pulse cycle.
AMPS
Pulse Time ON
Welding Amps (AC)
100
Pulse Amps (DC-)
50
Pulse Hz
Time
1S
2S
3S
8. Arc Force Control/Surge Amp Control. When stick welding, arc force is used to help improve weldability of certain
metals and welding rods. The arc force boosts current
flow to match the demands of arc length and position. As
an arc is held shorter, voltage tends to drop so extra amps
are introduced to help maintain a steady arc. Surge amps
boost the starting amperage briefly to heat up the welding
electrode and weld area so the arc starts cleanly, without
sticking or porosity. Both controls are inactive while welding in TIG mode.
9. Foot Pedal. 47k Ω. Select 2T on the panel. Select maximum amp value desired on the panel. The foot pedal will
only control amps up to the range governed on the front
panel. If more amperage is needed raise the amp level on
the panel. The foot pedal also controls both Welding
Amps and Pulse Amps through the ratio established by
selecting the pulse Amp % on the panel. Welding with
pulse and the foot pedal takes practice, as it will seem the
welder is welding at less amps than it is. Always set the
panel amps to about 25% more than what should be needed. Increasing the amps more than this margin on the
panel will reduce the accuracy of the foot pedal by lowering the resolution of the foot pedal. Be sure to turn the
start/end amps and up/down slope to the minimum
setting or it will interfere with pedal operation. The pedal
cannot override the start/end amp and slope controls. For
more accurate and responsive control, Everlast offers a US
made foot pedal available as an additional option.
10. Water-cooled/ Air-cooled torch. (20 and 9 series). A
water cooler is necessary for use with the water-cooled 20
series torch and to reach the maximum current potential
of the unit. Using a water-cooled torch even briefly without water can seriously and permanently damage your
torch! The Power Cool 300 may be purchased separately
from Everlast which is designed to cool the torch up to the
maximum amp capacity of the welder. If you do not have
a water cooler or have not purchased a water cooler, you
will need to use the air-cooled (gas -cooled) 9F series
torch that is included with the unit. Keep in mind that the
100% duty cycle mark on the 9 series is 125 amps DC, and
85 amps AC. The torch may be used at slightly higher amperages but the torch duty cycle will be reduced and the
potential to overheat and damage the torch exists. Overheated torches or water-cooled torches run without water
are not warrantable. Everlast has worked to ensure that
the TIG torch consumables are interchangeable with other
brands with similar 9 or 20 designations. They should be
available locally for purchase. No special consumables are
required. Although a small starter kit of consumables is
29
Section 3
included, you will need more consumables fairly quickly, so it’s a good idea to purchase a larger kit with the
welder or shortly after purchase. Note: No Tungsten is
included with the complementary starter kit. The
complimentary starter kit contents may vary in appearance and quantity. Everlast offers (available for
purchase) additional deluxe TIG kits with gas lenses
and stubby kits. These kits do include quantities of
tungsten which include a variety of types and sizes of
Tungsten. Tungsten however, can be sourced locally
at almost any well equipped welding supply store.
11. DINSE style connector. Everlast uses a 35-70mm²
connector for both negative and positive connectors,
which is considered a standard connector within the
welding industry. This is commonly known as a 1/2” or
35 series DINSE-style connector. The connector allows
the use of almost any brand or style of TIG torch.
Basic theory and function
revert back to the minimum amp setting on the welder
after the arc is terminated. It will not display maximum
set amps as the pedal It will only display maximum set
amps while the amperage is being actively adjusted. While
welding, the display will read output weld amperage.
After finishing the amperage adjustment, the display will
default back to the minimum amp reading within 3-4 seconds. When using 2T or 4T control modes, the display will
register the maximum set amps until the arc is started. To
see the maximum set amperage in the pedal mode without the arc on, simply make a small adjustment in the
main adjustment knob while the Welding Amps light is lit.
The unit will then revert to the adjustment mode and display the currently selected maximum amperage.
12. 7 pin remote/foot pedal connector. This 7 pin connector is available from Everlast should it become damaged. See Pin-out reference found in the appendix of
this manual.
