Everlast POWERPRO 256SI Operator's Manual
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Everlast POWERPRO 256SI Operator's Manual

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EVERLAST
256Si
POWERPRO
A Digitally controlled pulse tig/stick/Plasma Multi-Process welder/Cutter
CC
GTAW-P
SMAW
PAC
IGBT
AC/DC
Operator's Manual for the PowerPro 256Si
Safety, Setup and General Use Guide
Rev. 1
0 01207-15ETL
everlastwelders.com
Specifications and Accessories subject to change without notice.
1-877-755-9353
329 Littlefield Ave. South San Francisco, CA 94080 USA

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  • Page 1 256Si POWERPRO A Digitally controlled pulse tig/stick/Plasma Multi-Process welder/Cutter GTAW-P SMAW IGBT AC/DC Operator’s Manual for the PowerPro 256Si Safety, Setup and General Use Guide Rev. 1 0 01207-15ETL everlastwelders.com Specifications and Accessories subject to change without notice. 1-877-755-9353 329 Littlefield Ave. South San Francisco, CA 94080 USA...

  • Page 2: Table Of Contents

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

  • Page 3: Letter To The Customer

    Your unit registration is important should any information such as product updates or recalls be is- sued. 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 via 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

    Please carefully read this manual before you operate your Everlast unit. This manual is not only for the use of the machine, but to assist in obtaining the best performance out of your unit. Do not op- erate the unit until you have read this manual and you are thoroughly familiar with the safe operation of the unit.
  • 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 continued WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground clamp. Do not stand in water or damp areas while welding or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain or in extremely humid conditions.

  • Page 9: Introduction And Specifications

    18 Series Torch Assembly NOTE: Appearance and quantity of accessories are subject to change without notice. Full TIG and Plasma consumable kits may be purchased from Everlast. Starter consumable kits offer only enough to get started. Quantity and size of consumable kits vary.

  • Page 10: Unit Specifications

    Section 1 Introduction and Specifications PowerPRO 256Si TIG/Stick Welder/Plasma Cutter Specification Process AC/DC GTAW-P, DC SMAW and PAC Inverter Type DIGITAL IGBT Construction Minimum/Maximum Rated Output TIG AC: 20A/10.8V - 250A/20V (± 3A) DC: 5A/10.2V-250A/20V(± 3A) Minimum/Maximum Rated Output Stick 5A/20.2V - 200A/28V (±3A)

  • Page 11: General Overview

    TIG/Stick/Plasma multi- Duty Cycle. For the PowerPro 256Si, the TIG duty cycle is process welder/cutter unit. rated for 60% at 250 amps. The duty cycle is based off a C.
  • Page 12 Keep in mind, this unit has been designed to be a viable all have a a problem with the point gap due to hard starting of the arc, contact Everlast Tech Support before proceed- -in-one solution to many portable welding needs, where portability and space limitations are chief concerns.
  • Page 13 Section 2 QUICK SETUP AND USE GUIDE QUICK SETUP GUIDE: TIG CONNECTIONS TORCH (-) WORK (+) CONTROL PILOT 35 SERIES CONNECTOR 35 SERIES CONNECTOR AIR-COOLED TORCH STD. 9/17/26 SERIES TORCH CONTROL CONTROL 26 SERIES TORCH WITH TWO LINE DESIGN FOOT PEDAL 35 SERIES CONNECTOR GAS (Ar) NOTE: Torch switch and foot pedal con-...

  • Page 14: Quick Setup Guide, Plasma Connection

    When using lower amperage levels, the nozzles will need to be changed out for ones with a smaller diameter orifice. Everlast is an OEM supplier of the torch but not the torch manufacturer. Smaller diameter nozzles are available through authorized distributors of the Tecmo/Innotec PT/iPT60 torches or contact Everlast to purchase them direct.

