EVERLAST POWERTIG 350 EXT Digitally Controlled AC/DC Pulse TIG/Stick Welder CC GTAW-P SMAW IGBT AC/DC Operator’s Manual for the PowerTIG 350 EXT Safety, Setup and General Use Guide Rev.3 everlastwelders.com 1-877-755-9353 0 030103-17 Specifications and Accessories subject to change without notice. 329 Littlefield Ave.
Table of Contents Section……………………………………………………………..Page Letter to the Customer ………………...…………………. 3 Everlast Contact Information……………………………. 4 Safety Precautions………………………………………….... 5 Introduction and Specifications…………………….….. 9 Unit Specifications……………………….…………………… 10 General Overview…………….…..………………………….. 11 General Use and Care………...…………………………….. 11 Quick Setup Guide, TIG Torch/Cooler Connection 12 Quick Setup Guide, Stick Polarity………………………. 13 Rear Panel Gas Connection and Wiring.…………….
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Safety Precautions Everlast is dedicated to providing you with the best possible equipment and service to meet the demanding jobs that you have. We want to go beyond delivering a satisfactory product to you. That is the reason we offer technical support to assist you with your needs should an occasion occur. With proper use and care your product should deliver years of trouble free service. Safe operation and proper maintenance is your responsibility.
Safety Precautions These safety precautions are for protection of safety and health. Failure to follow these guidelines may result in serious injury or death. Be careful to read and follow all cautions and warnings. Protect yourself and others. Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can cause severe skin burn and damage. There are other potential hazards involved with welding such as severe burns and respiratory related illnesses.
Safety Precautions 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.
Safety Precautions WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground clamp. Do not stand in water or damp areas while welding or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain or in extremely humid conditions. Use dry rubber soled shoes and dry gloves when welding or cutting to insulate against electrical shock.
Section 1 Introduction and Specifications PowerTIG 350 EXT Accessories Qty Accessory 1 26 Series TIG torch and cable 1 18 Series TIG torch and cable 1 Everlast 22k Ω Pedal 1 Heavy duty work clamp 1 Heavy duty electrode holder 1 Regulator and hose assy. NOTE: Accessory and consumable appearance, style, length and quantity subject to change without notice.
Section 1 Introduction and Specifications PowerTIG 350EXT TIG/Stick Welder Specifications Process AC/DC GTAW-P/DC SMAW Inverter Type Digital Microprocessor Controlled, IGBT Module Minimum/Maximum Rated Output TIG DC 5A/10.2V– 350 A/24V Minimum/Maximum Rated Output Stick (DC Only) 20 A/20.8V - 270 A/24V Start Type Solid State HF and Lift Start HF Point Gap Heavy Duty Carbon Contact with .029”-.
Section 1 Introduction and Specifications General overview. The 350 EXT TIG/Stick welder is the largest of the advanced digital models in a new generation of inverter welders from Everlast. With a microprocessor and IGBT module design, the welder offers stable arc performance as well as convenient setup and use. Key features include: A. IGBT modules, microprocessor controller and an overall plug and play design improve reliability and reduces down time for service and repair. B.
Section 2 Quick Setup and Use Guide QUICK SETUP GUIDE: TIG CONNECTIONS NOTE: The TIG torch will always be negative polarity whether DC or AC! TORCH (-) 9/17 SERIES TORCH WORK (+) 35 SERIES CONNECTOR 35 SERIES CONNECTOR AIR-COOLED TORCH GAS (Ar) CONTROL CONTROL FOOT PEDAL 35 SERIES CONNECTOR GAS (Ar) GAS (Ar) NOTE: Torch switch and foot pedal control cannot be used at the same time.
Section 2 Quick Setup and Use Guide QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS WORK (-) TORCH (+) NOTE: In stick mode, the polarity will almost always be positive, except for special rods or circumstances. Consult the electrode manufacturer packaging material or website for proper polarity with specialty rods and for conditions where electrode negative would be appropriate. When changing over to TIG weld, do not forget to check and change the polarity.
Section 2 Quick Setup and Use Guide QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING (US/Canada) SUPPLIED PLUG IS A NEMA 6-50P, THE STANDARD PLUG FOR MOST 1 PHASE 240 V WELDERS IN THE US AND CANADA. GREEN GROUND 220V/240V COOLER OUTLET. USE WITH EVERLAST POWERCOOL WC 300 ONLY.
Section 2 Quick Setup and Use Guide FRONT PANEL FEATURES AND CONTROLS POWERTIG 350 EXT 1. CLEAR PROTECTIVE PANEL COVER 2. CONTROL PANEL 350EXT 3. NEGATIVE CONNECTOR DINSE 35-70mm² 6. POSITIVE CONNECTOR DINSE 35-70mm² 4.GAS OUTLET QUICK CONNECT 5.
