EVERLAST ULTRA-ARC 205 50 Amp Digital IGBT TIG/Stick/Plasma Cutter CC DC GTAW-P SMAW PAC IGBT 1 ~ PHASE DV 120/240V Operator’s Manual for the Ultra-Arc 205 Safety, Setup and General Use Guide everlastwelders.com Rev. 1 1-877-755-9353 329 Littlefield Ave. South San Francisco, CA 0 000226-20 Specifications and Accessories subject to change without notice.
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 Maintenance…...………...………………...…11 Quick Setup Guide, TIG Torch Connections..……………13 Stick Electrode Holder Connections...…………………..14 Plasma Torch Connections……………………………15 Rear TIG and Power Connections……………………...
Dear Customer, THANKS! You had a choice, and you bought an Everlast Product. We appreciate you as a customer and hope that you will enjoy years of use from your welder. Please go directly to the Everlast website to register your unit and receive your warranty information. Your unit registration is important should any information such as product updates or recalls be issued. It is also important so that we may track your satisfaction with Everlast products and services.
Serial number: ____________________________ Model number: ____________________________ Date of Purchase___________________________ Everlast USA: Everlast consumer satisfaction email: sales@everlastwelders.com Everlast Website: everlastwelders.com Everlast Technical Support: tech@everlastwelders.com Everlast Welding Support: performance@everlastwelders.com Everlast Support Forum: http://www.everlastgenerators.com/forums/ index.
Safety Precautions Everlast is dedicated to providing you with the best possible equipment and service to meet the demanding job requirements that you may have. We want to go beyond delivering a satisfactory product to you. That is the reason we offer free technical and basic welding support to assist you with your needs, should an occasion occur where it is needed. With proper use and care your product should deliver years of trouble free service.
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 ULTRA ARC 205 PACKAGE CONTENTS S-45 Series Plasma Torch (12 ft.) TIG Regulator Consumable and Plasma Pressure Regulator Kit 240V to 120V Adapter Work Clamp 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.
Section 1 Introduction and Specifications ULTRA-ARC 205 Specifications Inverter Type Digital IGBT (DC Output only) Memory Settings Up to 9 possible memory slots Minimum/Maximum Rated Output TIG 120V: 5A/10.2V-125A/15V 240V: 5A/10.2V-200A/18V Minimum/Maximum Rated Output Stick 120V: 5A/20.2V-100A/24V 240V: 5A/20.2V-160A/26.
Section 1 Introduction and Specifications NOTICE: This manual has been compiled to give an overview of operation and is designed to offer information centered around safe, practical use of the plasma cutter. Welding and cutting operations are inherently dangerous. Only the operator of this Welder/Plasma cutter can ensure that safe operating practices are being followed, through the exercise of common sense practices and training.
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).
Section 2 Quick Setup Guide TIG Connections: Front View of TIG Torch and Work Clamp TORCH GAS PILOT ARC CONTROL WORK PIECE IMPORTANT: The foot pedal and the torch switch cannot be connected at the same time.
Section 2 Quick Setup Guide Stick Connections: Front View of Electrode Holder and Work Clamp TORCH GAS PILOT ARC CONTROL WORK PIECE NOTICE: The stick function will require 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 electrodes can be run DCEN, however, consult the rod manufacturer suggestions for proper polarity.
Section 2 Quick Setup Guide Plasma Connections: Front View of Plasma Torch and Work Clamp TORCH GAS CONTROL PILOT ARC WORK PIECE IMPORTANT: Avoid firing the torch unless you are ready to cut. Excessive firing without cutting will wear the consumables at an accelerated rate. Do not attempt to control the amperage with the foot pedal connected. NOTICE: For correct operation, use the correct consumable for the amperage selected amperage. Cutting nozzles (tips) have different orifice sizes.
Section 2 Quick Setup Guide TIG Gas Connections and Power Connection NOTICE: The supplied plug is a NEMA 6-50P, This is the standard plug for welders in the USA and Canada. It is a 50 amp 3 prong plug. There is only a ground and no neutral in a welder circuit. For 120V use, use the supplied adapter. No switching or change of wiring is necessary for 120V use if the supplied adapter is used.
Section 2 Quick Setup Guide Plasma Connections: Compressor and Dryer Diagram To adjust air pressure: Select purge button. Then, Pull up on top slightly until click is heard to adjust. Push top back down to lock air pressure.. Deselect purge. Fittings (Push to Connect and 5/8” CGA) IMPORTANT: A separate air dryer between the air compressor and filter assembly must be installed, usually at the compressor or right before the regulator. This is a customer supplied item.
