Everlast PowerTIG 250EX AC/DC Pulse TIG Stick Welder User Manual

1. Introduction

This manual provides essential instructions for the safe and effective operation, setup, and maintenance of your Everlast PowerTIG 250EX AC/DC Pulse TIG Stick Welder. This machine is designed for both TIG (Tungsten Inert Gas) and Stick (Shielded Metal Arc Welding) processes, offering versatility for various welding applications. Please read this manual thoroughly before operating the equipment.

The PowerTIG 250EX features IGBT power modules for enhanced reliability, a low 5 amp start for TIG welding, and advanced controls for precise welding performance on both AC and DC modes.

2. Safety Information

WARNING: Welding can be dangerous. Always follow safety precautions to prevent injury or death.

• Electric Shock: Can kill. Do not touch live electrical parts. Wear dry welding gloves and protective clothing. Ensure proper grounding.
• Fumes and Gases: Can be hazardous to your health. Keep your head out of the fumes. Use ventilation or exhaust to remove fumes from the breathing zone.
• Arc Rays: Can burn eyes and skin. Wear a welding helmet with a proper shade filter and protective clothing.
• Fire and Explosion: Welding sparks can cause fire or explosion. Keep combustibles away from the welding area. Have a fire extinguisher readily available.
• Hot Parts: Can cause severe burns. Do not touch hot parts with bare hands. Allow equipment to cool before handling.
• Noise: Excessive noise can damage hearing. Wear ear protection.

Always ensure your welding area is well-ventilated, free of flammable materials, and that you are wearing appropriate Personal Protective Equipment (PPE).

3. Product Overview

3.1 Key Features

• IGBT Power Modules for increased reliability and performance.
• Low 5 amp start for TIG in AC and DC modes (+/- 2 amps).
• Pre-flow and Post-flow control for maximum shielding gas protection.
• Improved HF start circuit for reduced maintenance.
• Lift Start function for use when HF is not desirable.
• Expanded AC cleaning range for optimum aluminum welding performance.
• Color-coded controls for ease of use.
• Arc force control for Stick welding to reduce spatter and improve arc performance.
• Pulse up to 500 Hz in AC or DC modes.
• Built-in 240V receptacle for PowerCool 300 water cooler.

3.2 Included Components

The PowerTIG 250EX comes with the following accessories:

Image: The Everlast PowerTIG 250EX welder shown with its standard included accessories.

• 12 ft. Everlast 18 Series (Water-Cooled) TIG torch with 35 series DINSE style connectors and torch switch for 2T/4T operation.
• Everlast Argon Regulator (made from billet brass).
• Ground Clamp with 10 ft. cable and 35 series DINSE style connector.
• Foot Pedal (22K).
• Consumable Starter Kit (Tungsten not included).
• Stick Electrode Holder with 10 ft. cable and 35 series DINSE style connector.

3.3 Welding Capabilities

The PowerTIG 250EX is capable of welding various metals and thicknesses:

Image: Minimum and maximum welding capabilities for TIG and Stick processes.

• TIG Welding:
• Weld steel to a maximum of 1/2" single pass, 1+" multi-pass.
• Weld aluminum to a maximum of 1/2" single pass, 1+" multi-pass.
• Weld to a minimum of .007" steel.
• Weld to a minimum of .008" aluminum.
• Stick Welding:
• Weld with a minimum of 1/16" diameter electrode.
• Weld with a maximum of 3/16" diameter electrode.

Recommended Metals: Steel, Stainless Steel, Chrome Moly, Aluminum, Titanium, Copper, and virtually any weldable metal.

4. Setup Instructions

Proper setup is crucial for safe and effective welding. Follow these steps carefully.

4.1 Power Connection

Image: Rear panel of the PowerTIG 250EX, illustrating the AC 220V power input and circuit breaker.

1. Ensure the welder's power switch is in the OFF position.
2. The PowerTIG 250EX operates on 220V, 1 or 3 phase power. Connect the appropriate power plug (not included) to the welder's power cord.
3. Plug the welder into a dedicated circuit with adequate amperage capacity (refer to specifications for minimum circuit breaker requirements).

4.2 Shielding Gas Connection (TIG)

Image: The Everlast argon regulator, used for controlling gas flow.

1. For TIG welding, connect an argon gas cylinder to the Everlast Argon Regulator.
2. Connect the gas hose from the regulator to the gas inlet fitting on the rear of the welder.
3. Ensure all connections are tight to prevent gas leaks.

