Everlast Powertig 250EX Operator's Manual
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Everlast Powertig 250EX Operator's Manual

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EVERLAST
250EX
POWERTIG
CC
GTAW-P
SMAW
IGBT
1-3
~
PHASE
AC/DC
Operator's Manual for the PowerTig 250EX
Safety, Setup and General Use Guide
Rev. 5
0 00805-14
everlastwelders.com
Specifications and Accessories subject to change without notice.
1-877-755-9353
329 Littlefield Ave. South San Francisco, CA 94080 USA

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  • Page 1 250EX POWERTIG GTAW-P SMAW IGBT PHASE AC/DC Operator’s Manual for the PowerTig 250EX Safety, Setup and General Use Guide Rev. 5 0 00805-14 everlastwelders.com Specifications and Accessories subject to change without notice. 1-877-755-9353 329 Littlefield 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 performance/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

    Model number: ____________________________ Date of Purchase___________________________ EVERLAST Contact Information Everlast US: Everlast consumer satisfaction email: sales@everlastwelders.com Everlast Website: everlastwelders.com Everlast Technical Support: support@everlastwelders.com Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F 11am-4pm PST Sat.

  • Page 5: Safety Precautions

    Safe operation and proper maintenance is your responsibility. We have compiled this operator’s manual, to instruct you in basic safety, oper- ation and maintenance of your Everlast product to give you the best possible experience. Much of welding and cutting is based upon experience and com- mon sense.
  • 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 severe 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.
  • Page 8 SAFETY PRECAUTIONS continued 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 weld- ing or cutting.

  • Page 9: Introduction And Specifications

    Section 1 Introduction and Specifications PowerTIG 250EX Water-Cooled, 18 Series Torch Assembly 12.5 ft Argon Regulator Work Clamp Consumable Kit (Does not include Tungsten) 47K Ω Stick Electrode Holder Foot Pedal Assembly NOTE: Accessory and consumable style and quantities are subject to change without notice.

  • Page 10: Unit Specifications

    Section 1 Introduction and Specifications PowerTIG 250 EX TIG/Stick Welder Specification Process AC/DC GTAW-P/DC SMAW Inverter Type Analog, IGBT Module Construction Minimum/Maximum Rated Output TIG AC/DC: 5 A/10.2 V - 250 A/20 V (± 3A) Minimum/Maximum Rated Output Stick 5 A/20.2 V - 200 A/28 V (±3A) Start Type HF and Lift Start HF Point Gap...

  • Page 11: General Overview

    General overview: The new, redesigned 250 EX Pulse- such as unstable arc, or porosity. TIG/Stick welder from Everlast is the latest in a new gen- eration of analog style GTAW-P /SMAW inverter welders. Do not mount in areas that are prone to severe shock or With Infineon IGBT components the inverter cycles at a vibration.

  • Page 12: Quick Setup Guide, Tig Torch/Cooler Connection

    Section 2 QUICK SETUP AND USE GUIDE QUICK SETUP GUIDE: TIG CONNECTIONS TORCH (-) WORK (+) CONTROL 35 SERIES CONNECTOR 35 SERIES CONNECTOR AIR-COOLED TORCH GAS (Ar) 9/17 SERIES TORCH CONTROL CONTROL 26 SERIES TORCH FOOT PEDAL 35 SERIES CONNECTOR GAS (Ar) NOTE: Torch switch and foot pedal CONTROL...

  • Page 13: Quick Setup Guide, Stick Polarity

    Section 2 QUICK SETUP AND USE GUIDE QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS CONTROL TORCH (+) WORK (-)

  • Page 14: Rear Panel Gas Connection And Wiring

    SINGLE PHASE USE! RED WIRE IS FOR 3 PHASE 220/240 V USE ONLY! PLUG NOT INCLUDED! TO BE SUPPLIED BY CUSTOMER. EVERLAST NOTE: Use Ar or Ar/He only. Do not use more than 25% He in the Ar/He gas mix.

  • Page 15: Front Panel Features And Controls

    Section 2 QUICK SETUP AND USE GUIDE FRONT PANEL FEATURES AND CONTROLS 1. PROTECTIVE COVER 2. SPOT WELD TIME 23. AMP DISPLAY 3. SPOT WELD TIMER ON/OFF 22. AMP CONTROL 4. 2T/PEDAL/ OR 4T SWITCH 21. ON/TEMP/O.C 5. START/END AMPS 20.
  • Page 16 Activates Spot Weld Timer circuit. Use only in 2T with torch switch or foot pedal. It may also be used with CNC circuits to time spot welds. (Use pins 1 and 2) Contact Everlast for further support and use of the Spot weld timer with CNC related equipment if needed.
  • Page 17 Everlast. Over Current Indicator: Lights up when a voltage /amp surge has surpassed the units capabilities. Eliminate the source of the surge and manually cycle the power switch to reset.

