Everlast POWERPRO 256SI Operator'S Manual Download

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EVERLAST

POWERPRO

256Si

GTAW-P

SMAW

IGBT

AC/DC

Operator’s Manual for the PowerPro 256Si

Safety, Setup and General Use Guide

Specifications and Accessories subject to change without notice.

Rev. 1 0 01207-15ETL

everlastwelders.com

1-877-755-9353

329 Littlefield Ave. South San Francisco, CA 94080 USA

A Digitally controlled pulse tig/stick/Plasma Multi-Process welder/Cutter

PAC

Summary of Contents for POWERPRO 256SI

Page 1: ...Si Safety Setup and General Use Guide Specifications and Accessories subject to change without notice Rev 1 0 01207 15ETL everlastwelders com 1 877 755 9353 329 Littlefield Ave South San Francisco CA...

Page 2: ...fications and features are subject to change without notice While every attempt has been made to provide the most accurate and current information possible at the time of publication this manu al is i...

Page 3: ...pport available through the main company head quarters available in your country For best service call the appropriate support line and follow up with an email In the event you do not reach a live per...

Page 4: ...forums index php Main toll free number 1 877 755 WELD 9353 9am 5pm PST M F 11am 4pm PST Sat FAX 1 650 588 8817 Everlast Canada Everlast consumer satisfaction email sales everlastwelders ca Everlast We...

Page 5: ...t Do not op erate 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 Everlast Support The...

Page 6: ...ipment If no protection is availa ble exclude them from the work area Even brief exposure to the rays from the welding arc can damage unprotected eyes Always wear hearing protection because the weldin...

Page 7: ...ny 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 obtained Stop work completely and se...

Page 8: ...n 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 completed...

Page 9: ...Cooled 18 Series Torch Assembly Air and Argon Regulator NOTE Appearance and quantity of accessories are subject to change without notice Full TIG and Plasma consumable kits may be purchased from Ever...

Page 10: ...s I1MAX 40A Maximum Operating Amps Rated Effective I1EFF 32A Maximum Air Supply Pressure Plasma cutter 90 psi from Air Compressor Recommended Operating Pressure Plasma cutter 70 80 psi while air is fl...

Page 11: ...t air flow or movement of air around the welder Allow a buffer distance of 2 ft from all sides with a minimum distance of 18 clearance Do not oper ate the welder in the immediate vicinity of the weld...

Page 12: ...hould be set to anywhere between 030 and 045 with 035 being preferred 5 If adjustment is needed loosen the locking nuts slightly so that the end of the brass contact holder can be rotated with a small...

Page 13: ...RY COMPRESSED AIR AND GENTLY BLOW THROUGH THE LINES TO DISCOVER WHICH LINE EXHAUSTS THROUGH THE TORCH OR THROUGH THE RETURN LINE NOTE THE DIAGRAM ABOVE AND THE RETURN LINE ON SOME AFTER MARKET TORCHES...

Page 14: ...ller diameter nozzles are available through authorized distributors of the Tecmo Innotec PT iPT60 torches or contact Everlast to purchase them direct Note Not all parts or consumables listed may be st...

Page 15: ...lding electrodes rods may be rated for use with both electrode positive and electrode negative also referred to as DCEN or straight polarity by the electrode manufacturer However most electrodes are g...

Page 16: ...orth a manifold sys tem may be made from either a T configuration of two ball valves or a Y valve either must be supplied by the customer to switch between the plasma air input and TIG shielding gas a...

Page 17: ...R TOOLS OIL WILL DAMAGE THE TORCH AND CONSUMABLES AS WELL DAMAGE DONE TO THE CUTTER OR THE TORCH BY OIL IS NOT COVERED UNDER THE WARRANTY IT IS ADVISABLE TO USE THE PLASMA CUTTER WITH A NEW AIR HOSE L...

Page 18: ...ULSE FREQUENCY Hz 9 PULSE AMPS RATIO 10 PULSE TIME ON BALANCE 11 POSITIVE 35 SERIES 12 GAS QUICK CONNECT 9mm 13 TORCH PEDAL CONTROL PILOT ARC PLASMAONLY 14 NEGATIVE 35 SERIES 15 AC DC SELECTOR 17 AC F...

Page 19: ...as the 2T 4T beginning and final amp value while using the torch switch Allows the arc to start and end at a different amp value while using the torch switch Typically used to start the weld puddle mo...

