Everlast Power Equipment Hurricane 220 MTS-C Stick Welder Instruction Manual

: August 7, 2024
: Everlast Power Equipment

Hurricane 220 MTS-C Stick Welder

“`html

Specifications

Model: Hurricane 220 MTS-C
Input Voltage: 120/240V
Output Current: DC 225A (MIG/AC/DC Pulse TIG/DC Stick/Plasma
Cutter)
Duty Cycle: Refer to product specifications for details

Product Usage Instructions

1. Getting Started

Unpack your unit carefully and inspect for any damages during
transit.

2. Connecting to Power Source

Follow the wiring information provided to connect your unit to
the power source. Ensure proper grounding.

3. Air Compressor Connection

If using a compressor, connect it as per the instructions and
set appropriate regulators.

4. Torch Setup

Ensure correct polarity and connect accessories as needed for
your welding or cutting process.

5. Wire Installation

If using MIG, install the wire and spool gun connection securely
following the guidelines.

6. Welding Preparation

Familiarize yourself with the front panel controls and
components for easy operation.

7. Welding Setup

Manually set up the unit for welding and cutting based on your
requirements.

8. Power Mode Configuration

Adjust the powerset mode according to the type of welding or
cutting you are performing.

FAQ

Q: What should I do if I encounter an error code?

A: Refer to the troubleshooting section in the
manual to identify and resolve any error codes displayed on the
unit.

Q: How do I shape the tungsten electrode for TIG welding?

A: Follow the guidelines provided in the manual
for tungsten selection and shaping to achieve optimal welding
results.

Q: What is the duty cycle of the Hurricane 220 MTS-C?

A: The duty cycle information for the product
can be found in the specifications section of the manual.

“`

Publish Date: DEC. 2023 EVHCANE220MTSC Rev. 1 USA/North America ©Everlast Power Equipment

DC 225A

Safety, Setup and General Use Guide For The Hurricane 220 MTS-C

AC/DC 225A

DC 160A
DC 40A
120/240V

FUNCTION: MIG/ AC/DC Pulse TIG/DC Stick/Plasma Cutter PURCHASE DATE: MODEL NAME: SERIAL NUMBER: OPTIONAL ACCESSORY SERIAL NUMBER:
Operator’s Manual

Welders, Plasma Cutters, Multi-Process

TABLE OF CONTENTS

SPECIAL NOTICE AND CALIFORNIA PROPOSITION 65 WARNING

CUSTOMER GREETING AND EXPLANATION OF PROCEDURES

WARRANTY AND CONTACT INFORMATION

SAFETY DISCLAIMER AND HF WARNING

SAFETY WARNINGS, DANGERS, CAUTIONS AND INSTRUCTIONS

GENERATOR OPERATION INFORMATION/DUAL VOLTAGE INFORMATION

SPECIFICATIONS

DUTY CYCLE INFORMATION

PRODUCT SPECIFICATIONS FOR HURRICANE 220 MTS-C

GETTING STARTED, UNPACKING YOUR UNIT AND INSPECTION

CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION

CONNECTION OF AIR COMPRESSOR, REGULATORS

TORCH POLARITY AND ACCESSORY CONNECTIONS

INSTALLING THE MIG WIRE AND SPOOL GUN CONNECTION

FRONT PANEL VIEW AND COMPONENT ID

REAR PANEL VIEW AND COMPONENT ID

CONTROL PANEL LAYOUT

GETTING READY TO WELD/GENERAL INFORMATION AND USE

SETTING UP THE UNIT FOR WELDING AND CUTTING MANUALLY

SETTING UP THE POWERSET MODE

2T/4T GENERAL OPERATION INFORMATION

EXPLANATION OF MIG FUNCTIONS AND TERMS

MIG TORCH COMPONENT BREAKDOWN AND PARTS/CONSUMABLES (NORTH 24 SERIES)

EXPLANATION OF TIG FUNCTIONS AND TERMS

TIG TORCH COMPONENT BREAKDOWN AND PARTS/CONSUMABLES (26 SERIES AIR COOLED TORCH)

TUNGSTEN SELECTION AND SHAPING

EXPLANATION OF STICK FUNCTIONS AND TERMS

PLASMA CUTTING WARNINGS

EXPLANATION OF PLASMA CUTTING FUNCTIONS AND TERMS

PLASMA CUTTING TORCH BREAKDOWN AND PARTS/CONSUMABLES(IPT 40 INNOTEC TORCH)

ADDITIONAL TORCH INFORMATION

TROUBLESHOOTING ERROR CODES

TROUBLESHOOTING GENERAL OPERATION

NOTICE: Product Specifications and features are subject to change without notice. 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 exhaustive in its content regarding safety, welding, or the operation/maintenance of this unit. Due to multiple variables that exist in the welding field and the changing nature of it and of the Everlast product line, Everlast Power Equipment INC. does not guarantee the accuracy, completeness, authority or authenticity of the information contained within this manual or of any information offered during the course of conversation or business by any Everlast employee or subsidiary. The owner of this product assumes all liability for its use and maintenance. Everlast Power Equipment INC. does not warrant this product or this document for fitness for any particular purpose, for performance/accuracy or for suitability of application. Furthermore, Everlast Power Equipment INC. does not accept liability for injury or damages, consequential or incidental, resulting from the use of this product or resulting from the content found in this document or accept claims by a third party of such liability.
WARNING! California Proposition 65 Warning:
This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)
Warning: Cancer and/or Reproductive Harm www.P65warnings.ca.gov
3

