Why is my Everlast PowerTig tungsten rapidly consumed?
Rapid tungsten consumption can occur due to inadequate gas flow, using the wrong size or type of tungsten, using the wrong shielding gas (ensure you're using Argon only), or improperly using green tungsten (use red or another color, even in AC mode). Also, too much DCEP can cause this issue; readjust the balance control to 30%.
What to do if my Everlast Welding System weld has porosity or discoloration?
Porosity or discoloration in your weld, including a discolored tungsten, can be caused by a low flow rate of shielding gas, too short of a post-flow period, using the wrong TIG cup size, or excessive torch angle (tilt no more than 20 degrees from vertical). Also, check for gas leaks internally or externally due to loose fittings. The base metal may be contaminated with dirt or grease.
What to do if my Everlast PowerTig Welding System weld quality is poor or dirty/oxidized?
If your weld quality is poor, appearing dirty or oxidized, eliminate drafts and verify sufficient shielding gas in the tank. Check and adjust the gas flow to a higher rate. Listen for the audible click of the gas solenoid to confirm it's working. If you don't hear a click or gas flow, contact Everlast Support.
What to do if the Everlast PowerTig Welding System over current LED illuminates?
If the over current LED illuminates, it indicates the duty cycle has been exceeded. Allow the machine to cool down. Ensure the fan is not blocked, and clean the inside of the machine with compressed air.
Why is my Everlast PowerTig Welding System tungsten dull or contaminated?
A dull or contaminated tungsten can occur if the tungsten is dipping into the weld. Check and adjust the stick out to a minimum of 1/8 inch. If the tungsten is melting, reduce amperage or increase the tungsten size and brace off better. Improper gas or poor flow, drafts, or a poor torch angle may also be the cause.
How to fix unstable arc on Everlast Welding System?
An unstable arc can be caused by a poorly ground or shaped tungsten, or an improper Frequency control or AC balance control adjustment. Regrind the tungsten to a proper point, change the frequency, or move the work clamp to prevent wander.
What to do if Everlast PowerTig Welding System will not weld in either mode?
If the machine runs but won't weld in either mode, check for good work clamp contact. Ensure the work cable and TIG Torch are securely fastened to the lug and receptacle. Inspect the work clamp for a loose bolt. Verify that the switch is correctly selected for TIG or STICK. Ensure the Spot Timer switch position is turned to off, unless spot operation is desired.
What to do if my Everlast PowerTig Welding System will not operate in Stick mode?
If the unit won't operate in Stick mode, verify that Stick has been selected. Make sure the cables are securely in the lugs, and ensure good work clamp attachment and bolt tightness.
How to improve weld quality in MMA with Everlast Welding System?
To improve weld quality in MMA, check and adjust your settings. Adjust the polarity settings according to the electrode manufacturer's recommendations, typically DCEP (Direct Current Electrode Positive).
What to do if my Everlast PowerTig Welding System machine will not turn on?
Check the cords and wiring, looking for loose wires in the plug connection. Also, check the circuit breaker. If no fault is found, contact Everlast Support.
Notes on High Frequency (HF) waves generated by welding processes and their potential impact on electronic equipment and pacemakers.
Details on ultraviolet radiation hazards and the importance of appropriate eye protection, including safety glasses and welding helmets.
Emphasizes the necessity of hearing protection due to high noise levels during welding and cutting operations.
Outlines requirements for flame-proof clothing, leather boots, and insulated gauntlet gloves for comprehensive personal protection.
Warning for individuals with pacemakers regarding EMF radiation from welding and plasma cutting processes.
Highlights inhalation risks from welding fumes and gases, stressing the need for adequate ventilation and respiratory protection.
Warnings against welding on materials like galvanized steel, beryllium, titanium, and around chlorinated solvents due to toxic fumes.
Guidelines for safe handling, storage, and use of gas cylinders, including securing them properly and avoiding hazards.
Crucial warnings about electrical shock, emphasizing proper grounding, cable condition, and avoiding wet conditions.
Addresses trip hazards from cables and hoses and provides essential fire prevention measures for welding areas.
Stresses the importance of proper equipment maintenance, servicing by qualified personnel, and avoiding misuse.
A detailed comparison of features across different Everlast PowerTig models, including amperage, duty cycle, and specialized functions.