13. Argon quick connect. This is a 9 mm size quick connect nipple. These are commonly available from Everlast or online sites which carry torches and fittings.
Should you need a new one for your torch or damage
yours, consult Everlast. Do not use a nipple that is
scarred, bent or otherwise deformed. Damage to the
female connector may result. Serious leaks may occur.
14. Low amp starts and welding. The units have been
configured to be able to start at approximately 5 amps
AC/DC. After the arc is started in DC, amps may be
reduced to the minimum 3 amp minimum level. Start
Amps may also be increased for a “hot start” while in
TIG mode if required. To achieve the most stable low
amp starts, you will need to decrease gas flow, tungsten size, and standoff height. If inconsistency is experienced, drop to a smaller tungsten size, cup size and
reduce the flow rate to prevent turbulence. Stand-off
height at low amp start and operation must be maintained between .035-.060”.
15. Argon Regulator. The argon regulator is listed in
SCFH for North American markets. (subject to change).
NOTE ABOUT THE FOOT PEDAL MODE:
While using the welder with the foot pedal, and with
hand controlled amptrols that don’t feature an independent torch switch, the welder’s digital display will
30
Section 3
Basic theory and function
TUNGSTEN PREPARATION
1. Use a dedicated grinding
wheel or contamination may result.
Do not breath grinding dust! Wear eye
protection and gloves.

2. Hold Tungsten firmly.
3. Grind perpendicular to grinding
wheel face. Allow tungsten to
grind away slowly, creating point.
4. Rotate tungsten quickly as it is being ground to keep point even
and symmetrical.
DO NOT GRIND TUNGSTEN
PARALLEL TO WHEEL FACE OR
AN UNSTABLE ARC WILL RESULT.
2.5 – 3 X Ø (DIAMETER)

<50 A
>50 A
Use a point for low amp use to help
control arc. Create a slight truncation
on the tip for higher amp use for best
arc stability. Grind the tip so that it is
2.5 - 3 times longer than the diameter
of the tungsten.
DO NOT BALL THE TUNGSTEN TO
WELD IN THE AC MODE. AN ERRATIC ARC WILL RESULT. MAKE
SURE GRINDING MARKS RUN
PARRALEL TO TIP. CONCENTRIC
MARKS WILL CAUSE ERRATIC
ARCS AND DIFFICULTY STARTING.
IMPORTANT: Do not attempt to use Pure tungsten (green) or Zirconiated (white) tungsten to weld aluminum with this welder. These tungsten
types will not hold up well in an inverter. With modern inverters a ball is not desired for AC welding as in the past with traditional transformer
welders. A balled tungsten will yield an unstable, wandering arc. Many welding supply warehouses are not familiar with inverter TIGs and will
try to sell pure or zirconiated tungsten for welding AC. Do not use either. Any other type Tungsten, including Thoriated (red) may be used for AC.
31
Section 3
Basic theory and function
LIFT START TIG OPERATION
Note: A Lift TIG start should be done with a nearly seamless motion. Use a light touch and a quick motion for best results.
FOR DC USE. NOT RECOMMENED FOR AC.
5
1
3
2
4
<1/8”
1. Position the edge of the ceramic cup on the metal. Press and hold the torch switch or press the foot pedal.
Wait for the Pre-flow to start. (Make sure pre-flow is set for less than .5 seconds or start will be noticeably delayed.)
2. Quickly rotate cup so that the tungsten comes in brief contact (< .5 seconds) with the metal.
3. After contact with the metal, quickly rock the torch back so that the tungsten breaks contact with the metal.
4. An arc should form. As the arc grows, raise the cup up off the metal and slowly rotate the torch into welding position.
5. Leave 1/8” or less gap between the tungsten tip and the metal. Proceed with welding, leaving the torch inclined at a 15° angle.
HIGH FREQUENCY START TIG OPERATION
FOR AC OR DC USE.
1
<1/8
3
2
4
<1/8”
1. Position the point of the sharpened tungsten about 1/8” or less above the metal. Use less than 1/16” stand-off for low amp starts.