THANK YOU! We appreciate you as a valued customer and hope that you will enjoy years of use from your welder/plasma cutter multi-process unit. We work to please the customer by providing a well supported, quality product. To make sure that you receive the best quality ownership experience, please see below for important information and time sensitive details.
What to do right now:
1. Print your receipt from your confirmation email that should have been sent to you after your purchase and put it up for safe keeping. If you do not have one, contact us at 1-877-755-9353 (US customers) or 1-905-570-1818 (Canadian Customers). You will need this if anything should ever happen for original owner verification (if bought as a gift, original receipt will still be needed, or explanation sent to Everlast).
2. Read this manual! A large number of tech and service calls are a result of not reading the manual from start to finish. Do not just scan or casually peruse this manual. There are different features and functions that you may not be familiar with, or that may operate differently than you expect. Even if you have expertise in the field of welding, you should not assume this unit operates like other brands or models you have used.
3. Carefully unpack and inspect all items immediately. Look for missing or damaged items. Please report any issues within 48 hours (72 hours on weekend or holidays) of receiving your product,. Take pictures if you are able and contact us at 1-877-755-9353, ext. 207 if any issue is discovered between 9 am and 5 pm Eastern Time M-F (US customers) or at 1-905-570-1818 (Canadian Customers) between 9am and 4 pm weekdays except on Fridays when hours are from 9 am to 12pm Eastern. If outside of the US or Canada, contact your in-country/or regional distributor direct at their service number.
What to do within the next 2-3 days:
1. Make sure your electrical system is up to date and capable of handling the inrush and rated current of the unit. Consult and use a licensed and knowledgeable electrician. If you have downloaded this manual in expectation of delivery, get started now.
2. Make sure this machine is plugged in, turned on, and tested with every process and major feature, checking for proper function. You have a 30 day period to test and thoroughly check out the operation of this unit under our 30 day satisfaction period. If something is wrong, this policy covers shipping on the unit (30 day satisfaction policy applies to the USA only for the 48 lower states and D.C., territories and provinces are excluded) or any incidental parts that may be needed to resolve any issue. After this 30 day period, if you find something wrong with the unit, you will not receive the benefit of free shipping back and forth to resolve this issue. Your unit is still covered under the 5 year parts/labor warranty, but shipping is covered by the customer after the 30 day period is over. The first 30 days of operation with any electronic item is the most critical and if any issue will happen, it will often happen during this time. This is why it is very important that you put this unit to work as soon as possible. Any issue should be reported within 48 hours (72 if on the weekend or holiday). Everlast will not be liable for any shipping after that time.
What to do within the next 30 days:
Visit our website (US customers). Go to www.everlastwelders.com. Navigate to the resources tab and to the “product registration” page to register your product. While keeping your receipt/proof of purpose is still required for verification of ownership, registering will help us keep your details straight and establish a chain of ownership. Don’t worry, though, your warranty is still valid if you can’t do this. Remember: Always keep your receipt even if you register. You may want to staple a copy to your manual.
What to do if you have a warranty issue or problem with the unit:
1. Unplug the unit. (Also do this before any maintenance or cleaning is done.)
2. Do not attempt a self-repair until authorized by an Everlast representative. This does not include performing routine maintenance such as point gap adjustments or regular internal cleaning. Any third party repairs are not covered under warranty, and can further damage your unit.
3. Within 24-48hours, (or by the next working business day) you must contact U.S. tech support at 1-877-755-9353 ext 207(U.S. hours are 9 am to 5pm Eastern for tech support and 9 am to 5 pm Pacific for the business/sales office). If you are in Canada contact 1-905-570-1818 (Canada hours are 9am to 4pm M-Th, 9am to 12pm Fri). Although phone contact is preferred to establish a warranty claim, you may send an email to tech@everlastwelders.com (US) or mike@everlastwelders.ca (Canada) along with your contact information and brief explanation of the issue and ask for a follow up call. If you contact us via phone, and you do not reach a live person, please leave a brief message with the nature of your problem and your contact information. You should expect a call back within 24 hours. It is also a good idea to follow up the message with an email.
4. Be prepared with as much information as possible when you talk with a tech advisor, including a details of the failure, settings, and application of the unit. NOTE: A Proof-Of-Purchase (receipt) is required before returning the unit for warranty or before warranty parts can be sent to you.
5. Keep in mind that, you may be asked to check a few basic things. Before you call, having a screwdriver and volt/ohm meter at hand is a good idea and will save time. Many issues can be resolved over the phone. If the issue cannot be resolved over the phone/email, you may be given an option to return the unit, or have a part shipped to you, at Everlast’s discretion. Keep in mind, you may be asked questions that seem basic, or elementary to your knowledge base. These are not meant to question your knowledge, but rather to make sure nothing is overlooked. However the tech chooses to proceed, please cooperate with the process, even if you think you know what the cause or issue is. You may be asked to check something or open the unit during the diagnosis. This does not void the warranty! Opening the unit is a part of routine maintenance and cleaning. This is an important step. The willingness of the customer to work with tech support can save lots of time and accelerate the warranty process. For 4

warranty to be honored, you will need to make sure that you follow these guidelines. Units that are returned without an RMA (issued by the tech support department) may not be repaired under the warranty agreement and you may be charged for the repair and can result in a delayed repair as well.
What to do if you need setup help, guidance, weld issue diagnosis or have general product compatibility questions. Call us at 877-755-9353 ext. 204 for welding guidance and general welding issue diagnosis. Or email performance@everlastwelders.com with the basic issue you are having, along with your specific settings, and welding application.
Hey…wait, what is my warranty?
Warranties and service policies and procedures vary from country to country and are maintained and supported by the regional or in country distributor of Everlast welding equipment.
USA Customers Only: For full details on the 5 year parts and labor warranty, 30 day satisfaction policy, terms of sale, and how to proceed with a warranty claim, please visit: https://www.everlastgenerators.com/standard-warranty. Accessories are covered by a separate warranty and detailed information can also be found at the link above. Canada Customers Only: For full details on the 3 year parts and labor warranty, terms of sale, and related policies and procedures, please visit: https:// www.everlastwelders.ca/terms.php.
Who do I contact? USA Technical Support:
Email: tech@everlastwelders.com 1-877-755-9353 ext. 207 9am-5pm Eastern (Closed holidays) Monday-Friday
USA Welding Support and General Product Information:
Email: performance@everlastwelders.com 1-877-755-9353 ext 204 9am-6:30 pm Eastern (Closed holidays) Monday-Friday
USA Sales and Main Office:
Email: sales@everlastwelders.com 1-877-755-9353 ext 201 9am-5pm Pacific (Closed holidays) Monday-Friday
Canada Technical Support:
Email: mike@everlastwelders.ca 905-570-1818 9am-4pm Eastern Monday- Thursday 9am-12pm Eastern Friday
Canada Sales and Main Office:
Email: sales@everlastwelders.ca 905-570-1818 9am-4pm Eastern Monday- Thursday 9am-12pm Eastern Friday
Other Countries and Regions:
Visit the U.S. Website @ www.everlastwelders.com and click on the flag of the country or region represented that is closest to you. If your country or region is not found, call the U.S. office at 1-650-588-8588 between the hours of 9am to 5pm Pacific, Monday through Friday.
5

Safe operation and proper maintenance is your responsibility.
Everlast is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and maintenance of your Everlast product, it is no substitute for observing safe welding practices and behavior. Safe welding and related cutting operations require basic knowledge, experience and ultimately the exercise of common sense. Welding does significant hazards to your health and life! Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even life depends upon it.
WARNING! If you do not have proper knowledge or capability to safely operate this machine, do not use this machine until proper training has been received!
While accidents are never planned, preventing an accident requires careful planning. Stay alert!
Please carefully read this manual before you operate your Everlast unit.
The warranty does not cover damage or harm created by improper use. neglect of the machine or failure to follow safe operating practices.
NOTICE:
Welding and cutting operations may generate undesirable High Frequency (HF) and EMF energy. This can interfere with surrounding electronic equipment such as computers, routers, CNC equipment, televisions, radios, fluorescent lighting etc. If disturbance in surrounding electrical and electronic equipment is noted, consult a licensed electrician to help properly ground surrounding equipment to limit the interference. This machine may cause GCFI and ground fault outlets to malfunction. This unit is designed to be operated on a dedicated, properly grounded circuit.
6