  • Page 15: Quick Setup Guide, Stick Polarity

    Section 2 QUICK SETUP AND USE GUIDE QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS CONTROL WORK (-) TORCH (+) NOTE: Most stick (SMAW) electrodes require electrode positive(+) (also referred to as DCEP or reverse polarity) to weld correctly. Some welding electrodes (rods) may be rated for use with both electrode positive and electrode negative (-) (also referred to as DCEN or straight polarity) by the electrode manufacturer.

  • Page 16: Rear Panel Gas Connection And Wiring

    TIG to Plasma or vice versa. Calibrated in Cubic Feet Per Hour (CFH) EVERLAST NOTE: Use Ar or Ar/He only. Do not use more than 25% He in the Ar/He gas mix or arc starting difficulty may be experienced. Fe, Cu NOTE: TO PREVENT STRAY HIGH FREQUENCY INTERFERENCE, THIS UNIT PROVIDES AN ADDITIONAL GROUNDING POINT AT THE REAR OF THE UNIT.
  • Page 17 Section 2 QUICK SETUP AND USE GUIDE QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING (US/Canada) Caution: Do not exceed 90 psi supply pressure from air compressor! Use with compressors capable of a minimum of 5.3 cfm at 90 psi and with at least 25 gallon tank or larger. Compressor and Air hose with fittings (Customer Supplied) Regulator Assembly with built-in water trap...

  • Page 18: Front Panel Features And Controls

    Section 2 QUICK SETUP AND USE GUIDE FRONT PANEL FEATURES AND CONTROLS 23. OK TO CUT 1. PROTECTIVE COVER 22. AIR PRESSURE 2. ON/TEMP/O.C 21. AMP DISPLAY 256Si 20. AMP CONTROL 3. 2T/PEDAL/ OR 4T SWITCH 4. START/END AMPS 19. HF/CUT/STICK 18.
  • Page 19 If the light remains on after cycling the power switch, this may indicate an internal unit fault was created during the over current event. In this case, contact Everlast. Do not continue to reset the unit after two reset attempts.
  • Page 20 Section 2 QUICK SETUP AND USE GUIDE FRONT PANEL FEATURES AND CONTROLS CONTINUED POWERPRO 256Si FEATURES PARAMETERS PURPOSE 8. Pulse Frequency Control .5-250 Hz Represented as Hertz (Hz), the Pulse Frequency adjusts the number of times per sec- ond the pulse makes one complete cycle between the welding amp value (Peak) and the pulse amp value (Background current or base amps).
  • Page 21 If this happens while cutting, make sure something hasn’t become disconnected. If not then, listen for internal leaks. Also check air compressor for proper size and function. If you suspect internal leaks, contact Everlast. Over- pressurization of the system, greater than 90 psi will likely result in internal leaking.

  • Page 22: Rear Panel Features And Controls

    Section 2 QUICK SETUP AND USE GUIDE REAR PANEL FEATURES AND CONTROLS 1. 220V WATER COOLER CONNECTION 2. 2-POLE POWER SWITCH 6. REGULATOR ASSY. 1~220 VAC 3. POWER CABLE 1 ~ 220/240V 1~220 V INLET 5. HF GROUND BOLT 4. GAS INLET...
  • Page 23 Less than 5% is preferred. Operating the unit on a square wave output or modified sine wave generator is strictly prohibited. Contact the manufacturer of the generator for this information. Everlast does not have an “approved” list of generators. But, if the generator is not listed as clean power by its manufacturer, then operation is prohibited.

  • Page 24: Welder Function Summary And Explanations

    Section 3 Basic theory and function Welder Function Summary and Explanations. Most of the green coded controls on the welder panel are devoted to the use of the 2T/4T operation and 1. 2T/4T sequencer. The 2T/4T feature allows op- should not be used with foot pedal. The following eration of the TIG welder without a foot pedal.
  • Page 25 Section 3 Basic theory and function Cleaning/Frosted Area of Aluminum time length (50%), penetration is reduced and over 30% EP -cleaning results in wide etch lines running parallel Narrow bead/etching/sharp tungsten to the side of the weld. Not all weld conditions will be alike, so more cleaning is required at times than 50% EP others.
  • Page 26 Section 3 Basic theory and function 4. Pulse. The pulse creates two amp values, a high EXAMPLE 1 and a low value that cycle back and forth between Welding Amps: 100 amps, each other while welding. The upper amperage is PulseAmps: 50% called the Welding Amps (sometimes called Peak cur- Pulse Time On: 50%...
  • Page 27 Everlast. Do not use a nipple that is scarred, bent or welding at less amps than it is. Always set the panel otherwise deformed.

