Everlast POWER DIGITAL SERIES Page 1 Operator'S Manual Download

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EVERLAST

Power ® Series

Combination Tig//Smaw/Plasma Cutter Units

Operator ’ s Manual

Includes AC/DC PowerMaster and DC PowerUltra Units

Safety, Setup and General Use Guide

Rev. 1 0609-09

Summary of Contents for POWER DIGITAL SERIES

Page 1: ...1 EVERLAST EVERLAST Power Series Combination Tig Smaw Plasma Cutter Units Operator s Manual Includes AC DC PowerMaster and DC PowerUltra Units Safety Setup and General Use Guide Rev 1 0609 09...

Page 2: ...our warranty information Your unit registration is important should any infor mation such as product updates or recalls be issued It is also important so that we may track your satis faction with Ever...

Page 3: ...__________________________ EVERLAST Contact Information Everlast consumer satisfaction email sales everlastwelders com Everlast Website everlastwelders com Everlast Technical Support Support everlastw...

Page 4: ...nes 3 2 Shielding Gas Selection 3 3 Regulator Flow meter Selection 3 4 Regulator Connection 3 5 Regulator Adjustment 3 6 Machine Setup 3 7 Tungsten Selection 3 8 TIG Torch 3 9 TIG Welding Principles a...

Page 5: ...ut of your unit Do not operate the unit until you have read this manual and you are thoroughly familiar with the safe operation of the unit If you feel you need more information please contact Everlas...

Page 6: ...tive equip ment If no protection is available exclude them from the work area Even brief expo sure to the rays from the welding arc can damage unprotected eyes Always wear hearing protection because w...

Page 7: ...times Any burning of the eyes nose or throat are signs that you need to increase ventilation Stop immediately and relocate work if necessary until adequate ventilation is ob tained Stop work complete...

Page 8: ...xplosion Keep all combustible materials including rags and spare clothing away from area Keep all flammable fuels and liquids stored separately from work area Visually inspect work area when job is co...

Page 9: ...9 EVERLAST Introduction and Specifications Section 1 PowerTig DX LX and EX Models I Tig Models PowerMaster Series Includes 164 205 226 PowerUltra Series Includes164 185 205...

Page 10: ...W WP 18 28 Torch Power Series TIG GTAW Foot Pedal Assembly Power Series Deluxe Stick SMAW MMA Electrode Holder And Work Clamp Power Series TIG GTAW Torch Accessory Pack Ever last Everlast Power Series...

Page 11: ...al and weld condition en countered The use of High Frequency arc starting in the TIG mode greatly simplifies the TIG GTAW process The incorporation of the advanced Pilot Arc in the Plasma Mode elimina...

Page 12: ...220A 5 200A Rated Duty Cycle 60 DC Current Down slope Timer 0 10S Base Current Range 5 220A 5A 200A Pulse Width Ratio 0 1 0 9 TIG Pulse Frequency 0 5 25Hz After Flow Time 1 25s Arc Starting Method Hi...

Page 13: ...20 230 240V 50 60Hz Open Current Voltage 60 80V Rated Output Current 200A TIG MMA 50A CUT Rated Duty Cycle 60 Current Adjusting Range 10 5 200A TIG 10 5 200A MMA 20 5 50A CUT TIG Arc Plasma Starting M...

Page 14: ...axi mum amperage requirements for the pulse cy cle The amperage change will be reflected on the digital display Turn the pulse off by turning the pulse current control to lowest setting and use only t...

Page 15: ...rols the flow of shielding gas after the weld arc is termi nated Too little post flow time can cause weld contamination or torch overheating 12 Up Slope This controls the time that the machine takes t...

Page 16: ...t Current Electrode Positive DCEP or commonly known as re verse polarity In the case of the elec trode positive requirement connect the electrode holder cable to this side of the panel For Plasma cutt...

Page 17: ...he ground It is strongly recommended that you connect this ground as prescribed This will also help prevent shock from the high fre quency while it is in operation Temporary operation of the unit with...

Page 18: ...ng relationship with your local welding supplier then it is time to make a visit to purchase or lease a tank of shielding gas Many sizes of tanks are available Choose the size that best fits your long...

Page 19: ...t be followed and it is recommended that you consult with a local licensed elec trician if you are unsure of making the proper connection Under no circum stances does Everlast encourage im proper wiri...

Page 20: ...asic information about Tungsten selection and suitability Note Use only recommended sizes in Tig torches unless you purchase additional col lets to fit the electrodes snugly Loose fitting electrodes q...

Page 21: ...ions TIG welding is an elite form of welding Not many people learn to fully master the tech nique due to the patience and practice this art form requires This manual cannot make you a good welder Only...

Page 22: ...weld In cer tain applications TIG welding can be per formed without the use of a filler rod 3 11 Beginning the TIG weld One of the biggest issues for beginning welders is holding and maintaining an ar...

Page 23: ...electrode into electrode holder Position the electrode for the most com fortable position so that the electrode can be held directly over the work piece with a slight angle 2 Set Amperage to the recom...

Page 24: ...cular en dorsement of an E6011 rather a simple example of what may be used in develop ing proficient technique It is recom mended that a variety of electrodes be used and practiced with Consultation w...

Page 25: ...ing is an efficient and simple way to cut multiple metal types The super sonic plasma stream generated by ionized pressur ized air is capable of rapidly burning metal without overheating the surroundi...

Page 26: ...the sparks are exiting the piece of metal at a 10 15 degree angle If the sparks are exiting straight down then the cutting speed is too slow In crease cutting speed until a change of the spark an gle...

Page 27: ...pierce directly down into a piece of metal to initi ate a cut with out the benefit of starting on the edge of the material This is known as piercing To pierce simply start the torch with a 1 8 inch s...

Page 28: ...ut through Travel speed too slow Either increase cutting speed or reduce cutting amper age to fit metal thickness Too much standoff more than 1 8 inch Cut is beveled on one side All plasma cutters ten...

Page 29: ...gsten size Porosity of the weld Discolored weld color Tungsten is discolored Low flow rate of shielding gas Too short of post flow period Wrong TIG cup size Possible gas leaks internally or externally...

Page 30: ...30 EVERLAST EVERLAST...

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