  • Page 18: Rear Panel Features And Controls

    Section 2 QUICK SETUP AND USE GUIDE REAR PANEL FEATURES AND CONTROLS 1. WATER COOLER RECEPTACLE 2. 3-POLE POWER SWITCH 220/240 V WATER COOLER ONLY! 1~220 VAC 4. POWER CABLE 1/3 ~ 220/240V 1~220 V INLET 3~220v 6. HF GROUND BOLT 5.
  • Page 19 Contact the manufacturer of the generator for this information. Everlast does not have an “approved” list of generators. But, if the generator is not listed as clean power by its manufacturer, then operation is prohibited. Generators that do not at least meet the operating input requirements of the welder are also forbidden to be used with the welders.

  • Page 20: Welder Function Summary And Explanations

    Section 3 Basic theory and function Welder Function Summary and Explanations. Most of the green coded controls on the welder panel are devoted to the use of the 2T/4T operation and 1. 2T/4T sequencer. The 2T/4T feature allows op- should not be used with foot pedal. The following eration of the TIG welder without a foot pedal.
  • Page 21 Section 3 Basic theory and function Cleaning/Frosted Area of Aluminum the side of the weld. Not all weld conditions will be alike, so more cleaning is required at times than 30% EP others. Similarly, more penetration will be re- Narrow bead/etching/sharp tungsten quired at times than others.
  • Page 22 Section 3 Basic theory and function 4. Pulse. The pulse creates two amp values, a high EXAMPLE 1 and a low value that cycle back and forth between Welding Amps: 100 amps, each other while welding. The upper amperage is PulseAmps: 50% called the “welding amps”...
  • Page 23 Amps through the ratio established by selecting the need a new one for your torch or damage yours, consult Everlast. Do not use a nipple that is scarred, bent or other- pulse Amp % on the panel. Welding with pulse and the foot pedal takes practice, as it will seem the welder is wise deformed.

  • Page 24: Tungsten Preparation

    Section 3 Basic theory and function 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 grind- ing wheel face. Allow tungsten to grind away slowly, creating point.

  • Page 25: Lift Start And High Frequency Start

    Section 3 Basic theory and function LIFT START TIG OPERATION Note: A Lift TIG start should be done with a nearly seamless motion. Use a light touch and a quick motion for best results. FOR DC USE. NOT RECOMMENED FOR AC. <1/8”...

  • Page 26: Stick Starting Methods

    Section 3 Basic theory and function STICK OPERATION STARTING METHODS Tapping Method Scratch/Match Method 1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program. 2. Select the Stick mode with the HF/Lift Start/Stick selector switch. 3.

  • Page 27: Recommendations For Polarity/Amps/Tungsten

    Section 3 Basic theory and function GENERAL POLARITY RECOMMENDATIONS* *Follow manufacturer of stick electrode for complete polarity recommendations PROCESS TORCH POLARITY WORK POLARITY TIG (GTAW) STICK (SMAW) TIG (GTAW) OPERATION GUIDE FOR STEEL (ALUMINUM)* *As a general rule, set amperage using 1 amp for every .001” of metal thickness for aluminum. Less is required for DC. METAL THICKNESS WELDING AMPS TUNGSTEN DIA.

  • Page 28: Expanded View Of Tig Torch

    Section 3 Basic theory and function EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) 5/8” 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 or 3/32...

  • Page 29: Pin Connector Pin-Out

    Section 3 Basic theory and function 7 PIN CONNECTOR FOR 47K Ω FOOT PEDAL Bridge to 7 To Pedal or Torch Switch Bridge to 6 To Pedal or Torch Switch...

  • Page 30: Troubleshooting

    Check gas flow. Adjust for higher flow of gas. Listen for audible click of gas solenoid. If no click is heard, then contact Everlast Support. Clean weld properly, especially in Aluminum. Too short of post flow. Check tungsten stick out.

  • Page 31: Optional Accessories

    PCW300-240 Water Cooler EV-200UW US Deluxe Regulator (CFH) Everlast Brand Deluxe Torches* *Visit our website to view full selection of optional torches, and cable lengths and con- sumable kits. Also, be sure to ask us about our full line of CK-Worldwide TIG welding...

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