Everlast POWERTIG 210 EXT Operator's Manual
  1. Manuals
  2. Brands
  3. Everlast Manuals
  4. Welding System
  5. POWERTIG 210 EXT
  6. Operator's manual

Everlast POWERTIG 210 EXT Operator's Manual

Digital ac/dc pulse tig/stick inverter welder
Hide thumbs Also See for POWERTIG 210 EXT:
Table of Contents

Advertisement

Quick Links

EVERLAST
POWERTIG
DIGITAL AC/DC PULSE TIG/STICK INVERTER WELDER
CC
GTAW-P
SMAW
IGBT
1
~
PHASE
AC/DC
120V
240V
Operator's Manual for the PowerTig 210EXT
Safety, Setup and General Use Guide
everlastwelders.com
1-877-755-9353
329 Littlefield Ave. South San Francisco, CA 94080 USA
210 EXT
Specifications and Accessories subject to change without notice.
Rev. 3
0 00102 17

Advertisement

Table of Contents
loading

Related Manuals for Everlast POWERTIG 210 EXT

Summary of Contents for Everlast POWERTIG 210 EXT

  • Page 1 EVERLAST 210 EXT POWERTIG DIGITAL AC/DC PULSE TIG/STICK INVERTER WELDER GTAW-P SMAW IGBT PHASE AC/DC 120V 240V Operator’s Manual for the PowerTig 210EXT Safety, Setup and General Use Guide Rev. 3 0 00102 17 everlastwelders.com Specifications and Accessories subject to change without notice.

  • Page 2: Table Of Contents

    The owner of this product as- sumes all liability for its use and maintenance. Everlast Power Equipment INC. does not warrant this product or this document for fitness for any particular purpose, for performance/accuracy or for suitability of application.

  • Page 3: Letter To The Customer

    Your unit registration is important should any information such as product up- dates or recalls be issued. It is also important so that we may track your satisfaction with Everlast products and services. If you are unable to register by website, contact Everlast directly through the sales department through the main customer service number in your country.

  • Page 4: Everlast Contact Information

    Serial number: _____________________________ Model number: ____________________________ Date of Purchase___________________________ Contact Information Everlast US: Everlast consumer satisfaction email: sales@everlastwelders.com Everlast Website: everlastwelders.com Everlast Technical Support: support@everlastwelders.com Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F 11am-4pm PST Sat.

  • Page 5: Safety Precautions

    Safety Precautions Everlast is dedicated to providing you with the best possible equipment and service to meet the demanding jobs that you have. We want to go beyond delivering a satisfactory product to you. That is the reason we offer technical support to assist you with your needs should an occasion occur.
  • Page 6 Safety Precautions These safety precautions are for protection of safety and health. Failure to follow these guidelines may result in serious injury or death. Be careful to read and follow all cautions and warnings. Protect yourself and others. Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can cause se- vere skin burn and damage.
  • Page 7 Safety Precautions WARNING! Persons with pacemakers should not weld, cut or be in the welding area until they consult with their physician. Some pacemakers are sensitive to EMF radiation and could severely malfunction while welding or while being in the vicinity of someone welding. Serious injury or death may occur! Welding and plasma cutting processes generate electro-magnetic fields and radiation.
  • Page 8 Safety Precautions 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.

  • Page 9: Introduction And Specifications

    Introduction and Specifications Section 1 PowerTIG 210 EXT 12 ft. Air-Cooled 26 Series Torch Assembly 12 Ft. Air-Cooled 9 Series Torch Assembly Argon Regulator Heavy Duty 300A Work Clamp 22K Ω Foot Pedal Assembly Stick Electrode Holder NOTE: Accessory and consumable appearance, style and quantity subject to change without notice.

  • Page 10: Unit Specifications

    Introduction and Specifications Section 1 PowerTIG 210 EXT TIG/Stick Welder Specification Process AC/DC GTAW-P/DC SMAW Inverter Type Digital Microprocessor Controlled, IGBT Module Minimum/Maximum Rated Output TIG (120) DC: 3 A/10.1 V– 120 A/15 V (240V) DC: 3 A/10.1 V-210 A/24 V (120V) AC: 5 A/10.2 V–...

