Everlast POWER MTS 221STi, PowerMTS 252STi Operator's Manual

EVERLAST

POWER MTS 221STi

A Digitally

-

Controlled, Multi

-

Process MIG/AC

-

DC TIG/Stick Welder

CC

GMAW

SMAW

GTAW

IGBT

AC/DC

PULSE

Operator ’ s Manual for the PowerMTS 221STi

Safety, Setup and General Use Guide

Rev. 1 0 10308 18 everlastwelders.com

Specifications and Accessories subject to change without notice.

1 877 755 9353

329 Littlefield Ave. South San Francisco, CA 94080 USA

Table of Contents

Section ……………………………………………….

Page

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

Everlast Contact Information …………….………….

Safety Precautions ……………………………………

Introduction and Specifications …..…………………

Overview of Parameters and Specifications …….

Technical Parameters ……………………………...

General Description, Purpose and Features …….

Set Up Guide and Component Identification ….…...

Connections and Polarity ………………………….

Installing The Wire Spool ………………………….

Polarity/Gas/Amp Recommendations ……………

Front View Middle Panel ……………………….……

Middle Panel Item Description and Explanation..

Front View/Control Panel …………………………….

Control Panel Item Description and Explanation..

Side View …………………………………..…….......

Side View Item Description and Explanation..

…..

Rear View Back Panel ……………………………….

Rear Panel Item Description and Explanation …..

Basic Theory and Function ………………………….

MIG Operation …..…………………………………….

MIG Operation (Diagrams) …………..………………

Special Notes Concerning Operation ………….…

Stick Operation ………………………………………..

Basic TIG Operation ………………………………….

TIG Arc Starting …………………………………….

Tungsten Preparation ……………………………..

Pulse TIG Operation ………………………………….

AC TIG Operation …………………………………….

TIG Work Sheets …………………………………...

25 Series MIG Torch ………………………………

25 Series Consumables …………………………..

24 Series MIG Torch ………………………………

24 Series Consumables …………………………..

26/18 Series TIG Torch ……………………...……

Trouble Shooting Guide …………...………………...

Error Codes …………………………………………

52

54

55

56

58

61

64

65

66

67

68

70

71

37

38

39

40

40

45

48

50

14

23

24

26

27

28

39

36

3

4

5

9

9

10

11

14

2

Dear Customer,

THANKS! You had a choice, and you bought an Everlast product. We appreciate you as a valued 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 at the main customer service number in your country.

Your unit ’ s warranty will be registered and in full effect. Keep all information regarding your purchase, including date of purchase and receipt. In the event of a problem with your unit or other issue you must contact technical support before your welder can be a candidate for warranty service and returned. An over the phone review/ diagnosis must be performed BEFORE a RMA will be issued or before the unit can be sent in for service.

Please read the warranty statement published online and other important information found on the Everlast website of the division located in or nearest to your country. This includes the terms of the purchase and warranty procedure. Print it for your records and become familiar of its terms and conditions. Please note that

Guns, accessories and torches are covered under a separate, shorter warranty. Please be sure you visit the website and are familiar with all the warranty terms before you call for service.

Everlast offers full technical support, in several different forms. We have online support available through email, and a welding support forum designed for our customers and non customers to interact with each other. 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. This support is free to all

Everlast customers. For best service call the appropriate support line and follow up with an email, especially during weekends, holidays or any off hours when you cannot reach a live person. In the event you do not reach a live person, leave a message and your call will normally be returned within 24 hours, except for weekends and holidays. Also, for quick answers to your basic questions, join the company owned forum available through the website. You ’ ll find knowledgeable staff available to answer your questions. You also may 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: [email protected]

Everlast Website: everlastwelders.com

Everlast Technical Support: [email protected], [email protected]

Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php

Main toll free number : 1 877 755 WELD (9353) 9am— 5 pm PST M F

11am 4pm PST Sat .

FAX: 1 650 588 8817

Everlast Canada:

Everlast consumer satisfaction email: [email protected]

Everlast Website: everlastwelders.ca

Everlast Technical Support: [email protected]

Telephone: 905 630 8246 9am 4:30pm EST M F

Everlast Australia:

Sydney: 5A Karloo Parade Newport NSW 2106

(02) 9999 2949

Port Macquarie: 2B Pandorea Place Port Macquarie

(02) 6584 2037

After hours support: 0410 661 334

Everlast Technical Support: [email protected]

OTHER (Please record here for your records):

4

Safety Precautions

Everlast is dedicated to providing you with the best possible equipment and service to meet the demands of the welding applications that you have. We want to go beyond delivering a satisfactory product to you. That is the reason we offer technical support to assist you with your needs should an occasion occur. With proper use and care your product should deliver years of trouble free service.

Safe operation and proper maintenance is your responsibility.

We have compiled this operator ’ s manual to instruct you in basic safety, operation and maintenance of your Everlast product to give you the best possible experience. Overall, welding requires experience and common sense to obtain the best results in the safest manner. As thorough as this welding manual may be, it cannot substitute for the time, instruction and knowledge level required to learn how to weld. Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even life depends upon it. While an accident is never planned, preventing an accident requires careful planning.

Please read this manual carefully before you operate your Everlast unit. Do not operate this welder until you are thoroughly familiar with its safe and proper operation. If you feel you need more information please contact Everlast.

The warranty does not cover improper use, maintenance or consumables. Accessories such as guns, torches regulators, foot pedals etc. are not covered in the unit warranty. They are covered under a separate warranty. Do not attempt to alter or defeat any piece or part of your unit, particularly any safety device. Keep all shields and covers in place during unit operation should an unlikely failure of internal components result in the possible presence of sparks and explosions. If a failure occurs, discontinue further use until malfunctioning parts or accessories have been repaired or replaced by qualified personnel.

Note on High Frequency electromagnetic disturbances:

Certain welding and cutting processes generate High Frequency (HF) waves. These waves may disturb sensitive electronic equipment such as televisions, radios, computers, cell phones, and related equipment. High Frequency may also interfere with fluorescent lights. Consult with an electrician if disturbance is noted. Sometimes, improper wire routing or poor shielding may be the cause.

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

5


These safety precautions are for protection of your 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 from danger and injury.

Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can cause severe skin burn and damage . There are other potential hazards involved with welding such as severe burns and respiratory related illnesses. Therefore observe the following to minimize potential accidents and injury:

Use appropriate safety glasses with wrap around shields while in the work area, even under welding helmets to protect your eyes from flying sparks and debris.

When chipping slag or grinding, goggles and face shields may be required.

When welding or cutting, always use an approved shielding device, with the correct shade of filter installed. Always use a welding helmet in good condition. Discard any broken or cracked filters or helmets. Using broken or cracked filters or helmets can cause severe eye injury and burn. Filter shades of no less than shade 5 for cutting and no less than shade 9 for welding are highly recommended. Shades greater than 9 may be required for high amperage welds. Keep filter lenses clean and clear for maximum visibility. It is also advisable to consult with your eye doctor should you wear contacts for corrective vision before you wear them while welding.

Do not allow personnel to watch or observe the welding or cutting operation unless fully protected by a filter screen, protective curtains or equivalent protective equipment. If no protection is available, exclude them from the work area. Even brief exposure to the rays from the welding arc can damage unprotected eyes.

Always wear hearing protection because welding and cutting can be extremely noisy. Ear protection is necessary to prevent hearing loss . Even prolonged low levels of noise has been known to create long term hearing damage. Hearing protection also further protects against hot sparks and debris from entering the ear canal and doing harm.

Always wear personal protective clothing. Flame proof clothing is required at all times. Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose clothing is tucked in neatly. Leather aprons and jackets are recommended. Suitable welding jackets and coats may be purchased made from fire proof material from welding supply stores. Discard any burned or frayed clothing. Keep clothing away from oil, grease and flammable liquids.

Leather boots or steel toed leather boots with rubber bottoms are required for adequate foot protection. Canvas, polyester and other man made materials often found in shoes will either burn or melt. Rubber or other non conductive soles are necessary to help protect from electrical shock.

Flame proof and insulated gauntlet gloves are required whether welding or cutting or handling metal. Simple work gloves for the garden or chore work are not sufficient. Gauntlet type welding gloves are available from your local welding supply companies. Never attempt to weld with out gloves.

Welding with out gloves can result in serious burns and electrical shock. If your hand or body parts comes into contact with the arc of a plasma cutter or welder, instant and serious burns will occur.

Proper hand protection is required at all times when working with welding or cutting machines!

This welder contains moving parts that can result in injury. Keep hands, fingers, hair, and loose clothing away from the wire feeding mechanisms and fans while unit is switched on and in use. Do not attempt to defeat any safety feature. Always operate unit with guard in place on the wire feeder.

6


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 are 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


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

Overview of Parameters and Features*

Power i MIG 221STi**

MIG/TIG/Stick Amp Range

Volt Adjustment Range MIG

MIG Wire Feed Speed

Input Voltage

Welder Type

Wire Roll Size and Diameter

120V: MIG 30 125A/ TIG DC: 10 125A, AC: 20 150A / Stick 10 120A

240V: MIG 30 200A/ TIG DC: 10 250A, AC: 20 250A / Stick 10 200A

120V: 15.5

21V 240V: 15.5

26V

120V: 60 400 (.5

10 m/min) 240V: 60 to 600 IPM (.5

15 m/min)

120 240V Single phase (208V permissible)

Digitally controlled, IGBT inverter type with CV Synergic MIG , AC DC Pulse TIG, CC Stick functions.

.023” .045” wire diameters possible with optional drive rolls and guns. (.023

.030” Standard equipped)

8” diameter(10 12 lbs.); 4” Diameter supported but reconfiguration of the spool carrier is needed.

Pre/Post Flow Control MIG/TIG MIG: (Pre) 0 10 Seconds/ (Post) 0 10 Seconds; TIG (Pre) 0 10 Seconds/ (Post) 0 10 Seconds

Up/Down Slope of MIG Volts/ TIG Amps MIG: 0 1 Second; TIG: 0 10 Seconds

Synergic MIG/Manual MIG Synergic MIG function for wires from .023” to .045” in diameter, with mild steel, stainless and Aluminum settings. Synergic feature operates via speed control on MTS version of Spool gun as well. Manual MIG affords complete and independent control throughout the range of all MIG functions with no factory programmed settings.

MIG Burn Back Timer Control

Inductance/Arc Force Control

TIG Output Type

AC TIG Frequency

AC Balance

0

0

-

-

20

30

2 seconds

100%

-

-

200Hz

AC/DC with Pulse Control and Wave Form Selection (Advanced Square Wave, Triangular)

70% of Electrode Positive (+)

TIG Pulse Frequency

Base Pulse TIG Amps

TIG Pulse Time On/Balance

Memory

MIG Burn Back Timer

Stick Hot Start Timer

Stick Hot Start Intensity Control

Stick E6010 Capability

Power Cable Length

Accessories**

.5

3

5

0

-

-

Saves up to 9 programs.

-

150Hz

95%

95% of Peak Amps

2 Seconds

0 2 Seconds

Yes

9.5 ft. (3m)

0 100% over set amperage

15 Series MIG torch ( Optional 24 Series) torch 9.5 ft. (3m), 26 Series air cooled TIG torch, Work clamp with cable 9.5 ft. (3m). 300 A Stick Torch with cable (3m), Floating ball type regulator.

Weight, Nominal Dimensions 66 lbs. (bare unit)/30 Kg, Length: 26”, Width: 11”, Height: 16” (19” with handle)

Recommended Generator minimum*** 240V: 8500W Surge, 120V: 4500W Surge

*See next page for complete electrical and technical data.

** Due to minor changes in manufacturing and suppliers of accessories, specifications and accessories subject to change without notice.

***Any use with a generator must be used with a generator rated as providing “ clean power ” by the generator manufacturer. This is typically less than 5% THD. Any use with a generator not certified by its manufacturer as providing clean power may render the warranty void.

9


MODEL: PowerMTS 221STi

1~ f

1 f

2

S

S

S

1~ 50/60 Hz

PROTECTION

CLASS

IP21S

U

0

V

74V

U

0

V

74V

U

0

V

74V

U

1

120 240V

EVERLAST

POWERMTS 221STi

Serial No.

EN/ IEC60974.1

120V; DC: 30 150A; 15.5

20.3V 240V; DC: 30 200A; 15.5

26V

X

I2

U2

60%

125A

20.3V

100%

100A

19V

120V; DC: 10 125A; 10.4

15V

AC: 20A 125A; 10.8

15V

X 60% 100%

30%

200A

24V

60%

22V

160A

100%

130A

20.5V

240V; DC: 10 200A; 10.4

18V

AC: 20 200A; 10.8V to 200A/18V

35% 60% 100%

I2

U2

125A

14.8V

100A

14V

120V; DC: 10 100A; 20.4

– 24V

X

I2

U2

60%

100A

100%

80A

200A

18V

35%

NA

160A

16.4V

60%

160A

130A

15.2V

120V; DC 10 120A; 20.4V

24.8V

100%

130A

24V 23.2V

NA 26.4V

25.2V

120V I

1MAX:

33.2A I

1EFF

26A

240V I

1 MAX:

33.6A I

1EFF

23A

COOLING METHOD:

MULTIPLE

FULL TIME FANS

INSULATION: F WIRE SPEED:

240V: 60* 600 IPM

120V: 60* 400 IPM

*60 IPM is based on minimum useable feed rate.

NOTE: Environment, Maintenance and Safety: Keep this welder at least 18 inches away from all objects for proper cooling.

This unit uses multiple fans at different spots within the machine for cooling so proper spacing is imperative from all sides.

Do not exceed 40° C in environment or duty cycle will be reduced. Regularly inspect and clean the welder and circuitry on a monthly basis with dry compressed air. Remove the covers only after the unit has been turned off and unplugged for 30 minutes to discharge the capacitors and to prevent the possibility of electrocution. Do not grind or direct sparks near the welder to prevent damage to the panel face and internal components. Regular disassembly and cleaning with dry compressed air is highly recommended. Damage/failures resulting from metal/ dust buildup is not covered by the warranty.

Bare Weight: 30kg/66 lbs.

10


General Description, Purpose and Features. The Power

MTS 221STi multi process unit features an industry first

MIG TIG Stick unit with AC/DC TIG output. As with Everlast ’ s other compact MTS units, this unit employs HF arc starting for TIG as well as a Lift TIG arc start feature.

The TIG capability of this unit is further enhanced by a completely adjustable pulse. In MIG mode the unit features both standard and synergic MIG modes. Synergic

MIG is a useful feature to help simplify set up and reduce the need for extensive operator knowledge of ideal volts, amps and wire speed ratios. The spool gun capability of this unit allows the user to weld aluminum in MIG mode. The optional Parker spool gun is perfectly suited to this welder and is a good choice for welding aluminum at a faster rate than AC TIG typically allows.

But when thinner gauges are required, the TIG function offers the ability to weld aluminum down to .023”. The

PowerMTS 221STi also features a synergic function for spool gun use, which is also unique for this welder, allowing control of both amps and volts through one knob. This welder does not have the traditional bulk of an undercarriage which is normally associated with multi process welders of this range of capability, helping it retain portability. In addition, the welder can accommodate up to 8” rolls of MIG wire ( up to 12 lbs. typically). Although specially designed after market 4” spool adapters can be purchased from many after market suppliers, Everlast does supply a spool carrier that can be reconfigured and adapted for the 4” spools so smaller rolls may be used in the machine. If possible, always use the larger 8” rolls however due to concerns with excessive cast and spiral from the small diameter of the 4” wire roll. As it exits the gun, it may create a wandering arc. If 4” rolls are typical of your pattern of use, consider the spool gun option which is ideal for this type application. Additionally, it is far more economical to purchase wire in a 10 or 12 lbs. at a time than in a small 1 or 2 lb. roll if you consider price per pound of wire. The welder is capable of storing up to 9 programs for rapid setup and recall of favorite settings. This feature is helpful when storing favorite pulse programs.

The unit also features a heavy duty wire feeding mechanism with 4 driven drive rolls for maximum wire feeding capability. The multi process aspect of this welder features additional welding processes which include DC TIG and Stick. The TIG process also features an industry first for MIG/TIG/Stick welders: a fully adjustable TIG Pulse setting, which allows the unit to pulse up to 150 times a second between two selected amp values. The TIG process also features High Frequency (HF) start (which is another industry first) to allow contactless starting of the TIG arc. The PowerMTS 221STi is the first unit in the

11 industry to feature out the front controls for TIG, which also includes a solenoid controlled gas connection. See below for additional summary of features:

1) GMAW Process (MIG). The digitally controlled

MIG components precisely control arc functions and give real time feed back about the welding output parameters. As already mentioned, the welder is also spool gun (gun optional) ready for economical welding of Stainless and Aluminum wires if needed. The PowerMTS 221STi can also be used with flux core and dual shield wire (when equipped with optional flux core drive wheels.)

However, since there is no Flux Core/Dual Shield synergic setting, Flux Core/Dual Shield operation will not be optimized in synergic mode and manual mode should be used. Although the standard gun is competent to be used with flux core wire, a special flux core gun may be necessary for heavy duty Flux core (non gas) use. Or a special shielded consumable can be purchased locally from suppliers of the

15 series type guns. At this time, Everlast does not offer a flux core gun or shield for this unit. However, many after market suppliers of MIG guns do offer special flux core guns that can be equipped to fit the popular Euro Style power connector that the

PowerMTS 221STi utilizes.

