Everlast PowerARC 161STH Operator's Manual page 13

Section 2
less noticeable. This is most apparent when
welding with 120V. To achieve better starting
with 120V, smaller welding electrodes may need
to be used to achieve a better start.
Hot start works well to improve starts, but main-
taining the arc in less-than-favorable conditions
where the arc length must be held short is the
job of the arc force control. The action of the
arc force control is similar to the hot start in the
fact it boosts amps to prevent arc outage. But it
only does so when the arc voltage drops below a
threshold of approximately 20V. The amp rise
responds in proportion to the drop in voltage to
maintain overall wattage. Be sure to double
check (especially after TIG welding) that the
electrode holder cable is located in the positive
terminal, and the work clamp is located in the
negative terminal. In general most iron powder
fluxed rods and titania fluxed rods require arc
force settings of 30% or less. For cellulose,
higher arc force values from 40 to 60% may be
desirable. During 120V operation, E6010 perfor-
mance may be reduced due to the limits im-
posed on the arc force action. If necessary, drop
down to the next smaller electrode for best re-
sults. See the page dealing with arc striking
technique and general rod size selection later in
this manual. Briefly, the welding rod size while
operating on 120V is generally limited to 3/32"
max diameter electrode.
ing on 240V is generally limited to 1/8" diameter
electrode. Oversizing a rod will increase stick-
ing and can create undesirable cold lap (lack of
fusion at the weld toes). As with any type of
welding, practice will usually improve the re-
sults.
For stick, a Voltage Reduction Device (VRD) has
been added for safer operation in areas where
electrocution is an issue. In fact, on some job
sites the use of VRD may be required. Though
very rare, electrocution is a hazard that all weld-
ing activities present. The VRD, when selected,
reduces the Open Circuit Voltage to less than 24
Volts, (DC output). If the user were to become
part of the current path, in most circumstances,
this voltage would not be fatal, although a shock
may still be felt. The VRD is a safety feature
that can be used to help reduce the risk of elec-
trocution while conducting Stick welding activi-
ties. It cannot operate unless the VRD has been
turned on via the control button on the welder.
It cannot eliminate all risk. It does not eliminate
any risk of electrocution from the user coming
into contact with power input cables or internal
parts of the machine. Common sense and ad-
Rod size while operat-
General Setup and Operation
herence to safety practices should be employed
at all times when the VRD is required to be
used. VRD, while increasing safety, reduces arc
starting efficiency and can cause the arc to be
more difficult to start. If trying to start the arc
with VRD engaged, try using a quick "double
tap" of the electrode to get the arc started.
The Anti-Stick function of the welder helps to
prevent the welding rod from sticking fast in the
weld and flaming up the rod due to the rod turn-
ing red hot and overheating. The Anti-stick
function, when activated via the control button
on the welder, reduces weld output when the
rod contacts the metal and the arc is extin-
guished. The main goal of the anti-stick func-
tion is to help reduce the chance of a "firm
stick" of the rod, where it becomes fully fused
to the weld puddle, so reduced effort is needed
to break the welding rod loose. It also helps to
eliminate arc flashing when the rod does break
loose. This helps to protect bystanders and even
the operator against accidental flashing. It may
not eliminate accidental arc flashing in all cir-
cumstances, but does reduce the chances of
intense arc burn to the eyes if eye protection is
removed or the welding hood is lifted to remove
the stuck rod. The unit will auto reset and weld-
ing will resume once the stuck rod has been
cleared and contact has been broken with the
weld surface.
Note: Using the Anti-Stick and VRD together
can cause a greater issue with arc starting and
arc stability. If problems arise, and safety per-
mits, try turning one or both functions off.
2.3 Handling and General Maintenance.
Duty Cycle and Overcurrent:
Be careful to observe the duty cycle of the
welder. Do not intentionally overheat the
welder. Intentional or repeated overheating
will eventually damage the unit. This damage
is apparent upon inspection and not covered
under warranty.
Overheating may occur if the duty cycle is ex-
ceeded. Overheating will cause the unit safety
cutout to engage, will subsequently interrupt
output. Allow the unit to rest while remaining
switched on for at least 15 minutes if the duty
cycle safety has triggered. After that, reset the
unit by cycling the main power switch on the
rear. Even though the duty cycle rating is made
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