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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...
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Due to multiple variables that exist in the welding eld and the changing nature of it and of the Everlast product line it- self, Everlast Power Equipment INC. does not guarantee the accuracy, complete-...
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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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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.
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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.
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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 quali ed professional advice and training.
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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.
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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 traf c areas. CAUTION! Welded metal can stay hot long after welding is completed.
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13,000 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.
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6 minutes out of a 10 minute time period at the maximum output of the welder (275A MIG, 250A TIG and 220A Stick output). Everlast uses a maximum output rating to gure duty cycle on this unit. A duty cycle of 60% is considered to be a industrial duty cycle class welder and is suitable for daily commercial use for light to industrial manufacturing and production welding.
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Specifications Product Speci cations (Continued on next page) Welder Base Construction Type Digital IGBT Inverter-Based Design with 5” HD (720) Screen. (Full Diagonal Measurement) DC Processes GMAW/GMAW-P, FCAW, SMAW, GTAW (MIG/Single and DoublePulse MIG, Gasless Flux-Cored, TIG, Stick) Input Voltage/ Hertz/ Phase Voltage 240V (±...
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Specifications Product Speci cations Continued Spool Gun/ Push Pull Gun Options (use new style only) Spool Gun: Parker DSP360 Push/Pull Gun: North MPG 300A or Parker SGP360A Wire Jog function Gas Purge Function Work Clamp with Cable Length 300A, 9.5 ft. (2m) DINSE 35/50mm (1/2”...
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NOTICE: Cosmetic damage claims made after 30 days will not be accepted. Assemble the front, middle, and rear handles with the supplied screws. Do Unless Everlast is contacted and informed of such delay with legitimate not overtighten. Handle assembly is optional for some non-portable and reason for such a required for a delay (i.e.
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With this type connection, the TIG torch may be connected directly to the gas regulator with a variety of couplers and ttings that are customer sup- plied. This is the customer’s responsibility. Everlast does not provide a full 18” 18”...
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If you are not quali ed to make type and NEMA classi cation is different for various applications. It is these connections, don’t. Everlast is in no way liable for any damag- recommended to either install the line direct into an electrical cutoff box, es caused by improper connection of your welder.
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The gas flow is controlled directly on the torch handle. A combination of ttings (user supplied, locally sourced) may be required to connect the torch directly to the regulator. Everlast offers gas valve torches which are required for this style operation, but does not offer a complete connector package that directly hooks the gas line to the regulator.
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Gas cylinders come in a wide ranges of sizes. Cylinders range from about 20 The Cyclone 253DPi is a synergic welder which incorporates on screen Cu. Ft. to over 300 Cu. Ft. capacity. For this unit, there are at least two different recommendations for the type of gas needed for each process.
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Setup Guide SELECT THE PROPER TIG POLARITY AND CONNECTIONS. The electrode holder, or stick torch (also commonly called a “Stinger”) will almost always be connected to the left positive terminal of the machine Selecting the correct polarity for DC TIG is quite simple. To TIG weld any when welding in DC Mode.
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For dedicated Flux-Cored use or for extended periods of use, you use a Flux -Cored gun. Flux-Cored guns are available from after-market sources. Everlast does not provide Flux-Cored guns as optional equipment.
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There may also be problems for calibration. Use with NOTICE: Spool guns and push-pull guns connect in the same manner other brand guns not approved by Everlast will void the warranty. If a “will and are installed using the same connections and polarity. Both ver- t”...
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Setup Guide and dust cannot get to them. They will rust if not stored properly. How Do I Disassemble the MIG Gun? The top drive rolls are actually idler rolls used to hold tension and keep the 15 Series MIG gun wire in the groove.
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Setup Guide the drive roll is reinstalled, just lightly snug the screws with the screw NOTE: This unit is equipped with the 36 Series MIG Gun. However it can driver. Do not over tighten. also be used with the 24 series MIG gun or 15 series MIG gun (optional purchase.
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Setup Guide 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 3 to 3.5 on the dial. For flux-cored wire, use 2 to 3. For Aluminum use 2 to 2.5. Wire diameter also plays a small part in the amount of required tension that is needed.
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This welder uses a common Euro Style Connection for the MIG gun. This this case the spool gun is the best option. Also even with .030” stainless allows any Everlast gun or any after market gun with the same connection wire there may also some dif culty feeding wire with longer guns.
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Setup Guide Getting Started mum size of wire that should be used with this unit is .045”. A damaged liner should be checked and replaced as soon as any damage is suspected. The wire sizes and liner color codes are as follows: A steel liner is a tightly coiled hardened wire similar to a lawn mower or Blue Liner: .023”-.035”...