Safety Warnings, Dangers, Cautions and Instructions
NOTICE. This unit manual is intended for users with basic knowledge and skillset in welding. It is your responsibility to make certain that the use of this welder/plasma cutter is restricted to persons who have read, understand and follow the warnings and instructions in this manual. If you or the operator needs further instruction, contact Everlast welding support at 1-877 755-9353 ext. 204 or seek qualified professional advice and training.
WARNING! High Frequency (HF) energy can interfere with the operation of pacemakers and can damage pacemakers. Consult with your physician and pacemaker manufacturer before entering an area where welding and cutting equipment is in operation and before using this welder/plasma cutter. Some pacemakers have limited shielding. Alert any users or customers of this potential problem.
WARNING! Use approved safety glasses with wrap around shields and sides while welding and working in the weld area or serious eye damage or loss of vision may result. Use a grinding shield in addition to the safety glasses during chipping and grinding operations.
WARNING! When welding always use an approved welding helmet or shielding device equipped with at least an equivalent of a shade 9 or greater. Increase the shade number rating as amperage increase over 100 amps. Inspect helmet for cracks in lenses and in the helmet. Keep lens covers in good condition and replace as necessary.
WARNING! Welding/cutting operations carry inherent risks which include but not limited to possible cuts burns, electrical shocks, lung damage, eye damage and even death. Take all appropriate measures to use proper Personal Protective Equipment (PPE). Always use leather welding gloves, closed toe (preferably reinforced or steel toe leather shoes, and long -sleeved flame resistant clothing (i.e. denim). Do not wear Poly/Nylon blend materials.
DANGER! Welding/cutting poses shock and electrocution risks. Keep this welding equipment dry. Do not weld in the rain or where moisture accumulates. Use dry, rubber soled shoes, gloves and clothing when welding. Do not rest or contact work clamp (ground) when welding. Keep all parts of the body insulated from the part being welded when possible. Do not touch terminals or connections while the unit is on. Consider all parts to be “live” at all times even if no live work is being performed. Do not use frayed welding cables.
CAUTION! Fires are possible but also preventable while welding. Always remove flammable rags, papers, and other materials from the weld area. Keep rags stored in an approved flame proof canister. Keep a fully charged fire extinguisher at hand. Remove any fuels, oils, paint, pressurized spray cans, and chemicals from the weld area. Make sure any smoke/fire detectors are function properly. Do not weld on tanks, drums or barrels, especially if pressurized or sealed. Do not weld on any container that previously held fuel or chemicals. Make sure the weld area is clear of flammable materials such as grass or wood shavings solvents and fuels. Do not wear frayed or loose clothing. Visually inspect and recheck the work area after welding looking for smoldering debris or flames.
WARNING! Welding gas cylinders are under high pressure. Keep all gas cylinders upright and chained to a cart or held safely in a safety holding pen. Never transport gas cylinders in an enclosed car van or other vehicle. Transport gas cylinders securely. Keep all cylinders capped while not in use or during transport. Replace the cap on the cylinder when it is going to be more than 24 hours before use. Do not use or attempt to repair faulty regulators. Never weld on gas cylinders. Keep gas cylinders away from direct sparks.
7

Safety Warnings, Dangers, Cautions and Instructions
DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these hazards are immediate while others are cumulative in their effect. Do not weld in enclosed spaces or in areas without adequate ventilation. Fumes and gases released in the welding and cutting operations can be toxic. Use fans or respiration equipment to insure adequate ventilation if you are welding in a shop or garage area. Do not weld on galvanized metal under any circumstance. You may develop metal fume fever. Symptoms are similar to lulike symptoms. Seek medical advice and treatment if you are exposed to galvanized welding fumes.
If you experience any eye burning, nose or throat irritation while welding, these are signs that you need more ventilation.
If you feel these symptoms:
· Stop work immediately and relocate work area with better ventilation.
· Wash and clean your face and hands.
· Stop work completely and seek medical help if irritation persists DANGER! Never use brake cleaner or any chlorinated solvent to clean or degrease metal scheduled to be welded or other related equipment in the area being welded. The heating of this cleaner and its residue will create highly toxic phosgene gas. Small amounts of this vapor are harmful and can lead to organ failure and death. If degreasing of a part is necessary, use Acetone or an approved pre- weld cleaner. Use the proper personal protective equipment (PPE) when handling any cleaners/solvents. DANGER! People with pacemakers should consult a physician and pacemaker manufacturer before welding. There is a potential for damage or serious malfunction resulting in death. High Frequency energy (HF)/Electromagnetic Fields generated during welding can interfere with pacemaker signals, even permanently damaging it. Some pacemakers offer some shielding, but restrictions regarding amperage and HF starting of welding arcs may be placed upon the individual. Warn all potential bystanders that they should exit the work area if they have a pacemaker or similar medical equipment before welding. Severe electrical shock leading to injury or death may occur while using the plasma cutter if the user becomes part of the circuit path. While the Amp output of the plasma cutter is limited, the unit may produce an OCV of 300V or greater. Consult with a Physician if a pacemaker is expected to be implanted.
DANGER! Never defeat or modify any safety guards or shields. Keep all safety covers and shields in place.
Never place your fingers in or near a fan shroud or insert any object into the fan(s).
DANGER! Do not supply more than 100 PSI to the air-pressure regulator supplied with this machine. If you do, the regulator may leak or explode, causing severe injury or death. Use a separate regulator mounted at the air-compressor to control supply air pressure. Never use an air compressor without a separate compressor mounted air regulator!
8

Safety Warnings, Dangers, Cautions and Instructions
CAUTION! Trip Hazards exist around this unit. Cords, cables, welding leads and hoses pose a trip hazard. Be aware of their location and inform others of their location. Tape and secure them so they will stay out of high traffic areas.
CAUTION! Welded metal can stay hot long after welding is completed. Burns may occur. Always wear gloves or use tongs/pliers when handling welded or cut metal. Remember the heat from the metal may catch other material on fire. Always have a fire-proof area ready to place welded components until they fully cool. Use soap stone or a metal marking marker to label the metal as “HOT” to serve as a reminder to all present in the area. CAUTION! Welding and cutting operations generate high levels of ultraviolet (UV) radiation which can burn and damage skin and eyes. The intensity is so high that exposed skin and eyes can burn in a few minutes of exposure. Minimize direct skin and eye exposure to this intense form of radiation by using proper PPE and sun screen where appropriate. CAUTION! Do not allow bystanders. Do not allow others without proper Personal Protection Equipment (PPE) suitable for welding to stand in the welding area or to observe welding and welding related activities. If protection is not readily available, use a welding screen to separate the welding area from the rest of the area. If no protection or screen is available, physically exclude them from the welding area by a wall or other solid divider. Keep all pets and young children away from the welding area. CAUTION! Electromagnetic Fields can be generated by this unit and radiate into the work place. The effect of EMF is not fully known. Exercise caution when welding by: NOT draping welding leads (guns/cables) over your shoulders or arms, NOT coiling them around your body, NOT inserting yourself directly between the cables, and by NOT contacting the unit while welding. DO keep the work clamp connected as close as possible to the area of the weld and directly to the object being welded whenever possible. DANGER! Never touch connectors or fittings while this machine is turned on. Keep all safety covers in place when not in use. Never remove or replace the plasma consumables while the machine is turned On. Even though the torch is equipped with a “parts-in- place” safety disconnect, it is possible that overheating of the torch, excessive wear or damage to the consumables may cause this feature to malfunction. Make sure the brass safety cut out pins on the torch head remain in good repair and that the spring loaded function remains operational and keeps them fully extended when the torch cap is removed. The Open Circuit Voltage (OCV) while in plasma mode may exceed 300V. This is enough to cause burns, injury severe electrical shock, injury and instant death.
9

