Everlast ULTRA-ARC 205 Operator'S Manual Download Page 7

WARNING!    Persons with pacemakers should not weld, cut or be in the welding area until they 

consult with their physician.  Some pacemakers are sensitive to EMF radiation and could severely 

malfunction while welding or while being in the vicinity of someone welding. 

Serious injury or death 

may occur! 

 

Welding and plasma cutting processes generate electro

-

magnetic fields and radiation.  While the 

effects of EMF radiation are not known, it is suspected that there may be some harm from long 

term exposure to electromagnetic fields.  Therefore, certain precautions should be taken to mini-

mize exposure: 

 

 

Lay welding leads and lines neatly 

away 

from the body.  

 

 

Never coil cables 

around

 the body or limbs.   

 

 

Secure cables with tape if necessary to keep from the body. 

 

 

Keep all cables and leads on the same side the body.  

 

 

Never stand between  cables or leads.   

 

 

Keep as far away from the power source (welder) as possible while welding.  

 

 

Never stand between the ground clamp and the torch.   

 

 

Keep the ground clamp grounded as close to the weld or cut as possible.   

 

 

 

Welding and cutting processes pose certain inhalation risks.  Be sure to follow any guidelines 

from your chosen consumable and electrode suppliers regarding possible need for respiratory 

equipment  while  welding  or  cutting.    Always  weld  with  adequate  ventilation.    Never  weld  in 

closed rooms or confined spaces.  Fumes and gases released while welding or cutting may be 

poisonous.  Take precautions at all 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 obtained.   

 

Stop work completely and seek medical help if irritation and discomfort persists. 

 

 

 

WARNING!  Do not weld on galvanized steel, stainless steel, beryllium, titanium, copper, cadmium, 

lead or zinc without proper respiratory equipment and or ventilation. 

 

 

 

WARNING!  The use of this product can expose you to chemicals such as lead,  which is known to 

the State of California to cause birth defects, reproductive harm and cancer. Proposition 65 Warn-

ing. For more information visit:  www.P65Warnings.ca.gov  

 

 

 

DANGER!  Do not weld or cut around Chlorinated solvents or degreasing areas.  Release of Phos-

gene gas can be deadly.  Consider all chemicals to have potential deadly results if welded on or 

near metal containing residual amounts of chemicals. 

 

 

 

Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain regulations re-

garding high pressure cylinders can be obtained from OSHA or local regulatory agency.  Consult 

also with your welding supply company in your area for further recommendations. The regulatory 

changes are frequent so keep informed. 

 

 

 

All cylinders have a potential explosion hazard.  When not in use, keep capped and closed. Store 

chained so that overturn is not likely.  Transporting cylinders incorrectly can lead to an explosion.  

Do not attempt to adapt regulators to fit cylinders.  Do not use faulty regulators.  Do not allow cylin-

ders to come into contact with work piece or work.  Do not weld or strike arcs on cylinders. Keep 

cylinders away from direct heat, flame and sparks. 

 

Safety Precautions  

Summary of Contents for ULTRA-ARC 205

Page 1: ...General Use Guide CC IGBT Rev 1 0 000226 20 1 877 755 9353 Specifications and Accessories subject to change without notice 329 Littlefield Ave South San Francisco CA 94080 USA everlastwelders com 50...

Page 2: ...While every attempt has been made to provide the most accurate and current information possible at the time of publication this manual is intended to be a general guide and not intended to be exhausti...

Page 3: ...mer interaction Tech nical advisors are active on the forum on a regular basis We also divide our support into two divi sions technical and welding performance Should you have an issue or question con...

Page 4: ...Everlast Support Forum http www everlastgenerators com forums index php Main toll free number 1 877 755 WELD 9353 9am 5pm PST M F FAX 1 650 588 8817 Everlast Canada Everlast consumer satisfaction ema...

Page 5: ...contact Everlast Support The content of this manual is not meant to be an exhaustive primer on welding It is written to an audience that if not professional will have at least some basic knowledge of...

Page 6: ...welding Do not allow personnel to watch or observe the welding or cutting operation unless fully protected by a filter screen protective curtains or equivalent protective equipment If no protection i...

Page 7: ...yes 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 seek medical help if...

Page 8: ...welding or cutting outside make sure you are in a cleared off area free from dry tender and debris that might start a forest or grass fire Do not weld on tanks drums or barrels that are closed pressu...

Page 9: ...l original consumable kits are sold through Everlast Various diameter consumables for lower amp use are available The unit comes with a spare 30 Amp glass type slow blow fuse for the pilot arc Set thi...

Page 10: ...onds TIG Pulse Frequency 1 150Hz TIG Pulse Time On Pulse Amps P TIG 1 P TIG 2 P TIG 3 Fixed Time On Pulse Amp values set P TIG 1 50 50 P TIG 2 65 65 P TIG 3 75 35 Spot and Fast Tack Time 1 15S Stick H...

Page 11: ...ied adapter to the NEMA 6 50 plug on the plasma cutter and the unit will automatically sense the voltage that is being supplied When operating on 120V input please note the maximum output will be limi...

Page 12: ...ors 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...