  • Page 11: General Overview

    General overview: The new 210EXT TIG/Stick welder welder. Allow a buffer distance of 2 ft from all sides if from Everlast is the latest in a new generation of digi- possible, with a minimum distance of at least 18”. Do tal Pulse TIG/Stick inverter welders.
  • Page 12 Quick Setup and Use Guide Section 2 QUICK SETUP GUIDE: TIG CONNECTIONS TORCH (+) WORK (+) CONTROL 35 SERIES CONNECTOR 35 SERIES CONNECTOR AIR-COOLED TORCH GAS (Ar) 9/17 SERIES TORCH CONTROL CONTROL 26 SERIES TORCH FOOT PEDAL 35 SERIES CONNECTOR GAS (Ar) CONTROL WATER-COOLED TORCH...

  • Page 13: Quick Setup Guide, Stick Polarity

    Quick Setup and Use Guide Section 2 QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS CONTROL TORCH (+) WORK (-)

  • Page 14: Rear Panel Gas Connection And Wiring

    QUIRE S USE OF THE STEP-DOWN ADAPTER FOR 120 V OPERATION. CONTACT EVERLAST TO PURCHASE AN ADAPTER IF NEEDED. GREEN GROUND 120V/240V COOLER OUTLET. RECOMMENDED FOR DUAL VOLT- AGE EVERLAST POWERCOOL WC 300 ONLY. WARNING: DO NOT USE THIS OUTLET FOR ANY OTHER APPLICATION OR SERVICE! L1,BLACK; HOT L2,WHITE...

  • Page 15: Front Panel Features And Controls

    Quick Setup and Use Guide Section 2 FRONT PANEL FEATURES AND CONTROLS 1. CLEAR PROTECTIVE PANEL COVER 2. CONTROL PANEL GAS OUTLET CONTROL 6. NEGATIVE CONNECTOR 3.POSITIVE CONNECTOR DINSE 35 DINSE 35 4. GAS OUTLET 9MM QUICK CONNECT 5. 7-PIN CONTROL FOR PEDAL/TORCH SWITCH/AMPTROL...
  • Page 16 Quick Setup and Use Guide Section 2 FRONT PANEL FEATURES AND CONTROLS POWERTIG 210EXT PARAMETERS PURPOSE 1. Protective Cover Clear hinged cover protects panel from damage. Keep closed during welding opera- tions. 2. Main Control Panel Digital The main control features digital adjustment. It offers features that include Easy Start Up, Pulse, Advanced AC pulse, Stick welding feature, VRD Stick welding feature, Stick Hot Start, Arc force control, Lift start Tig, HF start TIG, 2T/4T/Pedal/Amptrol Control, and error code diagnosis.
  • Page 17 Quick Setup and Use Guide Section 2 MAIN CONTROL PANEL (FRONT) POWERTIG 210EXT PARAMETERS PURPOSE 1. Memory Function The unit has 9 programs which allow the operator to select parameters then save the settings to the selected program channel. To operate, use the selector button to select the desired program number where the program is to be stored.
  • Page 18 Quick Setup and Use Guide Section 2 MAIN CONTROL PANEL (FRONT) POWERTIG 210 EXT PARAMETERS PURPOSE 4. Upslope 0-25 Seconds Upslope ramps amps “up” from the start amp value to the welding amp value while starting the weld puddle. For best operation, value should be set to 0 with foot pedal in use.
  • Page 19 Quick Setup and Use Guide Section 2 MAIN CONTROL PANEL (FRONT) POWERTIG 210EXT PARAMETERS PURPOSE 11. Down Slope 0-25 Seconds Down Slope will ramp amps “down” from the welding amp value to the end amp value to give time to fill the crater left at the end of the weld bead. For best operation, value should be set to 0 with foot pedal in use.
  • Page 20 Quick Setup and Use Guide Section 2 MAIN CONTROL PANEL (FRONT) POWERTIG 210 EXT PARAMETERS PURPOSE 22. 2T/4T/ Pedal/Amptrol 2T, 4T, Pedal, This selects the operation of the torch switch, pedal, or hand amptrol. Selector Pedal with 2T, Pedal with 4T To operate with the torch switch, select 2T or 4T.

  • Page 21: Rear Panel Features And Controls

    Quick Setup and Use Guide Section 2 REAR PANEL FEATURES AND CONTROLS 5. 2-POLE POWER SWITCH 4. POWER CABLE 1x120V/240V AC 110V 1. HF GROUND BOLT AC 220V GAS INLET 1x110/220 V 3. ARGON GAS INLET 2. WATER COOLER RECEPTACLE...
  • Page 22 Less than 5% is preferred. Operating the unit on square wave output or modified sine wave generators is strictly prohibited. Contact the manufacturer of the generator for this information. Everlast does not maintain an “approved” list of generators. But, if the generator is not listed as clean power by its manufacturer, then it should not be used. Generators that do not at least meet the operating input requirements of the welder are also forbidden to be used with the welders.