2) GTAW (TIG). The TIG mode of the welder features both AC and DC output which is suitable for welding all metals when required. It includes a high frequency start and a lift start function to give the operator maximum flexibility welding in areas that restrict HF use. A fully adjustable AC mode with AC wave form selection feature allows the user to weld Aluminum and Magnesium. A fully adjustable pulse feature is also included to help control heat and distortion. It can also be used to improve bead appearance. A key feature of this welder ’ s design places all connections on the front of the panel instead of under the spool cover. No install kits are necessary to make the unit TIG ready. A gas solenoid is used to automatically control gas flow when the arc is started and stopped according to the time set on the panel. A foot pedal or torch switch is used to control the TIG function. The pedal controls the amps when plugged in. Similarly, the torch switch provided with the TIG torch can be used to control the functions on the panel sequencer graph. The sequencer can be used to preset amp and slope parameters to work in conjunction with the torch switch. It is also used to control other aspects of the weld parameters that may be

Section 1 Introduction and Specifications related to 2T/4T torch switch or foot pedal operation. The unit is ready to TIG weld (with the exception of Tungsten and shielding gas) when it arrives.

Additional TIG consumable kits can be purchased from Everlast which include stubby consumables or gas lens kits with Tungsten in the kit. Attention!

Be sure to read all the connection directions located in this manual and important information regarding proper connections of torch and work cable in TIG mode or damage or improper operation may occur.

3) SMAW (Stick). In stick mode the welder delivers a smooth DC low spatter arc. Professional, high quality welds are obtainable with E7018, 7014,

309L, 316L, 6011 and many other similar rods that are designed for use with any DC stick welder. This unit is optimized for welding E6010. This setting also works well with the easier welding E6011. The

Stick mode also features adjustable hot start time and hot start intensity controls which are designed to help reduce sticking during arc starts while simultaneously reducing porosity or inclusions during arc initiation. Note: This unit does not provide AC operation in stick mode. AC operation is for TIG only.

4) Stick Arc Force Control. The arc force control adjusts the quality and feel of the welding arc. It does so by modifying the volt/amp curve. As the voltage drops below approximately 20 volts when the arc gap (length) is shortened, the unit reacts by automatically boosting the amps over the original Amp setting. This helps to prevent the rod from sticking and helps keep the arc going as arc voltage falls.

This action also boots penetration and can be used to change the way the arc feels and acts.

5) Burn Back Control. Burn back control is used to control the length of the wire stick out after the trigger is released. It helps to prevent the welding wire from sticking in the coalescing weld puddle after the arc is terminated and saves the user from having to trim the wire before restarting the arc.

6) Synergic MIG Mode. Synergic mode may be engaged to simplify welder setup and adjustment.

This mode will allow the customer to input basic parameters and the machine will automatically set the wire feed speed (amps) and voltage based off of the user input. The unit ’ s programming is easily overridden and the welder will remember the new ratio of voltage to wire feed setting during the active welding session until the process is changed, or until the Synergic mode is deselected. The machine has three synergic modes, one for standard MIG

12 operation, one for standard Spool gun operation and one for standard push pull gun operation. If a setting is found that is desirable, be sure to save it under a program number and record it, or the settings will be lost once you leave the welding session/mode.

7) Pulse TIG Mode. The pulse TIG feature can be employed to control heat, wicking of the puddle and reduce the arc cone diameter, improving the directability of the arc. The Pulse TIG mode allows the setting of Pulse Amps, Pulse Frequency, and

Pulse Time On. Each features serves to change and shape the welding arc and puddle to control heat, wet in and penetration.

8) Pre and Post Flow Control. The adjustable Pre and

Post flow control features are designed to improve weld quality at the beginning and end of the weld where porosity from oxidation can be a problem.

This is accomplished by providing adjustable time controls for both pre flow and post flow of shielding gas. This control is active for both MIG and TIG.

9) MIG Start and Crater Fill (MIG End) Feature improves starts and starts, and helps prevent bead cracking and porosity in 4T mode.

10) Slow Run in of Wire. This feature improves arc striking quality in MIG modes by helping prevent arc stuttering (machine gunning) and push off during arc initiation by slowing the wire speed until the arc is established. Note: This feature does prevent the user from taking accurate measurements of wire feed speed manually as the wire will feed slower until the arc is struck and maintained. Adjustments to starting (upslope) may be made to further improve the arc starting properties of this welder.

11) Spool Gun Modes.

This welder is well equipped to handle the aluminum welding needs of most customers by being both spool gun ready. The unit can handle several different Everlast spool gun models, but the best is the 300 amp, Parker® DSP

360A spool gun. Also the user may want to consider the Everlast SM200N MTS gun which is a 200+

Amp gun with a 24 series barrel. A spool gun is an economical choice for light to heavy applications requiring a fast deposition rate of aluminum on materials 3/16” or greater in thickness. A spool gun is limited to 4” rolls (usually holding 1 lb of aluminum and 2 lbs of other filler metals) so numerous spools may be needed on larger projects .

Note: This unit does not support push pull gun operation. It only supports spool gun operation.


Basic Design and Construction.

This multi process welder features an intuitive control panel and couples it mode at 200 Amps and a rating of 60%@ 160 Amps while welding in stick mode(240V). The duty cycle rating is the amount of time (expressed as a percentwith digitally controlled IGBT inverter design that produces a stable arc while conserving energy. Everlast utilizes quality components from US, European, and

Asian based companies to ensure reliability and parts commonality. Major control components are of a modular, plug and play design which allows rapid diagnosis and repair of the welder. Welding parameters can be age) out of 10 minutes the unit can weld without a rest.

For MIG, the unit is capable of welding 3 minutes out of every 10 minutes at the maximum output of 200 Amps.

For the balance of the 10 minute period, the unit should be allowed to rest and cool while running. This rating is based off a 40° C maximum temperature. If the unit ’ s duty cycle has been exceeded, the Stop LED infinitely and continuously adjusted throughout the range, offering instant welding response for maximum control.

Installation. The basic construction of the PowerMTS

221STi is rugged and durable. It is considered ideal for circumstances where portability is of concern. Critical will come on and unit will cease welding output. An error code of “ E04 ” will be displayed If a duty cycle event has occurred. Allow the unit to run and cool for

15 minutes. After 15 minutes of cooling the unit while switched on without welding, cycle the power switch to reset the unit if needed. In the event of an overcurcomponents are protected by coatings to make the welder environmentally resistant and has a water ingress rating of IP21S, (the standard in the welding indusrent, the welding output will cease and the “ Stop ” LED will come on and an error code of EO2 will be displayed. In duty cycle and overcurrent events, the wire try to protect from vertically dripping water). However, some common sense care should be exercised to make sure that the welder offers the safest and best performay continue to feed without output. Overcurrent events can be caused by too low of supply voltage, running on undersized extension cords, too large of wire diameter, too high of settings for wire diameter, too mance. Please note the following items regarding safe and proper operations to ensure best service and results while welding: high of input voltage, or internal or external electrical fault. When an overcurrent has occurred, turn the machine off immediately, then check and remedy the fault

1) Do not use the welder in damp or wet areas. Perspiration and other forms of water in contact with before cycling the welder back on. If the error does not clear after cycling, cease operation and call Everlast

Technical Support. Do not intentionally and repeatedthe body can increase the risk of electrocution.

2) Do not use the welder in extremely corrosive environments. To maintain optimum power transfer, check main connections, clamps and cables frequently to ensure that components are not corroded. Excessive dirt, corrosion and oxidation can result in an unstable arc and excessive heat build up. ly trigger the duty cycle limiter. Doing so repeatedly will shorten the lifespan of the unit ’ s components.

Under or over voltages will also trigger the Stop LED.

The error code of E01 will be displayed. This is likely a result of a poor power supply, a long extension cable, or from running off of a generator that is malfunction-

If the work clamp becomes corroded or damaged, be sure to replace it with a heavy duty work clamp rated for at least 300 amps. If your work clamp ing. Note: If a generator is going to be used with this unit, please make sure that it is certified by it ’ s manufacturer to be “ clean power, ” which is normally stated appears to become extremely hot while welding, and all connections are clean and secure, replace the work clamp. Unstable arcs and hard starting, as less than 5% THD ( Total Harmonic Distortion). Everlast makes no recommendation or certification of any generator ’ s suitability for use with our units. The certification or statement of assurance from the manuespecially in MIG mode are often the result of poor work clamp condition or connection.

3) Store the welder covered with a moisture and fire facturer of wattage and clean output capability is to be obtained from the manufacturer of the generator.

For proper operation with a generator, make sure you resistant material.

4) If used on a mobile cart, strap or fix the welder to the cart so that accidental overturn is not likely.

Duty Cycle/Overcurrent/Under Voltage/Overvoltage

Warnings. Thanks to a quad cooling fan design, the

PowerMTS 221STi has a duty cycle rating of 30% at 200

Amps while welding in MIG. 35% while welding in TIG have at least a minimum 8,500 watts of surge capability and 6500 watts of continuous rated output capability. Any failure of the unit related to the unit running on “ dirty ” power or underrated wattage will not be covered under the warranty. Unit failure or damage is not always immediate or visible and can occur gradu-

13 ally over a long period of time.

Section 2 Setup Guide and Component Identification

CONNECTIONS AND POLARITY

REAR

ADJUSTMENT VALVE The Ball valve will float briefly once the main cylinder valve is opened and will then settle down and stop floating after 4 to 5 seconds. Fully open the cylinder when in use to prevent valve leaks. If the valve continues to float, you have a leak. Stop and check. To adjust the gas flow rate, the welder must be turned on. Select MIG or TIG and set post flow to maximum. Gas flow is actuated by pressing the trigger on the torch (or pedal) and tapping it. The small knob on top of the down tube that connects to the hose adjusts gas flow rate. Screw the valve counter clockwise to increase flow.

This meter will work with both Argon and Argon/CO2 mixes. The rate is calibrated in Cubic Feet per Hour (CFH) The pressure gauge only confirms pressure inside of the tank. The clear plastic tube determines actual flow rate. As the cylinder looses pressure near the end, flow rate may need to be readjusted. This is normal. Read the flow rate of the gas at the middle of the floating ball. Do not open the cylinder valve quickly or damage can occur to the regulator occur over time. Also, do not leave the regulator on when not in use or loss of cylinder contents may occur over time. Asphyxiation may occur if leaked cylinder contents flood the area.

FLOATING BALL

580 CGA

5/8” INERT

CYLINDER PRESSSURE

GAUGE

NEMA 6 50P 50A 240V 1

PHASE

TIG:

For All Metals:

Use 100% Argon

Only or Ar/He mix

No more than 25%

Helium for best arc starts.

MIG:

Steel: Ar/CO2 Mix,

75/25 or 80/20 for

Short Circuit

Stainless: Various including 98/2 Ar/

CO2 or Ar/O2 or Tri -

MIX Blends.

Aluminum: 100%

Argon

Only

NOTE: To safely connect the regulator to the cylinder, first make sure the cylinder is properly chained and secured. Then, before connecting the regulator and while standing to the side of the cylinder (not in front of the discharge), briefly crack the valve and allow a 1 to 2 second blast of gas to clear any dirt or contamination from the valve seat.

Then connect the regulator and screw clockwise until finger tight and finish tightening with a wrench. Do not use a pair of pliers. Make sure the fitting is tight and slowly open the valve to check the connection for leaks with luke warm soapy water (or approved leak detector solution) applied to the fittings at the valve. To connect the hose to the rear of the unit, connect the 5/8” gas fitting to the rear, rotating clockwise until finger tight. Then use two (2) wrenches to complete the tightening process. One wrench should be placed on the female machine side gas inlet nut and should be held while the other wrench is used to finish tightening the male fitting. Do not tighten with one wrench or damage to the female nut and fitting may occur (even though the fitting seems to be tight and secure enough to hold the pressure.) The female side must be held to prevent rotating in the housing, and stripping of the fitting inside. Check all fittings and connections for leaks once again. Do not use thread tape or sealant on threads of the unit, regulator or cylinder. These are compression fittings and will tighten up once proper pressure has been achieved. If hoses show sign of leaks, tighten the clamps with a pair of side cutters or end nippers. Simply squeeze the clamp tighter until the leak stops or add an additional clamp if necessary.

14



REAR (NOTES)

Connections: To safely connect the regulator to the cylinder, first make sure the cylinder is properly chained and secured. Then, before connecting the regulator and while standing to the side of the discharge (not in front of the discharge), briefly crack the valve and allow a 1 to 2 second blast of gas to clear any dirt or contamination from the valve seat. Then connect the regulator and screw the fitting clockwise until finger tight and finish tightening with one (1) 1 1/8” wrench.

Do not use a pair of pliers or other grip/lock devices. Use a large adjustable wrench if no other wrench is available. Make sure it is tight and slowly open the valve to check the connection for leaks with luke warm soapy water (or approved leak detector solution) applied to the fittings at the valve. To connect the hose to the rear of the unit, screw the 5/8” gas fitting into the gas inlet on the rear of the unit, rotating clockwise until finger tight. Then use two (2) 3/4” wrenches to complete the tightening process. One wrench should be placed on the female gas inlet nut and should be held tightly to while the other wrench is used to finish tightening the male fitting. Do not tighten with one only one wrench or damage to the female nut and fitting may occur (even though the fitting seems to be tight and secure enough to hold the pressure). The female side must be held to prevent rotating in the housing and stripping of the fitting inside. Check all fittings and connections for leaks once again. Do not use thread tape or sealant on threads of the unit, regulator or cylinder.

Plugging and sticking of the gas solenoid valves, regulator or torches may occur if thread sealants are used. The compression fittings used will tighten up once proper pressure has been achieved.

If the cylinder will not seal, the threads may be worn on the valve or mating surfaces scarred. If hoses show sign of leaks, tighten the clamps with a pair of side cutters or end nippers. Gently squeeze the clamp tighter until the leak stops or add an additional clamp only if absolutely necessary. If the regulator leaks, while under warranty contact Everlast for a replacement. Warning !

Never attempt to repair a leaking regulator yourself. The parts are under pressure. Serious i njury or death may occur.

Adjustment: The Ball valve will float briefly once the main cylinder valve is opened and will then settle down and stop floating after 4 to 5 seconds. Fully open the cylinder when in use to prevent valve leaks. If the valve continues to float, you have a leak. Stop and check. To adjust the gas flow rate, the welder must be turned on. Select MIG or TIG and set post flow to maximum. Gas flow is actuated by pressing the trigger on the torch (or pedal) and releasing (or holding depending upon the mode selected). The small knob on top of the down tube that connects to the hose adjusts the gas flow rate. Slowly screw the valve counter clockwise to increase flow and watch the ball begin to float. Read the scale where the ball is floating. The ball should float until the gas flow stops. This meter will work with both Argon and Argon/CO2 mixes. The rate is calibrated in Cubic

Feet Per Hour (CFH). The pressure gauge only confirms pressure inside of the tank. The clear plastic tube determines actual flow rate. As the cylinder looses pressure near the end, flow rate may need to be readjusted. This is normal. Read the flow rate of the gas at the middle of the floating ball. Do not open the cylinder valve quickly or damage can occur to the regulator can occur over time. Caution! Do not leave the regulator on when not in use or loss of cylinder contents may occur over time. Asphyxiation may occur if leaked cylinder contents flood the area as the gas will displace oxygen. Always use the welder with proper ventilation as well to prevent build up of spent gas.

15



STOP!

Read the information on this page and the following pages carefully. It contains important information on correct polarity of your torches and guns for all processes.

CAUTION!

Pay attention to the separate DC and AC TIG connections. Failure to do so can result in poor operation of the welder, and even damage if the unit is improperly connected. The AC connector is designed for use in TIG mode only and serves as the work clamp connection in AC mode. (Stick mode does not provide AC output.) Even if you switch the machine to AC, you will still need to move the work clamp cable to the AC output terminal connector. The TIG torch will always remain in the negative (

-

) connector. Remember to switch back to the positive (+) connector when reverting to DC TIG operation.

Remember!

Remove TIG and Stick torches and controls while MIG welding.

These connections remain live and can cause the torch to short out against any metal it is in contact with. The MIG gun may remain connected while welding TIG or stick but the nozzle must be insulated from contact. A small rubber hose or non conductive tubing may be slid over the tip of the gun to protect it if needed. Do not attempt to weld with the work clamp in the AC port. Check before welding.

16



MIG (GMAW)*

GUN + WORK -

*The feeder connection located under the spool cover must be located on the positive terminal. MIG requires that the gun be used with a positive polarity.

17



Flux

-

Core (F

-

CAW)*

GUN WORK +

* The feeder connection located under the spool cover must be located on the negative terminal. Flux -

Core wire requires that the gun be used electrode negative (EN) in most cases. Consult the wire manufacturer recommendations as the final authority . Dual shield wire is run

18



MIG (GMAW) with Spool Gun*

NOTE: This unit cannot be fitted with a push pull gun.

GUN +

CONTROL

WORK -

*The feeder connection located under the spool cover must be located on the positive terminal. MIG requires that the gun be used with a positive polarity. Keep in mind that if the gun is used with steel flux core wire the work connection must be positive and the gun connection must re connected negative under the spool cover.

19



DC TIG ONLY! (GTAW

-

DC)

Note: Pictured, Water Cooled Setup. Although fitted with a water cooler power plug on the rear, the water cooler is optional and must be purchased separately. The unit comes with a 26 series air cooled TIG torch to support the 200 amp capability of the welder. To connect the 26 series, the

DINSE connector return line pictured below as “ to cooler ” actually becomes the gas line. If needed, any series and brand torch, including any water cooled torch may be fitted to the unit, including water cooled A DINSE 35 connector will have to be purchased from the torch supplier in addition to the torch. However, to simplify this process, contact Everlast for a NOVA brand torch product that is for a high quality, flexible torch specifically designed to fit your unit.

GAS

TO COOLER

FROM COOLER

WORK +

TO CONTROL

TORCH -

PEDAL SWITCH

The foot pedal and the torch switch cannot be connected at the same time. The torch switch may remain attached to the torch, but since they both use the control connection and serve a similar purpose only may be used at a time. Note: The unit is supplied with a water cooled torch and the diagram depicts proper connection for water cooled torches. Do not use this torch without a water cooler or torch damage will occur. To determine the gas line blow through the lines with compressed air. Improper connection will result in no gas flow or water coming out of the torch head. For an air cooled torch alternative (all air cooled torches handle 200 amps or less), contact Everlast for a full range of Everlast and NOVA torches.