Section 2 Quick Setup and Use Guide FRONT PANEL FEATURES AND CONTROLS POWERTIG 350 EXT POWERTIG 350 EXT 1. Protective Cover PARAMETERS N/A PURPOSE Clear hinged cover protects panel from damage. Keep closed during welding operations. 2. Main Control Panel Digital The main control features digital adjustment.
Section 2 Quick Setup and Use Guide FRONT PANEL FEATURES AND CONTROLS POWERTIG 350 EXT 22 23 1 21 17 2 20 18 19 7 6 16 4 11 5 12 8 13 10 25b 14 9 3 15a 24 15b 25a 27 26 POWERTIG 350 EXT 1. Memory Function 2. Easy Start Up Menu 3. Pre-Flow 4. Start Amps PARAMETERS PURPOSE 1-9 The unit has 9 programs which allow the operator to select parameters and hen save the settings to the selected program channel.
Section 2 Quick Setup and Use Guide FRONT PANEL FEATURES AND CONTROLS POWERTIG 350EXT POWERTIG 350EXT PARAMETERS PURPOSE 0-25 Seconds Upslope ramps “up” from the start amp value to the welding amp value while starting the weld puddle. For best operation, the value will be automatically be set to 0 with standard foot pedal mode. NOTE: While in pedal mode, the select button will still cycle through the upslope and downslope settings.
Section 2 Quick Setup and Use Guide FRONT PANEL FEATURES AND CONTROLS POWERTIG 350EXT POWERTIG 350 EXT 12. Down Slope PARAMETERS 0-25 Seconds PURPOSE Down Slope will ramp amps “down” from the welding amp value to the end amp value to give time to fill the crater left at the end of the weld bead. For best operation, value should be set to 0 with foot pedal in use. If used with a hand amptrol, without a separate switch to control slope in 2T/4T mode, then the upslope should be set to 0 as well.
Section 2 Quick Setup and Use Guide FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT POWERTIG 255EXT 21. 2T/4T/ Pedal Selector 22. AC Waveform/DC Selector 23. Data Display 24. Standard/6010 Selector 25. Spot Weld Timer 26. Parameter Adjuster 27. Purge Gas PARAMETERS PURPOSE 2T, 4T, Pedal, Pedal with 2T, Pedal with 4T This selects the operation of the torch switch, pedal, or hand amptrol. To weld with the torch switch, select 2T or 4T. For 2T operation, simply press and hold the switch.
Section 2 Quick Setup and Use Guide REAR PANEL FEATURES AND CONTROLS 350 EXT 1 5 1x240V 4 6 3 2 21
Section 2 Quick Setup and Use Guide REAR PANEL FEATURES AND CONTROLS CONTINUED POWERTIG 350 EXT 1. Water Cooler Receptacle 2. HF Ground Bolt 3. Gas Input Connection 4. Power Cord 5. 2-Pole Power Switch 6. Fan PARAMETERS PURPOSE IEC 60320-1 “C-14” This connection supplies power to the Everlast PowerCool 300 water cooler and is designed specifically for it. This is a 220/240V AC 1 phase outlet. Do not use this connection to power any other device. 4 amp 240V maximum load.
Section 3 Basic Theory and Function Welder Function Summary and Explanations. 1. 2T/4T/Pedal sequencer. The 2T/4T feature allows operation of the welder without a foot pedal. In many circumstances, a foot pedal is not practical for use. So, the 2T/4T function has been created to allow programming of the welder to simulate the activities of the foot pedal while providing more accurate control.
Section 3 Basic Theory and Function have little or no way to change the ratio of EN to EP, which results in welding with a molten ball at the tip of the tungsten and a less stable arc. Electrode negative (EN) provides penetration in the TIG welding process. Electrode positive (EP) creates a strong reverse flow of electricity that breaks up the weld-resistant oxidation that covers aluminum and magnesium components. It also places a lot of heat on the tungsten.
Section 3 Basic Theory and Function EXAMPLE: AC EP (+) BALANCE Parameter Notes: 1 Hz (one full AC cycle) EP 50% EN 50% 50% Standard transformer welder balance 50% EN/EP= Balling tungsten, light penetration, wide cleaning area. EP 65% EN 35% 50% Extreme cleaning setting 65% EP= Shallow penetration, balling tungsten, excessive cleaning area. 50% EP 35% EN 65% Good penetration setting 35% EP= Deeper penetration, sharper tungsten, narrow cleaning area. NOTE: 1. 2. 3. 4. 5.