2. Press the torch trigger or press the foot pedal to initiate the arc. The HF arc will be initiated. It may appear briefly as a blue spark.
3. An arc should form, almost immediately after the pre-flow cycle is completed. HF arc initiation will be delayed by the amount of pre-flow
time used. If arc does not start after the pre-flow interval, and the HF is creating a spark, then check the work clamp contact with the work
piece. Move the tungsten closer to the work. Repeat steps 1 and 2.
4. Leave 1/8” or less gap between the tungsten tip and the metal and proceed with welding, leaving the torch inclined at a 15° angle.
General TIG Arc Starting Steps
Turn the welder on. Allow time for power up cycle to complete its start up process.
Select either HF or Lift Start TIG with the HF/Lift Start/Stick/Cut selector switch. Select an AC wave form or DC mode.
Plug in the TIG torch and select 2T, 4T, Pedal, 2T Pedal, or 4T pedal mode with the selector switch.
If using the torch switch or foot pedal, set start/end amps amperage by rotating the knob to increase or decrease amps.
If using the torch switch, select up/ down slope time by rotating the knob to increase/decrease the ramp up or ramp down time of the amperage.
Adjust amps with amp control knob.
Start arc as depicted above.
If using 2T, continue to hold the torch switch until you are ready to stop welding. Release the switch. The Arc will then cease.
If using pedal raise foot fully off the pedal and arc will stop automatically.
9. If using 4T, release the switch, after arc initiates. Continue to weld without holding the switch down. To stop, press and release the switch again.
1.
2.
3.
4.
5.
6.
7.
8.
32
Section 3
Basic theory and function
STICK OPERATION
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. Select the Stick mode with the HF/Lift Start/Stick/Cut selector switch.
3. Make sure electrode holder is located in the positive connector and the work clamp is located inthe negative connector.
4. Select the welding amps desired. Use the electrode diameter selection chart in this manual to determine
the approximate range of amps suitable for the rod size selected. Consult the welding electrode manufacturer’s recommendation for the proper amperage range. Each manufacturer has specific recommendations for
its electrodes, so exact settings may vary.
5. Use the arc force control to select the desired arc characteristics, creating the desired arc characteristic and
automatic amp response needed to maintain the arc when voltage falls below the threshold. 6010 and 6011
Cellulose electrodes will require more arc force control than other rods, but each brand and size will weld a
little differently. The arc force control setting will vary from person to person as well. Different rod angles,
positions, and arc lengths all factor into the arc force control performance and exact setting required.
6. Adjust hot start time and intensity to create a hotter start than the actual weld current to prevent rod sticking and improve starting reliability.
7. 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.
IMPORTANT: Do not attempt to weld in the TIG mode with the Stick electrode holder or Plasma torch still attached. Do not
attempt to select a new process with another torch attached to prevent accidental damage to the unit and torch!
33
Section 3
Basic theory and function
Plasma Cutting Technique
0°-15°
EDGE
1
PIERCE
40°-60°
2
TRAVEL
3
TRAVEL
1/16”
Piercing starts often result in rapid consumable
wear and excess blow back of molten metal deposited onto torch and consumables. This
should be performed only as necessary.
1. Tilt the torch in the direction of travel or
toward the side of the metal to be discarded
or wasted at a 40° to 60° angle. Slide the yellow safety lock and squeeze the trigger. Wait
for arc to start.
2. Once the arc starts, wait for the arc to transfer from pilot arc to the cutting arc.
3. As the torch penetrates it flame at an angle
rotate the torch slowly to the vertical position, as the arc penetrates the metal. Tilt the
torch from 0°-15° for thin metal cuts, or hold
it nearly perpendicular for thicker metal cuts.
4. Begin moving the torch in the direction of the
cut. Maintain 1/16” standoff height.
5. Move the torch fast enough so the sparks
and flame trails from the bottom edge at an
angle of no more than 30° and no less than
10° from perpendicular to the metal. Excess
angle of sparks/flame indicate too fast of
travel speed or practical cut capacity has
been reached. Little or no angle indicates
too slow of travel speed.
Edge Starts are the best type of start if possible
to promote consumable and torch life. This reduces blow back of molten material and allows a
smooth gradual start of the cut.
