Everlast PowerARC 161STH Operator's Manual
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Everlast PowerARC 161STH Operator's Manual

Dc stick/dc pulse tig inverter welder
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EVERLAST
POWERARC 161STH
DC Stick/DC Pulse TIG Inverter Welder
CC
GTAW
SMAW
IGBT
~
1
PHASE
DC
120V
240V
Operator's Manual for the PowerARC 161STH
Safety, Setup and General Use Guide
Rev. 2
1 000913-18
everlastwelders.com
Specifications and accessories subject to change without notice.
1-877-755-9353
380 Swift Ave. South San Francisco, CA 94080 USA

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  • Page 1 DC Stick/DC Pulse TIG Inverter Welder GTAW SMAW IGBT PHASE 120V 240V Operator’s Manual for the PowerARC 161STH Safety, Setup and General Use Guide Rev. 2 1 000913-18 everlastwelders.com Specifications and accessories subject to change without notice. 1-877-755-9353 380 Swift 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 per- formance/accuracy or for suitability of application.

  • Page 3: Letter To The Customer

    Your unit registration is important should any information such as product updates or re- calls 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___________________________ Everlast US: Everlast consumer satisfaction email: sales@everlastwelders.com Everlast Website: everlastwelders.com Everlast Technical Support: tech@everlastwelders.com Everlast Welding Support: performance@everlastwelders.com Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php Main toll free number: 1-877-755 WELD (9353) Sales: Ext 201 9am—5pm PST M-F Tech Support: Ext 207 9am—5pm EST 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 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: Section 1: Specifications

    Section 1 Specifications PERFORMANCE AND FEATURE COMPARISON Specification PowerARC 161STH Inverter Type Digitally Controlled IGBT Input Voltage (±10); Phase/Frequency 120/240V; 1PH/50-60Hz Maximum Inrush Amps(I max) 29.7A @120V/ 28.8A @ 240V Maximum Effective (rated running) Amps (I eff) 18A @ 120V/ 17A @ 240V 120V: TIG: 35% @ 90A/13.6V...

  • Page 10: Section 2: General Setup And Operation

    The user now has 3 PowerARC 161STH: choices for starting the arc, which can be cho- The PowerARC 161STH is a compact digitally sen to match the type of operation that is re- controlled inverter welder that provides DC stick quired in different circumstances.
  • Page 11 22k pedal for use with the unit direct from were not purged properly before use. Never use Everlast. Additionally a torch mounted Amptrol a mixed shielding gas for MIG welding, especial- which features a sliding action to control the ly any with CO2 in the mix.
  • Page 12 Section 2 General Setup and Operation small spark is the HF trying to start the arc. Do error code if the arc does not initiate following not try to weld with the work clamp detached. the burst of HF after 3 seconds. This prevents Once the arc transfers, the thin, blue spark will damage to the machine and limits HF exposure stop, and the snapping sound will cease.
  • Page 13 Section 2 General Setup and Operation herence to safety practices should be employed less noticeable. This is most apparent when at all times when the VRD is required to be welding with 120V. To achieve better starting used. VRD, while increasing safety, reduces arc with 120V, smaller welding electrodes may need starting efficiency and can cause the arc to be to be used to achieve a better start.
  • Page 14 But, while you are inside the unit for mainte- cycling the power switch (after the required nance, always check all plugs and connections amount of rest, if any), contact Everlast. for tightness before replacing the covers. Do not pinch any wires when reinstalling the covers.

  • Page 15: Front Panel

    Section 2 General Setup and Operation PowerARC 161STH Front Panel View IMPORTANT! READ OPERATO R’S MANUAL BEFO RE USE ! STICK 8.8.8. 6010 PEDAL HOT START INTENSITY POST FLOW HOT START STICK LIVE LIFT TIME ARC FORCE PREFLOW DOWNSLOPE START...

  • Page 16: Rear Panel

    General Setup and Operation PowerARC 161STH 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. MAIN POWER SWITCH GAS CONNECTION 1x1110/220V...