Important Information: Operating this unit with a generator or other off-grid service.
Minimum Required Surge Watt Rating: 8500W Required THD Rating: 5% or less
This multi-process unit should only be operated on a generator certified by its manufacturer to produce clean power. Clean power is equivalent to the quality of household or shop/garage type power. This means the generator must have 5% or less total harmonic distortion (THD) of the Sine wave. If you are unsure of the power output type of the generator, contact the manufacturer of the generator for verification. Do not operate on square wave or modified square wave generators or converters/inverters or damage or malfunction may occur. Damage caused by running this unit off of “dirty” power or modified sine waves may not be readily apparent and can be cumulative in nature. However, damage may present itself immediately. The damage caused by running this unit on “dirty” power usually leaves internal tell-tale signs and damages specific parts.
NOTICE! Operation of this unit with generators not rated by its manufacturer as providing clean power (5% or less THD) is prohibited and will void the warranty. Operation with modified sine wave, or square wave generators and inverters/converters/UPS that do not produce “sine wave” output is prohibited and doing so will also void the warranty. Use only with generators/inverters/converters that produce an equivalent type of sine wave used in shops, homes and “shore” type systems. The generator manufacturer determines this rating, not Everlast. Do not assume that a name brand generator, or a “new” generator automatically provides clean power. Price paid does not guarantee a clean power output either. There are multiple brands at various price points capable of producing clean power. Investigate this before purchasing a generator. The manufacturer will usually state that a unit is clean power in the advertising information and will state actual THD. If the manufacturer does not state it, contact the manufacturer directly for a statement concerning actual THD.
WARNING! Do not start or stop the generator with the unit switched on. Never use the generator in ECO mode or an auto-idle mode. Even with a clean power rated generator, this action can damage the unit. Turn the unit on only after full generator R.P.M. has been achieved and the engine is sufficiently warmed up. Closely monitor generator fuel level so that the engine R.P.M doesn’t drop or completely shut down with the unit plugged in. For best practice: do not start or stop the generator with this plasma cutter plugged in, even if it is turned off. Unplug the unit before shutting down the generator.
If using with a welder/generator, make sure the manufacturer has determined that the generator portion produces a clean sine wave. Many older models do not. Some newer models use “divided” power between welding and generating and cannot supply the full power to the unit unless the fine current control knob is turned to maximum. Do not use this unit with such welder/generators unless the Power/ fine current control is turned to 100%. Some welder generators do have a separate alternator for generating power. If this is the case, be sure not to weld or load the machine while this unit is in use.
WARNING! Always make sure any generator or welder generator is properly wired and grounded, according to local and national code. Ground the machine per the generator manufacturers instructions to meet code requirements. Improperly grounded generators may damage the machine and more importantly may cause severe injury or death.
Dual Voltage Single Phase 120/240V Operation:
This unit can be used with either single phase 120V or 240V output. Output will be reduced automatically when operating on 120V. However, for the higher voltage (since the standard of 240V is nominal and actual voltage may vary somewhat), the unit may be used with single phase 208V if the voltage does not drop below 205V. If using this unit on 208V, duty cycle and display accuracy may be affected. Rated and Inrush Amperage will rise proportionately as well. If you decide to use this machine on 208V, before installing permanently, have an licensed electrician monitor voltage fluctuations, particularly under load and during peak use times. If the voltage remains constant, and steady without dropping below the 205V threshold, this unit may be used. Damage caused by using on undervoltage power sources is not covered by the warranty. Always be aware of the voltage output and the quality of the power source being used. Voltages below 220V may result in MIG wire speed calibration issues that cause the wire speed set to be higher than actual output at the feeder.
REAR OUTLET WARNING!
If equipped, never use the electrical power outlet on the back of this machine for anything other than powering an Everlast brand water cooler. This is a special outlet designed to produce 240V with limited amperage draw. No other device or brand should be used in conjunction with this unit’s outlet. This outlet is designed to supply 240V only. Do not attempt to modify, or change this outlet for use with anything else other than an Everlast brand water cooler designed for 240V operation. Severe damage, fire or injury may occur if other devices or other brand equipment is connected. Not for use while operating on 120V!
10

Specifications
Duty Cycle Duty Cycle is simply the amount of time out of a 10 minute period in which the unit can operate. For example, if this unit has a duty cycle of 25% at maximum rated output means that the unit can be operated for 2.5 minutes out of 10 minutes at the maximum rated Volt/Amp settings. The rated operation time may be continuously, or intermittently during the 10 minute period of time. This rating standard (United States) is based on a maximum ambient temperature of 40 C. Operating above this point, or at lower temperatures with high humidity may reduce the duty cycle rating. Of course, the duty cycle may increase somewhat as ambient temperature drops. Regardless, this unit’s duty cycle is not controlled by a timer. Rather, this unit is equipped with a heat sensor located on a heat sink near the critical power components of the plasma cutter. If the operating temperature of the unit is exceeded, welding output will stop and an over-temperature warning light/error code will be displayed on the panel. If a duty cycle event is registered, do not turn the unit off! Allow the plasma cutter to continue to run at idle for at least 10-15 minutes until the temperature has fallen enough to reset the sensor and over-temperature warning light. Even if the unit resets, allow the unit to cool for a full 15 minutes, or the duty cycle will be more quickly triggered since the unit resets just below the heat threshold. The fan(s) must continue to run for a full 15 minutes to cool the unit properly after the duty cycle shut down has occurred. After 15 minutes of cooling, you may switch the unit off if you are finished welding. If the unit does not automatically reset after 15 minutes, turn the unit off. Wait for 15 seconds before turning the machine back on. If the unit does not reset, contact technical support for further advice and assistance. As a best practice, when you have completed welding and have been welding continuously for extended periods of time, keep your unit on for 10 additional minutes without welding to allow it to cool. Even at a setting where duty cycle equals 100%, this does not mean that the unit could not theoretically overheat in the 11th minute. Although this is not likely, the point is that a rating of 100% duty cycle, no matter the output is not a rating based on an infinite amount of time. The set rating standard of 10 minutes means that the unit should not go into an overheat cycle when used within the stated parameters until the 10 minutes is up. The intentional and/or repeated triggering of the duty cycle protection feature on this unit will shorten the lifespan of the unit’s electronics and can weaken internal components. The effect of overheating your unit repeatedly takes a cumulative toll on the unit. NOTICE: These units are tested by an international and independent certifying agency for their ability to sustain the claims of duty cycle, under lab induced conditions which are typically more stringent than average shop conditions.
11

Specifications
BREAKER SIZING AND WIRING REQUIREMENTS Before installation of this unit in any facility, always consult a licensed local electrician familiar with the requirements of properly wiring a plasma cutter into the electrical supply. Refer to the National Electric Code (NEC) and local codes. If needed, refer the electrician to Article 630 of the NEC during consultation to determine proper application and wiring needs. Use the I1MAX and the I1EFF ratings listed above to determine the proper breaker and conductor (wire) sizing required. Everlast plasma cutters are designed around use in industrial wiring applications and are intended to be used with modern electrical systems. Household wiring may need to be upgraded before this plasma cutter may be installed. Additional HF protection and isolation may be needed if this plasma cutter interferes with the operation of electrical/electronic equipment. IMPORTANT: Do not modify this unit’s wiring, power plug or conductors. This unit meets the standards for conductor sizing on the power cable and takes into account power cable length, duty cycle and rated current.
NOTICE: POSSIBLE HF INTERFERANCE FROM THE INVERTER AND WHAT TO DO IF IT OCCURS If any electrical disturbance is noticed as a result of the high frequency interference that is possible with the operation of the inverter switching and operation, the HF service bolt should be connected directly to a 12 gauge wire that is bonded directly to an outside copper ground rod driven into moist soil. Additionally, all metal items including any metal frame or sheeting of the building should be connected and grounded to separate copper ground rods driven into the ground at 10 foot intervals around the perimeter of the building. This includes items such as tables, carts, rack material, metal surrounds, etc. that may act as “antenna” to radiate/absorb HF energy. Additionally, all cords and welding leads should be twisted together and run directly to the work without coils or excess cabling. Normally, this will not be required, but it is supplied in the case of any interference that may be observed. This is usually observed in older or non standard installations where grounding and ground isolation is a problem.
NOTICE: DO NOT USE WITH DUAL SHIELD OR FLUX CORED OPERATION WITH GAS (FCAW-G)
This unit is not designed or recommended for use with Dual shield type welding. This is considered a heavy industrial process that this unit does not have typically enough output in voltage, amperage and duty cycle to sustain welding at recommended settings. Most dual shield applications use welding machines that are 300A and over. The synergic feature of the unit does not support dual shielded operation either. The Flux-Cored mode is a gas-less type of operation and does not include a gas shield function.
WARNING!
This unit is not designed for Air Carbon Arc Gouging/Cutting or for Plasma Gouging or Plasma scarfing operations. Do not this unit for these applications. It is not designed to sustain the high volt and long arc characteristics needed for Carbon Arc or Plasma gouging use.
12