1. Line up the hole on the tip of the electrode
on the edge of the cut. Hold torch perpendicular to the cut initially, about 1/16” off
the metal. Slide the yellow safety lock and
squeeze the trigger. Wait for arc to start.
2. Once the arc starts, wait for the arc to penetrate all the way through the metal.
3. As the torch penetrates its flame all the way
through the metal, tilt the torch so there is a
slight lead in the flame if metal is thin. If it is
thick, keep holding torch in a nearly vertical
position.
4. Begin moving the torch in the direction of
the cut. Maintain 1/16” standoff height.
5. Move the torch fast enough so the sparks
and flame trails from the bottom edge at an
angle of no more than 30° and no less than
10° from perpendicular to the metal. Excess
angle of sparks/flame indicate too fast of
travel speed or practical cut capacity has
been reached. Little or no angle indicates
too slow of travel speed.
IMPORTANT PLASMA CUTTER OPERATING NOTES:
1) If you use a standoff guide with the torch, it must be adjusted to provide no more than 1/8” standoff, less if possible. Too much standoff reduces cut capacity and quality. Kerf and dross will be increased. It will also increase consumable wear and may prevent the pilot arc from
correctly transferring to the work piece. However, do not drag the consumables unless you are using shielded consumables.
2) If arc fails to transfer check the work clamp connection. Make sure the work clamp is directly contacting the metal to be cut and is on a clean
section of metal. If not reroute the work-clamp so that it directly contacts the metal. If necessary, grind a spot clean to ensure good contact.
3) The design of the blow back start may cause a slight delay in the arc as the air pressure must built inside the torch tubing and head to create
the pressure needed to force the electrode off the nozzle seat. This may take up to two seconds. Restarting the arc with the post flow going
may not cause a delay. If the torch does not light after 3 seconds, let go of the trigger and press it again. If arc or arc start is inconsistent or
otherwise unstable check the nozzle and electrode for tightness and wear. Also make sure the swirl ring is installed and not damaged.
34
Section 3
Basic theory and function
TIP: For longer consumable life do not use the pilot arc unnecessarily. Select the 3 second
pilot arc feature and do not fire the torch unless you are near the metal and ready to cut.
For expanded metal cutting be sure to select “Normal” to re-fire the pilot arc automatically.
FLAME AT FAST TRAVEL SPEED
FLAME AT NORMAL TRAVEL SPEED
TRAVEL
TRAVEL
FLAME AT SLOW TRAVEL SPEED
TRAVEL
NOTE: When stepping down amps to cut thinner material, you must change to smaller orifice nozzle. Standard nozzle supplied is rated for 50-60 amp cutting. Nozzles are offered
through in different sizes which are appropriate for different amp levels. Too large of a diameter orifice will result in arc instability and a rough cut. Lowering the air pressure below 65 psi
to try to get the torch to cut will only result in a lazy, wandering arc.
IMPORTANT: Check consumables regularly for wear and change them out before they are
completely worn. Allowing the consumables to wear until they quit working may damage
related torch components, creating a more costly repair.
35
Section 3
Basic theory and function
RESULTS OF CUT AT CORRECT SPEED,
AIR PRESSURE AND TORCH ANGLE
RESULTS OF CUT AT FAST SPEED
SMOOTH, EVEN CUT LINES WITH A S REARWARD SWEEP
ROUGH, DISTINCT CUT LINES SPACED FAR APART
NOTICEABLE SMALL, HARD DROSS
MINIMAL EASY TO CLEAN DROSS
RESULTS OF TOO MUCH CURRENT OR
TOO MUCH STAND OFF HEIGHT
(SIDE VIEW)
RESULTS OF CUT AT SLOW SPEED
VERTICAL CUT LINES
MELTED TOP EDGE
SIGNIFICANT SOFT, POROUS DROSS
RESULTS OF WORN CONSUMABLE(S)
OR LOW AIR PRESSURE
(SIDE VIEW)
SEVERLY ANGLED CUT AT TOP
36
Section 3
Basic theory and function
AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING OUT A DISK SHAPED OBJECT
AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING HOLE IN AN OBJECT
NOTE: When cutting an object, particularly a pattern shape, where the torch must pierce or re-fire in-line at an
intersection of a cut, a lead-in cut should be employed. A lead-in is a cut that is made in the disposable part (also
known as a drop) of the object to “lead” into the main part of the cut so that the destructive force of the arc is
not directed into the desirable side of the cut itself. Also, all plasma cutters exhibit some angularity or bevel in
the cut which is greater on one side than the other. Keep this in mind when cutting an object to size to prevent
too much metal from being accidentally removed.
