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Everlast PowerPro 164Si, Operator'S Manual

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Everlast PowerPro 164Si Operator'S Manual Download Page 1

 

 

 

Operator

’

s Manual

 

Publish Date:  Feb. 2020

 

EVPP164SI2021  Rev. 1

 

USA/North America

 

©Everlast Power Equipment

 

AC/DC 

PULSE

 

160A

 

 

 

 

DC

 

130A

 

120/240V

 

1 Phase

 

 

Welders, Plasma Cutters, Multi

-

Process

 

Safety, Setup and General Use Guide 

FUNCTION:  AC/DC TIG with Pulse Function/ DC Stick/ Plasma

 

PURCHASE DATE:

 

WELDER SERIAL NUMBER:

 

OPTIONAL ACCESSORY SERIAL NUMBER:

 

 

DC

 

40A

 

Summary of Contents for PowerPro 164Si

Page 1: ...rica Everlast Power Equipment AC DC PULSE 160A DC 130A 120 240V 1 Phase Welders Plasma Cutters Multi Process Safety Setup and General Use Guide FUNCTION AC DC TIG with Pulse Function DC Stick Plasma P...

Page 2: ...NFORMATION 13 SHIELDING GAS INFORMATION AND CONNECTION OF GAS AND AIR COMPRESSOR REGULATORS 14 TUNGSTEN SELECTION AND GRINDING 17 CONNECTING YOUR UNIT AND READYING TO WELD POLARITY AND PANEL CONNECTIO...

Page 3: ...sation or business by any Everlast employee or subsidiary The owner of this product assumes all liability for its use and maintenance Everlast Power Equipment INC does not warrant this product or this...

Page 4: ...s unit to work as soon as possible Any issue should be reported within 48 hours 72 if on the weekend or holiday Everlast will not be liable for any shipping after that time What to do within the next...

Page 5: ...cessories are covered by a separate warranty and detailed infor mation can also be found at the link above Canada Customers Only For full details on the 3 year parts and labor warranty terms of sale a...

Page 6: ...use this machine until proper training has been received While accidents are never planned preventing an accident requires careful planning Stay alert Please carefully read this manual before you ope...

Page 7: ...ed or steel toe leather shoes and long sleeved flame resistant clothing i e denim Do not wear Poly Nylon blend materials DANGER Welding cutting poses shock and electrocution risks Keep this welding eq...

Page 8: ...y use Acetone or an approved pre weld cleaner Use the proper personal protec tive equipment PPE when handling any cleaners solvents DANGER People with pacemakers should consult a physician and pacemak...

Page 9: ...welding screen to separate the welding area from the rest of the area If no protection or screen is available physically exclude them from the welding area by a wall or other solid divider Keep all pe...

Page 10: ...on can damage the unit Turn on the welder only after full generator R P M has been achieved and the engine is sufficiently warmed up Closely monitor generator fuel level so that the engine R P M doesn...

Page 11: ...104 F 120V 60 90A 240V 60 130A Plasma Duty Cycle Maximum Output Rated at 40 C 104 F 120V 35 25A 240V 35 40A TIG Output Range V A DC AC 120V DC 10 2 14V 5 100A AC 10 8 14V 20 100A 240V DC 10 2 16 4V 5...

Page 12: ...ing of all the functions and features of the machine For testing and welding make sure work clamp is connected directly to the part being welded work Check for arc starting and stability If problems a...

Page 13: ...not modify or attempt to rewire your unit Standard Plug Configuration 1 Phase 240V NEMA 6 50P Setup Guide serves as G Ground Red will not typically be used as a conductor on a dedicated welder circui...

Page 14: ...are drained or serviced regularly to eliminate the possibility of contaminating the lines with both oil and water 4 Install a separate air dryer before the air reaches the regulator on the unit It is...

Page 15: ...even the most advanced user BE AWARE It is increasingly common for users to get cylinders of bad gas creating mysterious and difficult to identify issues An Argon cylinder is the same type of cylinder...

Page 16: ...d to be able to regulate the supply pressure down to 90PSI at the air compressor If you supply more than 100PSI to the cutter s regulator you may damage the regulator 3 You will need a separate air dr...

Page 17: ...all radiation risk posed as an alpha emitter Do not use the following types of Tungsten Pure Tungsten Green Band This will create arc instability The tungsten will not stand up well to the more intens...

Page 18: ...elder or an early invert er you were probably balling the tungsten when welding on AC In fact tons of literature exist about proper size ball how to ball etc In fact well meaning instructors and seaso...

Page 19: ...at low am perages is the best solution The tip angle and grind preparation will ultimately affect amperage carrying capability of the tungsten Machine wave form can also affect it Each type of Tungste...

Page 20: ...mp limit for operation with out water If you have a water cooled torch and no cooler you must order a cooler before you use the torch or purchase a separate air cooled torch If an air cooled torch is...

Page 21: ...ally to provide a softer arc or to reduce burn through SELECT THE PROPER PLASMA POLARITY The PowerPro unit features a Plasma cutter function built into the unit To operate properly however the torch m...