20



AC TIG ONLY! (GTAW

-

AC)

Note: Although fitted with a water cooler power plug on the rear, the water cooler is optional and must be purchased separately. The unit comes with a 26 series air cooled TIG torch to support the 200 amp capability of the welder. Any series and brand torch, including any water cooled torch may be fitted to the unit, including water cooled A DINSE 35 connector will have to be purchased from the torch supplier in addition to the torch. However, to simplify this process, contact Everlast for a NOVA brand torch product that is for a high quality, flexible torch specifically designed to fit your unit.

GAS

WORK (AC)

TO COOLER

FROM COOLER

CONTROL

TORCH -

PEDAL SWITCH

The foot pedal and the torch switch cannot be connected at the same time. The torch switch may remain attached to the torch, but since they both use the control connection and serve a similar purpose only may be used at a time. Note: The unit is supplied with a water cooled torch and the diagram depicts proper connection for water cooled torches. Do not use this torch without a water cooler or torch damage will occur. To determine the gas line blow through the lines with compressed air. Improper connection will result in no gas flow or water coming out of the torch head. For an air cooled torch alternative (all air cooled torches handle 200 amps or less), contact Everlast for a full range of Everlast and NOVA torches.

21



Stick (SMAW)*

TORCH + WORK -

*This is the typical setup for stick welding. Most all welding electrodes use electrode positive as the preferred polarity. Some will run electrode negative (EN) if needed. Most will not perform well in EN. Consult the electrode manufacturer ’ s recommendations for applications of EN. Usually E6011 is considered to be able to run EN, but runs better EP.

22

Section 2 Setup Guide and component Identification

INSTALLING THE WIRE SPOOL

To load the spool of wire:

1.

2.

3.

4.

5.

6.

7.

Loosen and remove the small threaded tensioning nut on the spool carrier by turning it counter clockwise.

Remove the tensioning spring and outer hub spacer.

Slide spool onto the shaft. Make sure wire is unwinding from the bottom of the spool. Lift the spool enough to ensure that the hub seats on the inner shoulder of the carrier. (For 4” rolls, spool will fit against inner shoulder). Some rolls, depending upon brand, may fit slightly different.

Reinstall the outer hub spacer, with the short side of the spacer ’ s shoulder facing in. (For 4” rolls, the long side will face in and sandwich the roll between the inner and outer hubs).

Reinstall the tensioning spring and threaded tensioning nut

Lightly spin the spool. If it free wheels more than 1/4 turn, tighten the tensioning hex nut slightly, 1/4 turn and retest the free wheel. If it does not free wheel at all, loosen the nut until it free wheels 1/4 turn.

Locate the end of the wire and clip the bent end of the wire so that it will feed through the wire feed mechanism smoothly. Carefully hold the spool of wire with one hand so the wire will not de spool. Be sure to clip the end of the wire with a pair of sharp wire cutters so the wire is cut completely straight . Proceed to instructions listed below: “ To thread wire from the spool properly through the feeder.

”

8

-

1

2

4

5

3

A.

B.

C.

To install the MIG gun (torch).

Align pins on the torch connector with the feeder receptacle.

C snug. Tighten only by hand or damage may result.

Twist the plastic hand nut on the connector clockwise until it is

B

6

5

A

C

To change the polarity of the MIG gun: Unscrew the screw from the (+) terminal. Move copper cable lug to the hole in the ( — ) terminal lines up with the hole in the buss bar. Reinstall the screw into the ( — ) terminal. Tighten until cable is secure and will not rotate if moved by hand.

4

Bottom Drive Roll Sizing

(See side for stamped size)

.6mm=.023

” .025”

.8mm=.030

”

.9mm=.035

”

1.0mm=.040

”

1.2mm=.045

”

To thread the wire from the spool properly through the wire feeder into the gun:

1.

Install the MIG gun as instructed in “ To install the MIG gun (torch) ” above. Loosen the top idler roller tensioner, rotating the black tensioner knob counter clockwise.

2.

3.

4.

5.

Flip the tensioner down, toward you, releasing the carrier arm that holds the top drive rolls.

Raise the carrier arm up. Inspect the drive rolls to make sure that each roller ’ s groove size matches the wire diameter. Also make sure correct type of drive rollers are used. i.e.

Flux Core drive rolls use special serrated rolls. (Top driven rollers do not have grooves and are not to be removed).

Reversal of the lower drive roll to select the right size drive groove may be necessary. To reverse the lower drive roll: Remove the retaining screw with the black plastic securing the lower drive roll. Remove the outer ring of the drive roll and flip the drive roll over. The drive roll is actually made of two pieces. Hold the inner assembly of the drive roll on with one finger (to prevent it from slipping off the shaft), while slipping the outer “ rim ” of the drive roll off with the other hand. NOTE: Both inner and outer parts of the assembly have locating keys. To reinstall: Line up the outer rim of the drive roll keyway with the locating key. Reassemble and tighten. Before finishing assembly, make sure the locating key is fully in place and have not slipped out of the key way during assembly. Lightly coat the inner mating surfaces with light weight lubricant oil if necessary to prevent future seizure. Do not lubricate the surfaces of the drive rolls or wire slipping and erratic feeding may result.

Follow instructions above: “ To Load Spool of Wire.

” Make sure the spool of wire is loaded correctly so that the wire unrolls from the bottom of the spool (counter clockwise).

Thread the wire into the coiled guide and over the matching groove in lower drive roll. Thread the wire fully through until it threads into the gun section 4” 6”. Lower the upper drive roll into contact with the lower drive roll while keeping the wire securely fixed in the groove. If needed, use a screwdriver with a fine blade or small pick to keep the welding wire from moving out of the grooves until step 6 is completed. Recheck once again that the correct drive groove has been selected.

6.

7.

8.

Raise drive roll tensioner back into place. Tighten it slightly so the wire will feed. Make a note of the visible markings on tensioner handle for future reference.

Remove the contact tip from the torch. (Not Shown). Hold the torch cable and gun as straight as possible, in direct line with the unit so feeding of the wire through the gun liner is smooth and easy. Press the gun trigger to feed wire until the wire exits the end of the torch. Reinstall the contact tip over the wire over the wire and tighten it.

To prevent bird nesting or slipping of the wire, adjust the tensioner clockwise until the drive rolls will not slip when the wire comes into contact with a hard surface. The wire will curl up on end while feeding under power. If you over tension the wire, you will increase the chances of bird nesting of the wire (balling up of the wire or curling of the wire around the drive rolls), so it is best to tighten just until wire stops slipping and is able to curl up. Extra tension can deform wire and prematurely wear the drive rolls. Slowing of the feeder may result as well. Remember not to test on any metal attached to the work clamp to prevent the wire from arcing while performing this test.

23


Table 1

GENERAL POLARITY RECOMMENDATIONS*

*Consult the manufacturer of the filler material recommendations concerning polarity .

PROCESS TORCH POLARITY WORK POLARITY

MIG (GMAW)

+

-

FLUX CORE (FCAW) -

+

STICK (SMAW)

+

-

TIG (GTAW) -

+ /AC

TYPICAL GAS SELECTION AND SETTING GUIDE

Table 2

PROCESS

MIG (GMAW) STEEL

MIG (GMAW) STAINLESS

MIG DUAL SHIELDED

MIG (GMAW) ALUMINUM

TIG (GTAW) STEEL/STAINLESS

GAS

80/20 Ar/CO2 or 75/25 Ar/CO2 or 100% CO2 for short Circuit MIG

80% or higher Argon content (recommend: 90/10 CO2 ) or similar content for true Axial Spray Transfer. See below for basic flow rates.

98/2 Ar/O2 , 98/2 Ar/CO2, or TriMix/ StainMIX with Helium (20 35 CFH)

Follow wire manufacturer ’ s recommendations in product literature.

100% Argon (35 to 40CFH is usually needed for cleaner welds)

100% Argon (10 30 CFH depending upon cup size and welding environment)

Table 3

MIG (GMAW) CURRENT/WIRE/SINGLE PASS THICKNESS GENERAL SUGGESTIONS

WIRE DIAMETER

.023” (0.6 mm)

.030” (0.8 mm))

.035” (0.9 mm)

.040” (1.0 mm)

.045” (1.2 mm)

WELDING AMPS (A) PLATE THICKNESS

25 110

35 200

.040”

.040”

-

-

.063” (1.0

.128” (1.0

-

-

1.6)

3.2)

45 200 +

45 200+

60 200+

.040”

.050”

-

-

.128”.(1.0

.25”+(1.2

.25”+ (6.0+)

-

3.2)

6.0+)

GAS FLOW RATE

15 20 CFH /7 10 lpm

20 25 CFH/ 10 14 lpm

20 25CFH/ 10 14 lpm

25+ CFH/ 14+ lpm

25+ CFH/ 14+ lpm

IMPORTANT: Use the synergic function of the welder if you are unsure of the best volt and wire feed/amp settings to use. This feature automatically sets a generally useable volt/amp ratio for you. After this is selected and wire type and diameter of the wire is selected it is a simple matter of turning the amps up or down until the arc is stable and the sound of the arc is a crisp frying sound. If no workable setting is obtained, the volt setting may be selected and adjusted up or down while in synergic mode. Adjusting the volts will reset the volt/amp ratio and create a whole new range of adjustment capability. Deviating from the standard the shielding gas mix for the metal/wire in MIG mode will affect how accurate the volt/amp ratio is. The synergic mode provides much better results in general than a chart can provide. Please note that in synergic mode, the unit display defaults to read in Amps, not the actual wire feed speed (IPM) while adjusting. This is not denoted by a separate LED light. Also, note that the unit will default to a relatively low amp setting. This is intentional as the welder does not compute the thickness of the metal being welded. You will need to adjust the Amps to match the metal thickness yourself.

Displaying in Amps in synergic mode is a more accurate method since the wire diameter and type is entered and actual amps can be pre computed before the gun trigger is activated. While actively welding in manual or synergic modes, both the volt meter and the wire feed/amp meter will display actual, real time output. There will be some variation in the reading as arc length, angle and even metal cleanliness constantly fluctuate. Keep in mind that wire feed speed controls amps, but the same wire feed speed feed setting on different diameter wires will change the amount of amps delivered at the same set feed rate.

Many wire manufacturers provide a range of amps and or wire speed feed, and volts for their wire type in the printed material in their brochures, packaging information, or in their online information.

Actual suggested wire feed speed/amp and volt ranges may differ somewhat from brand to brand. MIG inductance settings will also affect final preferred settings. You'll find that settings will vary according to the welding position and joint type. Any recommendation will not be 100% accurate and can vary widely. For additional help with manual or synergic setup, consider downloading one of the numerous welding apps available online. Before adjustment of volts and amps begins, set the inductance to approximately 65 75%, then fine tune the inductance only after all fine tuning of volts and amps has been completed. Stainless will usually require around 90 to 100% setting for inductance for proper wet in of the puddle but that also will vary a little based upon wire class and gas mix. Generally, in spray mode inductance is not much of a factor, but leave the setting at the recommended settings for short circuit transfer.

24


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)

TUNGSTEN DIA.

Ar FLOW RATE

1 3 mm/.040

” 1/8” 40 80 (60 125) 1 2 mm/.040

” 3/32” 8 15 CFH /4 7 lpm

3 6 mm/ 1/8” 1/4”

6 10 mm 1/4” 3/8”

80 200 (125 200) 2 3 mm/ 3/32” 1/8” 15 25 CFH/ 7 14 lpm

150 200 (200+) 3 6 mm/ 1/8” 1/4” 20+ CFH/10 15 lpm.

METAL THICKNESS

< 1 mm/.040

”

2 mm/.080

”

3 mm/ 1/8”

4 5 mm/ 3/16”

6 10 mm/ 1/4” 3/8”

STICK (SMAW) OPERATION GUIDE

ELECTRODE SIZE

1.5 mm/ 1/16”

2 mm/3/32 ”

3.2 mm/1/8 ”

3.2

4 mm/ 1/8”

4 – 5 mm/ 1/8” 5/32”

WELDING AMPS

20 40

40 90

90 110

90 130

130 200

Pure

TYPE

Thoriated

(slightly radioactive)

2% Thorium

Ceriated

Lanthanated

Lanthanated

Zirconiated

TUNGSTEN SELECTION GUIDE FOR AN INVERTER

PERCENT COLOR PROCESS RECOMMENDATION

100% Tungsten Green AC

2% Ceria

1% Zirconia

E 3/Tri Blend/Rare

Earth Mix

Various

Red

Orange AC/DC

1.5% Lanthanum Gold

2% Lanthanum Blue

Purple/ other

AC/DC

AC/DC

AC/DC

Brown AC

AC/DC

NOT RECOMMENDED!

Do not use in an inverter. Designed for use in a transformer only.

YES. Great for all purpose welding. Most economical. Best for DC, Good for AC. Excellent arc starting.

YES. Good for low amp use. Good for AC and

DC. Some fade out in performance at the higher end of the range may be observed over other types. Good arc starts.

YES. Best alternative to 2% Thoriated. Tough performer. Good for AC and DC.

YES. Slight advantage over 1.5% Lanthanated. Best for AC and DC use. Good arc starting. Holds point well in AC and DC.

NOT RECOMMENDED!

Do not use in an inverter. Designed for Transformer use only.

May be used with good results, but metal composition and quality may vary. Not an industry standardized type. Many blend in Zirconiated, which is typically not recommended for inverter use. Personal experience and brand experimentation may be required to obtain best and most consistent results.

25


FRONT VIEW/ CONNECTION PANEL POWER i MIG 221STi

7

6

5

4

GAS

OUTLET

CONTROL

3

2

AC

1

26


Middle Panel View and Explanation of Connections

1.

Negative Connector. The DINSE 35 Style connector is an industry standard sized connector.

The polarity of the terminal is always negative and does not change. This terminal is used as a work clamp location for MIG and Stick Welding.

For TIG the negative connector is always used as the location of the TIG torch, whether in DC or

AC modes. To connect the terminal, align the terminal tab on the male torch/work clamp fitting to the slot on the female fitting on the welder and twist clockwise until the connector is tight.

2.

AC Connector. The DINSE 35 Style connector is an industry standard sized connector. This terminal has one use only. It is designed to be used only in AC TIG mode. When AC TIG welding mode is selected, the work clamp should be relocated to this terminal. The TIG torch will remain in the negative. Warning: Never use this connection with the TIG torch or any other torch or mode of operation except AC TIG or damage may occur.

3.

Control Connector. This connector serves different functions in different modes. In TIG mode this connector is used to provide arc initiation in TIG mode. When the TIG torch switch is connected, it conveys the 2T/4T signal to operate the sequencer ( controls preflow, start amps, upslope, welding amps, downslope and end amps) When the foot pedal is connected for TIG mode, it serves not only to start the arc, but to regulate the amps. The foot pedal sends a signal to the welder to start the arc and a signal that tells the welder what relative position the foot pedal is in to increase or decrease the amperage.

In spool gun mode it serves to regulate the wire speed and initiate the arc. The control knob on side of the gun is used to change welding wire delivery speed, thereby regulating the amps.

The Gun trigger signals the welder to start feeding the wire, and to initiate the arc.

4.

Positive Connector. The DINSE 35 Style connector is an industry standard sized connector. The polarity of the terminal is always positive. This terminal is used as the torch (electrode holder) connection in stick mode. In DC TIG mode this is the location of the work clamp. This is used as the work clamp location, only while in DC TIG mode. In AC, mode the work clamp will be transferred to the AC Connector.

27

5.

Gas Connection. This is the gas connection when welding in TIG mode. The quick coupler is designed to offer quick and efficient coupling of the TIG torch gas line. If you are using a water cooled torch, before attempting to connect the gas line, blow through the gas line to verify that gas does indeed exit through the torch head.

Otherwise, improper gas connection may occur.

6.

Euro MIG Connector.

The MIG gun and Spool gun connect directly to this fitting. The connection offers quick and secure fitting of the MIG gun or spool gun directly to the unit. To secure the Gun to the fitting, align the small pins and large gas conductor fitting and slide together until it completely seats home. Then, gently screw the outer plastic hand nut on the torch connector clockwise until the fitting is secured. Do not overtighten or use any tool or pliers to further tighten the nut or damage may occur. Hand tight is sufficient.

7.

Clear Plastic Protective Cover. When the machine is in use, keep this protective cover down to prevent spark damage or UV damage to the panel from intense arc rays. When not in use the panel should remain down as well. The only time the panel should be raised is during adjustment..


FRONT VIEW/CONTROL PANEL POWER i MIG 221STi

3 4

5

8

1 2

14

9

11 6

13

10

12

12

7

28


Front Panel Description and Explanation of function:

1.

Volts/Seconds/Percent Display and LEDs. The

Volt/Function display works in conjunction with the LEDs directly beside the display. As different parameters are selected, the LED ’ s to the right of the display, that represent the unit of measure that is currently being represented will be lit.

The display represents Volts, seconds, and percent. After adjustment is completed to parameters other than Volts, the display will revert to displaying Volts after a few seconds of inactivity.

2.

Amps/Wire Speed/Hz Display and LEDs. The

Amps/Wire Speed/Hz display works in the same way as the Volts/Seconds/Hz Display and LEDs discussed in item 2 above. This display expresses value of the Amps, Wire Feed Speed or Hz

(PPS). As one of the Select buttons (#13) are pressed, it cycles through each LED function while the display shows the corresponding selected unit of measure for each function that the digital display is assigned to represent. NOTE:

Depending upon which process is selected, not all functions will be referenced during setup.

After selection/adjustment of the other display related functions is completed or if no adjustment is made after a few seconds, the display will default to the wire feed speed setting, displaying selected wire feed speed in Inches Per

Minute (IPM), until welding starts. When welding begins, actual amps output will be displayed dynamically. In the synergic modes, the wire feed speed no longer displays IPM, but displays in Amps. Amps is always represented as the default in synergic mode, as the LED is the same one used to represent IPM in standard and pulse modes. In stick mode, only Amps will be displayed.

