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Publish Date: Dec. 2020
EVPT255EXT2021 Rev. 1
USA/North America
©Everlast Power Equipment
AC/DC
AC/DC PULSE
ADV. AC PULSE
AC WAVE FORM
CONTROL
DC
240V
1/3 Phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide
Operator's Manual
FUNCTION: AC/DC TIG with Pulse Function/ DC Stick
PURCHASE DATE:
WELDER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:
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Table of Contents
Related Manuals for Everlast PowerTIG 325 EXT
Summary of Contents for Everlast PowerTIG 325 EXT
- Page 1 Publish Date: Dec. 2020 EVPT255EXT2021 Rev. 1 USA/North America ©Everlast Power Equipment AC/DC AC/DC PULSE ADV. AC PULSE Safety, Setup and General Use Guide AC WAVE FORM CONTROL FUNCTION: AC/DC TIG with Pulse Function/ DC Stick PURCHASE DATE: WELDER SERIAL NUMBER: OPTIONAL ACCESSORY SERIAL NUMBER: Operator’s Manual...
- Page 2 TABLE OF CONTENTS SPECIAL NOTICE AND CALIFORNIA PROPOSITION 65 WARNING CUSTOMER GREETING AND EXPLANATION OF PROCEDURES WARRANTY AND CONTACT INFORMATION SAFETY DISCLAIMER AND HF WARNING SAFETY WARNINGS, DANGERS, CAUTIONS AND INSTRUCTIONS GENERATOR OPERATION INFORMATION SPECIFICATIONS, INCLUDING DUTY CYCLE AND INPUT AMPERAGE INFORMATION GETTING STARTED, UNPACKING YOUR UNIT AND INSPECTION CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION SHIELDING GAS INFORMATION AND CONNECTION OF REGULATOR...
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Page 3: California Proposition 65 Warning
Due to multiple variables that exist in the welding field and the changing nature of it and of the Everlast product line, Everlast Power Equipment INC. does not guarantee the accuracy, completeness,... - Page 4 Many issues can be resolved over the phone. If the issue cannot be resolved over the phone/email, you may be given an op- tion to return the unit, or have a part shipped to you, at Everlast’s discretion. Keep in mind, you may be asked questions that seem basic, or ele- mentary to your knowledge base.
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Page 5: Who Do I Contact
Warranties and service policies and procedures vary from country to country and are maintained and supported by the region- al or in country distributor of Everlast welding equipment. USA Customers Only: For full details on the 5 year parts and labor warranty, 30 day satisfaction policy, terms of sale, and how to proceed with a war- ranty claim, please visit: https://www.everlastgenerators.com/standard-warranty. - Page 6 Safe operation and proper maintenance is your responsibility. Everlast is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and maintenance of your Everlast product, it is no substitute for observing safe welding practices and behavior. Safe welding and related cutting operations require basic knowledge, experience and ultimately the exercise of common sense.
- Page 7 It is your responsibility to make certain that the use of this welder is restricted to per- sons who have read, understand and follow the warnings and instructions in this manual. If you or the operator needs further instruction, contact Everlast welding support at 1-877 755-9353 ext. 204 or seek qualified professional advice and training.
- Page 8 Safety Warnings, Dangers, Cautions and Instructions DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these hazards are immediate while others are cumulative in their effect. Do not weld in enclosed spaces or in areas without adequate ventilation. Fumes and gases released in the welding and cutting operations can be toxic.
- Page 9 Safety Warnings, Dangers, Cautions and Instructions CAUTION! Trip Hazards exist around welders. Cords, cables, welding leads and hoses pose a trip hazard. Be aware of their location and inform others of their location. Tape and se- cure them so they will stay out of high traffic areas. CAUTION! Welded metal can stay hot long after welding is completed.
- Page 10 14,500 watt generators or larger. Operating the unit on under-powered generators and/or on generators not rated with 5% or less THD can damage your unit. The generator manufacturer determines this rating, not Everlast. Do not assume that a name brand generator, or a “new” generator automatically provides clean power. Price paid does not guarantee a clean power out- put either.