Section 2 Quick Setup Guide STOP! To set the air pressure or TIG torch Gas Flow Rate, use the “PURGE” feature to initiate air flow, then adjust the pressure while air is continually flowing. Do not fire the torch to initiate air or shielding gas flow. Firing the Plasma torch without cutting significantly increases consumable wear. Firing the TIG torch without welding increases wear on the HF Points. STOP! • • • • • • Turn the unit off to check and change torch consumables.
Section 2 Quick Setup Guide TERM 2T/4T DEFINITION AND EXPLANATION OF WELDING FEATURES AND TERMS In 2T or 4T modes, the torch switch is used to start and control the weld cycle. Simply put, in 2T mode, the torch switch is simply pressed and held down to start the arc and begin welding. The switch is then released to terminate the arc and stop welding. In 4T mode the trigger is pressed and held to start the arc. It is then released to weld.
Section 2 TERM Quick Setup Guide DEFINITION AND EXPLANATION OF WELDING FEATURES AND TERMS High Frequency Start This refers to the type of start in TIG mode. High Frequency (HF) provides an intense HF impulse from the internal HF board and point gap that jumps the gap between the Tip of the Tungsten and the Work Piece. This means no contact is made directly to the metal to start the arc. The foot pedal or torch switch is pressed and the arc will energize automatically after a brief HF spark is emitted.
Section 2 Quick Setup Guide Front Panel Controls 3 2 1 4 9 8 7 5 6 ITEM 1. 2. 3. 4. 5 6. 7. 8. 9. DESCRIPTION Memory. If you intend to save a program, press select to toggle to the desired number where you wish to save a program before you attempt setup. Make desired adjustments to program parameters. Once completed, press and hold the select/save button for 3 seconds to save the program. Once the program has saved, the “SAVE” button will light. Release the button.
Section 2 Quick Setup Guide Rear Panel ITEM DESCRIPTION 1 Switch. This switch serves as the main power switch for the unit. If a severe fault or short takes place, this breaker switch will trip. If the breaker trips, find and rectify fault before attempting to power the unit back on. If the switch does not reset, contact Everlast. 2 Fan. Keep the fan area clear and allow a minimum of 18” (500mm) clearance for proper air circulation and maximum duty cycle. The fan should run continuously.
Section 3 Operation V-GROOVE (60-80°) DOUBLE V-GROOVE U-GROOVE DOUBLE U-GROOVE BEVEL GROOVE J-GROOVE DOUBLE BEVEL GROOVE DOUBLE J-GROOVE Besides a butt joint and lap joint which are often used for thinner metal gauges, consider using one of these groove joints for best welding results. When grinding or cutting the bevels, especially with a single V-groove, it may be beneficial to leave a small land with a gap between the joint to achieve full penetration.
Section 3 Operation Basic TIG Operation General Setup. The process to set up the welder for the basic TIG mode with a foot pedal is as simple as plugging in the TIG pedal and setting the amperage. TIG voltage is not conventionally adjustable and is a product of the arc length. This is not to say voltage is not important to TIG welding, but it is not something that can be adjusted on the unit. In practical terms, voltage is not a concern to the user as it is self regulating.
Section 3 Operation Basic TIG Operation starts to melt before you dip, you have it too close, or you have the rod inclined too much so that heat is being directed too far in front of the puddle. As you add the filler wire, be sure to pause momentarily with the forward travel of the torch. If desired, a tiny back step motion may be used to improve weld appearance. There are other ways to add filler and to create a sound weld.
Section 3 AMPS Operation Basic EXAMPLE 1 Peak Pulse Amps: 100 amps, Base Amps: 50% Pulse Time On: 50% DC Pulse Frequency: 1 Hz Pulse Time ON TIG Operation Welding Amps 100 Pulse Amps 50 Pulse Hz 1S AMPS 100 2S 3S DC EXAMPLE 2 Peak Pulse Amps: 100 amps Base Amps: 65% Pulse Time On : 65% DC Pulse Frequency: 25Hz 65 DC 1S AMPS 100 EXAMPLE 3 Peak Pulse Amps: 100 amps Base Amps: 35% Pulse Time On: 75% DC Pulse Frequency: 3 Hz 35 1S DC 26
TIG ARC STARTING Section 3 Operation LIFT START OPERATION NOTICE: When using the TIG lift start function, the lift start should be performed using a 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 good candidates for Lift Start operation. To start the arc with Lift Start or Live Lift Start: 1. Position the edge of the ceramic cup on the metal.
Section 3 Operation TUNGSTEN SHARPENING •Use a dedicated grinding wheel or contamination may result. Do not breath grinding dust! Wear eye protection and gloves. •Grip the Tungsten firmly. •Grind the Tungsten perpendicular to the wheel face. Allow tungsten to grind slowly without much pressure. •Rotate the Tungsten quickly as it is being ground to keep the point even and symmetrical. •Alternatively you may use a drill to hold the Tungsten. Rotate slowly.