3.

LED ON Indicator. The On indicator should be lit anytime the machine is turned on and the unit is receiving power. If the unit is switched on but no ON light appears and the fans do not start, check for a tripped breaker and check for incoming power at the receptacle. You may notice that the ON indicator along with the displays and fan, may remain powered up to 10 seconds after the unit is switched off as the capacitors discharge. This is part of normal operation and not a defect.

4. LED Stop Indicator. This indicator will light up anytime a machine fault or an electrical issue is detected. When this lights up, machine output

29 will cease and an error code will be generated in the display. Wire feeding may continue if the Stop indicator is on, but welding output will cease. If an error code is generated, look up the error code in the troubleshooting section of the manual.

Most error codes will require a power down and power up cycle of the unit to clear the codes and restore the operation of the unit.

5.

Program Selector and Save Function. A combined total of 9 different programs may be saved, whether it is in MIG, TIG, Stick or Spool Gun operation. Nine program settings are sufficient to allow the most frequently used settings to be stored and instantly recalled by using the green selector button to toggle to the stored program number. To save a program, toggle with the green selector button to the desired number where you wish to save the program. During toggling, the Program number LED will light up. Make sure this is an unsaved program number or one that you are willing to have erased as the programming does not block you from saving over an old program. Make sure all desired settings are correct before you save. Then press and hold the green selector button for around 3 seconds. Release the selector button when the “ SAVED ” light illuminates. The “ SAVED ” light stay lit briefly to confirm the program has been properly saved.

After the program has been saved and selection activity ceases, the “ PROGRAM NUMBER ” LED will go out. Be sure to write down which program you have saved and the basic settings you wish to preserve in case you accidentally resave over an old program.

6.

Synergic Function. NOTE: In syneric mode, the unit will display in Amps instead of Inches Per

Minute (Wire Feed Speed rate). The reason will be explained later in the paragraph. The Synergic function is used to simplify setup and improve results while welding. While similar to “ Auto -

Setting ” features in other brands, it is different and more advanced as it takes into account wire diameter and wire type and allows fine tuning without a “ one size fits all ” approach that would prevent you from fine tuning the settings to meet the user ’ s requirements. This makes this type of

Synergic feature superior to “ Auto Setting ” MIG units. The Synergic feature of this welder presets a ratio of Amps to Voltage that is useful for operation when the operator knows the selected type of wire and wire diameter. However, it does not create a fixed setting based off a particular metal

Section 2 Setup Guide and Component Identification thickness. Instead, the Synergic function automatically defaults to a minimum Amp setting based off of the combination of wire type and wire diameter selected by the user.

Because of the minimum factory default setting, this does not necessarily create a ready to weld setting.

The user will have to select the correct amperage for the thickness being welded. However, it does create a useable ratio of voltage to Amps by linking and locking (or rather electronically synchronizing) them together, so that the Amp setting alone can control both voltage and Amps (Wire

Speed) simultaneously. A rise in Amps will result in a rise of Voltage. And of course, a decrease in

Amps will result in a decrease of Voltage. Even though the machine is in the Synergic mode and designed to couple and control both Voltage and Amps simultaneously through the Amp setting, the Voltage can be fine tuned at any time by simply toggling to the Voltage adjustment and manually readjusting the Voltage. By making a change in the Voltage manually, the user can easily reprogram and establish a new ratio of Volts to Amps. Once Voltage has been fine tuned manually by the user, the unit will remember the new ratio of Volts to Amps. The user will once again be able to use the Amp setting to control both the Amps and Voltage together through the Amp setting and the new ratio will be retained until reset or the synergic mode is exited. Note that If further fine tuning is needed, the Voltage can be adjusted individually at anytime without affecting a change in Amps.

As before, this new Volt/Amp ratio will be remembered as long as the welder is in the current

MIG synergic mode. Once the user has exited the Synergic mode or the unit is powered down, the user established ratio will be cleared from memory and the unit will revert back to the factory set ratio. The user may notice that the

Amps displayed in digital display do not appear to reflect much change, if any, while cycling between the different synergic wire types and wire diameters. This is normal. Keep in mind that the unit is programmed to default to a minimum factory Amp setting for each change in the combination of synergic input of diameter and wire type. If the machine did display in “ inches per minute ” instead of amps, a change would be observed in the wire speed feed rate. The reason that Amps are displayed instead of Inches Per

Minute (IPM) is as follows: Due to the Ampacity

30

(the current carrying capability of a specific wire because of its diameter and metal type) of different available wires, each change of wire diameter and type creates a different wire speed to maintain the same amperage. In other words, while welding, different wires that are feeding at the same Inches Per Minute value will deliver different

Amp values. Since the exact wire type and diameter are known and input in the synergic mode, the

Amps can be accurately computed. In manual mode, Amps are impossible to prefigure and only wire feed rate can be displayed . Adjusting the Amp value instead of the wire feed rate is a more accurate and standardized way of welding a specified thickness when varying wire thicknesses could be used in the same application by different users.

It should also be noted that while actively welding, this unit reads actual output amps regardless of manually adjusted or synergic modes. To operate, simply select the type and size of wire being used once the synergic mode is selected. Selectable options for wire type include: Steel, Aluminum, and

Stainless. Wire sizes for the synergic function include, .023”, .030”, .035”, and .045” wire diameters. Some exact wire sizes may vary from what is listed. The synergic mode is not calibrated for Flux -

Core or dual shielded wires, or every possible formulation of filler wire, but does offer a good starting ratio for most hard wires. Remember, the synergic mode is designed to assist in setting up the machine and greatly simplifies operation. Again, to emphasize, the synergic mode will not automatically select the correct Amperage. It will only choose the best identified ratio of Volts to Amps and is dependent upon using industry standard shielding gases for each metal. (ie 75/25 for steel, 98/2 for

Stainless, and 100% Ar for Aluminum). It is used in lieu of complicated setup charts which can be inaccurate and difficult to read. Use the Synergic setting as a tool, and keep in mind that experience is the ultimate resource for proper machine setup. Special Note concerning Synergic operation with the spool gun: Make sure if you purchase a spool gun for operation with this unit, that a MTS version of the spool gun is purchased. This will offer you excellent control of both Amps and Volts through the speed control knob located on the spool gun. This is something particularly useful and will allow you better control than any other brand or type of spool gun on the current market by reducing your need to visit the panel to make corrections to volt-

Section 2 Setup Guide and Component Identification age while welding. You will not be able to adjust amps/wire speed on the panel in synergic mode since wire speed/amp control is routed through the gun, but will still be able to fine tune voltage on the panel if needed. Otherwise, the synergic spool gun mode operates essentially the same as the Synergic MIG mode.

7.

Mode (Process) Selector. Select the desired process by toggling the arrow button. Each press of the button will advance and highlight the next process to the right. Select between the following processes: Standard MIG mode,

Synergic MIG mode, , Standard Spool Gun mode,

Synergic Spool Gun mode, AC Standard TIG mode, AC Pulse TIG Mode, DC Standard TIG mode, DC Pulse TIG mode, Standard Stick mode and E6010 (Cellulosic) Stick mode.

In standard

MIG or Standard Spool gun modes, volts and amps are controlled completely independent of each other. When Synergic MIG or Synergic

Spool gun mode is selected, the Synergic mode

LED will light above the synergic section to remind you that the operation is synergic instead of manual. In TIG mode, be sure to select the work clamp location that is appropriate for AC or

DC. If using with cellulosic rods, such as E6010, remember to adjust the arc force and hot start modes and keep a short arc if possible.

8.

Stick Arc Control Selector and VRD In stick mode, there are 3 additional functions besides

Amp adjustment that the user has control over.

The first is the arc force percent. The arc force percent will be represented in the left display and is adjusted from 0 100%. This gauges the amount of amp reaction, or boost, when the arc voltage begins to drop below satisfactory levels

(< 20V)while welding. This helps to prevent the arc from going out or the rod from sticking in the puddle when the rod is held close to the puddle while welding. The goal of arc force is to help maintain overall wattage. The setting range of arc force control is the % of available amperage over and above the standard welding amperage that the programming will boost the amperage to maintain the arc. . It can also be used to help increase penetration by “ pushing into the puddle ” when more heat is needed. This feature can also be referred to as “ Arc Dig ” as it allows the user to tightly control the arc without loosing needed fluidity of the puddle. As a good starting point, consider setting arc force for around 30 -

35%. If welding with a cellulosic rod, such as

31

E6011, more arc force will be needed. Begin at

50% and work up to 70% to maintain best arc performance. If E6010 is required, though not recommended due to possible arc stability questions, settings of 70% or greater may be required. The second adjustment is Hot Start %. This is similar to arc force control as it boosts Amperage, but different in the fact it is not arc length dependent.

The Hot Start boosts the Amps only at the start of the arc, to help bring the weld and rod up to temperature quickly, thereby reducing the effects of a colder start which usually results in porosity and poor fusion under the arc start area. It also helps to reduce failed arc start attempts. The Hot Start

% setting is often referred to Hot Start Intensity, as it adjusts how aggressive the Hot Start will be. A good preliminary setting is anywhere between 30 -

50%. The third adjustment is Hot Start Time. This adjustment simply is used to define how long the

Hot Start function stays engaged once the arc strike occurs. For a starting point, adjust Hot Start

Time to .2 to .3 seconds, increasing or decreasing from there, as needed. HINT: Use more Hot Start

Time and Intensity for thicker metals and thicker electrodes (rods) . In the separate subsection, the

VRD represents a safety feature that allows the

OCV to be reduced. When the Voltage Reduction

Device (VRD) is selected, OCV is dropped below 20

Volts to reduce the chance of electrical shock while welding stick in situations where the worker may become grounded and become a potential circuit path of the electricity. In some situations,

VRD is require to ensure the safety of the operator. VRD can in some cases make starting a little more delayed or difficult.

9.

Pedal/2T/4T selector. Press the button to select one of the torch switch or pedal function modes.

Select 2T for simple press and hold operation of the torch switch. For 2T operation with the torch switch: 1) Press and hold the switch to start the arc and weld. Release the switch to cease welding.

Select 4T for advanced use of the sequencer controls on the panel such as pre flow, post flow, up slope and down slope. To operate in 4T mode with the torch switch/remote: 1) Press and release the switch to start arc. 2) The current will begin to upslope to reach normal welding current.

3) Press and hold switch to begin the downslope cycle to fill the crater. 4) Release switch to terminate the arc. In 4T mode, if the puddle becomes too hot, it can be cooled by lightly tapping the switch to begin downslope and tapping again to

Section 2 Setup Guide and Component Identification restart upslope before end current is reached.

Setting a long downslope helps improve heat control in 4T as the torch switch is cycled between downslope and upslope before the arc is terminated. IMPORTANT: To use the foot pedal mode select pedal mode and adjust TIG amps to the maximum desired setting. The pedal will then control the amperage throughout the entire range of amps up to the maximum selected amperage, based off the pedal position.] The foot pedal is for TIG use only. The 2T /4T modes can be with TIG mode or MIG mode.

10.

TIG Start Type Selector. The unit features the capability to select from two start types when welding in TIG mode. The default mode is High

Frequency Start (HF Start). This allows the arc to be started while holding the tungsten just above the metal, without having to make contact. This results in smoother, contaminant free arc starts. A HF pulse is generated which will bridge the gap between the Tungsten and the work piece. This establishes the arc. This is a unique feature on the PowerMTS, but is an expected feature on any true TIG welder. The second type of start is the Lift Start. This requires the tungsten to be touched to the metal and lifted up to start the arc. This is not as clean of a start as HF and some tungsten and/or work piece contamination may occur from time to time. This is still a smoother start than a typical scratch type start but not as smooth or easy as an HF start. This is the same type start found on many MIG/TIG/Stick welders. It is a less clean start option, but does a good job when HF start is not required or is restricted in HF sensitive environments such as hospitals, near electronic equipment.

11.

Sequencer. The sequencer controls the arc cycle and other related parameters to the selected process ’ s function. These are controlled by the selector buttons in #12. The sequencer controls items such as pre flow, post flow, TIG/MIG

Upslope, TIG/MIG Down Slope, MIG Volts, MIG-

MIG Inductance, MIG Burn back, TIG Amps, TIG

Pulse Amps, TIG Pulse Frequency, TIG Pulse

Time On, AC Frequency and AC Balance.

12.

Selector Buttons. The selector buttons are used to highlight each function found in the sequencer. Pressing the left button will move the highlighted LED to the next applicable function in the sequencer chart. Pressing the right button will move the highlighted LED to the next applicable

32 function in the sequencer chart. Depending upon the process selected, some LED ’ s will be skipped over as the button is pressed. Do not let that confuse you as some features are not related to the process or settings you have chosen. As each function is selected, the value may be represented in seconds, volts, amps, percent or in Hertz. As the sequencer is cycled left or right, the display to be read to determine the value of the highlighted sequencer feature and the LED representing the unit of measurement may change. If no adjustment is made to the selected parameter, the unit will default back to display the wire speed feed/ amps.

13.

Adjustment Control. Any adjustable value, including volts and amps is controlled through this single knob. To adjust, highlight the desired LED related to the function you wish to adjust by using the Selector buttons (#12) for

MIG and TIG sequencer, or the Selector button for related Stick functions (#10). Then turn clockwise to increase the value of the feature, or counter clockwise to decrease the value of the feature. While turning, you will feel fine

“ clicks ” or stops in the movement of the knob.

This is normal and each click will increase or decrease the value by the smallest unit of measure the function is programmed to display. This may prove slow or tedious when large amounts of change in value are required.

To adjust in greater increments (10x), push the knob in slightly, until greater resistance is felt and turn the knob at the same time. This will expedite the adjustment process, when large changes are required. Release the button and it will automatically spring back and return to adjusting in smaller increments.

14.

AC Wave Form Control. This PowerMTS model features wave form control in AC mode. The

AC mode is a unique feature for this type of multi process welder. It is designed to work in conjunction with the TIG only. The wave form selection allows the user to tailor the arc to the look and feel that is desired. Each wave form has distinct patterns which distinguish them from one another. For the default wave form,

Advance Square Wave, the wave form produces a strong, fast wetting arc and puddle. Along with a very stable arc, It provides rapid welding speeds and provides the most “ heat ” in a weld.

The second wave form, the Triangular Wave, is

Section 2 Setup Guide and Component Identification good for light gauge metals and offers great control and good bead profile qualities on thin gauge metals. The way the wave form is shaped, it spends the least amount of time fully “ on ” at the peaks, so output will seem reduced and even the meter may show a lower top end output. However, due to the way the wave form is shaped, in laymen ’ s terms, the meter reads a lower output than actual computed output.

This is normal.

Generally, given the fact that the triangular wave form is intended for lighter gauge metals, the

“ cooler ” feel of the arc will not be an issue.

Additional features located within the Sequencer.

1.

MIG Inductance. (Located on the far left side of the Sequencer Graph.) Varies the current rise time while welding after the arc shorts to the puddle during the short circuit transfer process.

This affects the actual physical point where the current has risen sufficiently to melt back the wire, subsequently pinching off and depositing in the puddle. The physical point at which the wire has burned back is considered the “ pinch point ” of the arc. This is where the wire will melt back to before transferring the wire back to the puddle to once again short out. To put it in more practical terms, the user will see that the wire is sticking out longer or shorter from the MIG torch before it burns away, depending upon the exact setting. This controls spatter, penetration and bead profile. When the arc force knob is rotated from one extreme to the other, the operator will observe that the arc is more stiff at one end or more fluid at the other end. Bead profile changes will occur as well. A stiffer arc will produce a deeper but more narrow profile. A fluid arc will produce a wider, shallower weld, usually with an improved bead appearance and less spatter. Arc force control is also known as inductance control, slope or wave form control (MIG). By changing the level of inductance, the user can fine tune the arc performance so the welder responds in a manner that the user is accustomed to with other brands of machines. The arc sound will also change as the arc force is adjusted, going from a relatively high pitched whine to a frying sizzle. All MIGs, regardless of brand, without an adjustable arc force, do have some fixed level of inductance, though not all are set at the same level. A user can either adjust the inductance to have a familiar feel, or to improve arc behavior whenever welding position or condition change. This control is primarily useful for short circuit welding and has limited value in Axial

Spray. While using many types of flux core or dual shield, manufacturers will often specify a setting of

“0”, though “0” is a relative value, and inductance cannot be completely eliminated. In MIG, excessive or too little amounts of inductance can create a violent arc or an unstable one, so be careful about selecting too much or too little. A good starting point is around 60 or 70%. Make gradual, changes to fine tune the inductance. Giant swings will make other parameters harder to dial in properly as the inductance can greatly affect the feel of welding arc in both modes. Set the amount of inductance to the approximate level desired before tuning other parameters (whether you are in standard or pulse modes). Do not attempt to further alter inductance until all other parameters are fine tuned as much as possible. After Volt and

Amp adjustments are tuned to the best setting you can achieve, then fine tune the inductance level as the final stage of MIG adjustment.

2.

Burn Back Timer Control. (Located vertically on the

Sequencer Graph.) The burn back timer controls the amount of time that the arc stays engaged after the trigger is released and the wire feeding stops. This is to help reduce wire stick out and reduce the need to trim the wire before starting another weld. This also serves to prevent the wire from sticking in the weld puddle once the arc is stopped. For best results this should be used with the Post flow feature so that the wire does not become oxidized during the burn back phase. If too much burn back is used, the wire may burn back up into the tip. Increase burn back by only a tenth of a second at a time to prevent over adjusting the burn back and destroying the contact tip. Generally burn back control will produce consistent results and increase production. Different wire diameters and feed rates will change the burn back time requirement. Keep in mind burn back control is another tool designed to help increase quality and ease of welding. Time can be set at “0.0” without severely affecting weld quality.

3.

