General Overview; General Use And Care - Everlast PowerUltra 206Pi Setup And User Manual

Section 1
General overview: The new digitally controlled Power
Ultra 206Pi from Everlast is a DC TIG, stick and plasma
multi-purpose unit, designed for portable repair work and
small project use. It is ideal for the welding enthusiast or
hobbyist with basic non-aluminum repair needs and gen-
eral light welding requirements. The PowerUltra 206Pi
features a lightweight IGBT inverter design and can pro-
vide capable service for small projects and repairs. The
PowerUltra 206Pi is not intended for use in production or
for heavy fabrication chores. NOTE: This unit is not suita-
ble for welding aluminum.
General Use and Care: Care should be taken to keep the
unit out of direct contact with water spray. The unit is
rated IP21S, which rates it for light contact with dripping
water but should never be used in the presence of water
for safety. It is a good idea to remove the welder from the
vicinity of any water or moisture source to reduce the
possibility of electrocution or shock. Never operate in
standing water.
Every 1-2 months, depending upon use, the welder should
be unplugged, opened up and carefully cleaned with com-
pressed air. Regular maintenance will extend the life of
the unit.
IMPORTANT: Before opening the unit's case for any rea-
son, make sure the unit has been unplugged for at least
10 minutes to allow time for the capacitors to fully dis-
charge. Severe shock and/or death could occur.
Do not restrict air flow or movement of air around the
welder. Allow a buffer distance of 2 ft from all sides if pos-
sible, with a minimum distance of at least 18" clearance.
Do not operate the welder immediately in the weld area
or the force of the fan will cause welding issues such as
unstable arc, or porosity.
Do not mount in areas that are prone to severe shock or
vibration. Lift and carry the welder by the handle.
Do not direct metallic dust or any dirt intentionally toward
the machine, particularly in grinding and welding opera-
tions. Make sure the panel is protected from damage dur-
ing welding and cutting operations.
Duty Cycle. This unit can be described as a general pur-
pose, do-it-yourself type of multi-process unit and is in-
tended for hobby use and general small repair and build
activities. Care should be taken not to exceed the duty
cycle limit of the PowerrUltra 206i for maximum service
life. Once the duty cycle has been exceeded, heat may
continue to build in the electronics. The duty cycle is
Introduction and Specifications
based off a 10 minute duty cycle rating at 40° C. This
means that the unit is capable of being operated at the
maximum amps for the stated percent of time out of 10
minutes without a cool down break. For the balance of
the 10 minute time period, the welder should rest with-
out welding or cutting for maximum service life. The tem-
perature light will come on and the welder will automati-
cally stop welding or cutting when an overheat condition
has occurred. If this occurs, stop and allow the unit to
cool while switched on. Heat will continue to be generat-
ed by and transferred to the electronics after welding has
ceased. Welding in humid, or hot conditions can affect
duty cycle as well. Do not turn off the overheated welder
until it has safely cooled for at least 15 minutes. Once the
overheated condition has had time to clear, cycle the
power switch off and back on to reset the unit. Do not
operate the welder with the covers removed. The duty
cycles are rated at maximum amps and are as follows:
120V:TIG @ 60%, Stick @ 35%, Plasma @ 35%
240V:TIG @ 60%, Stick @ 35%, Plasma @35%
Over Current. Over currents can occur if there is a fault
in the power supply system or inside the unit. If this oc-
curs, and the LED lights up, turn the unit off, check for
external causes and remedy the problem. If none is
found, cycle the power switch off and then back on. If
the over current light does not clear after cycling the
power switch, contact Everlast for trouble shooting.
Blow Back and High Frequency Start. The welder uses
High Frequency to start the TIG arc. HF is generated by a
point gap system similar to an older automotive point/
coil system. A slight buzz, or hiss may be heard immedi-
ately upon start as the HF energizes. A bright blue light
may be emitted from the front or side panel as the spark
energizes. This is normal and safe as long as the covers
are in place. Do not activate the HF unless you are in
position and ready to weld to minimize point gap wear.
Point gap should measure between .030"-.045". The
Plasma cutting torch is an improved blow-back design
which eliminates the need for High Frequency and its
function is not dependent upon the HF points or point
gap adjustment. Compared to older TIG/Stick Plasma
designs, this helps to reduce point gap wear issues.
This manual has been compiled to give an overview of
operation and is designed to offer information centered
around safe, practical use of the welder. Welding is in-
herently dangerous. Only the operator of this welder, can
ensure that safe operating practices are followed,
through the exercise of common sense practices and
training. Do not operate this machine until you have fully
read the manual, including the safety section.
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