Specifications

Hurricane 220 MTS-C Product Specifications

Construction Type

Inverter (IGBT based, Digital Control)

Input Voltage

120V OR 240 V (± 10%) 50/60 Hz Auto-Adjusting

Phase

1 Phase 50/60Hz

I1MAX Current Rating (Inrush Amps)

120V: 28A 240V: 31A

I1EFF Current Rating (Rated Amps)

120V: 17A 240V: 16A

OCV

64V MIG/ Stick; 250V Plasma

MIG Duty Cycle @ Maximum Output (Rated at 40° C/104 F) *

120V: 35% @ 125A, 60% @ 100A, 100% @ 80A 240V: 25% @ 225A, 35% @ 200A, 60% @ 160A, 100% @ 130A

TIG Duty Cycle @ Maximum Output (Rated at 40° C/ 104°F)

120V: 60% @ 125A, 100% @ 100A 240V: 35% @ 225A 60% @ 200A, 100% @ 160A

Stick Duty Cycle @ Maximum Output (Rated at 40° C/104 F )*

120V: 35% @ 100A, 60% @ 80A, 100% @ 60A 240V: 60% @ 180A, 100% @ 140A

Plasma Duty Cycle @ Maximum Output (Rated at 40° C/104 F )*

120V: 60% @ 25A, 100% @ 20A 240V: 60% @ 40A, 100% @ 30A

MIG Output Range V/A (DC Output Only)

120V: 15.5-20.25V/ 30-125A 240V: 15.5-25.3V/ 30-225A

TIG Output Range V/A (AC/ DC output)

120V: AC 10.8-15V/20-125A, DC 10.5-15V/10-125A 240V: AC 10.8-19V/20-225A, DC 10.5-19V/10-225A

Stick Output Range V/A (DC Output Only)

120V: 20.4-24V/10-100A 240V: 20.4-26.4V/10-160A

Plasma Output Range V/A (DC Output Only)

120V: 88V-90V/20-25A 240V: 88-96V/20-40A

MIG Wire Feed Speed:

120V: 60-400 IPM 240V: 60-600 IPM

MIG Inductance

0-100%

MIG Burn Back Time

0-2 Seconds

MIG Spot Time

.5-15 Seconds

MIG Stitch Time

0-15 Seconds

MIG Wire Size Handling Capability

.023″-.045″ (with optional drive rolls, liner and contact tip sizes)

MIG Drive Roll Sizes Included (2 each for 4 roll system)

.030″ / .035″ (.8mm / .9mm) V-Groove for MIG .030″ / .035″ (.8mm / .9mm) Serrated Groove for Flux-Core

MIG/TIG Pre Flow Time

0-10 Seconds/0-10 Seconds

MIG/TIG/Plasma Post Flow Time

0-10 Seconds/0-10 Seconds/5-45 Seconds

TIG AC Frequency

20-200Hz

TIG AC Balance

30-75%

TIG Upslope Time

0-10 Seconds

TIG Downslope Time

0-10 Seconds

TIG Pulse Frequency

.5-150Hz

TIG Pulse Time On

3-95% of Welding

TIG Pulse Amps

5-95% of Welding Amps

Stick Hot Start Time

0-2 Seconds

Stick Hot Start Intensity

0-100% above set Amperage )

Stick Arc Force

0-100% above set Amperage

Stick 6010 Capable

Yes

Plasma Start Type

Blow-back style, with Pilot Arc. (Non High frequency)

Recommended Plasma Air Pressure

65 to 75 PSI while cutting. Max. supply pressure: 90PSI

Recommended Minimum Compressor Size

30 Gallon with 5.3 CFH or greater @ 90 PSI

MIG Gun Type/Length/ Connector Type

Innotec 15AK Series 12.5 ft/ 4m with Euro Quick Connect

250A Work Clamp with Cable Length

6.5 ft (2m) DINSE 35/50mm2 (1/2 nom. dia.)

250A Stick Electrode Holder Length

9.5 ft (3m) DINSE 35/50mm2 (1/2″ nom. dia.)

Plasma Torch Type and Length

Innotec iPT 40, 15 ft.

Power Cable Length

6.5 ft (2m)

Power Plug Type for Single Phase Operation 240V

NEMA 6-50P (Standard 240V Welder Type)

Cooling Type

Full Time, High Volume Fan(s)

Dimensions (Approximate without handles attached)

15.7 H X 11.1″ W X 27.5″ L (400mm X 280mm X 700mm)

Weight (Bare Unit with Cord and Handles Attached)

96lbs.

Ingress Protection Rating

IP21S

Setup Guide
WARNING!
Do not leave more than one torch connected at the same time. Leaving multiple torches connected at the same time may result in accidental arcing, and personal injury, or shock. Machine damage may also occur. Do not touch the connector terminals while the unit is on. All terminals have the potential to be live when any process is used. Keep any terminal covers in place for safety. Before changing processes: 1) Remove the torch in current use. 2) Select the new process desired. Observe the recommended polarity suggested on screen or in the manual. 3) Shut down machine. 4) Connect the torch associated with the desired process. Double check polarity. 5) Make sure the proper gas is connected to the rear of the unit. If it is plasma, try to adjust air pressure up before turning
on machine or error code will be present when machine is turned back on. If plasma is selected before air pressure is connected, and error code will be displayed. 6) Turn the machine on and check for leaks.
14

Setup Guide

Getting Started

UNPACK YOUR UNIT. Upon arrival, you will need to completely unpack your welder, and check things over. This is a time sensitive matter. Do not delay or hold the plasma cutter unopened in the box. First, make sure the unit is opened from the top. Be careful with using knives and sharp objects so you won’t cut cords and cables inside the boxes. Lay all items out and inspect them. You should have the following in your box: 1. Welder/Plasma Cutter Unit. 2. Air-Regulator with built in water trap/particulate filter. 3. Floating Ball Regulator for MIG/TIG 4. 24 Series MIG Gun/Torch. 5. 250A Work Clamp (approx. 9.5 ft with cable). 6. 250A Stick Electrode Holder (approx. 9.5 ft with cable). 7. Consumable Starter Kit for Plasma and Misc. Parts Bag(s). 8. iPT40 Plasma Torch. 9. 240V to 120V power cord adapter. 10. 26 Series 12.5 ft air- cooled rigid neck TIG torch 11. Foot pedal

your machine without any accessories installed except for air compressor and air pressure. Allow the unit to idle for 15 minutes. Check and observe operation of knobs, controls and buttons, cycling through each as required. Make sure the fan is running at full speed. After the test is completed, turn the unit off, connect the torches and cables. Then, conduct live testing of all the functions and features of the machine. For testing and cutting make sure work clamp is connected directly to the part being welded (work). Check for arc starting and stability. If you are testing the unit on 120V, the cutting arc may not be stable unless you have purchased the optional .6 or .8mm consumables listed on the torch page in this manual. If any welding or cutting problems are observed and they persist, contact Everlast. See page 5 for more contact information. NOTICE: Cosmetic damage claims after 30 days will not be accepted, unless Everlast is contacted and informed of such delay and reason for such a required delay (i.e. Overseas in deployment).
NOTICE: This unit includes one additional .030″ MIG contact Tip (it may also include a .040″ tip for specialty wires) and no other consumables for MIG. These

INSPECT AND ASSEMBLE YOUR UNIT.

are available direct from Everlast, online from other sources and are also

available locally for the 15 series MIG gun at many places that sell welders

Hurricane 220 MTS-C

and welding supplies. This unit does arrive with a basic plasma consumable starter kit, designed to get you only through a few days of plasma cut-

10 4 11

3 2

ting. You should have 5 (pipe/non-shielded) cutting tips and electrodes. You will need to purchase a more extensive kit soon after receiving and using your unit. These consumables are also available direct from Everlast, from other online sources, and from many local stores that sell welding and plasma cutting equipment. If you don’t order extra consumables soon after you receive this unit, you may run out more quickly than you expect.