  • Page 17: Stick Welding Configuration

    Section 2 General Setup and Operation PowerARC 161STH STICK WELDING CONFIGURATION IMPORTANT! READ OPERATO R’S MANUAL BEFO RE USE ! STICK 8.8.8. 6010 PEDAL HOT START INTENSITY POST FLOW HOT START STICK LIVE LIFT TIME ARC FORCE PREFLOW DOWNSLOPE START...

  • Page 18: Tig Torch Configuration

    NOTE: FOOT PEDAL IS OPTIONAL. Purchase a long life NOVA foot pedal or torch mounted NOVA Slider Amp Control direct from Everlast if needed. Additionally, optional TIG torches, including high quality NOVA torches are also available for purchase from Everlast.
  • Page 19 Section 2 General Setup and Operation PowerARC 161TH Gas Connection Start all fitting threads with fingers and turn clockwise until the male fitting begins to seat. Then, use only a wrench to tighten fittings. Do not use pliers or any type o f gripping device with locking jaws or serrated teeth. When tightening the tubing fitting to the we lder’s CGA 5/8”...

  • Page 20: Wire Connection

    EVERLAST IMPORTANT: While using the PowerARC 161STH on 120V power, be sure to maintain polarity and use the white wire as the common/neutral, with the black as the “hot” and the green serving as the ground or damage and malfunction may occur. Do not remove the NEMA 6 -50 plug to operate on 120V.

  • Page 21: Stick Operation Technique/Information

    Section 2 General Setup and Operation STICK OPERATION STARTING METHODS Tapping Method Scratch/Match Method Striking the Arc Make sure the unit is turned on and the startup cycle has finished. Select the Stick icon on the Process Selector. Make sure the electrode holder is in the Positive connector and the work clamp is in the negative connector. Select the Amp level desired.
  • Page 22 General Setup and Operation Section 2 Basic TIG Operation General Setup. The process to set up the welder running slowly without filler metal first. Keep the for the basic TIG mode is much less involved than torch head inclined away from the direction of trav- for basic MIG or Stick.

  • Page 23: Basic Tig Operation

    General Setup and Operation Section 2 Basic TIG Operation need to change your settings. Practice feeding the filler wire without actually welding. Manipulating filler wire without actually welding. Manipulating the wire takes practice and concentration at first. the wire takes practice and concentration at first. The wire should be held so that a flicking motion of The wire should be held so that a flicking motion of two fingers and the thumb can propel the rod for-...

  • Page 24: Tig Arc Start And Tig Tips

    General Setup and Operation Section 2 Note: A TIG lift start should use a nearly seamless motion. Use a light touch and a quick motion for best results. LIFT START OPERATION <1/8” Position the edge of the ceramic cup on the metal. Press and hold the torch switch or press the foot pedal. Wait for the Pre-flow to start.

  • Page 25: Tungsten Preparation

    General Setup and Operation Section 2 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 26: Kit Contents

    17 series TIG torch with torch switch, 12 ft (with starter consumable kit) Brass regulator (floating ball type) PowerARC 161STH DC Stick/DC TIG Inverter welder Manual 240V-120V Adapter (optional in some markets) NOTE: Kit contents, appearance, size and quantity are subject to change without notice.

  • Page 27: Tig Torch Assembly

    General Setup and Operation Section 2 EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) 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, 3/32, or 1/8”...

  • Page 28: Trouble Shooting

    (See next page) If unit will not strike arc or no power is produced, check torch switch and foot pedal operation. If the torch switch and foot pedal are functioning ok, then contact Everlast for full diagnosis. If one functions and not the other, then it is likely the switch mechanism has failed inside the torch or foot pedal.

  • Page 29: Foot Pedal Pin-Outs

    Section 3 Trouble Shooting 7 PIN CONNECTOR FOR FOOT PEDAL 10kΩ For NOVA Bridge to 7 To Pedal or Torch Switch Bridge to 6 To Pedal or Torch Switch The welder will accept 10k to 22k Ohm potentiometers.

  • Page 30: Point Gap Adjustment

    If you suspect you have a a problem with the point gap due to hard starting of the arc, contact Everlast Tech Support before proceeding with point gap adjustment for proper diagnosis and a more de- tailed adjustment procedure.
  • Page 31 NOTES:...

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