Everlast POWERTIG 185 DV Operator's Manual
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Everlast POWERTIG 185 DV Operator's Manual

Ac/dc pulse tig/stick welder
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EVERLAST
POWERTIG 185 DV
AC/DC Pulse TIG/STICK WELDER
CC
GTAW-P
SMAW
IGBT
~
1
PHASE
AC/DC
120V
240V
Operator's Manual for the PowerTIG 185 DV
Safety, Setup and General Use Guide
Rev. 2
0 01005-18ETL
everlastwelders.com
Specifications and Accessories subject to change without notice.
1-877-755-9353
1
329 Littlefield Ave. South San Francisco, CA

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Summary of Contents for Everlast POWERTIG 185 DV

  • Page 1 GTAW-P SMAW IGBT PHASE AC/DC 120V 240V Operator’s Manual for the PowerTIG 185 DV Safety, Setup and General Use Guide Rev. 2 0 01005-18ETL everlastwelders.com Specifications and Accessories subject to change without notice. 1-877-755-9353 329 Littlefield Ave. South San Francisco, CA...

  • Page 2: Table Of Contents

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

  • Page 3: Letter To The Customer

    Dear Customer, THANKS! You had a choice, and you bought an Everlast. We appreciate you as a customer and hope that you will enjoy years of use from your welder. Please go directly to the Everlast website to register your unit and receive your warranty information.

  • Page 4: Everlast Contact Information

    Serial number: __________________________ Model number: ____________________________ Date of Purchase__________________________ Everlast US: Everlast consumer satisfaction email: sales@everlastwelders.com Everlast Website: everlastwelders.com Everlast Technical Support: tech@everlastwelders.com Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php Main toll free number: 1-877-755 WELD (9353) Tech Support Extension: 207 Welding Support Extension: 204 FAX: 1-650-588-8817 Sales Hours: 9am—5pm PST M-F...

  • 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 merely delivering a satisfactory product to you. That is the reason we offer free 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 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

    Section 1 Introduction and Specifications PowerTig 185 DV and Accessories 17 Series Air-Cooled Torch 12 ft. (Style May Vary) Argon Regulator (CFH) 10 ft. Cable with Work Clamp Optional Foot Pedal Assembly (22K Ω) Consumable Kit Optional Stick Electrode Holder...

  • Page 10: Unit Specifications

    Damaged caused by operation on dirty power is not covered under warranty. Use only with generators rated by the generator manufacturer as “clean power”. Clean power is typically defined as less than 5% Total Harmonic Distortion (THD) in the sine wave. Everlast does not keep a n approved list of gener- ators or manufacturers due to frequent changes and model updates by manufacturers.

  • Page 11: General Welding Information

    Section 1 Introduction and Specifications 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* *As a general rule, set amperage using 1 amp for every .001” of metal thickness for aluminum. Less is required for DC.

  • Page 12: Overview Of Product Features And Care

    1. To ensure that your PowerTIG 185 DV is in top clean power. Consult the generator manufacturer condition when you receive it, carefully inspect the regarding the generator’s capability of providing...

  • Page 13: Expanded Description Of Features/Purposes

    This larger ball.) 120V breaker requirement is comparable to other brands, and is not unique to Everlast. Consult with a 4. Automatic Pre-Flow. The PowerTig 185 uses an licensed electrician in your area for proper infor- automatic pre-flow that is preset to provide a short mation about upgrading your wiring.
  • Page 14 PowerTIG 185 DV. The torch switch ing work. For many situations, however, pulse may enables greater flexibility, especially when welding in not be needed, and can be turned to “off”.
  • Page 15 Section 1 Introduction and Specifications Cleaning/Frosted Area of Aluminum the oxides that are formed on the metal break up 30% EP into small flakes or pieces. This action is needed to be Narrow bead/etching/sharp tungsten able to weld aluminum and magnesium. Both metals form an oxide layer that is difficult to deal with when 50% EP welding.
  • Page 16 Section 1 Introduction and Specifications settings. At the lowest settings, the arc may seem to flutter. Although it is possible to lower the frequency to 20 Hz, doing so is not likely to provide a lot of add- ed benefit. 200 Hz 60 Hz 11.