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Page 11: Specifications
National Electric Code (NEC) and local codes. If needed, refer the electrician to Article 630 of the NEC during consultation to determine proper application and wiring needs. Use the I1MAX and the I1EFF ratings listed above to determine the proper breaker and conductor (wire) sizing required. Everlast welders are designed around use in industrial wiring applications and are intended to be used with modern electrical systems. -
Page 12: Getting Started
(work). Check for arc starting and stability. If prob- cut cords and cables inside the boxes. Lay all items out and inspect lems are observed, contact Everlast. See page 5 for more infor- them. mation. NOTICE: Cosmetic damage claims after 30 days will not be... - Page 13 If you are not qualified to make 3 phase receptacle and cutoff (disconnect) close to where the unit will be in these connections, don’t. Everlast is in no way liable for any damag- use.
- Page 14 Setup Guide Getting Started a 580 CGA valve). If you do not have a cylinder wrench, an adjusta- CONNECT YOUR UNIT TO THE SHIELDING GAS. ble type wrench will work, but make sure it is properly adjusted to What Shielding Gas Should Be Used? prevent rounding of the fitting shoulders.
- Page 15 Setup Guide Getting Started SELECT THE PROPER TUNGSTEN TYPE. Purchasing Tungsten can be difficult. Local suppliers tend to put a premium price on Tungsten, and may be three times an online price What Type of Tungsten Do I Use? direct from a distributor. In many areas, the choice of tungsten may Selecting the correct tungsten for your welder is important.
- Page 16 Setup Guide Getting Started Choosing the proper grind angle is important to achieving the weld As you use the tungsten (depending upon the type you have select- penetration, bead appearance, and arc cone width that you desire. ed) you will notice that the tungsten will gently form more of a point- While there is no true “one size fits all”...
- Page 17 What Size of Tungsten Do I Use? NOTICE. Everlast advertises low arc start capability on their units. Surge Am- A tungsten such as a 1/8” diameter or larger may not start as cleanly perage to establish the arc are quite low. When starting an arc, at the minimum capable start amp of this unit.
- Page 18 Setup Guide Getting Started in color coding, so match the color codes of the torch to the cooler SELECT THE PROPER TIG POLARITY AND CONNECTIONS. couplings for best results). The line exiting from the DINSE connect- Selecting polarity for TIG is quite simple. The torch will always be or is no longer a gas line but a water line.
- Page 19 PowerCool cooler. If you have any questions about purchasing the E7018, and E7014 are highly recommended for use. correct cooler and assembly for your welder, contact Everlast. SELECT THE PROPER STICK POLARITY. The electrode holder, or stick torch (sometimes called a stinger) will...
- Page 20 Setup Guide Getting Started If you are needing basic help getting started, here are some general settings and selections to get you started. This guide is intended to be only a start- ing point, not a completely exhaustive source. Keep in mind that no guide is a substitute for practice and experience. You may find that your final set- tings may be different from the ones listed.
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Page 21: Front Panel View
Component Identification and Explanation Front Panel View Number Component Identification Component Note Protective Cover Keep down and in place during welding activities and in storage. Negative Terminal (-) Connect the TIG torch to this terminal for all TIG welding applications (DINSE 35/50 Type, 1/2”... -
Page 22: Rear Panel View
Component Note Water Cooler Plug (240V 1ph, 4A max) This plug is to be used with Everlast water coolers only. Do not use with any other application. (May not apply to 480V models) Input Cable and Plug* Plug is not included due to dual phase capability and the different wiring arrangements required. North America only: The unit may be operated on either 208-240V 1 phase or 208-240V 3 phase operation. -
Page 23: Control Panel Layout
Component Identification and Explanation Control Panel Layout Number Component Identification Value Function/Component Note Memory Function Used to Save up to 9 different programs. To save a program: select a program number by repeatedly pressing on the “select” button until the desired program number has been selected. Then make all necessary adjustments and selections on the panel. - Page 24 Component Identification and Explanation Control Panel Layout Number Component Identification Value Function/Component Note Adjustment Knob Used to adjust any parameter in the parameter/weld cycle graph found in item # 3. IMPORTANT! With the knob in the normal position, the knob adjusts incrementally. However, for a greater adjustment value, such as a whole number at a time rather than decimals, or to increase in values of 10 (depending on function type) press in on knob lightly and turn the knob while holding pressure in.
