Everlast Typhoon 500 Operator's Manual
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Everlast Typhoon 500 Operator's Manual

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Publish Date: January 2024
EVPTYP500 Rev. 1
USA/North America
©Everlast Power Equipment
AC/DC
400/500A
AC/DC
315/400A
240V
1 Phase
480V
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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Summary of Contents for Everlast Typhoon 500

  • Page 1 Publish Date: January 2024 EVPTYP500 Rev. 1 USA/North America ©Everlast Power Equipment AC/DC 400/500A Safety, Setup and General Use Guide AC/DC 315/400A FUNCTION: AC/DC TIG with Pulse Function/ DC Stick PURCHASE DATE: WELDER SERIAL NUMBER: OPTIONAL ACCESSORY SERIAL NUMBER: 240V 1 Phase Operator’s Manual...

  • Page 2: Table Of Contents

    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, OPERATING VOLTAGE AND OTHER GENERAL INFORMATION DUTY CYCLE EXPLANATION STATEMENT SPECIFICATIONS: DUTY CYCLE, PERFORMANCE SPECIFICATIONS AND INPUT AMPERAGE INFORMATION SETUP GUIDE: GETTING STARTED, UNPACKING YOUR UNIT, ASSEMBLY AND INSPECTION SETUP GUIDE: CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION...

  • Page 3: Special Notice And 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 it- self, Everlast Power Equipment INC. does not guarantee the accuracy, complete-...

  • Page 4: Customer Greeting And Explanation Of Procedures

    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.

  • Page 5: Warranty And Contact Information

    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: Safety Disclaimer And Hf Warning

    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: Safety Warnings, Dangers, Cautions And Instructions

    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: Generator Operation, Operating Voltage And Other General Information

    Single and Three Phase Operation: The standard Typhoon 500 may be operated on either single phase 240V or three phase 480V supply power. If 240V three phase power is available, this unit may be operated on it when only 2 power legs are used. (Use only the 2 balanced 120V to ground legs, not the high leg if 240V Delta.) This is the same as using single phase power.

  • Page 11: Duty Cycle Explanation Statement

    Ever- last. Everlast accepts and bears no responsibility, nor provides any guaranty or promise, to update programming, features, functions or ratings for older units already in service, free of charge or otherwise unless specifically stated in writing.

  • Page 12: Specifications: Duty Cycle, Performance Specifications And Input Amperage Information

    Specifications Product Specifications Construction Type Digital IGBT Inverter-Based Design with 5.1” HD (720) Screen. (Diagonal Measurement) Input Voltage/ Hertz/ Phase 240V (± 10% ) 50/60 Hz 1 Phase and 480V 3 Phase (±15%) 50/60 Hz Current Rating (Inrush Amps) 240V 1 Phase @ 63A 480V 3 Phase @ 24A Current Rating (Effective Rated Amps) 240V 1 Phase @ 50A 480V 3 Phase @ 19A) OCV/ OCV with Voltage Reduction Device Selected...

  • Page 13: Setup Guide: Getting Started, Unpacking Your Unit, Assembly And Inspection

    If the rails do not fit, 26 Series Air-Cooled Torch (NOVA Rigid/Straight Neck) 12.5 ft. contact Everlast Technical Support. Tighten rail screws after the rails test fit 18 Series Water-Cooled Torch (CK HD Rigid/Straight Neck) 12.5 ft.
  • Page 14 NOTICE: Cosmetic damage claims made after 30 days will not be accept- ed, unless Everlast is contacted and informed of such delay and reason for such a required delay (i.e. Overseas deployment or sudden disability).

  • Page 15: Setup Guide: Connecting Your Unit To The Power Source And Wiring Information

    If you are not qualified to make different for various applications. It is recommended to either install the these connections, don’t. Everlast is in no way liable for any damag- line direct into an electrical cutoff box, or wire a 3 phase receptacle and es caused by improper connection of your welder.