When you receive your package, inspect the unit for damage. Check for the presence and general condition of the accessories. Some slight rubbing or chaffing of some of the accessories may be present, but this is considered normal. Most notably, the MIG and Plasma torches may appear to be used or fired. This is because it has been live tested in the factory for proper operation before putting into the box. If any item is damaged or missing, please inform Everlast within 72 hours of product receipt. See pages 4 and 5 for more details. Assemble the front, middle and rear handles with the supplied screws. Use a hex key to tighten the socket head cap screws. (Screws may be found in the consumable bag if they are not preinstalled in the case.) IMPORTANT! Do not overtighten the screws. If desired for proper fitment or for space saving, the unit may be used without the handle. However, install the screws and tighten them to the cover anyway. Do not leave them out. Be sure to reinstall the handle if the unit is to be carried or lifted. Do not lift from any other point on the machine or damage may occur.

This kit contains stand-off type, non-shielded consumables that are sized for the maximum Amp operation of the unit are designed for stand-off cutting. Lower Amp operation, gouging or drag cutting will require the purchase of additional consumables (See torch parts page for amp ratings and sizes). Additionally, some miscellaneous parts may be found together with the consumable kit which may include fasteners, brackets and . If you think you are missing a needed part, check the consumable kit bag and box before calling Everlast for replacement. If you are missing parts, call 1 -877-755-9353 ext. 206 for help (Only in the USA, for other areas, contact the distributor in your region).
IMPORTANT:
Even though the unit features two separate gas input connectors, only one regulator is provided. Consideration should be given to purchasing a sec-

ond, optional gas regulator to keep from requiring the regulator to be

POWER UP AND TEST YOUR UNIT. You will need to fully test the unit as soon as possible. Within 72 hours

swapped each time to the MIG and TIG processes are changed over.

after receipt of the unit, be sure to have every thing you need at hand to

test the unit. Make sure the correct input power, wiring, and plug configu-

ration is being used. Make sure you have the regulator and air compres- GIVE YOUR UNIT SOME SPACE TO COOL.

sor installed (See following section). If you do not have them installed, when you select the plasma function you will immediately receive an error code of “E 06″ because air pressure is low/disconnected. Then, power up

This unit needs room to cool itself and maintain proper duty cycle. Place the unit in a place that will allow 18” from all sides to allow for proper cooling. This welder/cutter combination unit pulls air in from the rear, and

Setup Guide

Getting Started

pushes it through the unit’s heat sinks to cool the electronics. The air is

then exhausted through the front panel and side louvers of the unit. If any of sides is blocked or restricted, the duty cycle will be reduced, and over-

Standard Plug Configuration 1 Phase 240V

heating will occur, leading to possible damage if the restriction is severe

enough. Never attempt to restrict air flow by attaching filters to the vents.

Never modify the fans or circuits related to cooling.

CONNECT YOUR UNIT TO POWER. Your unit has been shipped with a NEMA 6-50P plug. This is the standard plug used for 240V 1 Phase welders and plasma cutters in North America. For single phase 240V connection, select a NEMA 6-50 Receptacle for operation with this unit. (Other regions/countries vary). A neutral is not used. In a dedicated circuit, the wire wires supplying power (the conductors and ground) are black, white and green. A red wire, which is traditionally used as a “hot” leg (power conducting wire) of power is not present in a three-wire 240V wire circuit of a plasma cutter. For plasma cutters, from the panel box, the Black wire serves as L1(Hot), White serves as L2 (Hot) and Green serves as G (Ground). A Red wire will not typically be used as a conductor in a welder circuit. No neutral wire is needed, so white is used as a “hot” conductor wire in this instance. It is recommended to either install a receptacle as close to the main panel as possible or install a subpanel cutoff as close to the outlet and welder as possible. Always follow local codes when making these connections. If you are using this unit in conjunction with a 240V air compressor, you must supply a separate, dedicated circuit for both. Do not share or piggy-back a circuit with this unit. When 120V operation is required, simply connect the supplied 240V to 120V pig tail adapter. This adapts the unit from the NEMA 6-50 Plug to the NEMA 5-15 Plug to allow the unit to be used with 120V input without further modification of the welder. No wiring or buss bar changes are required. Once the unit is plugged in, it will automatically detect the new power and boot up in 120V mode. To verify 120V mode, the display screen will reflect the power input mode with one of the center tree information boxes displaying “120V”. To change back to 240V input, shut the machine down, unplug the adapter, and reconnect to the 240V power supply. Turn the welder back on to reboot the unit back to 240V operation.

. NEMA 6-50P
240V to 120V Pigtail Adapter (Supplied)
NOTICE:
There are special rules centered around wiring service for a welding machine. The National Electric Code under Article 630 has developed specific regulations for wiring electrical service for welding equipment. These are different than for other types of service such as a stove or dryer in a household or even in a commercial application. You need to consult and/or employ a locally licensed electrician before installing this unit to make sure all national and local codes are followed. Do not wire connections for this machine if you are not qualified. Everlast is in no way liable for any damages caused by improper connection of this unit. Your welder should be operated on a dedicated branch circuit not far from an electrical disconnect box. Importantly, it should not share circuits with other shop or household items. Do not attempt to “adapt” existing circuits because conductor (wire) colors are different for welders with 3 wire configuration than for an appliance with 4 wire operation. (Unless adapting with an approved adapter when being powered with a “clean power” generator.) No neutral is used in a welder circuit. The white wire is a conductor in a single phase plasma cutter service. The red wire is not used. The input power cable conforms to North American standards for size, length, with consideration given to inrush amperage, rated amperage and duty cycle. Do not modify, or attempt to rewire your unit.
Selecting A Breaker and Wire Size
Select a breaker based off of the I1MAX rating of this unit. This is the maximum inrush current of the unit. The inrush is not a sustained current. The I1EFF rating of the unit is the maximum “rated” current of the machine. When combined with the length of the run from the main panel, this determines the conductor size. Refer your licensed, local electrician to Article 630 of the NEC and the specification page of this manual (or the specification grid printed on your unit) to select the correct breaker and wire size. A delayed trip breaker, or slow

Setup Guide

Getting Started

INSTALL THE AIR REGULATOR AND AIR COMPRESSOR.
NOTE: Connect the clear hose to the air inlet at the bottom rear and to the regulator. Use the couplings and hose clamps found in consumable/parts bag to connect the tubing to the regulator and fittings. If missing, contact Everlast. Make sure the air flow direction is correct according to the markings on the regulator. Do not overtighten the fittings. Lightly tighten the regulator securing nut to the bracket.
The male air quick coupling that is supplied with the unit is a 1/4″ industrial style connector. This connector is a common one in use in many small shops and home garages. Others may be substituted if this connector does not match the other connectors in use in the system. However, Everlast makes no provision for attachment of oversized couplings. The recommended minimum size of the air supply line is 3/8″, up to 25 foot. If a longer line is needed, consider upping the size of the air line to prevent air pressure loss. If a larger air line is needed, make sure you have the correct adapters to fit the fitting on the unit. A smaller fitting at the unit’s regulator/filter should not greatly affect flow, as long as the length of the restriction is kept to a minimum. The regulator comes in its own box in the packaging. It is fully assembled with the exception of a brass plug that is screwed into the middle opening onto the regulator. Usually this plug is installed, but due to the possibility of a change in manufacturing, the plug may be found in the consumable starter kit bag for the plasma cutter. To adjust the regulator: Pull up on the black cap until it clicks (approximately 1/8″). Turn the regulator clockwise to increase the pressure and counter clockwise to decrease the pressure. Snap the adjustment cap back down to lock the regulator into position.
Connect Air Regulator To Compressor And Unit.