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Setup Guide the base tting while using a wrench to do this. Do not allow the base the brass nut. Pull on the flange to remove the old liner completely. tting to unscrew. If the tting unscrews, it must be reinstalled before Once removed, set aside.
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Generally, for all types of welding 2% Lanthanated, should be used and prices and range of selection, so don’t rule them out until you have will perform best under most conditions in your Everlast welder. There checked. Also, there are some companies that may send you free samples are many modern “mixes”...
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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 Live Lift-start system on this unit. This system is able to is no true one-size- ts-all angle, there are some general rules of thumb to handle several different sizes of Tungsten.
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Component Identification and Explanation Front Panel View Component Identi cation 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.
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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 120V (240V 1Ph, 4A max)
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Component Identification and Explanation Control Panel Layout Component Identi cation 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.
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· Settings may not be perfect for all positions/applications/users. The Everlast Synergic Pulse MIG design provides easy adjustment of all · Presets may takes away from Pro user’s ability to tailor the settings to pulse-related parameters through the Amp control knob. When the user individual needs or worksite applications.
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If any malfunction of the control screen or the welder is observed, Make sure all ttings are tight and that your gas cylinder valve is fully contact Everlast Tech Support. open. Put on proper safety equipment (PPE) and re resistant clothing.
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Component Identification and Explanation GENERAL INFORMATION ON SETUP AND USE. Quick Steps to Setting-Up the Welder. The main display in the upper area serves to display the status, or Selecting the Process. value of a function or parameter. (1a) At the top of the panel (1) use the process selector buttons to select the ·...
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Component Identification and Explanation 3. The control knobs are used to increase or decrease a selected parame- The lower parameter rows/tiers. (4b and 5b) This area displays all the ter value, or make a status change in a selected function. information related to adjustable parameters and selectable functions of the unit.
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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.
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Component Identification and Explanation USING THE PROGRAM MENUS AND MEMORY FUNCTION. process is not selected at the top of the selector. (The selected pro- gram will override the process selector and display the saved program The memory function on this machine allows the user to save and name up and process.) to 30 different programs.
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Component Identification and Explanation distinctive without exceeding the character limit. Once the program has been entered, rotate the adjustment knob (3)to save selection or press cancel to exit the screen. If cancel is selected the program will not be saved on that line and the name or status of the line will not be changed.
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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.
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The 2T and 4T settings will show abridged, but similar versions of the panels. These altered ver- 16. Units. Everlast recognizes that there is a need to provide different sions will “gray” out a box and delete the parameter entirely because units of measures to different industries and regions of the world.
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Component Identification and Explanation NOTICE: If improper operation is observed, with on/off or regular stuttering of the arc is observed with the trigger pressed and held, this may mean that the Spot and Stitch timers have been turned on. Spot and Stitch in 2T Mode (Standard and Single Pulse) For tacking purposes or for creating regular, repeatable small welds, the Spot and Stitch function has been added to both the Standard MIG the Synergic Single Pulse setting.
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Component Identification and Explanation Synergic Single Pulse MIG: mode (1a). Voltage Input Con rmation. This con rms the correct voltage to be When the welder is switched to Synergic Single Pulse MIG mode, many supplied to the machine. The correct Voltage is 240V. If 220, 230 or parameters are the same as they are in standard MIG welding modes, but 208V is supplied the Voltage will still read 240V.
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Inductance values used for setting inductance on this model differ and ending point for the pulse value over or under the main welding from other non-pulse capable units in the Everlast lineup. These set- settings. Start Intensity is typically set higher than the pulse welding tings use a reciprocal value of the other Everlast models.
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Amps to the control knob on the gun. 17. Units. Everlast recognizes that there is a need to provide different units of measures to different industries and regions of the world.
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Component Identification and Explanation Timer sets an “arc-off” interval between a series of spot welds as the trig- ger is continued to be held down. This is useful for tacking up long seams on thin sheet metal such as body panels. It helps to provide regular spac- ing between the weld as long as the forward travel speed provided by the user remains fairly consistent.
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Component Identification and Explanation Synergic Double Pulse MIG. When a parameter or function is selected for adjustment, the numbers will turn from white to red. Arc Trim is the default setting of the left The Cyclone 253 DPi features a second type of pulse called “Double side display.
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AND USERS: Due to the nature of this welder’s Pulse MIG design, the Inductance values used for setting inductance on this model differ from other non-pulse capable units in the Everlast lineup. These set- tings use a reciprocal value of the other Everlast models. Inductance improves the wet-in of the weld.
