Everlast ULTRA-ARC 205, Operator'S Manual

Page: 12 / 40

12
Section 1 Introduction and Specifications
DUTY CYCLE:
The duty cycle of this unit has been tested and established at 60% at full rated output for TIG welding. For Plasma and Stick use the duty cycle
is 35% at full rated output. This duty cycle has been established under the standard rating temperature of 104 F (40 C). If you are not familiar
with Duty Cycle ratings, duty cycle is the percent of time out of a 10 minute time period at which a welder or plasma cutter can operate continu-
ously without overheating. Lowering output increases duty cycle. It is possible to achieve a 100% duty cycle by lowering the output Amps until
the 100% duty cycle threshold has been reached. (Additional duty cycle levels at rated lower - than - maximum outputs are listed on the data plate
on the welder. i.e. 60%, 100% ) However, 100% duty cycle is still based off a 10 minute time period and does not mean it has an “ infinite ” duty
cycle. Theoretically, if the machine were to go 11 minutes of uninterrupted operation even at a 100% Duty Cycle level of operation, you could
incur an overheat condition. Duty cycle on this machine is not controlled by a timer, but rather by one or more temperature sensors strategically
located on the heat sink(s) of the machines internal circuitry. If an overheat is detected the cutting output will be interrupted. A code of “ E01 ” will
be displayed. If this happens, allow the unit to continue to run and cool for at least 15 minutes . Do not turn the unit off during this time! If the
unit does not automatically reset after this time, cycle the machine off and back on to clear the code. If the code does not clear at this time,
contact Everlast for further remedy. Intentionally and repeatedly triggering the duty cycle can damage the unit over time. This type of damage
becomes apparent during repair and service and is not covered under warranty.
OVER/UNDER VOLTAGE/CURRENT:
This unit is equipped with a over/under voltage/current device which senses under or over voltage conditions caused by poor power supply or
internal faults and shuts down output. If you observe an error code “ E02 ” immediately turn the machine off. Evaluate the input power supply for
proper voltage. Also inspect the suitability of any extension cords for service. If code does not clear, after remedying common issues stated
below, contact Everlast. Do not continue to try to clear the code if it does not appear to have been corrected.
Common Items That Can Trigger the Over/Under Voltage Current:
• Operating on too long or undersized extension cord or service wiring. Damaged wiring.
• Improperly grounded service/ power supply.
• Operating on too small of a generator or on a generator not rated as “ Clean Power ” (5% or less THD).
• Too long of a cutting arc.
• Excessively worn or missing consumables or damaged torch head.
• Internal machine fault. (If code cannot be cleared after correcting other issues, call Everlast.)
GENERATOR REQUIREMENTS AND OPERATION
This unit may be run on a generator capable of 7500 Surge Watts. Additionally, the generator must provide “ clean power ”. Clean power is de-
fined as having 5% or less Total Harmonic Distortion (THD). This is a rating given by the manufacturer of the generator, and not Everlast. This
is similar to the power normally supplied at a wall outlet. This represents a sine wave (AC) that is mostly free of voltage spikes and electronic
noise. Many general purpose (GP) generators are not rated to produce clean power and are designed for emergency or construction use with
resistive loads such as lights or heaters. These generators can damage the plasma cutter. If damage does not occur immediately, the effect can
be cumulative, depending on how “ dirty ” the power actually is. Damage created by running this unit off a generator, or welder/generator not
rated for clean power output by its manufacturer will not be covered under warranty. If you are in doubt about your generator or welder/
generator, contact the manufacturer. Everlast does not keep an authorized list of generator brands or models. However, if the manufacturer rates
its generator for 5% or less THD, this is sufficient to meet our standards. However, do some additional research on the brand and model of the
generator to make certain there are no issues, recalls or reported equipment (electronics in particular) damage related to malfunctioning genera-
tors from the manufacturer. The generator should be properly grounded, according to the generator manufacturer instructions.
Never leave the unit on or connected while starting the generator. Never stop the generator while the unit is on or connected. Severe damage
will occur. This includes running the generator low on or out of fuel. This damage is not covered under warranty, even if the unit is rated as
“ clean powered ”. Always allow the generator to warm up before plugging the unit in and using it. A cold engine may not develop or maintain
proper RPM needed to provide stable, clean power even if the unit is rated to be “ clean power ”. Never use economy idle (ECO mode), or auto
idle modes with this unit. Always use maximum idle when this unit is plugged in and/or turned on.
NOTICE:
During TIG arc starting and during start up you may hear a quick “ buzzing ” sound coming from the machine. You may also observe a blue light
coming from the front panel vents. This is normal and not an issue. It does not present a danger to the machine. This is the High Frequency
(HF) circuit activating, allowing you to make a clean, touchless start. Inside the machine, toward the front of the welder, under the main metal
pan is a small HF board, with small set of points that the HF energy jumps between, creating a “ spark ”. You can view the HF points through the
front vents at just the right angle. This spark can also be seen briefly during the start of the weld (if in HF start mode) at the tip of the Tungsten.
Do not attempt to start the unit unless you are ready to weld. The unit discontinues the starting HF after approximately 3 seconds of attempting
to start the arc for safety and unit protection. It also discontinues after the arc starts.
Over time the points may become dirty or out of adjustment, making the HF starting more difficult. If HF starting is difficult, first regrind the
Tungsten, then make sure the work clamp is in direct contact with the work piece and not running through the work table or table leg. If starting
is still difficult, adjustment of the point gap may be needed. This is not a candidate for warranty. Point Gap adjustment, just as cleaning out/
blowing out the machine on a regular basis is considered a part of regular maintenance. Opening the machine for cleaning or point gap adjust-
ment does not void the warranty. Always unplug the unit for 10 minutes before entering the machine for maintenance to allow capacitor bleed
down. Remove only the rear plastic cover and the metal cover to access the unit. Never remove the front plastic cover unless directed by Ever-
last. See specification page for point gap adjustment range.