Page 20: ...e gas supply to the TIG and air supply to the Plasma torch To connect Push the torch fitting into the connector until the collar slides forward with a click To Release Slide the collar back 13 Control...

Page 21: ...ay N A Displays maximum selected amps until the weld is started Displays actual amps while welding Display may cycle rapidly and randomly after pulse has been turned on This is normal The meter sample...

Page 22: ...UP AND USE GUIDE Section 2 REAR PANEL FEATURES AND CONTROLS GAS INLET 1 220 V 1 220 VAC 2 2 POLE POWER SWITCH 5 HF GROUND BOLT 4 GAS INLET 3 POWER CABLE 1 220 240V 1 220V WATER COOLER CONNECTION 6 REG...

Page 23: ...ped Do not run the Argon gas through the air regulator filter A T fitting or Y fitting may be placed inline at the connection to leave both ar gon and air hooked up without having to swap out the line...

Page 24: ...starting point use approximately 1 second of post flow for every 10 amps set Of course fine tune post flow time as needed to suit your needs 2 AC Frequency The AC frequency only applies to the AC mod...

Page 25: ...in an inverter this is not necessary So the HF switch refers only to the Start of the arc and not to AC operation 2 The addition of Helium to Argon can increase the welding capacity of the welder and...

Page 26: ...mps are independently set Adjust the welding amps with the main control knob and the pulse amps with the pulse amp knob However when you adjust the pulse amps you are actually setting a fixed ratio of...

Page 27: ...tor The argon regulator is calibrated in cfh subject to change 30 50 Pulse Amp setting is typically used to help with timing the addition of filler metal to the weld puddle A higher pulse frequency le...

Page 28: ...help control the arc Create a slight truncation on the tip for higher amp use for best arc stabil ity Grind the tip so that it is 2 5 3 times longer than the tungsten is wide Diameter In AC mode do n...

Page 29: ...foot pedal raise your foot fully off the pedal and arc will stop automatically 9 If using 4T release the switch after arc initiates Continue to weld without holding the switch down To stop press and r...

Page 30: ...rc characteristic and automatic amp response needed to maintain the arc when voltage falls below the threshold 6011 Cellulose electrodes will require more arc force control than other rods but each br...

Page 31: ...rage using 1 amp for every 001 of metal thickness for aluminum Less is required for DC TUNGSTEN SELECTION GUIDE FOR AN INVERTER NOTE Thoriated tungsten is slightly radioactive but is commonly used in...

Page 32: ...e torch slowly to the vertical posi tion as the arc penetrates the metal Tilt the torch from 0 15 for thin metal cuts or hold it nearly perpendicular for thicker metal cuts 4 Begin moving the torch in...

Page 33: ...ing the air pressure below 65 psi to try to get the torch to cut will only result in a lazy wandering arc TIP For longer consumable life do not use the pilot arc unnecessarily Keeping the pilot arc en...

Page 34: ...ULTS OF CUT AT FAST SPEED SIGNIFICANT SOFT POROUS DROSS RESULTS OF CUT AT SLOW SPEED VERTICAL CUT LINES RESULTS OF TOO MUCH CURRENT OR TOO MUCH STAND OFF HEIGHT SIDE VIEW MELTED TOP EDGE RESULTS OF WO...

Page 35: ...ion of a cut a lead in cut should be employed A lead in is a cut that is made in the disposable part also known as a drop of the object to lead into the main part of the cut so that the destructive fo...

Page 36: ...ine will always be the one connected to the DINSE connector This should go to the in coupler on the water cooler which is color coded red The other water line should be connected to the out coupler on...

Page 37: ...s not the manufacturer of the Innotec Tec mo PT iPT 60 torch nor is it affiliated with either company other than as an OEM supplier of the torches More Innotec and Tec mo torch parts and consumables a...

Page 38: ...models before mid 2015 typically used a 47k pedal 22k is only for digitally controlled models of the PowerPro line after the mid 2015 model year Bridge to 7 Bridge to 6 To Pedal or Torch Switch To Pe...

Page 39: ...Re duce amperage or increase tungsten size Porosity of the Weld Discolored weld color Tungsten is discolored Low flow rate of shielding gas High flow rate of shielding gas Too short of post flow peri...

Page 40: ...consumables Premature wear on consumables Short consuma ble life Uneven wear of consumables melting of cup Moisture oil contamination of consumable Excessive pilot arc time Improper cutting technique...

Page 41: ...Foot Pedal 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 abo...

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