  • Page 16: Setup Guide: Shielding Gas Information And Connection Of Regulator

    Setup Guide Getting Started valve). If you do not have a cylinder wrench, a large ,adjustable-type CONNECT YOUR UNIT TO THE SHIELDING GAS. wrench will work. However, make sure it is properly adjusted to prevent What Shielding Gas Should Be Used? rounding of the shoulders of the fitting.

  • Page 17: Setup Guide: Tungsten Selection And Grinding

    Setup Guide Getting Started Purchasing Tungsten can be difficult. Local suppliers tend to put a premi- SELECT THE PROPER TUNGSTEN TYPE. um price on Tungsten, and may be three times an online price direct from What Type of Tungsten Do I Use? a distributor.
  • Page 18 Setup Guide Getting Started Choosing the proper grind angle is important to achieving the weld pene- Depending upon what arc properties you are looking for, you may periodi- tration, bead appearance, and arc-cone width that you desire. While there cally want to regrind your tungsten to maintain optimal arc characteristics. is no true one-size-fits-all angle, there are some general rules of thumb to IMPORTANT! Don’t Ball The Tungsten.
  • Page 19 What Size Tungsten Do I Use? The key to obtaining good, picture-perfect arc starts is to use properly Everlast advertises low arc start capability on this. The Start Amperage of sized and ground Tungsten. A properly sized Tungsten, combined with the arc is quite low.

  • Page 20: Setup Guide: Getting Started With Tig And Stick Basic Starting Point General Information

    Setup Guide Getting Started “stacked” passes on thicker plate. Multi-pass welds are typically stronger, TIG BASIC STARTING POINTS. have less defects and require less amperage. On heavy gauge plate, such This machine makes use of the Synergic PowerSet feature. However, If as 3/8”...

  • Page 21: Setup Guide: Connecting Your Unit And Readying To Weld (Polarity And Panel Connections)

    Setup Guide Getting Started in return line. Follow the color coding used by NOVA. SELECT THE PROPER TIG POLARITY AND CONNECTIONS. Selecting the correct polarity for TIG is quite simple. Whether you are TIG GET A COOLER FOR THE WATER-COOLED TORCH. welding in AC or DC, the TIG torch will always be connected to the nega- tive (-) output terminal located on the left side of the welder.
  • Page 22 Setup Guide Getting Started provide a slip free connection. Additionally, the units can be locked semi- mind you to operate with the electrode holder in the Negative Terminal. permanently together by installing the connecting screws with the bracket Not all welding rods can create a satisfactory weld in AC mode. Welding provided with the cooler.

  • Page 23: Front Panel View And Component Id

    Component Identification and Explanation Front Panel View Component Identification Function/Component Note Protective Cover Keep down and in place during welding activities and while in storage. Negative Terminal (-) Connect the TIG torch to this terminal for all TIG welding applications including AC. Connect the work (DINSE 35/50mm Type, 1/2”...

  • Page 24: Rear Panel View And Component Id

    Component Identification Function/Component Note Water Cooler Outlet This outlet is to be used with Everlast 240V rated water coolers only. Do not use with any other application. Do not operate with single (240V 1Ph, 4A max) voltage120V Everlast coolers. Input Cable 6.5 ft. (No Plug) North America only: The unit may be operated on either 240V 1 phase power or 480V 3 phase power.

  • Page 25: Control Panel Layout

    Component Identification and Explanation Control Panel Layout Component Identification Function/Component Note Welding Process Selector Press left or right arrow key to navigate back and forth to select the desired weld process. The LED will light to indicate which weld process has been selected. See Quick Setup Section. 5.1”...

  • Page 26: Starting Up The Welder

    If any malfunction of the control screen or the welder is ob- sories and dismounting them from the cart is important to prevent acci- served, contact Everlast Tech Support. dental triggering, arc flashing, welder damage and possible injury. When the welder is switched on at the rear of the unit and the start-up process begins, it will greet you with the start-up screen while it is booting TAKE CARE OF THE LCD SCREEN.