4 5

2 Phillips

Tank Mounted Regulator
Air Dryer

What do I need to be able to plasma cut?
The unit comes with everything you need as far as a basic starter kit for consumables, torch and regulator. However, you will need to supply a few things on your own.
1. You will need a suitable air-compressor and at least 3/8″ supply line hose. 1/2″ supply may be required for long distances. The input side on the regulator is the standard industrial 1/4″ quick connect fitting. Suitable compressor sizes should follow recommendations found in the product specification recommendations. Oiless and pancake compressors are not suitable.
2. You will need to be able to regulate your pressure at the air compressor. Do not use the pressure switch on the air compressor to control the air pressure. A gate or ball valve installed on the air compressor is not enough. You will need an adjustable regulator which will control the air pressure at the tank. The regulator that you install on the unit is to be used to regulate actual cutting pressure. You need to be able to regulate the supply pressure down to 90PSI at the air-compressor.If you supply more than 100PSI to the cutter’s regulator, you may damage the regulator.
3. You will need a separate air-dryer. Moisture is the enemy of any plasma system and destroys consumable life and eventually torches themselves. The regulator/filter included with the unit is not sufficient to remove moisture from the system. It is designed to trap particulates and slugs of water created by the coupling/ decoupling process. A refrigerated system is not necessary. We recommend you look at the cartridge type systems that have replaceable elements for a budget alternative. If these are not available, consider having a replaceable paint-gun dryer mounted inline and monitor the moisture, and replace it often.
4. You will need additional consumables with different sizes to match the cut Amperage. The stock consumables are designed for use at the maximum amperage of the machine. The orifice in the plasma tip is specifically designed for a range of Amps. To see that range, check the plasma torch pages of this manual, and each tip diameter corresponds to a specified amp range. Lowering air pressure to try to compensate for lower Amps results in poor quality cuts and inconsistent arc behavior. Always match the consumable size to the Amperage being used. NOTICE: For direct on-the-metal drag cutting, use special shielded consumables are available for most of the Innotec® iPT series torches. However, limited drag cutting may be done under 30A with stock consumables, but consumable wear will be increased. Since Everlast does directly manufacture the plasma torches, every consumable configuration for every torch may not be stocked or available. For these or other special applications, consult OEM distributors of the iPT/PT/PTM series torches in the North American Markets.

Setup Guide

Getting Started

CONNECT YOUR UNIT TO THE CORRECT SHIELDING GAS.
What Shielding Gas Should Be Used?
The Hurricane 220 MTS-C is a synergic unit which incorporates the type of gas and metal wire being welded with as a base to make accurate “PowerSet” settings. It is important to pay attention to the type of gas used while in “PowerSet” mode or the unit may not determine an accurate setting. The following gases should be used and are the best choices in the gas selection during initial setup after powering the unit up:
MIG: Steel: 75%/25% Ar/CO2 (75/25 or C25) OR 100% CO2 (C100) Axial Spray begins around180A with .035″ 90%/10% Ar/CO2 (90/10 or C10) This capability is limited on this machine due to max Amps. Stainless (Inox): 98%/2% Ar/CO2 (98/2 ) Aluminum: 100% Ar ( Argon)
TIG: All Metals: 100% Ar (Argon)
Notice that Steel has a couple of gas choices. In the North American Market, 75/25 is the standard gas choice for short circuit MIG. It provides less spatter than CO2 and a cleaner, less oxidized weld in general. 100% CO2 is cheaper, but can require more cleanup and descaling after the weld is completed. In other markets, 100% CO2 is more commonly available, or may offer slightly different combinations. If 75/25 gas mix is not available for use with the PowerSet setting, and 80/20 is an option, then this gas may be used on the 75/25 setting, but may require slight tuning to achieve perfect performance.

ing of the fitting shoulders. Do not use pliers, or a serrated-jawed wrench such as a pipe wrench or basin wrench to tighten the fitting. The design of the fitting means that no thread sealing tape or compound needs to be used.
Connect the regulator tubing to the regulator. The regulator may be supplied with a hose barb connection, or a threaded connection for the tubing. If the regulator supplied has a hose barb, make sure the hose barb fitting is tight on the regulator. Tighten with a 3/4″ (19mm) wrench. If it is a threaded connection, use two 3/4″ (19mm) wrenches to hold both the regulator and the tubing connection at the same time. Hold counter pressure on the regulator connector while tightening the hose fitting to prevent damage to the regulator and to ensure maximum sealing. After connecting the tubing to the regulator, connect the other end of the tubing to the 5/8″ CGA fitting on the unit. Hold the fitting on the unit with one 3/4″ (19mm) wrench firmly while tightening the hose fitting with another 3/4″(19mm) wrench.
Important: Do not use thread tape or pipe sealant on any cylinder, regulator or unit connection. The residue and debris may get into the gas solenoid and cause operational issues.
CAUTION!
Do not tighten the rear unit connection without holding the female 5/8 CGA fitting located on the unit with a wrench, or damage may occur to the bezel and the fitting as the fitting may turn in the housing while the hose fitting is being turned.

Stainless gas mixes can range throughout the industry. However, in the industry. this unit is designed to be used with 98/2 Ar/CO2 blend when welding Stainless Steel. While there are other gas choices, such as “TriMix” this is typically the most widely available and economic one for welding Stainless Steel (Inox).

Connect Regulator To Cylinder And Unit.

Aluminum will always require the use of pure Argon (100% Ar) shielding gas while welding in MIG mode. This is a widely available and a standard gas throughout the world.

Of course, if you choose manual mode, different gas mixes other than what is suggested may be used. If you choose to use a different gas, be sure to select the next closest gas on the panel during setup that matches your selection and keep “PowerSet” turned off. This will allow proper operation.

Always wear safety glasses when changing a cylinder. Before installing any cylinder, stand to the site of the valve, away from the discharge, and quickly open the cylinder to give it a quick blast. This will dislodge any dirt or particles stuck in the valve or the connection seat. This will help reduce the chance of dirt particles making its way into the solenoid valve, causing sticking issues later on.
Connecting your cylinder will require a cylinder wrench (1 1/16″)to connect the regulator to the cylinder (North American Cylinders with a 580 CGA valve). If you do not have a cylinder wrench, an adjustable type wrench will work, but make sure it is properly adjusted to prevent round-
18

Setup Guide

Getting Started

The on screen programming will remind you what polarity to use, but in

CHECK FOR GAS AND AIR LEAKS. Be sure to check for gas or air leaks before attempting to weld or cut.

case you forget, refer to the illustrations below.