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17. Units. Everlast recognizes that there is a need to provide different units of measures to different industries and regions of the world.
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Amp setting. However, for certain applications or for certain technical requirements, these settings may prove to be to intense or too weak to achieve the required effect. The Cyclone 253DPi features a hidden menu to help assist the user with ne tuning the factory pulse settings for single and double pulse.
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Component Identification and Explanation 10. Burnback. This offsets the amount of time in % that is prescribed by the factory settings. 11. Base Amps Offset. This is the amount of time that the Base Amps are offset from the factory prescribed settings. 12.
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Component Identification and Explanation DC TIG MANUAL MENU which is a synergic, more automated mode. (See the TIG PowerSet section). The DC Lift Start TIG manual menu is a very basic TIG menu. Since it is lift Reminder/Information Area. The area in yellow is designed to inform start only with no automatic gas flow support, there are no adjustments or remind the user to check or change polarity and to con rm which other than for Amperage.
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Component Identification and Explanation DC Stick Manual Menu: ment knob. By default this display area indicates the Amperage. In adjustment mode, the function or parameter selected will display and The stick manual menu is simplest menu of all the manual menus. Howev- the display numbers/letters will turn red to indicate adjustment mode.
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Component Identification and Explanation Remember: In Manual Welding Modes, What Are the Welder’s Default Settings? Any setting or value pre- The welder is designed to include many extra features and sent in the parameter area functions in the Manual mode that aren’t included with basic welders.
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Component Identification and Explanation Using the PowerSet Menus. ommendations as well for single pass. The unit does offer higher settings and may recommend a gas change as the wire speed and voltage enter the The PowerSet function is an advanced synergic function designed to pro- Globular and Spray transfer range to perform single pass welds (MIG C25 vide the user with a simpli ed set up process by using a combination of process selection).
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Component Identification and Explanation upon the parameter being adjusted, the graphic may change in ap- while there are items that correspond to the manual mode, the arrange- pearance. For Volts, Amps and Wire Feed Speed, the graphic appears ment and number of adjustable functions is different. Overall the number as shown above in the picture.
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Inches Per Minute (IPM), Me- 11. Units. Everlast recognizes that there is a need to provide different ters Per Minute) M/Min or Amps. This is the default setting of the units of measures to different industries and regions of the world.
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Component Identification and Explanation Arc Trim. Use the left adjustment knob to modify the Arc Trim setting. The Arc Trim is a relative voltage setting (-5 to +5) which replaces the Voltage setting used in the other MIG modes. The arc trim is used to adjust the average pulsed voltage to control the arc length.
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Typically Start 12. Units. Everlast recognizes that there is a need to provide different Intensity (8) is set to 115% to 130% higher than welding Amperage.
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Component Identification and Explanation Double Pulse MIG: PowerSet mode in Double Pulse MIG is similar to the PowerSet Mode in Single Pulse except a few more items are added to the menu. As with other modes, the selection of the type of Remote setting used will dictate the amount and type of functions available/required for adjustment.
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Component Identification and Explanation weld. The weld is continued without the torch trigger being held down. The trigger is once again pressed, held and then released to terminate the arc. See more detailed 2T/4T Remote information and explanation found later in this manual. The Synergic Pulse MIG mode additionally offers two more settings: 2TSP (Special) mode and 4TSP (Special) mode which allows additional programmable settings when selected not available in non pulse MIG modes.
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Material thickness may also eliminate certain wire size choices. Voltage Input Con rmation. Voltage Input Con rmation. This con rms 13. Units. Everlast recognizes that there is a need to provide different the correct voltage to be supplied to the machine. The correct Voltage units of measures to different industries and regions of the world.
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Component Identification and Explanation DC Stick: Stick performance relies upon the proper selection of the rod type/class to work well. However not all possible welding rods are listed. If a rod is not listed, pick the selection with properties nearest the rod type listed. This may not work in every case.
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Component Identification and Explanation which is a synergic, more automated mode. In PowerSet mode, some functions may not be available for adjustment and will be preset for best general performance. If optimum performance is not achieved, discontinue use of PowerSet and use the full manual set- ting to achieve better results.
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Component Identification and Explanation NOTICE: The following sections cover MIG, Synergic Pulse MIG, TIG, and Stick terms, de nitions, 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 speci c to the process being used.
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Component Identification and Explanation Using The Trigger/Torch Switch Remote Functions Operating the 2T/4T Remote Function The Remote Torch Control function works with both the MIG and Pulse MIG processes. The MIG Trigger is designed to allow the user to program the welder so that the stages of the weld cycle can be controlled via opera- tion of the torch switch.
