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Everlast POWER DIGITAL SERIES Operator's Manual
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Everlast POWER DIGITAL SERIES Operator's Manual

Everlast POWER DIGITAL SERIES Operator's Manual

Digital tig ac/dc
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EVERLAST
POWER ® DIGITAL SERIES
DIGITAL TIG AC/DC
Operator ' s Manual
Includes DIGITAL AC/DC 210 EXT/ 320 EXT
Safety, Setup and General Use Guide
1
Rev. 1
0612-12

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Summary of Contents for Everlast POWER DIGITAL SERIES

  • Page 1 EVERLAST POWER ® DIGITAL SERIES DIGITAL TIG AC/DC Operator ’ s Manual Includes DIGITAL AC/DC 210 EXT/ 320 EXT Safety, Setup and General Use Guide Rev. 1 0612-12...
  • Page 2 Information in this document has been derived from third parties, and though Everlast believes it to be reliable as at the time of printing. Everlast makes no representation or warranty as to the accuracy, reliability or...
  • Page 3 Telephone: 905-637-1637 9am-4:00pm EST M-F 10am-2pm EST Sat. FAX: 1-905-639-2817 Everlast Austrailia: Sydney: 5A Karloo Parade Newport NSW 2106 (02) 9999 2949 Port Macquarie: 4/18 Acacia Avenue Port Macquarie (02) 8209 3389 After hours support: 0413 447 492 Everlast Technical Support: support@pickproducts.com...
  • Page 4   Please review the current online warranty statement and informa on found on the website of the Everlast division located in or nearest to your country. Print it for your records and become familiar of its terms and condi ons.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION PAGE General SECTION 1 Safety Precautions SECTION 2 Know your Machine 10-17 SECTION 3 Gas Tungsten Arc Welding (GTAW/TIG) 18-26 SECTION 4 Welding Materials 27-29 SECTION 5 Trouble Shooting 31-33...

  • Page 6: General

    Safe operation and proper maintenance is your responsibility. We have compiled this operator’s manual, to instruct you in basic safety, oper- ation and maintenance of your Everlast product to give you the best possible experience. Much of welding and cutting is based upon experience and com- mon sense.

  • Page 7: Safety Precautions

    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 severe skin burn and damage.
  • Page 8 SAFETY PRECAUTIONS continued 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.
  • Page 9 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 weld- ing or cutting.

  • Page 10: Know Your Machine

    SECTION 2 KNOW YOUR MACHINE 2.0 Connecting your Everlast TIG AC/DC ma- chine 2.1.1 TIG 210EXT This machine is designed to operate on 240v +/- 15% input single phase AC outlet. Ensure there is adequate ventilation around the machine when it is connected to the main power supply.
  • Page 11 SECTION 2 KNOW YOUR MACHINE Description of the Control Panels Number Function Description Pre-Flow Start Amp Indicator For TIG welding Upslope Time Indicator Period in TIG welding during which the start amps are increased to the specified main current. Welding Amps Indicator Main current P.P Current Indicator Pulse Peak Current (1-100%)
  • Page 12 SECTION 2 KNOW YOUR MACHINE Number Function Description Pulse On Indicator Pulse Off Indicator Sine Indicator Sinusoidal waveform indicator OFF Indicator 100% rectangular waveform REC Indicator Rectangular waveform AC Frequency Indicator Set-up Indicator Lights up if under setting status Over Heat Indicator Lights up if the power source overheats (because the duty cycle Save the data has been exceeded) For more information on this see the trouble...
  • Page 13 SECTION 2 KNOW YOUR MACHINE Number Function Description 5 pin connection socket for remote control TIG torch or foot pedal Control Plug control Output Nozzle Shielding gas output Negative Output Positive Output Power Switch Switching the power source on and off Power Input Cord Shielding Gas Connection...
  • Page 14 SECTION 2 KNOW YOUR MACHINE 2.5.2 For DC Pulse TIG Welding SDC welding of thin material can be enhanced by using the pulse mode. When using the pulse mode for DC application the current will be varied between the welding current and the set background current.
  • Page 15 SECTION 2 KNOW YOUR MACHINE 2.6 Technical Specifications Model PowerTig 210EXT PowerTig 320EXT 240V 1 phase 220V, 380V & 460V 3 phase (depending on Power Voltage (V) Country) 50/60 50/60 Frequency (Hz) Fuse Rating (A) Stick 10-160 Stick 10-320 OutPut Current (A) DC TIG 5-210 DC TIG 5-210 AC TIG 10-210...
  • Page 16 SECTION 2 KNOW YOUR MACHINE 2.7 .1 Schematics PowerTig 210EXT...
  • Page 17 SECTION 2 KNOW YOUR MACHINE 2.7.2 Schematics PowerTig 320EXT...