Section 3 Operation STICK ARC STRIKING METHODS 1.Make sure the unit is turned on and the boot cycle has finished. 2.Select the Stick Process on the Selector. 3.Make sure the electrode holder is in the Positive connector and the work clamp is in the negative connector. 4.Select the Amp level desired. No voltage adjustment is available. Select and adjust Hot Start Amps % (Intensity) to improve starting reliability.
Section 3 Operation NOTICE: The design of the blow back start may cause a slight delay in the arc as the air pressure must built inside the torch tubing and head to create the pressure needed to force the electrode off the nozzle seat. This may take up to a second, especially when using longer torches or marginal air supply systems. Restarting the arc in tip saver mode requires retriggering the torch. If the torch does not light after 3 seconds, let go of the trigger and press it again.
Section 3 Operation NOTICE: For longer consumable life do not use the pilot arc unnecessarily. FLAME AT FAST TRAVEL SPEED FLAME AT NORMAL TRAVEL SPEED TRAVEL TRAVEL FLAME AT SLOW TRAVEL SPEED TRAVEL IMPORTANT: Check consumables regularly for wear and change them out before they are completely worn out. A good practice is to check consumables before turning the machine on each time you go to cut. It takes only a few seconds and can save yourself a lot of extra effort later.
Section 3 Operation RESULTS OF CUT AT CORRECT SPEED, AIR PRESSURE AND TORCH ANGLE RESULTS OF CUT AT FAST SPEED SMOOTH, EVEN CUT LINES WITH A S REARWARD SWEEP ROUGH, DISTINCT CUT LINES SPACED FAR APART NOTICEABLE SMALL, HARD DROSS MINIMAL EASY TO CLEAN DROSS RESULTS OF TOO MUCH CURRENT OR TOO MUCH STAND OFF HEIGHT (SIDE VIEW) RESULTS OF CUT AT SLOW SPEED VERTICAL CUT LINES MELTED TOP EDGE SIGNIFICANT SOFT, POROUS DROSS RESULTS OF WORN CONSUMABLE OR LOW AIR PRESSURE (SIDE VIEW) SEVERLY ANGLED CUT
Section 3 Operation AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING OUT A DISK SHAPED OBJECT AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING HOLE IN AN OBJECT NOTICE: When cutting an object, particularly a pattern shape, where the torch must pierce or re-fire in-line at an intersection of a cut, a lead -in cut should be employed.
Section 3 No. Operation Description Order BW S-45 Complete Torch G1/4 5M 33013101 BW S-45 Complete Torch M16x1.5 5M 33013102 BW S-45 Complete Torch M14x1.5 5M 33013103 BW S-45 Complete Torch M14x1 5M 33013104 BW S-45 Complete Torch Central Adaptor 5M 33013105 1 BW S-45 Torch Head 3302270 PF0125 2a Electrode 20-30A 33031551 PR0110 2b Short Electrode 40A 33031552 PR0105 2c Long Electrode 20-40A 33031553 PR0106 3 Swirl Ring 3305140 PE0106 4a Nozzle 0.
Section 3 Operation EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) 11 1 2 10 9 3 4 5 6 7 12 8 5/8” 9 14 13 15 NO.
Section 4 Troubleshooting TIG/Stick Trouble shooting: CAUSE/SOLUTION Machine will not turn on. Check cords and wiring in the plug. Check circuit breaker. Wrong Wiring. 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. Running on a generator that is Dirty Power.
Section 3 Troubleshooting When TIG welding is your Tungsten burning up rapidly or is your weld turning gray or dull? • • • Make sure your welder is at least 5 to 6 feet away from the area you are welding. The fans from the welder can blow your gas off the weld and create a draft that blows the shielding gas off the weld. Make sure you have 100% Argon. Contaminated gas can be a real issue. A cylinder can be mislabeled, or improperly filled.
Section 4 Troubleshooting TROUBLE: CAUSE/SOLUTION Machine will not turn on. No fan, no display. Check cords and wiring in the receptacle. Check circuit breaker. Check plug condition. Air flows but arc does not start within 2-3 seconds. Check consumables for wear and tightness. Check fuse. Check Air Pressure. Sticky or slow spring/piston on torch blow back mechanism. Release trigger and try again. Air flows but pilot arc does not start or spark but arc starts when nozzle is rubbed on the metal.
Section 3 Troubleshooting Having trouble setting up your unit for best cutting? Try the following: • • • • • Keep your standoff to less than 1/8” distance from the work piece. Always use dry air. Drain compressor daily to improve effectiveness of air dryers and to prevent them from prematurely failing. Make sure work clamp is attached directly to the part being cut. Make sure the work clamp is attached to freshly cleaned metal.