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Component Identification and Explanation Using The Trigger/Torch Switch Remote Functions Lift-TIG arc starting requires practice and technique. However, this type of arc-start is used everyday in the eld on steel and stainless. It is a very common way of welding.
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Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms EXPLANATION OF GENERAL WELDER FUNCTIONS. If large amounts of spatter are present, the puddle seems fluid (appears wet) and the wire speed is within the targeted range, decrease volts a little Volt and Amp Settings (Short Circuit MIG).
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Component Identification and Explanation comes quickly with a little practice. Pushing can result in shallower pene- MIG and TIG welding requires a well prepped surface to obtain a sound tration but the molten puddle is easier to see and the arc sits easily on the weld.
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Component Identification and Explanation Single Pulse MIG Operation. typically set to 0.0. While one would be led to believe this would be the optimal, best setting, it typically needs to be further adjusted for best performance, operator At its core, Single Pulse MIG function is comprised of 3 parts, Pulse Voltage style, position etc.
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Component Identification and Explanation Spray Arc Transfer. It should be accepted that there may be a slight fall off machine gun, or slow re rattle at lower Amperages. The exact pitch or in travel speed over Spray Arc. There may be a tendency for a user to try sound should not concern the user, unless irregular feeding begins to to achieve faster or similar travel speeds to Spray Arc Transfer by adjusting occur.
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Component Identification and Explanation Key Notes to Remember About Synergic MIG Welding good idea to maintain a straight, even travel forward to maintain maximum weld quality and heat control. If any manipulation is required to ll or · Always adjust Amps before adjusting Arc Trim to control the weld. bridge a gap, use a Z motion and maintain steady forward travel speed.
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Component Identification and Explanation Arc Length and Contact Tip to Work Distance in Welding. Joint Preparation Keeping a tight, short arc for TIG and Stick is important to prevent inclu- sions in the weld, especially while weaving. It helps control the puddle. V-GROOVE (60-80°) DOUBLE V-GROOVE Keep arc length ≤...
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Component Identification and Explanation 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 pro le. Push is always recommended for welding Aluminum and Pulsed MIG.
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Component Identification and Explanation The TIG Arc Start is a Live lift type. Starting The Stick Arc. Live Lift Start requires direct, purposeful contact with the surface of the Stick is a fairly simple process. Arc starting can be done with a scratch or metal to create continuity followed by a quick lift-off of the Tungsten to tapping method.
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Component Identification and Explanation Amps (TIG/Stick). Shortened from “Amperes.” Amps is a measurable value Titanium, and more. Not used with Aluminum and Magnesium. For MIG of Current. Amperage is used to refer to the magnitude of Current. Amps this is the standard method of MIG welding with all metals. This is the will also be displayed while actively welding in MIG mode as well instead preferred method of stick welding.
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Component Identification and Explanation Open Circuit Voltage (OCV). OCV is the voltage that is present when the of settings based off the user inputs. It will limit and preset most all other arc is not struck. OCV is particularly important to stick arc starting. OCV parameters and functions so that the user doesn’t have to go through an is reflected in the left main display area as the default when not welding.
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Component Identification and Explanation Synergic MIG Pulse. Synergic pulse in MIG is similar to the pulse in TIG. input of wire type and diameter Amperage can be computed mathematical- However, instead of pulsing Amperage between high and low settings as ly instead of using the wire feed speed and “guessing”...
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Component Identification and Explanation maintain consistency between different wire sizes and helps eliminate some user error.
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Component Identification and Explanation North SN24 SERIES MIG TORCH PARTS BREAKDOWN (MB24KD Style) North SN 24 Series MIG Gun (MB24KD Style) Item Part Number Description 200300 Gas Cone/Nozzle 12.5mm EB2206 Contact Tip .6mm M6x8x26 (.023” Heavy Style) EB2208 Contact Tip .8mm M6x8x28 (.030” Heavy Style) EB2209 Contact Tip .9mm M6x8x28 (.035”...
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Component Identification and Explanation North SN36 SERIES MIG TORCH PARTS BREAKDOWN (MB36KD Style) *Denotes Standard Build for Most Sales Regions...
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DC: 150A @ 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.
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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.
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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.
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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.
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If this does not clear after releasing the switch, turn off unit immediately and check torch switch for stuck contact. If the torch trigger is engaged without attempting toweld for more than 3 seconds this will activate. OTHER CONTACT EVERLAST...
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11. Clean bezel vents and fan blades. Fan blades accumulate build-up which can cause reduced cooling ef ciency, 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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