Pre Flow and Post Flow of Shielding Gas. Both

Pre flow and Post flow are functional in the MIG and TIG welding processes. However, many MIG welders do not provide Pre and Post flow of shielding gas. This is one reason that some professionals do not consider MIG for high quality welds, where porosity must be minimized. However, by providing a Pre flow and Post flow of shielding gas in MIG

33

Section 2 Setup Guide and Component Identification mode, the weld will be much cleaner, with less porosity at both the beginning and the end of the weld. Additionally the wire ball will not be oxidized, reducing the need to trim the wire before starting. However, if you are trying to conserve

MIG gas, the Pre and Post flow time may be set to “0.0” if the MIG welding is not of a critical nature. For best results, set Pre flow time for about .5 seconds and Post flow time for at least

2 seconds. Add more time as amps are increased if needed. While In TIG mode, Pre flow is required to prevent balling and oxidation of the tungsten when the arc is struck. It also helps to flood the area to be welded with shielding gas before the arc is initiated. Post Flow in TIG mode is also essential to providing shielding of the tungsten and weld as they cool together to prevent oxidation of the tungsten and porosity in the coalescing weld. As a starting point, set at least .2 seconds Pre Flow time. For Post Flow set approximately .5 seconds of Post Flow for every

10 12 amps used. HINT: The arc start of both

MIG and TIG will be delayed until the Pre Flow time has been satisfied. This is not considered to be a fault. The arc simply cannot be started until the defined amount of Pre flow time has expired. If arc start feels excessively delayed, check your Pre Flow settings.

4.

MIG and TIG Upslope/Downslope. This control is active in both MIG and TIG modes. In the TIG mode, the function is only necessary if you are operating with the Torch switch instead of the foot pedal. If operating in either TIG mode with a foot pedal, set both Upslope and Downslope to

“0.0” if the programming allows. (Some program versions may allow adjustment of slopes with the foot pedal while others may block this feature with the foot pedal.) In TIG mode, Upslope adjusts the amount of time it takes for the amps to be raised from the minimum arc start amps to the maximum selected amps. Start amps are factory preset and this point is not adjustable.

Downslope is similar in TIG mode except it is the amount of time it takes for the unit to decrease

Amps from the maximum set amps to the minimum arc termination amps. End amps where the arc is terminated is factory pre set and nonadjustable. For MIG operation, the up and down slope functions are similar in concept, except the unit is actually upsloping and downsloping wire feed speed, expressed in Amps. MIG Upslope changes the wire run in (ramp up) speed to help soften (or increase) the run in effect. The run in works similar to MIG hot start and has a similar effect, helping to reduce porosity at the beginning of the weld. For MIG Downslope, the goal is to help aid in filling the weld crater. This is works with the final motion of the trigger, to gradually cool the weld and fill the crater just before the arc terminates. Note: In MIG 2T and 4T mode, the arc will continue once the trigger is released to help assist in crater filling and prevent possible weld cracking. This effect may be disconcerting at first, especially if burn back time is added to the down slope.

To help eliminate any “ broken ” arcs, simply hold the torch in place to allow the unit to “ wind ” down the feed rate and initiate the burn back and any set post gas flow. Using these features can greatly increase weld quality. The amount of time allowed for slope (Up or Down) is different than TIG because of the short run in time that is programmed into the machine and the limited time needed for crater filling. If the standard run in is satisfactory or standard operation is desired, either of these settings may be kept at “0”.

5.

MIG Wire Speed, TIG and Stick Amps. Amperage, simply described, controls penetration during welding. Amp adjustment is allowed in all modes.

However in the standard MIG and spool gun modes, Amps are controlled by adjusting the wire feed speed rate in Inches Per Minute (IPM). The faster the wire feeds into the puddle, amperage will climb proportionately according to the wire size. The larger the diameter of the wire, the slower the wire needs to feed to obtain the same amperage. In the same manner, more wire speed is needed with a smaller diameter wire to obtain an equal amp value of a larger diameter wire. You will notice as you set up the synergic mode that the unit displays selected amperage instead of wire feed speed (IPM). This is because the synergic mode, requires you to enter the wire diameter and wire type. This allows the unit ’ s programming to accurately pre figure amps being set based off these two parameters. Amps are a more accurate figure to use in this situation. Regardless of what process is selected, the function of the display changes to reflect the real time amp output while welding. If adjustments are completed, the unit will default to back to Amps within 3 seconds. If used in the Pulse TIG mode, the unit will default to

“ TIG Pulse Amps.

”

6.

MIG Volts. Voltage dictates the height and width of the bead while MIG welding. If Voltage are set too

34

Section 2 Setup Guide and Component Identification low, the weld will appear ropey and cold and the wire may even stub into the puddle. If the voltage is set too high, undercut may develop at the toes of the weld, or burn though may occur.

Voltage is not adjustable in TIG or Stick mode. In these processes, Voltage is controlled by arc length. Heat generated by voltage in stick mode can be managed through consistent feeding of the rod into the puddle to control the arc length.

7.

AC Frequency. The AC Frequency will only be adjustable in AC TIG or AC Pulse TIG mode. The

AC frequency dictates how fast the welder cycles between Electrode Negative and Electrode Positive. On a standard transformer welder, this is a fixed value, which is 60Hz (Hz= cycles per second). But on an inverter this can be adjusted.

On the PowerMTS STi model, the Hertz can be dialed down to 20 Hz and increased up to 200 Hz.

The helps shape the arc cone width and affects wet in, penetration, and provides superior arc stability over 60Hz transformer models. For more info, see the related section later in this manual. For a good baseline setting, start at 100

Hz and tune up or down in increments of 5% to achieve the desired results.

8.

AC Balance. The arc force is able to be adjusted only in AC TIG and AC Pulse TIG modes. This controls the ratio of Electrode Negative (EN) to Electrode Positive (EP) during a single cycle. The reading is oriented toward 100% EP. 100% EP provides full cleaning. However, this is not desirable as it overheats the tungsten and provides little to no penetration. For best results the AC balance should be regulated generally to around

30% EP for best combination of penetration and cleaning action.

9.

Other Features. See the general discussion later in the manual that pertains to the relevant process for more information and an expanded discussion.

35


SIDE VIEW POWER MTS 221STi

(Note: Image scale is compressed horizontally to fit this format)

1

2

4

3

-

36


Side Description and Explanation:

1.

Wire Spool Carrier Assembly. Make note of the correct assembly order if disassembled. The order in which they are assembled is important to be able to provide enough resistance to prevent de spooling of the wire. To install remove tensioning nut , spring and collar. Install the spool, positioning it onto the inside hub shoulder. (See picture on this page) Hold this in place while installing the outer hub collar. Install the tensioning spring onto the shaft so that it fits into the recess on the outer hub collar. Finally, tighten the tensioning nut (which compresses the tensioning spring) so that the wire will not continue to roll more than one quarter of a turn after the wire has stopped feeding. Do not tighten the tensioning nut to the point that the drive roller slips or the feeder motor strains while feeding the wire. The spool carrier assembly accommodates rolls of wire that are 4” or 8” in diameter. When using 4” rolls, the roll is sandwiched between the two hubs. In order to center the wire, the outer hub collar may need to be reversed.

2.

Polarity. Note the “+” and “ ” symbols located on the inside of the unit next to the polarity terminals. The unit is shipped with the torch polarity connected to the positive terminal. Positive polarity is designed to weld with solid wires. To weld with most Flux core or dual shielded wires, the polarity must be changed to negative. To change the polarity to negative, take a Phillips head screw driver and remove the screw located on the positive polarity terminal holding the cable. Place the cable on the negative terminal and reinstall the screw to retain the cable. Always remember to alter your work clamp to reflect the polarity change if using flux core. If the buss bar is connected to negative, then the work clamp should be in the “+” positive output terminal.

Standard polarity for MIG is “+” (DCEP) with the work clamp in the negative. Warning: Do not install work clamp into the AC terminal for MIG!

3.

Wire Feed Assembly. Note the printed numbers on the side of the tensioner. These numbers are a reference point to help properly tension the wire so that the drive roller will not slip. Do not over tension the wire because it can create a condition known as birds nesting. This is where the wire will tangle up around the feeder and will if the wire burns back into tip, sticks fast in the weld puddle or other hard resistance is met. This will continue to wrap the wire around the drive mechanism or will jam wire inside the gun liner until the trigger is released. Considerable effort is usually needed to clear out a bird ’ s nest condition.

Too little tension will result in regular slipping of the wire and will cause rapid wear of the drive components. Do a feed test before beginning a weld. An occasional cleaning of the feeder mechanism is necessary to prevent wear and damage to the feeder and to the MIG gun liner. Monitor any metal flaking and dirt build up that may occur in the wire feed area. Clean it away gently with compressed air. Also, to improve MIG gun liner service life, blow out the gun liner with compressed air regularly to prevent debris accumulation in the liner. Felt wire lubricators may be bought and used to keep feeding cleanly while using steel or stainless wire.

Do not use heavy weight oil to lubricate any add on felts. Do not use harsh cleaners or solvents to maintain the cleanliness of the feeder mechanism. When changing wire diamters, don ’ t forget to change the drive roll sizes (opt.) and the contact tip size as well.

Depending upon the diameter of the wire used, the MIG gun liner may need to be changed to work properly. However, the 15 series gun should be able to feed most MIG wire diameters without requiring a liner change. If trouble is experienced with feeding, purchase a liner specifically sized for your diameter wire. For steel,

.030” diameter wire is a good beginning choice for wire and can span a wide range of settings, greater than .023”/.025” diameter wire. Generally, for

Aluminum, .035”/.040” is a better choice for main for spool gun use than .025/030” wire.

Spool Carrier Assembly. See item 1 this page.

4” Roll Location

Inner Hub Shoulder

Inner Hub Collar

(Note Shoulder Position)

Tensioning Spring

(Hidden from View)

Tensioning Nut

37


REAR VIEW/BACK PANEL POWERMTS 221STi

3

1x220V

6

2

4

38

1

5

Section 2

Rear Panel Description and Explanation:

1.

Gas Supply. Connect the Gas regulator hose to this point via the brass barb fitting. (Regulator is customer supplied and not provided as standard equipment at time of publication.) The hose barb connection must be tight to prevent gas leakage. Install extra clamp if needed to prevent gas from escaping.

2.

Power Switch . Turns unit on or off. This is a 2 pole single phase 120/ 240V breaker type switch. If it is switched to the left, this means the unit is switched off. If it is switched to the left, and the unit is plugged into a good power supply, the unit should power up. Note: When switched off, the unit will continue to run and appear to be switched on for up to 10 seconds as the capacitors discharge. This is normal.

However, If the unit will not switch off for some reason, the switch may be damaged. Turn off the unit at the main circuit breaker, and contact

Everlast technical. Do not continue to use.

3.

Power Input Cable and NEMA 6 50P Plug. The

PowerMTS 221STi requires 220/240 V single phase 50/60 Hz power input. If necessary this unit will operate on 208V input as it is within th e 10% voltage allowance. If actual voltage is below 205 volts, the unit may not function correctly. For 120V operation, use the pig tail adapter. No internal changes are necessary.

NOTE: Output will be reduced on 120V. Do not run unit on less than a 20 amp, time delay circuit on 120V. If operating on 120V at sustained use at maximum capable output some nuisance tripping of the circuit may be observed . If using on 240V, a 40 amp breaker will be required. If used on a generator, the generator must labeled as “ clean power ” and provide less than

5% THD. Consult your generator manufacturer for information regarding the clean power rating on specific units. Everlast does not provide a list of approved generators. Manufacturers rate their units as clean power independently according to industry standards. The plug is the NEMA 6 50P. This is the standard plug for welders operating on 240V in the US and Canada. Other countries will have different configurations.

4.

Fans. The unit is equipped with a 4 fan system, which offers quieter and more efficient cooling.

It must operate free of obstruction to preserve the high duty cycle which it offers. Keep all objects or restrictions at least 12” from all sides of

Setup Guide and Component Identification if the unit for proper cooling. If possible allow

18”. Allow the unit to rest on the rubber pads/ feet mounted on the welder. Do not have the bottom of the unit supported directly on the metal pan so air can circulate around the bottom as well. Do not run in an enclosed space such as a cabinet or work box. Do not grind or weld where sparks are directed toward the rear of the unit or metallic particles will build up on the fan blades and also on interior components.

If metal builds up on the fan blades, it can cause the them to vibrate and ultimately fail.

5.

Ground Bolt. The unit is equipped with an additional grounding point for applications requiring a bonded ground. Under most conditions, the use of the ground is not required. Consult a local licensed electrician for installation and use of this connection.

6.

Water Cooler Plug. (NA on early models) This is a 240V cooler plug designed for use with Everlast Water Coolers. Do not use this plug for any other application. This is a low amperage outlet and is not designed to power any tools or other accessories.

39

Section 3 Basic Theory and Function

MIG OPERATION

General Setup of Amps and Volts.

When welding in standard with the PowerMTS 252S-

Ti, the two main functions that require adjustment are Voltage and Wire feed speed. The function of voltage in MIG welding is to control the overall width and to a great extent, the height of the weld bead. In other words, voltage controls the bead profile. The wire feed speed directly controls the amps, and in turn amps control penetration. When setting the welder up you will notice that the wire speed is displayed in Inches Per Minute. However, while actively welding, the display will change function and display actual amp output. The relationship between wire diameter, wire speed and amps is easily figured with the following approximate industry conversions:

.023”: 3.5 x Amps = Inches per minute (IPM)


.030”: 2 x Amps = Inches per minute (IPM)


.045”: 1 x Amps = Inches per Minute (IPM)

To convert wire speed (IPM) into approximate Amps, use the following conversion formula:

.023”: IPM ÷ 3.5 = Amps

.025”: IPM ÷ 3.1 = Amps

.030”: IPM ÷ 2 = Amps

.035”: IPM ÷ 1.6 = Amps

.045”: IPM ÷ 1 = Amps

Keep in mind these are approximate conversions and do fall off in accuracy as amps are increased into the upper current limits for the given wire diameter.

Even though you will find general recommendations about setting the Amps, Volts and even shielding gas through a variety of free downloadable apps and online calculators, every filler metal manufacturer has its own specific parameters for Volt and Amp settings for each wire diameter and class of wire.

The ranges of volt and amp parameters generally varies somewhat from brand to brand, so be sure to read the packaging and/or manufacturer literature to determine what range of settings are recommended. The wire diameter also limits the practical maximum thickness of what can be reasonably welded. The issue with following charts, graphs and calculator recommendations is that most people find them either too hot or too cold. For some people, it may not even close. However, nothing can substitute for watching the arc and listening to the sound of the arc. A crisp, steady sound, frequently referred to as a “ Bacon frying sound ”” should be heard. The actual frying sound can vary somewhat and may have somewhat of a high pitch whine to it somewhere between the sound of a flying bee and a mosquito. If these sounds are present, look at the arc to see if it is steady, and producing low amounts of spatter. If large amounts of spatter are present, the puddle seems fluid (appears wet) and the wire speed is within the targeted range, decrease volts a little at a time to reduce the spatter. If this does not correct the problem, change the torch angle and torch height. Hold the torch more vertical, with less than a 15 degree deviation from vertical and reduce stick out of wire to 3/8” or less. If this still does not help, reduce the wire speed. Some spatter is normal, though it should be minimal overall.

The wire can also pop and spatter if the voltage is too low for the wire speed and/or wire diameter.

This is mostly observed as flying bits of red hot but un melted wire, along with popping as the wire inconsistently stubs into the puddle. This is followed by the wire pushing back against your hand pressure while the wire visibly turns white/red hot before burning off. Too low of voltage will also produce a high piled bead with the toes (edges) of the weld not properly wetting in resulting in poor fusion.

Arc Force Control/Inductance

The third important variable in setting up the Power

MTS is the arc force control. This third adjustment can greatly vary the feel of the arc at any given volt and amp setting. It is used to balance the stiffness of the arc against the wetness of the arc. Some professionals refer to the “ buttery ness ” of the arc.

“ Buttery ness ” is arguably somewhat a subjective term. However, it generally refers to how smooth and fluid the arc feels and looks. In fact, the inductance alone can affect how much wire speed or voltage is needed in any given application. It does not typically require altering of the Volts or the Wire

Speed settings. However the arc force control can expose poorly selected Volt/Wire Speed parameters by magnifying the effects.

40


MIG OPERATION

While Everlast uses the term “ arc force ”, it is known by many different terms. Often it is referred to as inductance, choke or slope. Simply put, the arc force

(Inductance) adjustment controls how long it takes the current to recover and rise to the established welding current to melt the wire after the wire contacts the puddle and the current falls. This process is happening many times a second so it isn ’ t visible to the naked eye. But the overall effect is visible as the wire burn off height is changed and a change in the wetness of the puddle and how easily the molten metal flows in toward the toes of the weld as it melts off. If the unit has sufficient arc force, the edges of the weld will easily wick into the puddle with little or no spatter with little or no manipulation of the torch required. The pitch of the arc will be medium. With too much inductance the puddle may be uncontrollable and the arc will have a throaty, raspy sound. Too little inductance and the puddle will be narrow and possibly have a high ridge in the center.

The pitch will be very high and the puddle will seem sluggish and less fluid.

All MIGs have a preset inductance or arc force that is inherent in the machine ’ s design. But few MIGs have the adjustable Arc force. Arc force is part of the personality of a MIG welder. It ’ s one reason that some people prefer the arc of one brand over the other as people develop personal preferences in arc performance. With that in mind, having an adjustable arc force serves several functions:

1) The arc force allows the user to dial the machine to a performance level that the user is accustomed to. This helps if multiple users are present and improves the operator ’ s performance with the welder.

2) The arc force can help improve control and weldability in out of position welds (weld positions other than flat) without having to change other parameters.

3) Different shielding gases require different levels of inductance for optimum performance. The arc force improves performance with different gas mixes by being able to adjust the arc to render the best and smoothest possible arc for the shielding gas being used. This is especially helpful when pure CO2 is used.