37
Section 3
Basic theory and function
GENERAL POLARITY RECOMMENDATIONS*
*Follow manufacturer of stick electrode for complete polarity recommendations
PROCESS
TORCH POLARITY
WORK POLARITY
TIG (GTAW)
-
+
STICK (SMAW)
+
-
TIG (GTAW) OPERATION GUIDE FOR STEEL (ALUMINUM)*
*As a general rule, set amperage using 1 amp for every .001” of metal thickness for aluminum. Less is required for DC.
METAL THICKNESS
WELDING AMPS
(A)
1-3 mm/.040”-1/8”
40-80 (60-125)
TUNGSTEN DIA.
Ar FLOW RATE
1-2 mm/.040”-3/32” 8-15 CFH /4-7 lpm
3-6 mm/ 1/8”-1/4”
80-200 (125-200) 2-3 mm/ 3/32”-1/8” 15-25 CFH/ 7-14 lpm
6-10 mm 1/4”-3/8”
150-200 (200-250) 3-6 mm/ 1/8”-1/4”
20+ CFH/10-15 lpm.
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”
40-50
3 mm/ 1/8”
3.2 mm/1/8”
90-110
4-5 mm/ 3/16”
3.2-4 mm/ 1/8”
90-130
6-10 mm/ 1/4”-3/8”
4–5 mm/ 1/8”-5/32”
130-200
TUNGSTEN SELECTION GUIDE FOR AN INVERTER
TYPE
Pure
PERCENT
100% Tungsten
COLOR
PROCESS
RECOMMENDATION
Green
AC
NOT RECOMMENDED!
Do not use in an inverter.
Thoriated
2% Thorium
(slightly radioactive)
Red
AC/DC
YES. Great for all purpose welding. Most economical.
Ceriated
2% Ceria
Orange
AC/DC
YES. Good for low amp use.
Lanthanated
1.5% Lanthanum Gold
AC/DC
YES. Best alternative to 2% Thoriated. Tough
performer.
Lanthanated
2% Lanthanum
Blue
AC/DC
YES. Slight advantage over 1.5% Lanthanated.
Zirconiated
1% Zirconia
Brown
AC
NOT RECOMMENDED!
Do not use in an inverter.
NOTE: Thoriated tungsten is slightly radioactive, but is commonly used in the US. Care should be used when grinding so as
not to breath the dust. If you have concerns about Thoriated (red) tungsten, choose from Lanthanated or Ceriated tungsten.
38
Section 3
Basic theory and function
EXPANDED VIEW OF TIG TORCH
(Actual appearance may vary slightly from what is listed.)
1
1
2
1
9
3
4
5
6
7
12
8
13
5/8”
5/8”
9
14
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Basic part diagram for 18 or 20 Series Torch ( STYLE MAY VARY)
Long Back Cap with O-Ring
Short Back Cap
Torch Head
Insulator
Collet 1/16 or 3/32
Collet Holder
Ceramic Cup #5,6, or 7
Tungsten (customer supplied)
Torch Cable
Torch Handle (Blue ergo handle std, not pictured)
Torch Switch (Built into ergo handle, separate on straight handle)
Torch Switch Connector
9mm (1/8”) b quick connect coupling (male)
Power Connector
Protective Synthetic Rubber Cover
39
QTY.
1
Opt.
