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27 

EVERLAST 

Section 3 

Getting started 

continued  

5.6 Gouging. 
The Everlast Power Series Plasma func-
tion is  able to perform light to medium 
gouging, depending upon the type of  
metal with the standard cutting tip and 
electrode.  To gouge, simply lower the air 
pressure until the air pressure light sig-
nals low pressure. Allow the air pressure 
to stabilize and increase the air pressure 
5-10 pounds above the warning light 
threshold.    
Lean the torch at a 30-35 degree angle to 
the work piece and begin to gouge.   If you 
experience problems, experiment with the 
air pressure to accomplish the desired 
type of gouge.  For certain applications,  a 
special gouging tip may be required.  For 
this special need, contact Everlast in ad-
vance of the expected time of need to de-
termine availability of special gouging 
electrodes.   
 
5.7 Piercing. 
 
Occasionally, the need will arise to 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 stand-off at the desired 
spot.  If possible, lean the torch at a slight 
angle so that blowback does not become 
a problem and will not foul the tip.  Make 
sure that you tilt the torch away from the 
piece being cut out to prevent marring.   
Allow the torch to slowly burn its way 
through the metal. As the torch plasma 
stream burns down through the plate, 
straighten the torch into the cutting posi-
tion.  As sparks begin to exit the bottom, 
you may shorten the stand-off and begin 
your cut.  Excessive use of piercing will 
significantly reduce consumable life, par-
ticularly with an inexperienced operator.  
Do not attempt to pierce an object that is 
thicker than 50-60% of the rated cut ca-
pacity to ensure long torch life. 
 

Note :  Piercing can produce a lot of 
blowback of molten metal.  Protective 
gear is absolutely required, especially 

face shields and fire proof clothing.   
 
 

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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