4) The arc force can improve weldability of thinner metals without having to step down a size in wire. While ultimately there are limits to what any given wire can weld on the lower end of it ’ s range, it does help improve the low amp welding characteristics of the wire diameter.

For the best possible experience welding with the

Power i MIG, adjust arc force after the wire speed and voltage have been tuned. This will keep the user from constantly having to hunt for the best balance of the other two adjustments. Usually once a particular arc force setting is selected that is suitable to the user, it will work well throughout the range of adjustments and will rarely require readjustment once set to the operator ’ s satisfaction.

However, this is not to say that readjusting the arc force from time to time is not beneficial. When the operator must weld out of position, readjusting the arc force control can help reduce clogging of the nozzle and even make the puddle more controllable.

Avoid the temptation of setting the control at the mid point or even full left or full right without performing a few test welds first. Few users will find these settings to their liking. Turning the arc force to the minimum setting does not turn the feature off.

A good starting point is somewhere between 6 and 8 with mixed gas. This will usually produce a desirable arc with for most people and will produce minimal spatter. Fine tune the adjustment from there increasing in half increments to find the best performance.

Burn Back Control.

After the trigger is released on the welder, it ’ s natural for a small extra amount of wire to coast out of the gun. This small amount of extra wire may stick fast in the weld as the molten puddle begins to cool.

This will require the operator to break it loose and spend time trimming the wire. Even if the wire does not stick in the puddle, it will often be left sticking too far out from the contact tip for a proper restart.

Trimming is usually required with a pair of MIG pliers or wire cutter before restarting the arc. With burn back control, however, the arc can be kept energized long enough to continue supplying power to the wire long enough to burn the wire back to the desired length after the wire stops feeding. The timer control located under the cover sets the length of

41

Section 3

1/4”

-

3/8”

(6mm– 9mm)

Basic Theory and Function

BASIC MIG OPERATION

time the that the arc remains on after the trigger is released.

If the burn back control is set too long it can cause the wire to burn back into the tip itself and welding of the wire to the tip. Begin with setting the unit for a little less than a quarter second. If the burn back control is set correctly, it will leave about 1/4” 3/8” wire sticking out beyond the contact tip. If a large ball develops on the end of the wire, reduce the burn back time so that it creates a balance between ball size and stick out. The short amount of post flow that is built into the programming of the Power i MIG helps shield while the wire is burning back.

This helps control balling and prevents oxidation during burn back. This is a unique feature that is not found in many welders with burn back control. Burnback control without post flow can cause erratic restarts due to the oxidized or over balled wire tip.

Even with the burn back control properly adjusted, due to operator error, an occasional quick trim of the wire may be necessary for best arc starts. But overall, when used in a production setting or in a fabrication shop, the burn back control can save on labor and aggravation.

Starting the Arc and Welding.

Starting the arc is a relatively simple process. Before beginning, the wire should initially be trimmed to between 1/4 to 3/8”. Once the wire is trimmed, the gun should be firmly grasped to prevent a phenomenon often referred to as “ machine gunning ”. A light grasp, especially at start, can cause the arc to stutter as the wire pushes back on the gun, lengthening the wire stick out and creating an irregular start and a porous weld.

The end of the wire should be positioned just barely above the metal when the trigger is pulled for the cleanest start. This will position the end of the contact tip about 1/2” above the weld. The gun should be in the vertical position, with no more than 5 degrees lean in either side to side direction. Holding the wire too far off from the metal will result in rough starting and too long of wire stick out.

Once the arc has been established, the gun can then either be pushed or pulled in the direction of the weld. In either case, the gun nozzle should be positioned directly over the weld without angling the wire to one side or the other of the weld as already mentioned. The gun should have no more than 15 degrees lean pointed into (push) or pointed away from (pull) the direction of travel. In most cases a push motion is desired. However, a lot of texts offer conflicting information on whether to push or to pull the gun. In reality, both are correct if used correctly and with each having particular strength and weakness. Either one done with too much gun angle will result in undesirable results. Most open minded people who are well versed in MIG quickly develop a sense of when to push and when to pull the gun.

Even for novices, a sense of when to push and pull the gun comes quickly with a little practice. Pushing can result in shallower penetration but the molten puddle is easier to see and the arc sits easily on the leading edge. It will usually leave a aesthetically pleasing bead. However, be careful to prevent the gun from leaning toward or away from the direction of travel too much as spatter will increase and shielding gas flow may become turbulent, creating porosity in the weld. Pulling will result in deeper penetration, but can result in a narrow bead without much side fusion. It also can leave an undesirable humped appearance if not done correctly or if travel is too slow. Whenever MIG welding with Aluminum, whether with the standard MIG gun or the

Spool gun ALWAYS push the gun. If using Flux Core, a dragging motion is almost always recommended.

Weaving (oscillating the torch from side to side in one pattern or the other), particularly a MIG bead, is a topic of controversy as much as whether to push

42


MIG OPERATION

or pull the MIG gun. Stringer beads are often best for novice welders. Stringers are simply straight beads that move forward with little or no side to side travel or oscillation. These will offer the soundest welds for a beginner. Stringer welds leave little or no room for contaminates to enter the weld and are the fastest to produce without creating an opportunity for cold lap. Moving too quickly however with a stringer can create undercut which will weaken the weld. The best policy is to move a slow steady speed, making sure the sides of the weld are filled. If undercut is present, it is either from too much voltage or moving before the wire has time to fill the area the arc has melted.

Think of weaving as a method of “ sewing ” the metal together. If weaving is of interest to you, start with the basic weave pattern. Simple weaves using one variation or the other of a cursive “ e ” motion are best to begin with. Other weave patterns can be used of course. C ’ s, V ’ S, U ’ s , Triangles and many more weave patterns can be used depending upon the application. Weaves are employed for a number of reasons. Weaves are often considered to have a more pleasing appearance and can help bridge gaps where fit up is a problem. A weave is also frequently used to manage heat build up. For example: when welding vertically weaves are almost always used to prevent the molten metal from sagging due to the force of gravity. The major drawback of weaving is that it introduces a greater possibility of getting inclusions and other forms of contamination in the weld. Properly done weaving is a valuable tool, but it must be practiced before employing it in any structural or critical application.

Metal Cleaning.

MIG welding requires a well prepped surface to obtain a sound weld. The removal of paint, rust mill scale, or other contaminate such as grease should be done before welding. Stick welding is more forgiving of rust and mill scale, but when MIG welding, contaminates will result in porosity and inclusions in the weld, weakening it. A grinder will usually prep the metal sufficiently to remove oxidation and paint.

However, to remove grease a degreaser such as acetone should be used. Do not use any degreaser such a brake cleaner with chlorinated solvents or death or serious injury may occur!

A MIG wire such as ER70S 6 or ER70S 2 includes a sufficient level of deoxidizers such as silicone and copper that are formulated to allow it to handle minor to moderate amounts of rust and mill scale.

These deoxidizers will float out most moderate amounts of contaminates out of the weld and will appear in the usual form of glassy like deposits on top of the cooled metal. They are easily brushed off before starting the next pass. They should not be welded over. Any pinholes that appear are a result of trapped gas in the weld and should be ground out before the next pass. It should be noted that some

MIG wires such as ER70S 3 have low levels of deoxidizers and must be thoroughly cleaned and ground before welding.

Multiple Pass Welds.

One of the common misunderstandings that people have when beginning to MIG weld is that if the welder has the power, then a single heavy pass will do to weld up in a single pass. This is a primary way to introduce cold lap and incomplete fusion to the weld. Single pass welds should not exceed 1/4” even with the heaviest wire the welder is capable of handling. A thick pass may also begin to cool before contaminates and gas pockets have the time to float out to the surface. It ’ s far better to make multiple smaller passes to complete a plate weld for a higher quality result. For best results, this requires that most joints 1/4” and over be prepared with a grinder to accept multiple weld passes. The weldment edges should be ground to form a V, U or J shaped groove to create a recess where the welds can be welded one on top of another. For welding with .035” wire and under, create a bead no thicker than 3/16” in a single pass, no more than 1/8” with .030” wire, and with .025” wire and smaller no more than 3/32 for best results. This will help maintain proper fluidity of the weld and prevent gas from being trapped in the weld and give time for any minor contaminates to float out of the weld. It will also help to maintain reasonable forward travel speeds. Too slow of travel speeds will create excess build up and can tend to create cold lap at the weld toes resulting in poor tie in. One issue created with a weaving technique even if the metal deposited is the correct thickness s that it can slow the forward progress down. If weaving is too wide, one side of the puddle will cool and oxidize before the torch is brought back across to that side. This is a point

43


MIG OPERATION

where porosity and inclusions can be introduced.

44


MIG OPERATION

V GROOVE (60 80 °)

U GROOVE

BEVEL GROOVE

J GROOVE

DOUBLE V GROOVE

DOUBLE U GROOVE

DOUBLE BEVEL GROOVE

DOUBLE J GROOVE

JOINT PREPARATION

Besides a butt joint and lap joint which are often used for thinner metal gauges, consider using one of these groove joints for best welding results. When grinding or cutting the bevels, especially with a single V groove, it may be beneficial to leave a small land with a gap between the joint to achieve full penetration. In this case a temporary backer plate can be used to support the bottom of the weld to create the root pass.

The root weld will weld the backer to the main plate.

This backer can later be ground or cut off. However, in many cases a plain open root can be used as a backer plate adds to the time and labor involved. A knife edge is also acceptable so long as the joint is fully penetrated when the weld is completed. Open root gaps without a backer can range from 1/16” to

1/8” depending upon wire diameter and application.

≥ 1/4”

Fillet

≥ 1/4”

Fillet

s

≥ 1/4”

Butt Joint

≥ 1/4”

V Joint

When welding material 1/4” and over be careful about trying to put too much metal down in a single pass. Use multiple passes to complete the weld along with any necessary joint preparation especially with wires of smaller diameter. As metal thickness goes up so does the number of required passes. Depending upon the wire diameter and power settings used, a

1/4” joint may only require 1 or 2 passes, but a 3/8” joint in plate metal or pipe will require not only beveling but 4 to 6 overlapping weld passes including a cap and root pass.

45


MIG OPERATION

NO

Problem: Gun is not being held vertical from side to side. Wire is not being directed to the center of the puddle. This concentrates heat on one side of the joint and results in poor fusion on the neglected side. It also can create more buildup on one side of the joint than the other.

Correction: Hold the gun so that the angle of the neck stands perpendicular from side to side.

VERTICAL

GUN

YES

Correct Technique: The gun is held in a near vertical position. A variance of 5 degrees or less is acceptable from side to side. The purpose is to prevent the arc from being concentrated on one side of the weld joint or the other. This balances the heat on both sides of the joint and keeps the bead centered. Don ’ t confuse this with push or pull angle in the travel direction.

OK

PULL ≤15 °

Correct Technique: The gun is angled toward the back of the weld when traveling forward.

This angle should not exceed 15 degrees. This provides a narrower but more deeply penetrating weld. Use this method when Flux Core wire is being used. Use this method where the unit may be reaching its maximum welding capacity. Not for use with Aluminum wire.

YES

Correct Technique: The gun can be angled toward the front of the weld when traveling for-

PUSH ≤15 ° ward. This angle should not exceed 15 degrees.

This provides a wider and generally more pleasing weld. However it is shallower penetrating.

This method typically allows a much better view of the arc. Use for most types of welding unless deeper penetration must be achieved.

46


MIG OPERATION

NO

Characteristics: Concave weld, poor filling, possible undercutting resulting in weak weld.

Possible Causes: Voltage too high, not enough wire speed, too short of wire stick out, wrong gun angle.

Remedy: Decrease voltage, use push motion, increase wire speed.

NO

Characteristics: Small Convex weld possibly with bulging sides/cold lap and/or an inconsistent arc.

Possible Causes: Not enough Voltage or Amperage.

If weld is ropy and thin without bulging at the toes, travel speed is too fast or using a pull technique.

Remedy: Increase voltage and amperage, slow down to fill joint more. Use push technique.

NO

Characteristics: Large convex weld with bulging at toes, weld legs exceed thickness of the metal being welded.

Possible Causes: Not enough voltage, too much wire speed, overfilling due to too slow of forward travel speed, and/or poor weaving technique.

Remedy: Increase voltage, increase forward travel speed, reduce weaving width.

Proper Weld Characteristics: Weld is slightly convex, weld legs (vertical and horizontal width of weld) are equal in length and match the thickness of the metal being welded. No traces of undercutting,

Proper tie in of the weld at the toes with no cold

YES

lap. Weld is not overfilled or under filled with no significant amounts of spatter, soot or contaminates around weld. Weld is not oxidized and is bright.

47


Special Notes Concerning Operation.

1.

Shielding Gas Selection for MIG and TIG.

While welding aluminum with the Spool gun or MIG gun you must use 100% Argon. You cannot use a mix as you would with steel or stainless. For Steel or Stainless, there are a variety of gases that are used. The type of gas used with Steel or

Stainless depends upon whether you are using short circuit transfer, or spray transfer. In general, the best general gases mixes for welding with Steel are gas mixes that are less than 80% Argon with the balance CO2, or CO2 and O2. A Common mix, usually referred to as a C25 mix,

(75% Argon, and 25% CO2 ) is typically the most economical of the steel gas mixes. 100% CO2 is permissible as well, and is the most economical option for steel welding. However, more spatter and less aesthetic welds will result, requiring more labor during cleanup. For Spray Transfer, or, gas mixes with greater than 80% Argon content is recommended. Common spray transfer gases for steel are 90/10

Ar/CO2, 95/5 Ar/CO2, 98/2, Ar/CO2 or

98/2 Ar/CO2. Some welding suppliers also suggest Trimixes of Ar/CO2/O2 for spray transfer or pulse spray transfer welding of Steel. For Stainless, there are several recommendations for welding with stainless whether in Short circuit transfer. But there is mixed consensus on the best gas for use for short circuit,

Pulsed spray transfer and Axial Spray transfer. Stainless develops a more sluggish puddle and wet is not as smooth and easy flowing as steel or aluminum. 98/2

Ar/CO2, or 98/2 Ar O2 is often recommended for spray transfer welding when economy is needed. In fact other less Argon rich blends are sometimes recommended, and it is possible. But when

48 more CO2 is added, the rust resistance of stainless goes down due to the added carbon content. Ideally, there are several Tri gas mixes out there that are well suited to welding stainless. These include the addition of Helium to the mix as either the primary or secondary component of the mix.

The Helium tends to help improve wet in and fluidity of the puddle, but a higher voltage may be needed to weld if the Helium content is too high. It is also much more expensive. Welds made with Tri gas mixes tend to hold their rust resistance better. But to reduce the heat that is put into the weld , and reduce warping, there are stainless tri– gas mixes on the market that have a content of approximately 35% or lower Helium. These still are great for preserving rust resistance of the stainless alloys. Wet in is still excellent and cost is much lower than higher Helium content blends. While welding in any of the TIG modes you must also weld use 100% Argon for any metal type. (This unit is not designed to weld aluminum with TIG, but if it could 100% Argon would still be used.)

In some cases, blends of Ar/He may be used for TIG for welding thicker metal thicknesses, but the cost to do so is quite high as He/Argon mixes are expensive by comparison.

2.

MIG Welding Aluminum. While welding aluminum with the Spool gun or MIG gun you must use the next size up tip or a special oversize tip for the wire because the heat will cause the aluminum wire to swell and it will either drag or seize in the tip, due to the dissimilar expansion rates of the copper tip and aluminum wire. If you are suffering burn backs while welding Aluminum (and in some cases stainless), change to a larger tip, and reduce burn back time. While welding aluminum with the MIG process, best results are

Section 3 Basic Theory and Function achieved by using a dedicated stainless steel brush to remove the oxide layer and using acetone or aluminum cleaner before welding to remove any residues. Even though aluminum may appear shiny and clean, it still has an oxide layer and a thin layer of oil left over from the manufacturing process. Some soot will appear in most

Aluminum MIG welds but if a lot is noticed, you have either contaminated metal, or insufficient gas flow. You can also induce turbulence by having too much of a torch angle. Start with a 90 degree angle and then lean the gun slightly (about 15 degrees) to the “ push ” position. Welding aluminum is not typically a short circuit process. It is a spray transfer process or a

Pulsed Spray process. Spray and Pulsed -

Spray transfer are processes that are used to weld many metals, but in Aluminum it must be used to obtain the most sound quality welds.

3.

Spool Gun Selection. When using the optional spool gun, the amp/wire speed control is controlled on the spool gun. You must purchase a MTS version of the spool gun to operate correctly. You may purchase a compatible spool gun directly from

Everlast for your unit. For the best match up, we recommend the Parker

4.

Flux Core Operation. Flux Core welding requires the use of serrated drive rollers.

These grip the wire and feed it correctly at a steady speed. Flux Core drive rolls are available for purchase as an optional item.

Full time use of Flux Core filler wire will require the purchase of a flux core specific gun. Everlast does not supply this type of gun, but many after market Gun suppliers can supply a Flux core gun with a Euro connect fitting and will work. Part time or occasional Flux core use with the standard

MIG gun is acceptable as long as the nozzle is kept free of spatter.

5.

When running this unit on a generator, the manufacturer of the generator must certify it as a having “ Clean Power ” output.

This means the unit produces a truer sine wave and is not a modified sine wave generator and is largely free from harmonic distortion. A clean power generator is usually listed as such, but the manufacturer of the generator should be able to clarify the clean power status of the generator through the technical department of the generator manufacturer. Everlast does not keep a list of approved generators nor does it make endorsements of generators that are listed as clean power output. The generator power requirement for this unit is unit is 8500 continuous watts with a surge capacity of 12,000 watts required.

6.

MIG/TIG 2T/4T settings for the sequencer.