  • Page 28: 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 29: Lift Start And High Frequency Start

    Section 3 Basic theory and function HIGH FREQUENCY START TIG OPERATION FOR AC OR DC USE. <1/8 <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.

  • Page 30: Stick Starting Methods

    Section 3 Basic theory and function STICK OPERATION STARTING METHODS Tapping Method Scratch/Match Method 1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program. 2. Select the Stick mode with the HF/Cut/Stick selector switch. 3.

  • Page 31: 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 32: Plasma Cutting Technique

    Section 3 Basic theory and function Plasma Cutting Technique 0°-15° EDGE PIERCE 40°-60° TRAVEL TRAVEL 1/16” Piercing starts often result in rapid consumable Edge Starts are the best type of start to use if wear and excess blow back of molten metal de- possible to promote consumable and torch life.
  • Page 33 Section 3 Basic theory and function TIP: For longer consumable life do not use the pilot arc unnecessarily. Keeping the pilot arc engaged for long periods of time will quickly wear consumables and cause poor quality cuts and eventual torch malfunction. Routinely check the consumable orifice for wear. While the pilot arc is engaged, amperage will automatically be lowered to reduce wear.
  • Page 34 Section 3 Basic theory and function RESULTS OF CUT AT CORRECT SPEED, RESULTS OF CUT AT FAST SPEED AIR PRESSURE AND TORCH ANGLE ROUGH, DISTINCT CUT LINES SPACED FAR APART SMOOTH, EVEN CUT LINES WITH A S REARWARD SWEEP MINIMAL EASY TO CLEAN DROSS NOTICEABLE SMALL, HARD DROSS RESULTS OF TOO MUCH CURRENT OR RESULTS OF CUT AT SLOW SPEED...
  • Page 35 Section 3 Basic theory and function AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING OUT A DISK SHAPED OBJECT AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING HOLE IN AN OBJECT NOTE: When cutting an object, particularly a pattern shape, where the torch must pierce or re-fire in-line at an intersection of a cut, a lead-in cut should be employed.

  • Page 36: Expanded View Of Tig Torch

    Section 3 Basic theory and function EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) Note: Depending upon the torch manufacturer’s supplier of the collet body, the collet body should be screwed in loosely to allow room for the backcap’s o-ring to come into contact with the back of the torch head and create a seal.

  • Page 37: Expanded View And Parts List Of Tig Torch

    Section 4 Pt/IPT 60 Plasma torch...

  • Page 38: Pin Connector Pin-Out

    Section 5 Foot pedal connection 7 PIN CONNECTOR FOR 22K Ω FOOT PEDAL Note: Previous models before mid 2015 typically used a 47k pedal. 22k is only for digitally controlled models of the PowerPro line after the mid 2015 model year. Bridge to 7 To Pedal or Torch Switch Bridge to 6...

  • Page 39: 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, especially in Aluminum. Too short of post flow. Check tungsten stick out.
  • Page 40 Faulty Clamp. Arc continuity is not being sensed. cuts or only “scratches” the surface of the metal or If these steps do not correct the issue, contact Everlast. cut is extremely slow on thin materials.) Arc Sputters.

  • Page 41: Optional Accessories

    PCW300-240 Water Cooler EV-200UW US Deluxe Regulator (CFH) Everlast Brand Deluxe Torches* *Visit our website to view full selection of optional torches, and cable lengths and con- sumable kits. Also, be sure to ask us about our full line of CK World-wide and other...

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