Everlast Thunder 215 Operator's Manual
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Everlast Thunder 215 Operator's Manual

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Publish Date: June 2024
EVTHU215 Rev. 1.0
USA/North America
©Everlast Power Equipment
DC
215A
DC
215A
DC
175A
120/240V
1 Phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide
Operator's Manual
FUNCTION: MIG/ DC TIG with Pulse Function/ DC Stick
PURCHASE DATE:
WELDER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:

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  • Page 1 Publish Date: June 2024 EVTHU215 Rev. 1.0 USA/North America ©Everlast Power Equipment 215A Safety, Setup and General Use Guide 215A 175A FUNCTION: MIG/ DC TIG with Pulse Function/ DC Stick PURCHASE DATE: WELDER SERIAL NUMBER: OPTIONAL ACCESSORY SERIAL NUMBER: 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 12,13 SETUP GUIDE: GETTING STARTED, UNPACKING YOUR UNIT, ASSEMBLY AND INSPECTION...

  • 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

    Surge 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 provides clean power.

  • Page 11: Duty Cycle Explanation Statement

    3.5 minutes out of a 10 minute time period at the maximum output of the welder (215A MIG/TIG output and 175A Stick output). Everlast uses a maximum output rating to figure duty cycle on this unit. A duty cycle of 35% is considered to be a commercial duty cycle class welder and is suitable for daily commercial use for light to medium manufacturing and production welding.

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

    Specifications Product Specifications (Continued on next page) Welder Base Construction Type Digital IGBT Inverter-Based Design with 4.4” HD (720) Screen. (Full Diagonal Measurement) DC Processes GMAW, FCAW, SMAW, GTAW-P (MIG, Gasless Flux-Cored, TIG, Stick) Input Voltage/ Hertz/ Phase Dual Voltage 120/240V (± 10% ) 50/60 Hz 1 phase Current Rating (Inrush Amps) 120V: 33A / 240V: 37A Current Rating (Effective Rated Amps)
  • Page 13 Specifications Product Specifications Continued Spool Gun/ Push Pull Gun Options Spool Gun: Parker DSP360 Push/Pull Gun: North MPG 300A Work Clamp with Cable Length 250A, 9.5 ft. (2m) DINSE 35/50mm (1/2” nominal lug diameter) Stick Electrode Holder Length 250A, 9.5 ft. (3m) DINSE 35/50mm (1/2”...

  • Page 14: Setup Guide: Getting Started, Unpacking Your Unit, Assembly And Inspection

    NOTICE: Cosmetic damage claims made after 30 days will not be accepted, When you receive your package, inspect the unit for damage. Check for unless Everlast is contacted and informed of such delay and reason for the presence of and the general condition of the accessories. Some slight such a required delay (i.e.
  • Page 15 The recom- cated leak testing solution available from welding suppliers) and spray on mended Everlast/ NOVA Cart 375 LF has ample room for cooling built into all connections, including the TIG torch connections at the head, and back the design of the cart.

  • Page 16: Setup Guide: Connecting Your Unit To The Power Source And Wiring Information

    NEMA 6-50P al and local codes are followed. If you are not qualified to make these connections, do not try to make them. Everlast is in no way liable for any damages caused by improper connection of your weld- er. Your welder should be on a dedicated branch circuit not far from an electrical disconnect box.
  • Page 17 Setup Guide Getting Started CONNECT YOUR UNIT TO SHIELDING GAS. damage is likely occur to the bezel and the female fitting as the fitting may turn in the plastic housing. Overtightening will cause the fitting to snap-off Always wear safety glasses when changing a cylinder. Before installing the in the solenoid housing or crack down the threads.

  • Page 18: Setup Guide: Shielding Gas Information And Connection Of Regulator

    Selecting the correct polarity for TIG is quite simple. Whether you are TIG The Thunder 215 is a synergic unit which incorporates on screen recom- welding in AC or DC, the TIG torch will always be connected to the nega- mendations for the type of gas needed for each process.