  • Page 18: Gas Tungsten Arc Welding (Gtaw/Tig)

    SECTION 3 GAS TUNGSTEN ARC WELDING (GTAW/TIG) Straight polarity is used mainly for welding 3.1 INTRODUCTION  Carbon steels The Tungsten Inert Gas, or TIG process  Stainless steels uses the heat generated by an electric arc  Copper alloys struck between a non-consumable tung- The increased amperage provides sten electrode and the workpiece to fuse...
  • Page 19 SECTION 3 GAS TUNGSTEN ARC WELDING (GTAW/TIG) (continued) Alternating Current with High Frequency Welding with alternating current Welding with alternating current combines both direct-current characteristics:  In the positive phase, cleaning action occurs in the weld puddle.  During the negative phase, heat is con- centrated in the weld puddle.
  • Page 20 SECTION 3 GAS TUNGSTEN ARC WELDING (GTAW/TIG) 3.4 SHIELDING GAS SELECTION Material Sheilding Gas Benefits Aluminum Alloys Argon 1) Used with high frequency AC: good stable arc; good cleaning ac- tion Argon/Helium 1) Used with high fequency AC: good cleaning action; higher weld- ing speed;...
  • Page 21 SECTION 3 GAS TUNGSTEN ARC WELDING (GTAW/TIG) 3.5 CONSUMABLE SELECTION a) Welding Wire The following table includes the recommended welding consumable for the most commonly weld- ed materials. Base Material Consumable C-Mn and low Carbon Steels Mild steel TIG wire Low Alloy Steels 1.25 Cr/0.5Mo CrMo1...
  • Page 22 SECTION 3 GAS TUNGSTEN ARC WELDING (GTAW/TIG) b) Non Consumable Tungsten Tungsten Electrode Se- lector Chart Base Metal Type Thickness Range Desired Results Welding Current Electrode Type Aluminum Alloys & Mag- General purpose ACHF Pure (EW-P) nesium Alloys Zirconiated (EW-Zr) 2% Thoriated (EW- Th2) 2% Ceriated (EW-...
  • Page 23 SECTION 3 GAS TUNGSTEN ARC WELDING (GTAW/TIG) b) Non Consumable Tungsten (continued) Shielding Gas Tungsten Performance Characteristics Argon Ball easily; low cost; tends to spit at higher currents; used for non-critical welds only Argon Balls well; takes higher current; with less spitting and with better arc starts and arc stability than pure tungsten 75% Argon / 25% Helium Higher current range and stability;...
  • Page 24 SECTION 3 GAS TUNGSTEN ARC WELDING (GTAW/TIG) b) Non Consumable Tungsten (continued) Once the tungsten has been sharpened, install it into the torch, with approximately 1/8 of an The tungsten must be shaped prior to initiating inch of the tungsten sticking out. an arc.
  • Page 25 GAS TUNGSTEN ARC WELDING (GTAW/TIG) SECTION 3 continued The following table supplies basic information about Tungsten selection and suitability. DIRECT CURRENT, A ALTERNATING CURRENT, A Straight Polari- Reverse Polar- Unbalanced Balanced Electrode Diameter ty DCEN ity DCEP Wave Wave .020" .050mm 5–20 5–15...
  • Page 26 GAS TUNGSTEN ARC WELDING (GTAW/TIG) SECTION 3 3.6 Joint Preparation...

  • Page 27: Welding Materials

    SECTION 4 WELDING MATERIALS 3.0 TIG Welding of Materials 3.1 Application Summary Material Type of Current Polarity Direct Current (-) DC Negative C-Min Steel Direct Current (-) DC Negative Alloyed Steel Direct Current (-) DC Negative Copper and Cu Alloys Direct Current (-) DC Negative Nickel and Ni Alloys...
  • Page 28 SECTION 4 WELDING MATERIALS 3.3 Alloyed Steel TIG welding may be used for welding alloy steels but because deposition rates are low, it is usually only used for welding sheet and thin sections for high quality applications, small components, and root passes of multipass butt joints in plate and pipe.
  • Page 29 SECTION 4 WELDING MATERIALS 3.5 Aluminum Is a high quality process widely used for welding aluminum, particularly in section size up to about 6mm. The process may be operated with or without filler. TIG welding of aluminum can be carried out using any of the three standard operating modes, alternating current (AC), direct current electrode negative (DCEN) and direct current electrode positive (DCEP).
  • Page 30 SECTION 4 WELDING MATERIALS 3.7 Copper and Copper Alloys Cleanliness is important when welding copper, and all dirt, grease and other contaminants must be re- moved before welding. Copper alloys containing aluminum will from a surface oxide film and this must also be removed before welding.

  • Page 31: Trouble Shooting

    SECTION 5 TROUBLE SHOOTING Problem Cause Solution Excessive electrode 1.Inadequate gas flow 1. Increase gas flow consumption 2. Improper size electrode 2. Use larger electrode for current required 3. Operating reverse polarity 3. Use larger electrode or change polarity 4. Electrode contamination 4.
  • Page 32 SECTION 5 TROUBLE SHOOTING Problem Cause Solution Porosity in Weld De- 1. Entrapped impurities, hy- 1. Don not weld on wet material. Remove condensation posit drogen, air, nitrogen, water from line with adequate gas pre-flow time vapour 2. Defect gas hose or loose Check hoses and connections for leaks connection 3.
  • Page 33 SECTION 5 TROUBLE SHOOTING Problem Cause Solution Arc Blow 1. Induced magnetic field 1. Change to ACHF current. Rearrange the split ground from DC weld current. connection. 2. Arc is unstable due to mag- 2. Reduce weld current and use arc length as short as netic influence.

This manual is also suitable for:

Powertig 320extPowertig 210ext