For TIG, the 2T/4T feature allows operation 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 sequencer programming of the welder to simulate the activities of the foot pedal while providing more accurate control. In TIG mode you are controlling

Pre Flow, Post Flow, Up and Downslope of the Amps with the sequencer. For MIG, the 2T/4T feature allows control of the sequencer programming giving the user the choice of operation styles. This allows the unit to be operated without keeping the trigger pressed. This allows the user to improve productivity while reducing fatigue. In some circumstances, it allows the unit to be used with some auto welding machines. When used in MIG mode, you are controlling the Pre flow, Post Flow, Up and downslope of the Volts with the sequencer. NOTE: For MIG operation, the

49

Section 3 user must choose between the two.

There is no other operation style similar to a foot pedal for MIG. The “ T ” refers to the number of “ travels ” of the remote switch required to operate the programming of the sequencer. 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. In

4T mode, while welding at full selected value (MIG: Volts, TIG: Amps), no finger contact with the switch is required. Following the graphic lines below, you can visually trace 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.

See the graphics below for further explanation. The up and down arrows indicate the switch travel direction.

2T Torch Operation Effect on Weld Cycle. (Start/End Values are fixed.)

WELD VALUE WELD VALUE

PREFLOW

START VALUE END VALUE

POST FLOW

= UP ON SWITCH

= DOWN ON SWITCH

4T Torch Operation Effect on Weld Cycle. (Start/End Values are fixed.)

WELD VALUE

START VALUE

PREFLOW

END VALUE

POST FLOW


50


STICK OPERATION

STARTING METHODS

Tapping Method Scratch/Match Method

Striking the Arc

1.

Make sure the unit is turned on and the startup cycle has finished.

2.

Select the Stick icon on the Process Selector.

3.

Make sure the electrode holder is in the Positive connector and the work clamp is in the negative connector.

4.

Select the Amp level desired. Use the guide on page 16 to determine approximate amps suitable for the rod size selected. You should consult the welding electrode manufacturer ’ s recommendation for proper amperage as the ultimate authority. No voltage adjustment is available. Select Hot Start Time and Hot Start Amps % (Intensity) to improve starting reliability.

5.

Use the arc force control to select the desired arc characteristics, creating the desired arc characteristic and amp response needed to maintain the arc. Cellulose electrodes may not have the same arc force behavior as other welding electrodes, but each brand and size will weld a little differently. Typically rods such as the E6011 will require a setting over 50% for best results. The arc force control setting will vary from person to person as well, with different rod angles, positions, and arc lengths all factoring into the arc force control performance. If you are new to using a transformer welder, there are some aspects that will seem different. One of the main ones is that the arc is better controlled in most situations by “ pushing in ” when the arc seems to get weak or unstable and the arc force will kick in as the voltage drops. Holding too long of an arc will signal the inverter to shut down and to terminate welding output. This threshold is shorter than most transformers, and an extremely long arc cannot be maintained. However, with a little practice, the arc will be easy to manage.

6.

Strike the arc with either the tapping method or the match strike method. Beginners usually find that the match strike method typically yields the best results.

NOTE: Pay particular attention to the Arc Force setting as it affects the aggressiveness of the arc and the amp response. Set the Arc force to approximately 30 50% and readjust it from that point to find the optimum setting. Adjust in increments of 5% up or down from there to obtain the best results Usually, an increase in the arc force for cellulose based flux welding rods is helpful. Lowering the Arc force setting is generally desirable for rods iron powder/Titania based flux. Too much arc force will create overheating of the welding rod, and even cause them to flame up. Too little can lead to sticking and arc snuffing. Use the Hot Start features to improve arc starting and cut down on failed arc strikes. Hot Start Amps refers to the % over the set amps that the amps will be boosted during arc striking until the arc is established.

Hot Start Intensity controls the amount of time that the Hot Start stays engaged after the arc is struck. Start by setting Hot Start to somewhere between 30% and 50% and set hot start time to .2

.3 seconds. Adjust in increments of 5% up or down to obtain best starting results.

When welding, the weld will be slower than MIG speed. One of the most common mistakes for users transitioning from MIG to Stick welding is the travel speed. Allow the metal to fill the puddle as the rod travels forward. Be sure to try to separate the difference between the slag and the molten pool of metal. The slag will coalesce behind the puddle if travel and rod angle is correct. Do not let the slag travel in front of the puddle. Keep the top of the rod inclined to the direction of travel around 10 20 degrees while welding in the flat position (Electrode holder should be in front and inline of the puddle). To begin, simply start the arc, and then drag the rod slowly and carefully along the metal, allowing the rod flux to provide a standoff between the metal filler and the puddle. Be sure to keep feeding the rod steadily downward into the puddle as the rod melts. In the case of E6011, a slight stepping motion in front of the puddle about 1/8” 1/4” in front of the puddle can be used as a key hole opens up in the weld joint, ahead of the puddle. This is also called “ whipping ” the rod. Do not flip the end of the rod away from the puddle in a arc motion or the arc may terminate while using E6011 or similar cellulosic rods. When experience is gained, numerous manipulation methods may be used with rods such as E7018, 7014, 6013, and 7024. Weave the rod no more than 2.5 times the width of the welding rod. To begin weaving, weave small, tight patterns similar to C ’ s, cursive E ’ s, V ’ s, or even figure 8’ s.

51


Basic TIG Operation

General Setup. The process to set up the Welding. If you are new to TIG welding, it ’ s welder for the basic TIG mode is much less inimportant that you understand that TIG weldvolved than for basic MIG. TIG voltage is not ing is much slower than MIG or Stick welding. conventionally adjustable and is a product of It requires patience and steady practice to bethe arc length. This is not to say voltage is not come proficient at TIG welding. However, important to TIG welding, but it is not somemost people can achieve some level of profithing that can be adjusted on the unit. In pracciency at TIG welding if they are patient, and tical terms, voltage is not a concern to the user are willing to analyze and adjust the way they as it is self regulating. Amperage however, is are welding. To start welding, set the amps adjustable. Setting up Amperage correctly for desired for the metal thickness you are about

TIG is different as there is no “ sound ” to listen to weld. Before striking the arc, make sure the for. But for each given thickness of metal, shielding gas is on, and properly set. Also adthere is an acceptable range of adjustment for just your Tungsten stick out to about 1/8” -

TIG. Traditionally, a general rule of thumb for 1/4” to begin with. Then follow the arc

TIG setup is to set approximately 1 amp for starting methods on the next page. Once the every .001” of metal thickness. For modern arc is started, keep a loose but sure grip on the inverter technology, that may be too many TIG torch to prevent cramping. An underhand amps in all but the thickest weld material, parhold is good, similar to the way a pencil is held. ticularly for a DC inverter TIG welder such as A foregrip may be used as well, but offers less this one. In many cases, you will only need to fine control at the beginning and requires use 75% to 80% of that amperage. But if you more propping to keep the torch steady. are setting up the unit to use a foot pedal, use Practice running slowly without filler metal the rule of thumb to begin with as you can alfirst. Keep the torch head inclined away from ways back off the amperage as you are weldthe direction of travel, so the Tungsten stays ing by letting up some on the foot pedal. For just above the puddle, pointed toward the basic details for setup, consult the guide on front of the puddle. Move slowly and methodpages 15 and 16. Also much of the information ically, gauging your forward movement to in the “ Basic MIG Operation ” guide in this make sure it is steady and paced. Imagine a manual is useful and applicable for TIG weldthick coin is able to be placed between the tip ing. Pay particular attention to the subsecof the Tungsten and the weld puddle. As your tions about metal cleaning and multiple pass skill progresses, you will want to add filler wire welds. If needed, there are several online TIG to your practice. The angle created between apps and calculators that you can give you the filler rod should be about 90 degrees. In starting points for welding almost any thickbetween the filler rod and the torch, your ness as well as general settings for tungsten size, and gas flow rates. The general inforhead should be placed so that you can clearly see the arc. Feed the filler rod into the front mation found on pages 40,41, and 42 can also edge of the puddle, being careful not to place be applied to basic TIG welding procedures. the filler on top of the Tungsten, or touch it in

Use the information on the following pages to help guide you through arc starting and tungany way. If you dip the tungsten into the filler rod or into the puddle, you must stop and resten preparation.

grind it or the ar will become unstable. Feed the filler in regular, timed dips as the puddle

52


Basic TIG Operation

forms. If you need, count as you time your dips until you can do it without thinking. As you proceed to dip your rod into the edge of the puddle, keep the rod close to the puddle, within the gas cone. If the filler metal starts to melt before you dip, you have it too close, or you have the rod inclined too much so that heat is being directed too far in front of the puddle. As you add the filler, be sure to pause momentarily with the forward travel of the torch. If desired, a tiny back step motion may be used to improve weld appearance. There are other ways to add filler and to create a sound weld. You can keep the filler wire in the puddle, with the rod laying in a flatter profile and weld. As the torch moves forward and middle finger grasp the rod with the thumb propelling it forward. Other rod manipulation variations may be used, but the key is to develop a comfortable, natural movement that is regular and consistent. If feeding difficulty is encountered, there are some feeding devices that reduce the effort to feed the filler wire and smooth out the feeding process. Do not let feeding the filler wire hold up the learning process. There are numerous accounts of welders making home made jigs or devices that help feed the TIG rod smoothly. One helpful hint is to make sure you have gloves that offer protection without compromising dexterity. With a proper fitting TIG glove, you should be still able to pick the filler wire up the rod melts, the filler can be slid, with gentle pressure, into the puddle as needed to fill the weld. This is known as the Lay Wire technique. Another method of welding has more to do with torch manipulation than it does filler addition, is called walking the cup. The cup is rested on the metal while the torch head is oscillated in a figure 8 pattern. This will require a forehand grip typically, and a good bit of motion of your forearm to accomplish. The filler metal should be moved from side to side to provide an evenly filled puddle under the

Tungsten. This method requires much practice and effort, but yields beautiful welds when performed correctly. If you cannot see the puddle or your helmet flashes (auto darkening from the table top with your fingers.

There are a lot of hurdles to becoming a proficient TIG welder. But if you will practice when you are not tired, and are comfortable in your surroundings, it will help you learn the art a lot faster than if you are practicing when you are too tired, or over heated.

types), you need to change your settings.

Practice feeding the filler wire without actually welding. Manipulating the wire takes practice and concentration at first. The wire should be held so that a flicking motion of two fingers and the thumb can propel the rod forward into the puddle without loosing grip on the filler rod. The rod should rest on the two fingers furthest from the thumb, while the index and

53


Note: A TIG lift start should use a nearly seamless motion. Use a light touch and a quick motion for best results.

LIFT START OPERATION

5

3

4

<1/8”

2 1

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 .4 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 tip of the Tungsten and the metal. Proceed with welding, leaving the torch inclined at a 15° angle.

HIGH FREQUENCY START OPERATION

<1/8

1

2

4

3

<1/8”

1.

Position the point of the sharpened tungsten about 1/8” or less above the metal.

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

1.

Turn unit on, allow time for power up cycle to complete its start up process before selecting TIG or Pulse TIG mode.

2.

Select either HF or Lift Start TIG with the “ HF/Lift Start ” selector switch.

3. Plug in the Torch and select “4 T “ or “2 T ” mode with the selector switch OR plug in foot pedal and select “ Pedal ”.

4. If using the torch switch, select “ Upslope ” or “ Downslope ” time by rotating the knob to increase/decrease the ramp up or ramp down time of the amperage.

5. Adjust amps to the desired maximum settings.

6.

Start arc as depicted above.

7.

If using 2T, continue to hold the torch switch until you are ready to stop welding. Release the switch. The Arc will then cease.

8.

If using the foot pedal raise your 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.

54

Section 3



2.5 – 3 X Ø (DIAMETER)


TUNGSTEN PREPARATION



<50 A

>50 A

1. Use a dedicated grinding wheel or contamination may result. Do not breath grinding dust!

Wear eye protection and gloves.

2. Grip the Tungsten firmly.

3. Grind the Tungsten perpendicular to the wheel face. Allow tungsten to grind slowly without much pressure.

4. Rotate the Tungsten quickly as it is being ground to keep the point even and symmetrical.

Do not grind the Tungsten parallel to wheel face or an unstable arc will result.

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 tungsten is wide (Diameter).

Do not ball the Tungsten while welding, or an erratic arc will result. Make sure that the grinding marks run parallel to the tip. Concentric marks will also cause an erratic arc.

NEVER USE PURE (GREEN) TUNGSTEN IN AN INVERTER WELDER.

SEE FOLLOWING RECOMMENDATIONS ABOUT TUNGSTEN SELECTION FOUND IN THIS MANUAL ON NEXT PAGE.

55


Pulse TIG Operation

TIG Pulse. The TIG 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 “ TIG Pulse

Amps ” (sometimes referred to as “ Peak ” current.) The lower amperage is called “ TIG

Pulse Base 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. . This welder features three adjustable parameters concerning the TIG pulse:

1.

Peak and Base Pulse Amps . Both (Peak)

Pulse Amps and Base pulse amps are independently set. When selecting the

Pulse Mode, the welder will bypass the standard TIG Amps LED and will default to the Peak Pulse Amps LED instead.

When you adjust the base Amps, you are actually setting a ratio of Amps. Base amps are expressed as a percentage of

TIG Pulse (Peak) Amps. So, when you set base amps, you are only setting it as a percentage, not the actual Amps. As you increase Peak Pulse Amperage, the pulse will maintain the same ratio of Amps you have selected, raising the base Amps automatically. To adjust the base Amps to a desired setting, using an example of

100 Peak Pulse Amps, setting the base

Amps to 50% yield s a 50 Amp value for the pulse base Amps. The foot pedal will control both Peak and Base Pulse Amps together, according to the percent of base Amps selected on the panel.

2.

Pulse Frequency. Pulse speed or frequency as it is referred to is measured in

100

50

100

50

25

AMPS

EXAMPLE 1

Peak Pulse Amps: 100 amps,

Base Amps: 50%

Pulse Time On: 50%

DC Pulse Frequency: 1 Hz

Pulse Time ON

Welding Amps

Pulse Hz

1 S

AMPS

2 S 3 S

EXAMPLE 2

Peak Pulse Amps: 100 amps

Base Amps: 50%

Pulse Time On : 50%

DC Pulse Frequency: 25Hz

1 S

100

AMPS

EXAMPLE 3

Peak Pulse Amps: 100 amps

Base Amps: 25%

Pulse Time On: 75%

DC Pulse Frequency: 3 Hz

1 S

Pulse Amps

DC

DC

DC the standard unit “ Hertz.

” Simply, it is the number of pulses per second that occur. Pulse frequency controls the arc constriction and also helps with heat management.

3.

Pulse Time On (Balance). Pulse Balance is the percentage (%) of time that the pulse stays in the TIG (Peak) pulse Amp stage of the cycle. Increasing the Pulse

56


Pulse TIG Operation

time on will increase the duration the

Peak Amp stage of the cycle which in turn will increase the heat and will increase penetration. Pulse Balance is also known in the industry as duty cycle. For welding purposes the term “ Pulse Time On ” is used here.

Setting up the pulse is not a process where a fixed adjustment procedure can be assigned or rigidly recommended. 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 50 75%

Pulse Base Amp setting is typically used to help with timing the addition of filler metal to the weld puddle. A higher pulse frequency level that is combined 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 profile 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. Regardless of how you choose to adjust the pulse, always keep in mind, that the basic purpose of the pulse is to average the heat input while maintaining penetration and welding speed.

AC Pulse TIG operation is the same. Do not confuse AC cycling between EP and EN as pulse. It is not. You are still adjusting the amperage of the AC pulse, and skewing the balance and changing the frequency similarly to the DC pulse.

57


AC TIG Operation

AC TIG operation is a new and unique feature for compact MIG/TIG/Stick multi process units. With that said, this welder is a well developed machine, with both HF start and

AC TIG/AC Pulse TIG features with industrial capability in all processes. To be capable of all processes, there are some equally unique technological challenges to address. Everlast has sought to include everything possible without compromising performance or quality without over complicating the machine.

While it is certain that others in the industry will follow Everlast ’ s first to market model, none will likely be as simple and convenient to operate with less points of failure. In order to eliminate the most points of failure possible, we have chosen to include a separate circuit for AC, which outputs directly from the AC part of the inverter to a separate AC terminal (DINSE connector) that is to be used with the work clamp only when in

AC TIG or AC Pulse TIG modes. By doing this, we have isolated possible interference from the AC side of the machine with other circuits used for other processes. This has simplified internal structure and reduced the need to compromise performance. But you will always need to make sure that the work clamp is moved over to the AC terminal when you change over to AC TIG. You will not need to move the torch, as it will always stay in the negative terminal. If you do not manually relocate the work clamp to the AC output terminal, you will experience erratic operation, and in the long term, possibly incur damage the internal components.

With the addition AC to the unit, there are a few more items that should be covered in greater detail to help the user to understand exactly what is going on.

58

AC Wave Forms. The wave form control is a useful feature for achieving a desired type of arc performance in AC mode. There are

2wave forms to choose from. These are the most commonly useful forms, though there are other types of wave forms. The standard, default 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. Total heat output is affected regardless of an amperage. Using the triangular wave form at the same amperage of the Advanced Square wave form will demonstrate the difference. You should notice a colder puddle with a different bead profile. At the beginning, for all our users, regardless of experience, we suggest that you use the Advanced Square wave until you are familiar with the machine.

AC Frequency. The AC frequency only applies to the AC mode. Standard transformer welders typically have a fixed frequency of

60 Hz which is essentially the line input frequency supplied by the power company. But with inverters, the capability of AC frequency adjustment is practically limitless due to the

IGBT components that create its own frequency. Frequency adjustment capability is useful to help improve directional 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. All wave forms can be adjusted from 20 200 Hz.

The AC output is formed by rapidly alter-

Section 3 nating polarity between electrode negative and electrode positive, creating something that resembles a wave when viewed on an oscilloscope. Normally, with standard transformer welders, both standard sine wave and even square wave welders have little or no way to change the ratio of EN to EP, which results in welding with a molten ball at the tip of the tungsten and a less stable arc. Electrode negative (EN) provides penetration in the TIG welding process. Electrode positive (EP) creates a strong reverse flow of electricity that breaks up the weld resistant oxidation that covers aluminum and magnesium components.