1
1
1
1
1
0
1
1
1
1
1
1
1
15
Section 3
Basic theory and function
POWERPRO 205 iPT/PT 60 PLASMA TORCH*
* Note: Not all items, accessories or parts are sold directly through Everlast. In this case parts are provided as general information. Everlast is not the manufacturer of the Innotec/Tec.mo
PT/iPT 60 torch nor is it affiliated with either company other than as an OEM supplier of the torches. More Innotec and Tec. mo torch parts and consumables are available from national
distributors of the Innotec/Tec.mo brands. Innotec and Tec.mo are trademarked brands. Information courtesy of Tec.mo. Back striking design is patented.
40
Section 3
Basic theory and function
7 PIN CONNECTOR FOR 47K/22K Ω FOOT PEDAL OR AMPTROL
Bridge to 7
To Pedal or Torch Switch
Bridge to 6
To Pedal or Torch Switch
41
Section 4
Trouble Shooting
TROUBLE:
CAUSE/SOLUTION
Machine will not turn on.
Check cords and receptacle wiring. Check circuit breaker.
Machine runs, but will not weld in either mode.
Check for sound work clamp and cable connections. Make
sure work cable and TIG Torch are securely fastened to the
Dinse style connector. Reset main power switch if overcurrent light is on. Contact Technical Support.
Arc will not start unless lift started or No “spark”.
Too long of stand off. Failed HF module. Contaminated
tungsten. No tungsten or stick out too short.
Tungsten is rapidly consumed.
Inadequate gas flow. Too small of tungsten. Wrong shielding gas or contaminated shielding gas. Use only Ar. Using
green tungsten. Use red thoriated or other color. Wrong
polarity . Too much AC cleaning.
Tungsten is contaminated, arc changes to a green color. Tungsten is dipping into weld. Check and adjust stick out
to minimum 1/8 inch. Tungsten is melting. Reduce amperage or increase tungsten size.
Porosity of the Weld. Discolored weld color. Tungsten
is discolored.
Low flow rate of shielding gas. High flow rate of shielding
gas. Too short of post flow period. Wrong TIG cup size.
Possible gas leaks internally or externally due to loose
fittings. Base metal is contaminated with dirt or grease.
Weld quality is poor and is dirty/oxidized with possible
porosity.
Eliminate drafts. Check if there is sufficient shielding gas
left in tank. Check gas flow. Adjust for higher flow of gas.
Listen for audible click of gas solenoid. If no click is heard,
then contact Everlast Support. Clean weld properly, especially in Aluminum. Too short of post flow time. Check
tungsten stick out. Consider using gas lens.
Over current/Duty cycle LED illuminates. Machine runs,
but no output with code.
Duty cycle exceeded or Over current. Allow machine to
cool. Reset main power switch after full cool down period.
Make sure fan is not blocked. Check wiring. Loose cord.
Unstable Arc.
Poorly ground or shaped tungsten. Regrind to proper
point. Too much stand off height. Drafty conditions. Welder fan is blowing on weld area. Move welder to a cart.
Wrong polarity. Aluminum: Too much AC positive polarity. Reduce balance to 30% or less. Increase AC Frequency. Possible magnetized base. Reroute cables and/or coil
around table leg. Work clamp too far from work piece.
Move work clamp close to weld area and clamp direct.
HF spark but no welding arc (often referred to as seeing
lightning bolt or small blue spark)
No ground connection. Wrong polarity. Too great of distance between tungsten and work piece. Too large of
tungsten with too little amps. Contact Everlast after
checking all above issues for possible internal issue.
Unstable arc or irregular starts at low amps. Arc flashing on and off, oscilating between HF and arc.
Start amps/End amps too low for tungsten diameter. Use
smaller tungsten. Too far from work piece or inconsistent/
shaky standoff height. Reduce tungsten to work distance
to 1/32”to 1/16” for low amp start. Move work clamp.
Other issues.
Contact Everlast support.
42
Section 4
Trouble Shooting
PLASMA TROUBLE SHOOTING:
CAUSE/SOLUTION
Air Flows but arc does not start within 2-3 seconds.
Check consumables for wear and tightness. Check fuse.
Check Air Pressure. Sticky or slow spring/piston on torch blow back
mechanism. Release trigger and try again. Preflow turned on.