  • Page 27: Control Panel Operation And Navigation

    Repeat Step 4 through 7 until all desired parameter adjustments are made. Typhoon 500 NOTE: Adjusting some parameter values may be tedious due to the wide range of adjustment. To speed up adjustment, push in on the knob and hold it...
  • Page 28 Component Identification and Explanation Control Panel Operation and Navigation QUICK NAVIGATION GUIDE: FUNCTION SELECTION AND ADJUSTMENT OF MANUAL MENU Complete startup and process selection steps 1 through 3 on the previous page before following these directions. Complete steps 1 through 3 on the previous page before completing the following instructions. To select a Function, press the selection key once to select the bottom parameter line.
  • Page 29 Component Identification and Explanation Control Panel Operation and Navigation QUICK NAVIGATION GUIDE: ADJUSTMENT AND NAVIGATION OF POWERSET MENU The basic navigation of the PowerSet screen is similar to the manual setup screen. However there are differences that should be noted. The PowerSet Menu requires input of various pieces of information by the user.
  • Page 30 Component Identification and Explanation Control Panel Operation and Navigation QUICK NAVIGATION GUIDE: SELECTING AND ADJUSTMENT OF BACKGROUND MENU The Background Menu screen contains several user preference settings along with welder status information that are not normally adjusted or in need of monitoring.
  • Page 31 Component Identification and Explanation Control Panel Operation and Navigation QUICK NAVIGATION GUIDE: PROGRAM AND SAVE FUNCTION The Program and Save function can save up to 30 different programs, of any combination of TIG, Stick or PowerSet mode settings. It also features a lock setting to ensure quality control by preventing tampering of the base saved program unless purposefully unlocked by a unique button press.
  • Page 32 Component Identification and Explanation Control Panel Operation and Navigation QUICK NAVIGATION GUIDE: GAS PURGE FUNCTION AND FLOW RATE ADJUSTMENT The Gas Purge function allows you to test and set the shielding gas flow rate. The Gas Purge key itself controls this, but it also serves as the lock func- tion while saving a program, and it is used in simultaneous combination with the Save/Program key to access the hidden menu.
  • Page 33 Component Identification and Explanation Control Panel Operation and Navigation wise. The knob will then scroll one parameter or function for each NAVIGATING THE PANEL AND SCREEN: MANUAL MODE.* click the knob makes. To highlight and select the function and to The controls of the Typhoon are simple to use.
  • Page 34 Component Identification and Explanation Control Panel Operation and Navigation 10. Weld Cycle Graph Line. The Weld Cycle Graph line serves as a key select the Function Line for adjustment. Then, rotate the knob and visual guide that helps the user to better understand the role that the press and release it to adjust the status of the function.
  • Page 35 Component Identification and Explanation Control Panel Operation and Navigation NAVIGATING THE PANEL AND SCREEN: POWERSET MODE.* What is the PowerSet Mode? Navigation in the PowerSet mode is similar to navigation in the Manual The PowerSet menu screen simplifies setup by providing a starting point mode.
  • Page 36 Component Identification and Explanation Control Panel Operation and Navigation the nature of the PowerSet mode, both the push-to-select and the fast • Tungsten Diameter. Select the Tungsten diameter for use adjustment function have been deactivated. with the machine. Tungsten size will affect the range of adjustment and will limit some choices for work thickness.

  • Page 37: Weld Cycle And Graph Line Details

    Component Identification and Explanation Weld Cycle and Graph Line Details be considered recommended settings or even default settings of the unit. weld graph line is covered separately.) The actual graph line will change depending upon what functions and settings are selected. However, the UNDERSTANDING THE GRAPH LINE OF THE TIG WELD CYCLE.
  • Page 38 Component Identification and Explanation Weld Cycle and Graph Line Details “Advanced AC Pulse” is selected, this becomes the DC Electrode AC Frequency. Value is in Hertz (Hz). Negative parameter of the pulse. Value is in percent of welding Amps AC Balance. Value is in Percent of Electrode Positive. (% of EP+) or Electrode Negative (if Independent Amplitude is selected).
  • Page 39 Component Identification and Explanation Weld Cycle and Graph Line Details Pulse Amperage. This appears only when Pulse is selected. Value is mode, even though it is far more simple, it is still offers a full compliment in percent of Welding Amperage. of practical features that help the user to maintain maximum control.