4.3 TIG Torch Connection

1. Connect the 18 Series TIG torch power cable to the appropriate DINSE connector on the front panel of the welder.
2. Connect the torch's gas hose to the gas outlet on the welder.
3. If using a water cooler (recommended for extended high-amperage TIG welding), connect the water lines from the torch to the water cooler, and the water cooler to the welder's built-in 240V receptacle.

4.4 Ground Clamp Connection

1. Connect the ground clamp cable to the designated DINSE connector on the front panel.
2. Attach the ground clamp securely to the workpiece or welding table, ensuring good electrical contact.

4.5 Foot Pedal Connection

Image: The Everlast 22K foot pedal, used for amperage control during TIG welding.

1. Plug the foot pedal cable into the corresponding receptacle on the front panel of the welder.
2. The foot pedal provides variable amperage control during TIG welding.

5. Operating Instructions

Familiarize yourself with the control panel and welding modes before beginning operation.

5.1 Control Panel Overview

The PowerTIG 250EX features color-coded controls for easy identification and adjustment of welding parameters. Refer to the labels on the front panel for specific functions such as amperage, pulse settings, AC balance, pre/post flow, and mode selection (TIG/Stick, AC/DC).

5.2 TIG Welding Operation

1. Select Mode: Choose TIG mode (AC for aluminum, DC for steel/stainless steel).
2. Set Amperage: Adjust the main amperage knob or rely on foot pedal control.
3. Gas Flow: Set argon flow rate using the regulator (typically 15-25 CFH).
4. Pre/Post Flow: Adjust pre-flow to purge air from the torch and post-flow to protect the weld puddle and tungsten as it cools.
5. HF Start/Lift Start: Select High-Frequency (HF) start for non-contact arc initiation or Lift Start for sensitive applications where HF interference is a concern.
6. Pulse Settings (Optional): If using pulse, adjust pulse frequency (up to 500 Hz), peak current, and background current as needed.
7. AC Balance (AC TIG only): Adjust for cleaning action on aluminum. Higher cleaning provides more oxide removal but less penetration.
8. 2T/4T Operation: Use the torch switch for 2-touch (press and hold for arc) or 4-touch (press to start, press to stop) operation.

5.3 Stick Welding Operation

1. Select Mode: Choose Stick mode (DC+ or DC- depending on electrode type).
2. Set Amperage: Adjust amperage according to the electrode manufacturer's recommendations.
3. Arc Force Control: Adjust arc force to prevent the electrode from sticking and to improve arc stability, especially in short arc conditions.
4. Insert the stick electrode into the electrode holder.
5. Strike the arc and maintain a consistent arc length and travel speed.

6. Maintenance

Regular maintenance ensures the longevity and optimal performance of your welder.

• Cleaning: Periodically clean the exterior of the welder with a dry, soft cloth. Use compressed air to blow out dust and debris from cooling vents.
• Cable Inspection: Regularly inspect all welding cables, torch hoses, and power cords for cuts, cracks, or damaged insulation. Replace damaged components immediately.
• Connections: Ensure all electrical and gas connections are tight and free from corrosion.
• TIG Torch Consumables: Inspect and replace tungsten electrodes, collets, collet bodies, and ceramic cups as they wear out.
• Gas Regulator: Check the gas regulator for proper function and leaks.

WARNING: Disconnect power before performing any maintenance or inspection.

7. Troubleshooting

This section addresses common issues you might encounter. For problems not listed here, contact customer support.

• No Power: Check power cord connection, circuit breaker, and ensure the welder's power switch is ON.
• No Arc (TIG): Verify ground clamp connection, gas flow, tungsten condition, and proper torch connection. Check for HF start or Lift Start activation.
• No Arc (Stick): Ensure electrode is properly inserted, ground clamp is secure, and amperage is set correctly.
• Poor Weld Quality: Check gas flow, tungsten type/preparation, material cleanliness, amperage settings, and travel speed.
• Gas Leaks: Check all gas hose connections for tightness. Listen for hissing sounds or use a leak detection solution.
• Overheating: Ensure cooling vents are clear and not obstructed. Allow the machine to cool down if the thermal overload indicator is active.

8. Specifications

9. Warranty and Support

For warranty information and technical support, please refer to the documentation provided with your purchase or visit the official Everlast Welders Canada website. It is recommended to register your product upon purchase to ensure full warranty coverage.

When contacting support, please have your model number (PowerTIG-250EX) and serial number ready.