Air Flows but arc does not start or spark when nozzle is
rubbed on the metal.
Pre Flow is turned on. Fuse blown. Missing swirl ring. Worn or loose
consumables. IGBT issue. PCB issue.
OK to cut light is not on. Will not start arc.
Increase air Pressure. Make sure air is connected.
Pilot arc will not light.
Fuse blown. Check fuse. Make sure consumables are correct.
Pilot arc will not transfer and amps read approximately Check work clamp connection. Make sure rust is removed from work
25-27 amps while switch is held. (Arc barely cuts or only clamp contact area. Faulty Clamp. Arc continuity is not being sensed. If
“scratches” the surface of the metal or cut is extremely these steps do not correct the issue, contact Everlast.
slow on thin materials.)
Arc Sputters.
Inadequate air flow or air pressure. Improperly sized nozzle. Decrease
size as amps are lowered. Increase air pressure to 70-75 psi while air is
flowing through torch. Loose consumables. Check tightness.
Consumables are dirty, smutty looking upon inspection. Moisture, oil contamination of consumable. Wrong consumables. Poor
Premature wear on consumables. Shortened consum- quality aftermarket consumables.
able life.
Premature wear on consumables. Short consumable
life. Uneven wear of consumables, melting of cup.
Moisture, oil contamination of consumable. Excessive pilot arc time.
Improper cutting technique. Wrong piercing technique. Wrong/
mismatched consumables.
Arc will not start. Air will not flow. Machine runs.
Torch cup is loose, safety contact pins dirty or not making contact with
cup face. Torch switch wire is loose. Problem with connector. Torch is
not properly connected.
Arc will not start. Air flows. Machine runs.
Swirl Ring damaged or missing. Wrong Polarity. Wrong process selected.
Unstable Arc at lower amps.
Consumable orifice size is too large. Reduce orifice size. Wrong air pressure. Poor work clamp connection. Check clamp and connectors.
Arc tries to start but irregular, dancing arc and/or arc
melts through side of nozzle.
Missing swirl ring, or worn electrode or both. Check and replace. Make
sure swirl ring is not cracked.
Arc will try to start if touched to the metal, but no air
flow while switch is pressed.
Stuck or dirty solenoid valve. Contact Everlast. Wrong Process selected.
Air flows continuously.
Post flow turned set too long. Preflow is turned on. “Gas Test” is selected. Solenoid is stuck. Contact Everlast.
Excessively Beveled Cut.
Worn consumables, too high of stand-off height.
Cup and/or nozzle is melting or cracking.
Improper cutting technique/excessive piercing.
Power input circuit breaker trips repeatedly.
Improperly sized circuit. Internal issue. Contact Everlast.
Arc “Blows Out” when ready to cut.
Too high of air pressure. Reduce to 72 psi. Use smaller nozzle
Arc will not stop when switch is released.
Unit is in 4T. Switch to 2T. Torch trigger is stuck.
43
Section 4
Trouble codes
DIAGNOSIS
TROUBLE CODE WITH WARNING LIGHT/
UNIT STOPS WELDING BUT IS TURNED ON.
801
OVER OR UNDER VOLTAGE. Check power input cable for length/size, check input voltage. Running on poor
quality power supply or dirty/low power from generator.
802
OVER CURRENT. Check to make sure input power cable is correct length and size. Internal unit fault or low
input voltage. Possible issue running on generator .
804
OVER TEMPERATURE/DUTY CYCLE EXCEEDED. Allow unit to rest for at least 15 minutes while running. Do not
turn the unit off. Allow the fan to continue to cool the unit. Check for obstructions, clean welder and heat
sinks. Make sure unit is unplugged for 30 minutes before opening up for cleaning.
805
TORCH SWITCH IS STUCK CLOSED. Turn off welder immediately and check torch switch for stuck contact.
Check foot pedal for complete return or stuck micro-switch. Do not hold down the switch or pedal without
attempting to strike an arc. Doing so for more than 2 seconds without starting will cause this error code.
806
Air Pressure is too low (Plasma).
OTHER/No Code displayed
CONTACT EVERLAST
44
NOTES:
45
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