  • Page 17: Quick Setup Guide, Tig Torch Connection

    Section 1 Introduction and Specifications QUICK SETUP GUIDE (US/Canada) TIG TORCH WITH SWITCH TORCH (-) CONTROL WORK (+) FROM SWITCH FROM PEDAL FOOT PEDAL WORK CLAMP NOTE: FOOT PEDAL IS OPTIONAL. POLARITY: FOOT PEDAL AND TORCH SWITCH CONNECT AT “CONTROL.” TIG MODE: TORCH NEGATIVE (-), WORK POSITIVE(+) PEDAL AND SWITCH CANNOT BE CONNECTED AT THE SAME TIME.

  • Page 18: Quick Setup Guide, Stick Torch Connection

    Section 1 Introduction and Specifications Optional Stick Electrode Holder Polarity Configuration (US/Canada) NOTE: Unit is not recommended for use with E6010. However, E 6011 may be used. CONTROL WORK (-) TORCH (+) WORK CLAMP POLARITY: STICK MODE: TORCH POSITIVE (+), WORK NEGATIVE(-) TORCH/ELECTRODE HOLDER...

  • Page 19: Front Panel View And Descriptions

    Section 2 Know Your Machine Front Panel View 1. AMP DISPLAY 2. ON/ TEMP/ OVER CURRENT 3. AMP CONTROL 4. POST FLOW 15. AC FREQUENCY 5. DOWNSLOPE 14. AC BALANCE 6. PULSE 7. REMOTE 8. AC/DC 9. MODE 13. NEGATIVE (-) 35 SERIES CONNECTOR CONTROL 10.
  • Page 20 Section 2 Know Your Machine 2.1 Front Panel Features. The Everlast PowerTig 185 welder off and on does not clear the condition. (DV) has a simple panel layout with basic but functional 3. AMP Control. Sets the welding Amp value. While controls and features.
  • Page 21 PowerTIG 185 DV. 11. Positive Connector (+). DINSE 35 style (1/2”). 15. AC Frequency Control; 20-250 Hz. Increasing...

  • Page 22: Rear Panel View And Descriptions

    Section 2 Know Your Machine Rear Panel View CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE WIRING YOUR FACILITY FOR YOUR UNIT. EVERLAST IS NOT RESPONSIBLE FOR DAMAGE OR INJURIES RESULTING FROM IMPROPER WIRING. 1. MAIN POWER SWITCH 1x110/220V 6. REGULATOR 2.
  • Page 23 Con- bolt should be used to connect an additional tact Everlast if the cause cannot be identified. Gas Connection. This is a 5/8” -18 CGA female ground wire to the metal rod driven in the ground.
  • Page 24 100-120 Hz for the AC Frequen- cy for most welding tasks. Never use pure tungsten, even for welding AC in the PowerTIG 185 DV. Pure tungsten will cause a ball and an unstable arc. Small amounts of Helium may be mixed with Argon to add greater welding capability.

  • Page 25: Point Gap Adjustment Procedure

    If you suspect you have a a problem with the point gap due to hard starting of the arc, contact Everlast Tech Support before pro- ceeding with point gap adjustment for proper diagnosis and a more detailed adjustment procedure.

  • Page 26: Tungsten Preparation

    Section 3 Getting Started 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 grinding wheel face. Allow tungsten to grind away slowly, creating point.

  • Page 27: Tig High Frequency And Lift Starting Procedure

    Section 3 Getting Started 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” 1.

  • Page 28: Stick Starting Methods

    Section 3 Getting Started 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/Lift Start/Stick selector switch. 3.

  • Page 29: Expanded View Of Tig Torch

    Section 3 Getting Started EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) 5/8” PARTS FOR 17 Series Torch ( STYLE MAY VARY) QTY. Long Back Cap with O-Ring Short Back Cap Opt. Torch Head Insulator Collet 1/16 or 3/32 Collet Holder...

  • Page 30: Pin Connector Pinout

    Section 3 Getting Started 7 PIN CONNECTOR FOR 22K Ω FOOT PEDAL Bridge to 7 To Pedal or Torch Switch Bridge to 6 To Pedal or Torch Switch...

  • Page 31: Troubleshooting

    Pre Flow does not start. Post flow does not Solenoid sticking or wires disconnected to control board. Sticking solenoid by shut off after timing out have dirt, rust or debris in valve body. Can be cleaned. Call Everlast to receive instructions on cleaning/checking.
  • Page 32 (i.e. Using with a generator not rated as “clean power” output < or = to 5% THD.) Voltage source could have intermittent problem. If unable to resolve, contact Everlast as soon as rea- sonably possible. Over Current Operating machine on too small of a conductor or too far from source.

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