  • Page 19: Setup Guide: Polarity

    Setup Guide Getting Started polarity” is an older term, this is still used to refer to Stick torch polarity as ing with gasless flux cored wire. No pre or post flow control is used. This is DCEP. Most all welding electrodes (rods) weld primarily in DCEP. applies to the PowerSet settings as well.
  • Page 20 Flux-Cored For spool gun applications, the optional Parker DSP 360 gun is recom- mended for this unit. The optional Everlast/North SM200N-MTS gun can also be used but may overheat due to a lower Amp and duty cycle rating. The Everlast/North MPG300A Push-Pull gun recommended for this unit is Euro-Quick the “snake-head”...

  • Page 21: Setup Guide: Mig Gun, Liner, Drive Roll, Wire Spool Information

    Setup Guide Getting Started the inside of the machine. How Do I Disassemble the MIG Gun? The drive roll is held in place by a black thumbscrew. Remove the screw 15 Series MIG gun to expose and change the drive roll. The drive roll is mounted on a bush- ing.
  • Page 22 Setup Guide Getting Started position, confirm the wire is still in the groove and is not riding up on the rotate the tension lever clock-wise. Different types of wires require differ- shoulders of the drive roll. ent tensions. There is no exact tension that works for all wire types. How- ever, for steel wire, you will generally tension to at least 4 on the dial.
  • Page 23 This welder uses a common Euro Style Connection for the MIG gun. This before it begins to enter globular transfer range. allows any Everlast gun or any after market gun with the same connection Even though .023” Stainless wire is supported, it may not be available in to be connected to this unit.
  • Page 24 Setup Guide Getting Started liners are sized for .045” and larger for Aluminum use. The Aluminum liner will be smooth and will be composed of three pieces, the liner tube, brass collet and o-ring. It is also important to check and change the contact tips as well to match Both liners are installed from the rear of the gun and not from the top of the wire diameter.
  • Page 25 Setup Guide Getting Started if the liner is badly damaged inside the outer cable conduit. visible with the contact tip holder installed. If the liner is not visible, remove the contact tip hold to check for visibility (some guns the Make sure the gun and gun cable is held straight.

  • Page 26: Setup Guide: Tungsten Selection And Grinding Information

    Setup Guide Getting Started SELECT THE PROPER TUNGSTEN TYPE FOR TIG. Purchasing Tungsten can be difficult. Local suppliers tend to put a premi- um price on Tungsten, and may be three times an online price direct from What Type of Tungsten Do I Use? a distributor.
  • Page 27 Choosing the proper grind angle is important to achieving the weld pene- tration, bead appearance, and arc-cone width that you desire. While there Everlast uses a HV start system on this unit. This system is able to han- is no true one-size-fits-all angle, there are some general rules of thumb to dle several different sizes of Tungsten.

  • Page 28: Front Panel View And Component Id

    Component Identification and Explanation Front Panel View Component Identification Function/Component Note Protective Cover Keep cover down and in place during welding activities and while in storage. Euro-Style Quick MIG Connector Connect the MIG gun to this connector. (Only one gun may be connected at a time.) Connect the Spool Gun to this connector.

  • Page 29: Rear Panel View And Component Id

    If this occurs, immediately remove from service and mark and tag as out-of- service according to required work regulations and contact Everlast Tech Support for further diagnosis and/or repair options.

  • Page 30: Control Panel Layout

    Component Identification and Explanation Control Panel Layout Component Identification Function/Component Note 1. Welding Process Selector Press left or right arrow key connected to the process selector LEDs to navigate back and forth to select the desired weld pro- cess. The LED will light to indicate which weld process has been selected. See Quick Setup Section. 2.

  • Page 31: Starting Up The Welder

    If any malfunction of the control screen or the welder is observed, Before the first start and use of the machine, check all your connections. contact Everlast Tech Support. Make sure all fittings are tight and that your gas cylinder valve is fully TAKE CARE OF THE LCD SCREEN.

