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Everlast ULTRA-ARC 205, Operator'S Manual

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Everlast ULTRA-ARC 205 Operator'S Manual Download Page 9

9 

ULTRA ARC 205 PACKAGE CONTENTS

 

NOTICE!  Accessory and consumable style and quantities are subject to change without notice. Consumable starter kits provide only enough consumables to get  

started.  Extra consumables can be purchased through Everlast or through other local and online iPT 60 Innotec distributors.  Full 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 this fuse aside where you can find it.  Replacement fuses may be bought locally (use part number printed on fuse for reference) or directly from Everlast.   

 

Consumable and Plasma Pressure Regulator Kit

 

Work Clamp

 

Section 1                                                  Introduction and Specifications  

S

-

45 Series Plasma Torch (12 ft.)

 

TIG Regulator

 

240V to 120V Adapter

 

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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