Page 13: ...ection 2 Quick Setup Guide TIG Connections Front View of TIG Torch and Work Clamp GAS CONTROL TORCH WORK PIECE PILOT ARC IMPORTANT The foot pedal and the torch switch cannot be connected at the same t...

Page 14: ...ire you to move the torch to the work piece setting for DCEP Reverse Polarity In this case ignore the marking and remember the left terminal is negative and the right terminal is positive Some electro...

Page 15: ...edal connected NOTICE For correct operation use the correct consumable for the amperage selected amperage Cutting nozzles tips have different orifice sizes If you are operating on 120V the maximum out...

Page 16: ...ng Do not modify the welder wiring Refer to Article 630 of the NEC for more information concerning proper wiring of welders NOTICE The unit has a common connection point for both the plasma air supply...

Page 17: ...desiccant type dryer used in automotive paining is enough to get started Damage caused by operating the unit without the additional dryer filter is not covered under warranty Never use this plasma cut...

Page 18: ...o not rely on the supplied water trap filter Drain compressor daily to improve effectiveness of air dryers and to prevent them from prematurely failing Don t greatly air pressure to try to reduce kerf...

Page 19: ...iron powder rods such as E7014 and E7018 and for rods like E7018 Arc force values of 20 to 40 are all that are usually required For operation with more difficult rods such as E6011 higher arc force v...

Page 20: ...Setting Pulse Time On Balance and Frequency Of the three parameters only Frequency is adjustable in each of the pre programmed pulse programs However the Pulse programming for Base Amps and Pulse Tim...

Page 21: ...e of a foot pedal or torch switch Touching down and lifting up will initiate the arc and start gas flow See instructions later in the manual on how to lift start both types of lift start Lift Start re...

Page 22: ...bing must be removed the outer collar must be pressed in gently to release the tubing Hold the collar while removing the tubing 5 Ground Bolt This is to be used in cases where High Frequency H F inter...

Page 23: ...in many cases a plain open root can be used as a backer plate adds to the time and labor involved A knife edge is also acceptable so long as the joint is fully penetrated when the weld is com pleted O...

Page 24: ...coin is able to be placed between the tip of the Tungsten and the weld puddle As your skill progresses you will want to add filler wire to your practice The angle created between the filler rod shoul...

Page 25: ...ith a proper fitting TIG glove you should be still able to pick the filler wire up from the table top with your fin gers There are a lot of hurdles to becoming a proficient TIG welder But if you will...

Page 26: ...Pulse Frequency 3 Hz 100 65 35 100 1 S DC EXAMPLE 2 Peak Pulse Amps 100 amps Base Amps 65 Pulse Time On 65 DC Pulse Frequency 25Hz AMPS AMPS DC 1 S EXAMPLE 1 Peak Pulse Amps 100 amps Base Amps 50 Puls...

Page 27: ...light touch and a quick seamless motion Lift Start with a remote is often used anywhere HF use is restricted particularly in hospitals or where computers are in close proximity Steel or Stainless are...

Page 28: ...ng and splitting Pure Tungsten Green should never be used with this unit Zirconiated is not for use with this welder either Thoriated 2 Red Tungsten works well with DC Inverters and is still the stand...

Page 29: ...force setting is generally desirable for rods iron powder Titania based flux Too much arc force will create overheating of the welding rod and even cause them to flame up Too little can lead to sticki...

Page 30: ...etal tilt the torch so there is a slight lead in the flame if metal is thin If the metal being cut is thick keep holding torch in a nearly vertical position 4 Begin moving the torch in the direction o...

Page 31: ...s are available if repair is not an option Sticking of the electrode like this causes starting issues Most often this condition occurs be cause of moisture and dirt that makes it way into the system A...

Page 32: ...IGNIFICANT 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 WORN CONSUMABLE OR LOW AIR PR...

Page 33: ...yed 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 force of the arc is not directed into the de...

Page 34: ...0A 33031551 PR0110 2b Short Electrode 40A 33031552 PR0105 2c Long Electrode 20 40A 33031553 PR0106 3 Swirl Ring 3305140 PE0106 4a Nozzle 0 8mm 20 30A 33031561 PD0116 08 4b Short Nozzle 1 0mm 40A 50A 3...

Page 35: ...32 1 6 Collet Holder 1 7 Ceramic Cup 4 5 6 or 7 1 8 Tungsten customer supplied 0 9 Torch Cable 1 10 Torch Handle Style may vary 1 11 Torch Switch B 1 12 Torch Switch Connector 1 13 Power Connector 1 1...

Page 36: ...Discolored weld color Tungsten is discolored Low flow rate of shielding gas High flow rate of shielding gas Too short of post flow period Wrong TIG cup size Possible gas leaks internally or externally...

Page 37: ...with point gap adjustment for proper diagnosis and a more detailed adjustment procedure WARNING If possible do not touch unrelated circuits and components especially capacitors during this adjustment...

Page 38: ...melting of cup Moisture oil contamination of consumable Excessive pilot arc time Improper cutting technique Wrong piercing technique Arc will not start with pilot arc or by drag scratch starting nozzl...

Page 39: ...s used to scour the surface to establish continuity so that the cutting arc will transfer If you experience difficulty cutting and the arc seems to barely penetrate the metal cutting speed is slow or...

Page 40: ...40...

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