  • Page 32: General Information On Setup And Use, General Navigation Information

    Component Identification and Explanation GENERAL INFORMATION ON SETUP AND USE. Understanding the Anatomy of the Menu Screen. Selecting the Process. Quick Steps to Setting-Up the Welder. The main display in the upper area serves to display the status, or value of a function or parameter. (1a) At the top of the panel (1) use the process selector buttons to select the •...
  • Page 33 Component Identification and Explanation The lower parameter rows/tiers. (4b and 5b) This area displays all the information related to adjustable parameters and selectable functions of the unit. In the PowerSet mode, only one line may be displayed due to the simplified input design. When a parameter or a function is selected, the screen will display the value or status of the function in two places: At the top of the screen in the main display area.
  • Page 34 Component Identification and Explanation Why Are Some Settings Limited or Blank? • In some cases a gray area will become an adjustable area if certain functions like Spot weld is selected for use. If so, the area(s) will turn There are two basic reasons some settings are limited in adjustment or from gray to green and will display additional parameters related to completely blank.

  • Page 35: Using Programmable Memory Functions

    Component Identification and Explanation USING THE PROGRAM MENUS AND MEMORY FUNCTION. To recall any program, quickly press and release the save program button (1). This may be done from any process, even if the desired The memory function on this machine allows the user to save and name up process is not selected at the top of the selector.
  • Page 36 Component Identification and Explanation characters that can be entered to name a program is a total of 15 in any combination. The keypad will not hold more than a 15 total char- acter program and will block more from being entered once the maxi- mum is reached.

  • Page 37: Using The Manual Menus

    Component Identification and Explanation USING THE MANUAL MENUS many functions may not be available for adjustment and will be pre- set. (See the MIG PowerSet section). Each process menu operates in the basic same way. Navigation is similar Main Right Display, Default Wire Feed Speed Display. Adjust the between all the functions.
  • Page 38 60 to 80% or so. Flux-Cored 15. Units. Everlast recognizes that there is a need to provide different behaves a little differently with a 40 to 50% starting point. Of course, units of measures to different industries and regions of the world.
  • Page 39 Component Identification and Explanation Control Panel Operation and Navigation DC TIG Manual Menu: unchanged. Torch polarity in TIG mode will always be negative (-). The recommended shielding gas will always be 100% Argon. The TIG manual menu is arranged similarly to the MIG menu and some of the features and parameters overlap.
  • Page 40 Component Identification and Explanation Control Panel Operation and Navigation 12. Spot/Stitch Timer. The Spot timer must be turned on for the Stitch function to appear to the right of the Spot Timer function. When Spot is turned off as shown in the picture above, the Stitch function is no longer selectable and the space will turn gray and will remain blank.
  • Page 41 Component Identification and Explanation Control Panel Operation and Navigation the pulse is cycling every second. and not AC mode. (This welder supplies DC output only for Stick) NOTICE: Pulse is only used in TIG mode and is not a function of MIG on Manual/PowerSet Mode.

  • Page 42: Using The Powerset Menus

    Component Identification and Explanation Control Panel Operation and Navigation reached. The PowerSet is also equipped with visual graphical aids to help the user see and visualize the settings. The settings will have a tapered graphic is also color coded to indicate a normal range of a setting and guide the user further in fine tuning.
  • Page 43 Component Identification and Explanation Control Panel Operation and Navigation • For Stick, the required user input parameters are Rod type (Electrode Selection, Rod Diameter and Material Thickness. MIG,TIG and Stick process specific PowerSet information. MIG/Flux-Cored: The range of inductance is limited to the range that will produce the most acceptable results.
  • Page 44 Component Identification and Explanation NOTICE: The following sections cover MIG, TIG, and Stick terms, definitions, and basic operation. Some of the terms overlap from process to process and serve essentially the same functions. Take note that some terms will repeat from process to process, but will be described in a way that is specific to the process being used.

  • Page 45: Using The Trigger/Torch Switch Remote Functions

    Component Identification and Explanation Using The Trigger/Torch Switch Remote Functions Operating the 2T/4T Remote Function The Remote Torch Trigger function works with both the MIG and TIG pro- cesses. The Trigger function is designed to allow the user to program the welder so that the stages of the weld cycle can be controlled via operation of the torch switch.