  • Page 40: Ac Tig Screen Setup, Functions And Parameters

    Component Identification and Explanation AC TIG Screen Setup, Functions and Parameters For the following pages, keep in mind that while there is only one hidden Basic AC TIG Parameters: menu screen designed for adjusting functions that are not commonly (In order of logical flow of the weld cycle from left to right.) changed or used, the screen menu and graph line do alter the shape, size Pre-Flow Time Setting: 0-30S.
  • Page 41 AC cycle. It is also used as the “peak” current value for Pulse when pulse is selected. The Typhoon 500 maximum output will vary according to the input voltage of the unit. For 240V 1 Phase maximum output is Additional Functions of Independent Amplitude: 400A.
  • Page 42 Component Identification and Explanation AC TIG Screen Setup, Functions and Parameters Pulse Amps/DC Pulse Amps: 3-100% of Welding Amps. When • CANNOT BE USED WITH SPOT FUNCTION Standard Pulse Mode is being used, this represents the low Amper- In AC mode, the pulse is available for selection with any function setting age phase (Base Current) of the Pulse.
  • Page 43 Component Identification and Explanation AC TIG Screen Setup, Functions and Parameters flict with achieving sufficient AC cycles to provide necessary cleaning. AC Pulse Functions with Amplitude Turned On. Stitch Timer: 0-5S. The Stitch timer duration is the “Arc Off” time. This is designed to cycle the arc off for a specified period of time and Pulse, Standard Mode and Advanced AC Pulse Mode.

  • Page 44: Dc Tig Screen Setup, Functions And Parameters

    Component Identification and Explanation DC TIG Screen Setup, Functions and Parameters For the following pages, keep in mind that while there is only one hidden except Foot Pedal Mode. When the Spot Function is selected, it be- menu screen designed for adjusting functions that are not commonly comes unavailable for adjustment.
  • Page 45 Component Identification and Explanation DC TIG Screen Setup, Functions and Parameters be used together. When the Spot or Fast-Tack function is selected, even is located on the weld graph line with the parameters, even though though it is available to select while Pulse is turned on, Pulse is automati- the control is located on the Function line.
  • Page 46 Component Identification and Explanation DC TIG Screen Setup, Functions and Parameters Stitch Timer: For Spot 0-5S; For Fast-Tack 0-25ms. The Stitch timer duration is the “Arc Off” time. This is designed to cycle the arc off for a specified period of time and to provide a repeating pattern of ON/ OFF cycles.

  • Page 47: Ac And Dc Stick Screen Setup, Functions And Parameters

    Amperage control. Con- between AC and DC Stick welding is the polarity recommendation. AC, tact Everlast for more options. because of the way it references electrode positive when adjusting the AC Voltage Reduction Device (VRD): Less than 24V. This function reduc- balance, will require the Electrode Hodler to be located in the negative es the OCV to below 24V when required for safety.
  • Page 48 Component Identification and Explanation AC and DC Stick Screen Setup, Functions and Parameters Voltage Reduction Device (VRD): Less than 24V. This function reduc- es the OCV to below 24V when required for safety. May make arc starting more difficult. Anti-Stick: Off or On. This function when turned on helps to ease rod removal by reducing output when the rod sticks.

  • Page 49: Background Menu Screen Setup And Parmeters Of Operation

    Component Identification and Explanation Background Menu Screen Setup and Parameters of Operation The unit features only one hidden background menu. It is used to access Water Cooler Control: ON/OFF. When set to “Off” the cooler runs full secondary control functions and operating temperatures of the unit. See time.

  • Page 50: Tig Arc Starting, Remote Functions And Operation

    Component Identification and Explanation TIG Arc Starting, Remote Functions and Operation The TIG arc start can be performed in three basic ways. considered an HV start, it electronically simulates the HF start. It is re- ferred to HF on the Function line of the machine to eliminate confusion by The first and primary arc starting method used is High Frequency Start.
  • Page 51 These two modes (older models used 2T+Finger/4T+ Finger designations) operate the same way as 2T and 4T modes, but allow the use of the rolling amp control function of the special torch offered by Everlast. Since the = UP ON SWITCH = DOWN ON SWITCH 2T/4T operation has been covered, the operation is not illustrated.