Section 3 6. Standard Pulse. (AC and DC) The pulse creates two amp values, a high and a low value that cycle back and forth between each other while welding. The upper amperage is called the “welding amps” (sometimes called peak current) and the lower amperage is called “pulse amps “ (sometimes called background or base current). This creates a situation where penetration can be achieved without overheating the metal, particularly on metals that are prone to structural deterioration or burn through.
Section 3 Basic Theory and Function 50-75% Pulse Amp setting is typically used to help with timing the addition of filler metal to the weld puddle. A higher pulse frequency level with variations in Pulse Time On and a narrow/wider ratio can be used to prevent burn through and speed up welding on thin materials. It can also help maintain a proper bead on a thin edge weld or prevent burn through on extremely thin metal.
Section 3 Basic Theory and Function No special consumables are required. Although a small the main adjustment knob while the Welding Amps light is starter kit of consumables is included, you will need lit. The unit will revert to the “setting” mode and display more consumables fairly quickly. These can be bought selected maximum amperage. directly from Everlast in single pieces or in kits.
Section 3 Basic Theory and Function TUNGSTEN PREPARATION 1. Use a dedicated grinding wheel or contamination may result. Do not breath grinding dust! Wear eye protection and gloves. 2. Hold Tungsten firmly. 3. Grind perpendicular to grinding wheel face. Allow tungsten to grind away slowly, creating point. 4. Rotate tungsten quickly as it is being ground to keep point even and symmetrical. DO NOT GRIND TUNGSTEN PARALLEL TO WHEEL FACE OR AN UNSTABLE ARC WILL RESULT. 2.
Section 3 Basic Theory and Function LIFT START TIG OPERATION Note: A Lift TIG start should be done with a nearly seamless motion. Use a light touch and a quick motion for best results. FOR DC USE. NOT RECOMMENED FOR AC. 5 1 3 2 4 <1/8” 1. Position the edge of the ceramic cup on the metal. Press and hold the torch switch or press the foot pedal. Wait for the Pre-flow to start. (Make sure pre-flow is set for less than .5 seconds or start will be delayed.) 2.
Section 3 Basic Theory and Function STICK OPERATION STARTING METHODS Scratch/Match Method Tapping Method 1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program. 2. Select the Stick mode or Stick VRD with the HF/Lift Start/Stick/ VRD selector button 3. Make sure electrode holder is hooked into the positive connector and the work clamp is hooked the negative connector. 4. Select the amps desired.
Section 3 Basic Theory and Function GENERAL POLARITY RECOMMENDATIONS* *Follow manufacturer of stick electrode for complete polarity recommendations PROCESS TORCH POLARITY WORK POLARITY TIG (GTAW) - + STICK (SMAW) + - TIG (GTAW) OPERATION GUIDE FOR STEEL (ALUMINUM)* *As a general rule, set amperage using 1 amp for every .001” of metal thickness for aluminum. Less is required for DC. METAL THICKNESS WELDING AMPS (A) 1-3 mm/.040”-1/8” 40-80 (60-125) TUNGSTEN DIA. Ar FLOW RATE 1-2 mm/.
Section 3 Basic Theory and Function EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) 1 1 2 1 9 3 4 5 6 7 12 8 13 5/8” 17 9 14 16 NO.
Section 3 Basic Theory and Function 7 PIN CONNECTOR FOR 22K Ω FOOT PEDAL To Pedal or Torch Switch ON/OFF 1 2 Bridge a Jumper to Pin 7 6 Bridge a Jumper to Pin 6 7 To Pedal or Torch Switch ON/OFF 5 3 4 Middle Low High Potentiometer (VR) Foot Pedal (22k Ω) Note: This unit is equipped with a 22K (25K) pedal. However, the unit is designed to accept several different Ohm values, including the older 47K (50K) Ohm pedal without significantly affecting operation.
Section 4 Troubleshooting TROUBLE: CAUSE/SOLUTION Machine will not turn on. Check cords and receptacle wiring. Check circuit breaker. Machine runs, but will not weld in either mode. Check for sound work clamp and cable connections. Make sure work cable and TIG Torch are securely fastened to the Dinse style connector. Reset main power switch if overcurrent light is on. Contact Technical Support. Arc will not start unless lift started or No “spark”. Too long of stand off. Failed HF module.
Section 4 Troubleshooting TROUBLE CODE WITH WARNING LIGHT/UNIT STOPS WELDING BUT IS TURNED ON. DIAGNOSIS 801 OVER OR UNDER VOLTAGE. Check power input cable for length/size, check input voltage. Running on poor quality power supply or dirty power from generator. 802 OVER TEMPERATURE/ DUTY CYCLE EXCEEDED. Allow unit to rest for 15 minutes. Check for obstacles, clean welder, and heat sinks. Make sure unit is unplugged for 30 minutes before opening up for cleaning. 804 OVER CURRENT.
Notes: 37