200 Hz 60 Hz

AC Balance. The AC output is formed by rapidly alternating polarity between electrode negative and electrode positive, creating something that resembles a wave when viewed on an oscilloscope. Normally, with standard transformer welders, both standard sine wave and even square wave welders have little or no way to change the ratio of EN to EP, which results in welding with a molten ball at the tip of the tungsten and a less stable arc. Electrode negative (EN) provides penetration in the TIG welding process. Electrode positive (EP) creates a strong reverse flow of electricity that breaks up the weld resistant oxidation that covers aluminum and magnesium components also places a lot of heat on the tungsten. In a

“ balanced ” wave where both EP and EN are equal in time length (50%), penetration is



reduced and over cleaning results in wide etch lines running parallel to the side of the weld. Not all welds conditions will be alike so more cleaning is required at times than others. Similarly, more penetration will be required at times than others. Ordinarily, about 30 35% electrode positive is considered an ideal amount (65 70% electrode negative). This means that more heat is put into the work than placed on the tungsten and a sharper point can be used. Cleaning is still sufficient at that level. Good results can be achieved with about 30% EP or less. The cleaning action is still significant 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 piece of metal is particularly heavily oxidized or dirty, more cleaning action will be required.

If too much cleaning action is used, the tungsten will begin to ball and even may start to 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. (In MIG some soot is normal while welding aluminum.) 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 heaviest oxide layer so less EP is needed and better penetration can be achieved. Even if the aluminum has a mirror like shine, it is still oxidized.

59


Cleaning/Frosted Area of Aluminum

30% EP

Narrow bead/etching/sharp tungsten

50% EP

Wider bead/etching/balled tungsten

65% EP

Wide bead/etching/balled/consumed tungsten

EXAMPLE: AC EP (+) BALANCE

1 Hz (one full AC cycle)

EN 50% 50%

EP 50%


Standard transformer welder balance: 50% EN/EP

Balling tungsten, light penetration, wide cleaning area.

NOTE:

1.

Due to the rapid switching of the inverter, High Frequency (HF) is not needed except to start the arc. The HF TIG only refers to the initial arc start, and can be used for DC as well.

In a transformer welder, the HF could be switched to continuous to stabilize the AC arc, but in an inverter, this is not necessary. So, the HF switch refers only to the Start of the arc, and not to AC operation. However to reduce tungsten contamination with aluminum, you should only operate the

AC mode with the HF start selected. Lift start is recommended only for DC, or for AC 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 computer/CNC equipment.

2.

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.

3.

If arc wandering in AC is a problem, reduce cleaning percent, then 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.

4.

AC controls only apply to AC operation, and do not affect the settings on DC.

5.

Too slow of travel speed will increase the etching/cleaning area.

EP 65%

EN 35% 50%

Extreme cleaning setting. 65% EP:

Shallow penetration, balling tungsten, excessive cleaning area.

EN 65%

50% EP 35%

Good penetration setting 35% EP:

Deeper penetration, sharper tungsten, narrow cleaning area.

60


TIG OPERATION

TIG Work Sheet 1

Steel Grade_______

Metal

Thickness

NOTES:

Tungsten

Size/Type

Filler

Diameter

Gas Flow

Rate/Type

Welding

Amps

Peak Amps

(If Applicable)

Base Amps %

(If Applicable)

Pulse Frequency

(If Applicable)

Pulse Time On%

(If Applicable)

PGM #

61


TIG OPERATION


Stainless Steel Grade_______

Metal

Thickness

NOTES:

Tungsten

Size/Type

Filler

Diameter

Gas Flow

Rate/Type

Welding

Amps

Peak Amps

(If Applicable)

Base Amps %

(If Applicable)

Pulse Frequency

(If Applicable)

Pulse Time On%

(If Applicable)

PGM #

62


TIG OPERATION


Aluminum Grade_______

Metal

Thickness

Tungsten

Size/Type

Filler

Diameter

Gas Flow

Rate/Type

Welding

Amps

AC

Freq.

Hz

AC

Balance

%

Pulse

Peak Amps

(If Applicable)

Pulse

Base Amps %

(If Applicable)

Pulse

Frequency Hz

(If Applicable)

Pulse

Time On%

(If Applicable)

PGM #

NOTES:

63


15 SERIES MIG TORCH

Expanded View

NOTE : Some components may appear slightly different as design/supplier changes are made from time to time. At time of publication, the standard MIG gun provided with Power MTS is commonly known as the 15 Series. The Innotec® listed above is currently the default supplier of the 15 series.

Everlast is not the torch manufacturer, but equips the PowerMTS unit with some of the most proven torches in history. Numerous manufacturers all over the world make and use interchangeable variations of these torches including Binzel and Trafimet. Most consumables and parts are interchangeable with other manufacturer ’ s guns designated as a “15”. The widely used Euro Connecter on the MIG torch also ensures that the customer can fit and install almost any after market MIG torch to meet any requirement or to standardize torch consumables in a shop environment, since most manufacturers offer their torches with a Euro Connector configuration as an option.

64


NOTE: Over time, pressure on the drive rolls causes metal fragments from the filler wire ’ s surface to find its way to the gun cable liner. If the wire guide is not cleaned, it can gradually clog up and causes wire feed malfunctions. If feeding difficulty is observed, clean the liner in the following manner ：

1) Remove the welding gun ’ s gas nozzle, contact tip and contact tip adapter.

2) With an air nozzle blow compressed air through the wire guide. Wear eye protection!

3) Blow out the wire feed mechanism and reel housing with dry compressed air.

4) Reassemble components. Tighten the contact tip and contact tip ’ s adapter with the spanner included to ensure tightness. Do not overtighten any fittings or stripping of the threads may result.

The MIG torch liner may eventually become worn and will need to be replaced. When welding aluminum with the main gun, a Teflon liner must be used, necessitating a liner change. A spool gun is the preferred method to weld Aluminum. To change the liner:

1) Remove the securing nut of the liner (#15 in previous page) which exposes the end of the wire guide.

2) Straighten the gun cable and withdraw the liner from the gun.

3) Carefully push a new wire guide in to the gun. Make sure that the wire guide travels all the way to the contact tip.

4) Make sure the O ring at the machine end of the gun is installed

5) Tighten the wire guide in place.

6) Cut the liner 2mm from the mounting nut and file the sharp edge of the liner.

7) Reattach the gun and tighten all parts.

8) Re thread wire through gun as normal.

65


24 SERIES MIG TORCH (OPT)

Expanded View

66


TORCH CONSUMABLE LIST FOR

24 SERIES MIG TORCH (OPT.)

1

1

2

2

2

2

2

3

Item # Part # I

1

1 ICS086

4

5

7

ICU 0004 -

10

Ref # T

MCO300 145.0062

Nozzle

MC0301 145.0080

Nozzle Std.

MC0302

MC0303

MD0008

MD0008

MD0008

MD0008

MD0008

-

-

-

-

-

06

08

09

10

12

Ref# B

145.0128

145.0174

140.0008

140.0059

140.0177

140.0253

140.0387

Description

Nozzle

Spot Nozzle

M6 Contact Tip

M6 Contact Tip

M6 Contact Tip

M6 Contact Tip

M6 Contact Tip

ICU

ICF -

00683

0539

MD0138

ME0584

00 142.003

M6 Contact Tip

Holder

012.0183

Gas Diffuser Ceramic

ICZ 0630 MF0180

IHQ0070

12.0001

185.0031

Torch Neck

Trigger

19 IC0 560 02 GM0510 2 124.0025

Liner

Size

17x63.5mm

12.5x63.5mm

10x63.5mm

17x68mm

.023” /.6mm

.030”/.8

mm

.035”/.9

mm

.040”/1.0

mm

.045”/1.2

26mm

20mm mm

Image

.8

1.2mm

NOTE : At time of publication, the standard torch provided with Power i MIG 210 is commonly known as the 24 series with some models featuring a 25 series torch. This torch may be supplied by Binzel®, Trafimet®, Innotec® or other similar manufacturer. However the consumables and many parts for series 24 torches generally interchange from brand to brand except the torch handle design and trigger. The widely used Euro connecter on the MIG torch also ensures that the customer can fit and install almost any other type MIG torch since most manufacturers offer torches with a Euro connector as an option. This list is provided as a general cross reference and does not guarantee that every variation or type is directly available from Everlast. In the left column, are the OEM part numbers. Trafimet ® and

Binzel® part numbers are listed as a reference where similar or interchangeable. You can also find the list of stocked consumables for the

Everlast website for the 24 and 25 series.

67

Section 3

5

4

3

1


EXPANDED VIEW OF TIG TORCH

(Actual appearance may vary slightly from what is listed.)

1

2

9

1

6

7

12

8

17

13

14

5/8”

9 15

16

NO.

TYPICAL PARTS FOR 26/18 Series Torch ( STYLE MAY VARY)

6

7

8

9

10

1

2

3

4

5

11

12

13

14

15

16

17

Long Back Cap with O Ring

Short Back Cap

Torch Head

Insulator

Collet 1/16 or 3/32

Collet Holder

Ceramic Cup #4, 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) (Water IN, 20 series)

Power Connector

Protective Cove (Denim, synthetic rubber or nylon)

Gas IN (9 series) / Water OUT (20 Series)

Gas IN (20 series only)

QTY.

1

1

0

1

1

1

Opt.

1

1

1

1

1

1

1

1

68

Section 4 Troubleshooting Guide

NO.

Trouble

1

2

Unit is switched on, but the power light isn ’ t on

After welding machine is overheating and the fan does not work

3

4

5

6

7

9

10

11

12

13

14

15

16

17

When torch switch is pressed, no gas Flows

Wire feeder does not work Wire reel turns

No arc, or no output voltage

Welding stops and warning light is on, Wire continues feeding but no arc is present.

Welding Voltage/Current is uncontrollable

Intermittent Arc/ Wandering arc

Excessive spatter

Wire reel does not turn

Weld sooty or oxidized looking

Bird nesting of the wire around the drive roll

Wire feeds irregularly

Wire burns back and seizes in tip

Nozzle arcs to work piece welding

In Stick mode will not arc

In Stick mode, the rod sticks

Possible Cause Solution

Switch damaged.

Unit Fuse damaged.

Power breaker tripped.

Fan damaged.

Fan power connector is loose.

No gas in the gas cylinder.

Gas pipe leaks gas.

Gas solenoid valve damaged.

Torch switch damaged.

Control board damaged.

Replace.

Replace.

Reset.

Check fan housing and fan. Replace if necessary.

Tighten wires, check for dislodged connectors.

Replace.

Resolve .

Check and clean/replace.

Repair or Replace.

Inspect the circuit.

Motor damaged/Fuse blown.

Control circuit damaged.

The tensioner is loose or wire slips on rollers. Wrong size drive roll.

Wire is not mated in drive groove.

The drive roller doesn ’ t fit the diameter of weld wire.

Wire Spool is damaged.

Check and Replace.

Check the board.

Increase tension. Check for proper drive roll size/type.

Make sure wire is in groove not riding on top of the drive roller shoulder.

Change roller or wire size to match.

Gun liner is jammed.

Contact Tip is jammed because of slag or burn back.

Work clamp engaged in wrong connector.

Control circuit damaged.

Change out wire spool.

Repair or change it, clear wire from liner/clean liner with compressed air.

Clean or replace. If with Aluminum, increase tip size to next size.

Change polarity.

Self protection has engaged.

Potentiometer damaged.

Control board damaged.

Work Clamp is not secure or it is damaged. Too windy/breezy.

Voltage too high too high arc force/

Too high wire speed. Too much torch angle. Wrong size nozzle

Check the circuit.

Check over voltage, over current, over temperature, lower voltage and over temperature. Allow unit to cool if over heated. If an OC, use a shorter wire stick out or smaller diameter wire or reduce power settings with large diameter wires. Check power plug for problems.

If easily tripped the Resistor value too low. (Contact

Everlast if OC is tripping regularly with normal settings.)

Repair or Replace it.

Check the circuit.

Check and/or Work Clamp, change position of clamp and attach direct to the work. Move out of wind.

Lower voltage or increase wire speed. Check torch angle for less than 15° push or pull. Change arc force settings to reduce spatter. Change nozzle size.

Poor metal prep, poor gas flow, too much torch angle, wrong gas type, windy or breezy. Plugged nozzle

Thoroughly clean metal, check gas flow and reposition gun so gas flow is not creating turbulence. Move indoors if necessary. Reposition the welder so its fan will not blow on the weld area. Clean nozzle.

Jammed gun liner, wire too soft

(aluminum), gun hose is kinked or coiled too tightly. Too much tension / pressure on wire feeder .

Wrong drive roller or wrong size drive roller, too little tension on wire, wire in wrong groove.

Wrong contact Tip size or too much burn back time set.

Reduce wire feed tension so that drive will slip if it encounters too much resistance Check Gun and liner and replace if necessary. Straighten cable.

Check and match wire size to groove size, increase tension on drive rollers. Check to make sure the wire is not riding on the shoulder of the drive roller.

Match tip size for wire diameter. Reduce burn back time. If using with aluminum, use tip designed for aluminum or use one size larger tip than the wire.

Nozzle plugged with spatter Check/clean nozzle and use a nozzle dip.

Cables not connected, inverter issue Check connections.

Arc force/Hot Start is set too low, arc striking method is poor, wrong polarity, too low of amperage. Wet welding rods or wrong kind.

Check polarity. Check Hot Start settings. Increase arc force control/Hot Start. Change arc striking method.

Increase amperage. Use fresh welding rods when possible.

69


NO.

Trouble

18

19

Arc will not start unless lift started.

Tungsten is rapidly consumed.

Possible Cause Solution

Points misadjusted, worn or dirty.

HF not selected

Check HF point gap. Clean and set to .035” Contact

Technical Support for details. Make sure unit is set to

HF

Inadequate gas flow. Too small of tungsten. Wrong shielding gas. Use only Ar. Using green tungsten.

Wrong polarity. Possible contamination of shielding gas from gas supplier.

Check gas flow. Check for Leaks thoughout system/ regulator/tank. Check for 100% Argon. Use red thoriated or any other type besides Green (Pure) or Zirconiated. Put torch in Negative.

20 Tungsten is contaminated, arc changes to a green color.

21

22

Porosity of the Weld. Discolored weld color. Tungsten is discolored.

Weld quality is poor. Weld is dirty/ oxidized, or porous.

Tungsten is dipping into weld. Too long of stick out.

Check and adjust stick out to minimum 1/8 inch. Tungsten is melting. Reduce amperage or increase tungsten size. Reduce stick out to less than 1/4”.

Low flow rate of shielding gas. High flow rate of shielding gas. Tungsten stick out is too far. 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.

Increase flow rate on regulator. Check for kinks in tubing. Increase post flow time. Reduce stick out to less than 1/4”. Increase cup size, or use gas lens. Clean metal thoroughly with approved metal cleaner, or use acetone and a rag to clean metal

Drafty conditions. Unit is located on the workpiece and is blowing gas off due to fan activity. Solenoid is sticking. Too short of pre flow or post flow

Eliminate drafts. Move welder. 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. Increase pre flow or post flow.

23 Unstable Arc.

24 AC TIG will not weld properly

Poorly ground or shaped tungsten.

Bad work clamp connection. Metal is indirectly connected through table or other item.

Regrind to proper point. Wrong polarity. Place torch in

DC negative ( ). Connect work clamp directly to item being welded.

Wrong connection of work or torch Check and change immediately.

70


Error Codes

Error Code Meaning

E01 Over Voltage/Under Voltage

Possible Cause

Check Power Source, Correct Wiring.

E02 Over Current

E04 Over Temperature

Operating machine on too small of a conductor. Internal machine fault

Duty Cycle exceeded. Blocked cooling.

Fans not operating properly.

E05 Stuck Switch Gun switch is held too long without attempting to strike an arc.

71

72

Everlast POWER MTS 221STi, PowerMTS 252STi Operator's Manual

EVERLAST

POWER MTS 221STi

A Digitally

Controlled, Multi

Process MIG/AC

DC TIG/Stick Welder

CC

IGBT

AC/DC

Operator ’ s Manual for the PowerMTS 221STi

Safety, Setup and General Use Guide

Table of Contents

These safety precautions are for protection of your 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 from danger and injury.

§

Overview of Parameters and Features*

EVERLAST

POWERMTS 221STi

STOP!

Read the information on this page and the following pages carefully. It contains important information on correct polarity of your torches and guns for all processes.

CAUTION!

) connector. Remember to switch back to the positive (+) connector when reverting to DC TIG operation.

MIG (GMAW)*

Flux

Core (F

CAW)*

MIG (GMAW) with Spool Gun*

DC TIG ONLY! (GTAW

DC)

AC TIG ONLY! (GTAW

AC)

Stick (SMAW)*

+

+

+

+ /AC

SIDE VIEW POWER MTS 221STi

MIG OPERATION

MIG OPERATION

1/4”

3/8”

(6mm– 9mm)

BASIC MIG OPERATION

MIG OPERATION

MIG OPERATION

MIG OPERATION

Fillet

Fillet

Butt Joint

V Joint

MIG OPERATION

NO

YES

OK

YES

MIG OPERATION

NO

NO

NO

YES

Special Notes Concerning Operation.

Tapping Method Scratch/Match Method

Basic TIG Operation

Basic TIG Operation

LIFT START OPERATION

HIGH FREQUENCY START OPERATION

TUNGSTEN PREPARATION

Pulse TIG Operation

Pulse TIG Operation

AC TIG Operation

AC TIG Operation

AC TIG Operation

TIG OPERATION

TIG Work Sheet 1

Steel Grade_______

TIG OPERATION

TIG Work Sheet 2

Stainless Steel Grade_______

TIG OPERATION

TIG Work Sheet 2