  • Page 23: Welder Function Summary And Explanations

    END AMPS PREFLOW POST FLOW = UP ON SWITCH Everlast 26 series hand amptrol torch = DOWN ON SWITCH 3. AC Wave Forms. The wave form control is a useful feature for achieving a desired type of arc perfor- 4T Torch Operation Effect on Weld Cycle mance in AC mode.
  • Page 24 Section 3 Basic Theory and Function ics older transformer welders. This is the softest cleaning is required at times than others. Similarly, wave form, and offers less arc definition and con- more penetration will be required at times than oth- trol than other wave forms.
  • Page 25 Section 3 Basic Theory and Function Parameter Notes: EXAMPLE: AC EP (+) BALANCE 1 Hz (one full AC cycle) EP 50% EN 50% Standard transformer welder balance: 50% EN/EP Balling tungsten, light penetration, wide cleaning area. EP 65% EN 35% Extreme cleaning setting.
  • Page 26 Section 3 Basic Theory and Function 6. Standard Pulse. (AC and DC) The pulse creates two EXAMPLE 1 amp values, a high and a low value that cycle back and Welding Amps: 100 amps, forth between each other while welding. The upper PulseAmps: 50% amperage is called the “welding amps”...
  • Page 27 The Power Cool 300 may be purchased separately from signed to show the relationship and interaction be- Everlast which is designed to cool the torch up to the maxi- tween the AC and DC parts of the pulse and does not mum amp capacity of the welder.
  • Page 28 Should you need a new one for your torch or damage yours, consult Everlast. Do not use a nipple that is scarred, bent or otherwise deformed. Damage to the female connector may result. Serious leaks may occur.

  • Page 29: Tungsten Preparation

    Section 3 Basic Theory and Function TUNGSTEN PREPARATION 1. Use a dedicated grinding wheel or contamination may re- sult. Do not breath grinding dust!  Wear eye protection and gloves. 2. Hold Tungsten firmly. 3. Grind perpendicular to grind- ing wheel face. Allow tungsten to grind away slowly, creating point.

  • Page 30: Lift Start And High Frequency Start

    Section 3 Basic Theory and Function LIFT START TIG OPERATION Note: A Lift TIG start should be done with a nearly seamless motion. Use a light touch and a quick motion for best results. FOR DC USE. NOT RECOMMENED FOR AC. <1/8”...

  • Page 31: Stick Starting Methods

    Section 3 Basic Theory and Function STICK OPERATION STARTING METHODS Scratch/Match Method Tapping Method 1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program. 2. Select the Stick mode or Stick VRD with the HF/Lift Start/Stick/ VRD selector button 3.

  • Page 32: Recommendations For Polarity/Amps/Tungsten

    Section 3 Basic Theory and Function GENERAL POLARITY RECOMMENDATIONS* *Follow manufacturer of stick electrode for complete polarity recommendations PROCESS TORCH POLARITY WORK POLARITY TIG (GTAW) STICK (SMAW) TIG (GTAW) OPERATION GUIDE FOR STEEL (ALUMINUM)* *As a general rule, set amperage using 1 amp for every .001” of metal thickness for aluminum. Less is required for DC. METAL THICKNESS WELDING AMPS TUNGSTEN DIA.

  • Page 33: Expanded View Of Tig Torch

    EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) 5/8” TYPICAL PARTS FOR 9 or 26 Series Torch. See Everlast website for QTY. consumables, optional complete torch kits and different types and styles of torches. Torch sizes are different, but parts and design is essentially the same, along with order of assembly.

  • Page 34: Pin Connector Pinout

    Section 3 Basic Theory and Function 7 PIN CONNECTOR FOR 22K Ω FOOT PEDAL Bridge to 7 To Pedal or Torch Switch Bridge to 6 To Pedal or Torch Switch NOTE: The new digital EXT models are designed to accept multiple potentiometers values, but the performance of different ohm pedals cannot be guaran- teed.

  • Page 35: Troubleshooting

    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, espe- cially in Aluminum. Too short of post flow time. Check tungsten stick out.

  • Page 36: Trouble Codes

    (make sure unit is unplugged for 30 minutes before cleaning) OVER CURRENT/ Check to make sure cable is correct length and size. Internal unit fault or low voltage TORCH SWITCH IS STUCK CLOSED/ Turn off welder immediately and check switch. OTHER CONTACT EVERLAST...
  • Page 37 Notes:...

Table of Contents