Provides an overview of the manual's purpose, emphasizing safe and practical machine use and general operational suggestions.
Instructions for inspecting the unit upon receipt for damage and recording the serial number for warranty purposes.
Explains the inverter-based technology, IGBT transistors, and advantages like non-contact starts and precise arc control.
Details on understanding duty cycles to prevent overheating and the importance of keeping cooling fans and vents unobstructed.
Detailed explanation of the front panel controls and features for an EX series unit, including power indicators and digital display.
Describes the 3-position rocker switch for pulse control (Off, Low, High) and its function in amperage cycling.
Explains the pulse frequency control that governs the number of pulse cycles per second (Hz) for precise amperage modulation.
Details on Pulse Amps control for proportional amperage and Pulse Time On (Width) for cycle time ratio.
Explains the main amperage control for welding current and the Arc Force control for arc intensity and penetration.
Information on AC Frequency control for arc narrowing and AC Balance control for DCEN/DCEP cycle adjustment.
Describes the rocker switches for selecting AC/DC current modes and 4T/2T weld cycle control via torch trigger.
Explains the Spot Timer for automated spot welds and the TIG/Stick switch for selecting welding modes.
Details on Pre Gas Flow for purging and Post Flow for shielding gas after welding to prevent contamination.
Describes Up Slope for ramping current and Down Slope for controlling the end of the weld to prevent crater cracking.
Explains Start Current for initial puddle development and End Current for filling the weld crater at the end of the weld.
Details the lower front panel connectors, including positive/negative lugs and quick connect gas outlet.
Describes the rear panel components such as serial number, power switch, fan, gas inlet, and power cord connections.
Basic guidelines for unit operation and maintenance, stressing safety rules and prohibiting untrained personnel operation.
Crucial information on selecting the proper shielding gas for TIG welding to protect the weld pool from atmospheric contamination.
Guidance on choosing and connecting a regulator/flow meter for shielding gas tanks, ensuring correct gas flow and type.
Instructions for adjusting the regulator/flow meter to the recommended settings for optimal gas flow during welding.
Details on power plug installation, wiring for 220V, and the importance of proper grounding for HF interference.
Guidance on selecting the correct tungsten electrode type and size for TIG welding, including material properties and recommendations.
A table providing information on electrode diameter, direct current (DC) polarity, and alternating current (AC) suitability for various tungstens.
Identification and explanation of the parts of a typical TIG torch assembly, including cap, collet, cup, and gas insulator.
Basic principles of TIG welding, emphasizing safety gear, practice, and the fundamental steps of creating a weld bead.
Instructions and diagrams on correctly sharpening tungsten electrodes for DC and AC welding applications to ensure arc stability.
Guidance on selecting filler rods and the initial steps for starting a TIG arc using High Frequency, including amperage adjustment.
Steps for forming a weld bead, managing the keyhole, adding filler material, and maintaining consistent torch movement.
Proper techniques for terminating a weld, filling the crater, and preventing cracking or weld failure at the end.
Instructions for operating the machine in MMA/Stick (SMAW) mode, including electrode insertion, amperage setting, and striking an arc.
Using Arc Force and Amp adjustments to alter arc qualities and achieve desired weld finish in stick welding.
Guidance on electrode classification (AWS system), selection criteria, and practicing with different electrodes for stick welding.
Identifying common weld defects like overlap and undercutting and using destructive testing to improve skill.
Solutions for the machine not turning on or running but not welding, checking cords, clamps, and switch settings.
Troubleshooting for non-illuminating displays, rapid tungsten consumption, and dull/contaminated tungsten.
Addresses issues like porosity, discoloration, poor weld quality, unstable arcs, and nearby electronic interference.
Detailed explanation of foot pedal usage, its interaction with torch switch settings, and potential malfunctions.
Information on the necessity and use of water cooler systems for high amperage operation to protect torches and consumables.
Details on compatible torches and consumables, including aftermarket options and connector types for the welders.
General| Pulse Function | Yes |
|---|---|
| TIG Welding | Yes |
| Stick Welding | Yes |
| AC Frequency | 20-250 Hz |
| AC Balance Control | Yes |
| AC/DC Capability | Yes |
| Welding Processes | TIG, Stick |
| Input Voltage | 120/240V |
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