  • Page 52: Explanation Of Tig Parameters, Functions And Welding Terms

    Cleaning/Etched Area of Aluminum tive. So what would be a “safe” 30% electrode positive setting on the Ever- last, becomes a 70% electrode negative setting on other brands. Everlast, Symptoms of too much Positive Balance: Tungsten balling, wide etched along with other brands has chosen this way polarity orientation since the area, grainy weld.
  • Page 53 Component Identification and Explanation Explanation of TIG Parameters, Functions and Welding Terms AC Frequency. AC frequency is the number of times per second that the When combined with ideal AC Balance Control settings, the synergistic AC completely cycles between positive and negative polarity. Frequency is effect of both working together can greatly extend the capability of this measured in Hertz (Hz).
  • Page 54 When used with the torch switch, this is the final current set used type of start on a welder, contact Everlast for other product information. to taper off and fill the crater at the end of the weld. For foot pedal use, The other type of lift start is a “remote lift start”.
  • Page 55 Component Identification and Explanation Explanation of TIG Parameters, Functions and Welding Terms PowerSet. The Typhoon series of welders offer a unique power set menu duration the Peak Amp phase of the cycle which in turn will increase mode that allows the user to input several operating parameters such as the heat and will increase penetration.
  • Page 56 Component Identification and Explanation Explanation of TIG Parameters, Functions and Welding Terms does a good job on heat management. Represented by a where each pulse cycle contains both AC and DC current. This can be square on the graph line. used to greatly increase the welding range (and penetration) of the welder by up to 50% or more while welding Aluminum.
  • Page 57 Component Identification and Explanation Explanation of TIG Parameters, Functions and Welding Terms cylinder. The regulator should never be left turned on. Leaks can and do weld cycle to varying extents. The unit has multiple Remote settings to develop over time or suddenly. Gas solenoids can fail to close properly. choose from.
  • Page 58 When used with Fast-Tack, this can be used wave form shape developed by Everlast to offer a new level of control to to create a rapid succession of flash welds that help weld thin materials the user.

  • Page 59: Explanation Of Stick Parameters, Functions And Welding Terms

    This means the foot pedal can be used to control stick Amperage, if need- as “Dig” and “Inductance” in the industry. Arc force is set as a percent of ed. For more options, contact Everlast. Amps over the set welding Amps. As the welder nears the top end of the Reverse Polarity.
  • Page 60 Component Identification and Explanation Explanation of Stick Parameters, Functions and Welding Terms can be used in adverse conditions where TIG cannot. Straight Polarity. This is the same as DC Electrode Negative Polarity (DCEN-). It is an older term that is still around that many welders use which can be confusing.

  • Page 61: Torch Parts And Assembly

    Component Identification and Explanation 18/26 Series TIG Welding Torch (Typical Type) Parts and Assembly. Typical Everlast and NOVA Torch Assembly (17,18, 26 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 62: Pin Connector Pinout And Information For Remote

    Component Identification and Explanation 7 PIN CONNECTOR FOR 10K Ω NOVA FOOT PEDAL To Pedal or Torch Switch ON/OFF Bridge a Jumper to Pins 6 and 7 To Pedal or Torch Switch ON/OFF High Middle/Common Potentiometer (VR)

  • Page 63: Trouble Shooting: Common Welding Issues

    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.

  • Page 64: Trouble Shooting: Error Codes

    If this does not clear after releasing the switch, turn off unit immediately and check torch switch for stuck contact. If the pilot arc or HF Start is engaged without attempting to cut or weld for more than 3 seconds this will activate. OTHER CONTACT EVERLAST...

  • Page 65: Maintenance

    11. Clean bezel vents and fan blades. Fan blades accumulate build-up which can cause reduced cooling efficiency, vibration and eventually failure. 12. Once cleaned, reassemble unit in reverse order. IMPORTANT: Never remove the front cover or upper operator’s panel unless instructed by Everlast.

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