- Page 25 0% electrode negative. Some brands express this with a recip- rocal value of Electrode Negative. So what would be a “safe” 30% electrode positive setting on the Everlast, becomes a 70% electrode negative setting on other brands. Everlast, along with other brands...
- Page 26 Everlast Tech Support. CAUTION! Don’t continue try to make the arc start without somewhere for the HF to travel, ie to the work piece.
- Page 27 HF establishes a current path and the HF If you need this type of start on a welder, contact Everlast for other shuts off. On this unit if the HF stays on, but does not start an arc or product information.
- Page 28 Component Identification and Explanation Explanation of Functions and Welding Terms lines. As the slightly swollen gas lines stabilize, extra gas is pro- addition of filler metal to the weld puddle. A higher pulse frequency pelled as the solenoid opens relieving the back pressure. .3 to .7 level that is combined with variations in Pulse Time On and a narrow/ seconds is usually enough to allow the “gas rush”...
- Page 29 Component Identification and Explanation Explanation of Functions and Welding Terms AC Pulse TIG operation is setup the same. Do not confuse AC cy- initially, but with practice, this feature can be used as a valuable tool. cling between EP and EN as pulse. It is not. You are still adjusting When DC is adjusted to a low % setting, while welding on thin met- the amperage of the AC pulse, and skewing the balance and chang- als, the bead profile will change and additional control will be given.
- Page 30 “press and hold”. The second allows the switch to be released to weld, but offers separate motions to start and stop the arc. See below E6011. For best results with stick welding, Everlast recommends for how each function is activated by movements of the torch switch.
- Page 31 Component Identification and Explanation Explanation of Functions and Welding Terms wet in and a generally buttery, but controllable weld. This is less likely to consume Tungsten as rapidly, but some “heat” loss going into the weld will be experienced. Use with Lanthanated or Ceriated Tungsten. Triangular Wave Form.
- Page 32 9 Series Air-Cooled Welding Torch (Typical Type) Parts and Assembly. DC 125A @ 60% Duty Cycle; AC 90A @ 60% Duty Cycle Typical Everlast and NOVA Torch Assembly (9/20 Series) (Some parts may not appear exactly the same but are equal in assembly order and type.) Tungsten not included, but available in select Consumable Kits on the website at www.everlastwelders.com.
- Page 33 20 Series Water-Cooled Welding Torch (Typical Type) Parts and Assembly. DC 250A @ 100% Duty Cycle; AC 200A @ 100% Duty Cycle Typical Everlast and NOVA Torch Assembly (9/20 Series) (Some parts may not appear exactly the same but are equal in assembly order and type.) Tungsten not included, but available in select Consumable Kits on the website at www.everlastwelders.com.
- Page 34 Component Identification and Explanation 7 PIN CONNECTOR FOR 10K or 22K Ω FOOT PEDAL Bridge a Jumper to Pin 7 To Pedal or Torch Switch ON/OFF Bridge a Jumper to Pin 6 To Pedal or Torch Switch ON/OFF High Middle Potentiometer (VR) Foot Pedal (10k-22k Ω) Note: This unit is designed to accept several different Ohm values, including the older 47K (50K) Ohm pedal without significantly...
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Page 35: Troubleshooting
Possible issue running on generator with dirty power. Identify cause, plug directly into the receptacle. Cycle the switch one time. If the code does not clear, call Everlast TORCH SWITCH IS STUCK CLOSED. This simply means that the arc has been trying to start and the HF has been cycled on for too long. - Page 36 Check gas flow. Adjust for higher flow of gas. Listen for audible click activity. Solenoid is sticking. Too short of pre- of gas solenoid. If no click is heard, then contact Everlast Support. Clean flow or post-flow weld properly. Increase pre flow or post flow.
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Page 37: Maintenance
This is important to keeping your welder running for many years into the future. It is important to note that cleaning doesn’t void your warranty, but rather ensures it! Keep your welder covered when not in use. You can purchase a cover for your welder direct from Everlast.