  • Page 46: Explanation Of Parameters, Functions And Welding Terms

    Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms EXPLANATION OF GENERAL WELDER FUNCTIONS. have somewhat of a higher pitch whine to it. If these sounds are present, look at the arc to see if it is steady, and producing low amounts of spatter. Volt and Amp Settings (MIG).
  • Page 47 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms versed in MIG quickly develop a sense of when to push and when to pull Metal Cleaning. the gun. Even for novices, a sense of when to push and pull the gun MIG and TIG welding requires a well prepped surface to obtain a sound comes quickly with a little practice.
  • Page 48 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms can be introduced. Joint Preparation Arc Length in Welding. Keeping a tight, short arc for TIG and Stick is important to prevent inclu- V-GROOVE (60-80°) DOUBLE V-GROOVE sions in the weld, especially while weaving. It helps control the puddle. Keep arc length ≤...
  • Page 49 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms Drag or Push MIG? MIG Welding is fairly simple. Just keep travel angle and direction in mind when welding. A push angle is often recommended for short circuit MIG and Spray Arc Welding for the least amount of spatter and bead profile. Push is always recommended for welding Aluminum.
  • Page 50 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms The TIG arc start can be performed in three basic ways. technically is considered an HV start, it electronicallysimulates the HF start. The first and primary arc starting method used is High Voltage Start. HV The second method is Lift Start which requires direct, purposeful contact start is a contactless start which is performed by holding the Tungsten off with the surface of the metal to create continuity followed by a quick lift-off...
  • Page 51 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms Amps (TIG/Stick). Shortened from “Amperes.” Amps is a measurable value under the start function, this is a touchless type of start. It is actually an of Current. Amperage is used to refer to the magnitude of Current. Amps simulated HF electronic controlled start, but due to the familiarity of users will also be displayed while actively welding in MIG mode as well instead with HF, it is labeled as such to avoid confusion.
  • Page 52 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms in manual mode check the PowerSet mode. The PowerSet function gives stabilize, extra gas is propelled as the solenoid opens relieving the back excellent range recommendations for each wire feed function. Inductance pressure.
  • Page 53 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms base Amps. The foot pedal controls both Peak welding Amperage and the heat and will increase penetration. Pulse Balance is also known Base Amperage simultaneously, using the pre-set ratio. in the industry as “duty cycle”.
  • Page 54 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms TIG Pedal mode is the most straight forward. Operation is quite simple. Stitch timer is an “Arc-Off” timer which works in a continuous cycle as The maximum amperage is set on the panel. Then the foot pedal is used long as the switch is continually held.

  • Page 55: Nova Wireless Foot Pedal Option

    Component Identification and Explanation Wireless Foot Pedal Option Can I Use a Remote Wireless Pedal? The Thunder series is able to be used with the NOVA wire less pedal system. This system is composed of the pedal and internal transmitter and and the external dongle receiver.

  • Page 56: Series Mig Gun And Parts

    Component Identification and Explanation North 24 Series MIG Gun...

  • Page 57: Torch Parts And Assembly

    26 Series Air-Cooled Welding Torch (Typical Type) Parts and Assembly. DC: 200A @ 60% Duty Cycle; AC: 175A @ 60% Duty Cycle 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 58: Trouble Shooting: Common Welding Issues

    Weld is dirty/oxidized, or porous. fan activity. Solenoid is sticking. Listen for audible click of gas solenoid. If no click is heard, then contact Everlast Support. Clean weld properly. Increase pre flow or For Flux Core, a certain amount of spatter, post flow.
  • Page 59 Check gas flow. Adjust for higher flow of gas. Listen for audible click Weld is dirty/oxidized, or porous. 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 60 Arc length too short with anti-stick turned on. Turn off anti-stick. Unstable Arc. Arc length is too long Shorten arc length and increase arc force. Metal is indirectly connected through table or Connect work clamp directly to item being welded. other item. Other. Contact Everlast.

  • Page 61: 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 62: 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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