Page 22: ...t is a special connector designed for use with the Plasma torch only The control connector functions as the connection for the torch switch Additionally this torch fea tures a pilot arc The torch arc...

Page 23: ...p to 3 to 5 passes may be required Additionally beveling of the joint is required for complete joint penetration even at higher amperages The thickness rating takes into account the heat sink capabili...

Page 24: ...this is not con nected the torch Pilot arc will not start the arc 5 Negative Terminal DINSE 35 50 Type 1 2 nominal dia Connect the torch to this terminal for all TIG welding DC and AC and Plasma cutt...

Page 25: ...that may be caused by the HF start of this unit 4 Shielding Gas Inflow Connector 5 8 CGA North America 5 8 CGA connector Other Markets Hose Barb connection 5 Fan location Periodically check for prope...

Page 26: ...ive EP this controls the cleaning penetration of the arc when welding in AC mode Usually set between 20 and 40 Higher settings result in tungsten balling 5 AC Frequency 20 250Hz Represented in Hertz t...

Page 27: ...just the balanced between the positive and negative cycles allows more penetration with less amps narrower less un sightly cleaning lines and the ability to weld without a ball on the end of the tungs...

Page 28: ...ent arc outages and allowing the user to hold a tight arc and maintain better control DC Direct Current Used to weld Steel Stainless Steel Inox Chrome Moly Titanium and more Not used with Aluminum and...

Page 29: ...Post Flow is the amount of time in seconds that the shielding gas flows after the arc is terminated This is an important function The flow of shielding gas after welding is stopped helps to 1 Cool th...

Page 30: ...e or more of several adjustable parameters of the pulse This welder features a basic pulse with 2 preset options where these parameters are not adjustable The following discussion is adapted from a di...

Page 31: ...panel Down Slope should remain zeroed out or set at the minimum allowed setting 2T mode and 4T mode offer two modes used with the torch switch that is included with the TIG torch This is used to cont...

Page 32: ...de negative and electrode positive polarity The wave form created by traditional power companies is considered to be a sine wave This sine wave when viewed on an oscilloscope is very smooth and regula...

Page 33: ...4mm 2 Collet 1 8 NVA10N25 3 10N25 3 2mm 3 Torch Body Handle 17 26 or 18 Call for App Varies by Type 4 Heat Shield 17 26 18 NVA HS172618 Heat Shield Interchanges with similar aftermarket 5 Collet Body...

Page 34: ...designed for Oxy Fuel use These usually do not offer sufficient UV protection unless stated otherwise CAUTION Keep the torch switch isolated and the consumables in place on the torch while the unit is...

Page 35: ...ormed on With the iPT60 torch the inside swirl ring can be flipped over to change the bevel side If circle cutting be sure you have identified the direction of bevel Changing clock rotation of the tor...

Page 36: ...ss than 10 from perpendicular to the metal Excess angle of sparks flame indicate too fast of travel speed or practical cut capacity has been reached Little or no angle indicates too slow of travel spe...

Page 37: ...and pushing your thumb or finger down on the electrode The electrode should depress slightly and spring back quickly without a delay If it does not the torch head may need to be disassembled cleaned...

Page 38: ...VERTICAL CUT LINES SMOOTH EVEN CUT LINES WITH A REARWARD SWEEP ROUGH DISTINCT CUT LINES SPACED FAR APART RESULTS OF TOO MUCH STANDOFF OR WORN CONSUMABLES TOP DROSS SLIGHT BEVELING AT TOP What other p...

Page 39: ...cted by the orifice diameter in the consumable tip and by the cut height of the torch and to some extent the thickness of the metal Of course the best way to determine kerf width is to make a test cut...

Page 40: ...01 Nozzle 0 8mm 20 30A PD0116 08 4b PTF0432 02 Short Nozzle 1 0mm 40A PD0102 10 4c PTF0432 03 Long Nozzle 0 9mm 20 40A PD0103 09 5 PTF0434 Shield PC0116 6 PTF0438 Site Wheel CV0024 7 PTF0420 Handle TP...

Page 41: ...e High Foot Pedal 10k 22k Note This unit is designed to accept several different Ohm values including the older 47K 50K Ohm pedal without significantly affecting operation The pinout of the pedal is u...

Page 42: ...URRENT Check to make sure input power cable is correct length and size Internal unit fault or low input voltage Possible issue running on generator with dirty power Identify cause plug directly into t...

Page 43: ...n 1 4 Reduce amperage or increase tungsten size 8 Porosity of the Weld Discolored weld color Tungsten is discolored Low flow rate of shielding gas High flow rate of shielding gas Tungsten stick out is...

Page 44: ...t consumable life Uneven wear of consumables melting of cup Moisture oil contamination of consumable Excessive pilot arc time Improper cutting technique Wrong piercing technique 7 Arc will not start w...

Page 45: ...between the points Access may be tight but try several angles to get the feeler gauge in between the points The gap should be set to anywhere between 030 and 045 with 035 being preferred 5 If adjustm...

Page 46: ...46...

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