Connect all the lines and tighten and recheck any related clamps, plugs and fittings. If you hear or suspect leaks, use warm, soapy water (or a dedicated leak testing solution available from welding suppliers) and spray

Where Do I Connect The Stick Torch?

on all rear external connections. If any leaks are present, bubbles will form

around the area of the leak. Tighten any clamps or fittings found to be

Electrode

leaking. If the MIG gas regulator is leaking, discontinue use and contact Everlast technical support. Do not attempt to modify or repair this regula-

Holder

tor. If the air regulator is leaking, make sure the pressure is not more than

90 psi, and tighten the small screws on the regulator with a screw driver.

If too much pressure is applied, the regulator may have blown internal and external O-rings or seals. If it is the air regulator, check and remedy the

DINSE 35/50 Adapter

problem if the regulator persists in leaking. If it is the gas regulator, dis-

continue use and contact Everlast. If the problem cannot be remedied, or

internal leak is suspected contact Everlast. NOTICE: While plasma cutting, a small drop in set air pressure and operating pressure (while cutting) is

DINSE 35/50 Adapter

normal. This does not indicate a leak. This drop should never be more

than 4 to 5 psi and is usually less than 3 psi. If the pressure drops more

than this, this usually indicates the air supply hose for the plasma function

is too long or too small in diameter for the length it is running before

reaching the unit. It may also indicate another restriction. Always keep the

air supply hose as short as possible.

DISTANCE YOUR WELDER FROM YOUR WORK. As a best practice technique, be sure to locate your welder away from the immediate work area. Sparks and debris thrown by the welding and plasma cutting processes can enter the unit and cause damage. This includes any grinding or milling operations that may occur in the area.

Work Clamp

Work

For most all applications, connect the electrode holder to the posi-

tive terminal. Connect the work clamp to the negative terminal.

WARNING!
Make sure plasma torch polarity is correct or damage and malfunction of the torch and machine may result! Remove the torch before changing to another mode. Install the other torch after the mode is selected. Do not attempt to weld or cut while the unit is in a mode that is not supported by the connected torch! Do not leave the plasma or stick torch connected while using another process. The MIG torch may be left connected if the torch is isolated from contact with metal. If the MIG torch must remain in place, a piece of rubber tubing slid down over the (cool) MIG torch nozzle will help prevent accidental contact and arcing of the torch when not in use. As a best practice, remove the MIG torch when not being used for MIG or FluxCored welding. Accidental cross-arcing can cause the machine to fail.
Never touch a bare or exposed part of the connectors, cables, or consumables while the unit is in use, especially while in the plasma cutting mode. Turn the machine off to replace or check plasma consumables. Severe injury, burn or electrocution may occur if contact is made. Keep all cables and covers in place and in good repair. Do not operate if damage occurs to any cable or safety device. Discontinue use immediately and contact Everlast for replacement or repair of the affected part.
19

Where Do I Connect The Plasma Torch?
iPT Series Torch

DINSE 35/50 Adapter

Central Connector iPT Series Torch

Work Clamp

Work

Connect the work clamp to the positive terminal. Connect the plasma torch to the negative terminal. Make sure the central connector is fully seated and the connector locking ring fully tightened by hand.

Setup Guide

Getting Started

SELECT THE CORRECT MIG AND FLUX-CORED POLARITY.
Even though similar in concept, MIG/MAG (GMAW) and Gas-less Flux-Cored (FCAW) welding require a polarity change when transitioning between the two. The unit will remind you with an on-screen prompt to change polarity when you change between the processes, but this is an often over-looked issue, even when reminded by the machine. Failure to change polarity will result in erratic operation, bird’s nesting of the wire, poor fusion and excess spatter. Use illustrations below as a guide.
How Do I Change Polarity For MIG?

How Do I Change Polarity For Flux-Cored?
Flux-Cored
Euro-Quick Connector

MIG/MAG

DINSE 35/50 Adapter

Euro-Quick Connector

DINSE 35/50 Adapter

Torch
Work Clamp Work
The MIG gun must also be correct in polarity. Drop open the cover on the left side of the MIG to access the wire spool and feeder. Just above the feeder, the are two terminal lugs. The upper is Positive, and the lower is negative. If there are no positive (+) or negative (-) symbols, there may also be a label that says “Gas MIG” and “Gasless” or something similar. Regardless, the top terminal is positive and the bottom terminal is negative. For MIG, the wire feeder cable should be connected to the top, positive (+) terminal with via the provided screw. See below.
MIG/MAG Position

Torch
Work Clamp Work
When welding most all flux-cored wires, polarity will be negative. There are a small number of exceptions. However, if the manufacturer doesn’t state the polarity, assume it is negative. Drop open the cover on the left side of the MIG to access the wire spool and feeder. Just above the feeder, the are two terminal lugs. The upper is Positive, and the lower is negative. If there are no positive (+) or negative (-) symbols, there may also be a label that says “Gas MIG” and “Gasless” or something similar. Connect the wire feeder cable to the bottom terminal lug via the provided screw.
Flux-Cored Position

NOTICE:
This unit is not designed for or intended to be used in dual shield operation (FCAW-G). The Flux-cored operation that this machine supports is a gasless process (FCAW). The PowerSet and manual function is programmed for this type of operation.
20

Setup Guide

Getting Started

INSTALLING THE OPTIONAL SPOOL GUN.
The Parker DSP 360A Spoolgun is recommended for use with this unit and provides the best duty cycle and amperage rating. The SM200N may also be used but is rated for an Amperage and duty cycle that is lower than the machine, which may lead to shortened gun and consumable life.
Where Do I Install The Spool Gun?

How Do I Select TIG Polarity?
AC or DC TIG
DINSE 35/50 Adapter

Spool Gun

Euro-Quick Connector
Control Connector

DINSE 35/50 Adapter

Control Foot Pedal
TIG Torch Switch

Power Cable/Argon Line

Spool Gun
Work Clamp Work
The spool gun connection process is similar to the MIG torch connection and uses the same Euro Quick Connect connection. Polarity is the same as MIG except when Flux-Cored wire is being used.

TIG Torch

Work Clamp

Work

NOTICE: Choose between the torch switch operation (2T/4T) or the foot pedal operation. Both cannot be connected or used at the same time.

WARNING!

SELECT THE CORRECT TIG POLARITY.
TIG polarity will always remain constant, regardless of whether you choose AC or DC operation. The torch polarity will always be negative. This means the work clamp will be installed in the positive terminal. If the polarity is reversed the tungsten will be rapidly consumed and wasted. If the polarity is reversed in AC, it is possible that it may work if the AC balanced is focused the wrong direction. This may not be noticeable right away. But arc starts will be harder since the HF start arc is coming from the wrong direction. It can cause welder overheating in the long run. If TIG welding near or over 200A is expected for long durations of time, it is advised to purchase a water- cooler and a separate 18 or 20 Series water-cooled torch. The water cooler will plug into the rear of the welder so the two can be used in tandem and the welder can be used to switch the cooler on and off at the main power switch in the rear of the welder. Consider the PowerCool 300 (not stackable) or the PowerCool 400 (stackable) for this welder.

Keep all caps and covers in place while not in use. For example, install the cap over the Euro MIG connection when the related process not in use. This protects the fitting and protects against accidental contact which may result in severe injury or shock. The connections may remain live during use with other processes. Disconnect any unused torch or clamp when other processes are in use or damage may occur to the machine.

Setup Guide

CHECK AND CHANGE YOUR DRIVE ROLL.

Getting Started
drive roll. Install the drive roll with the size stamp facing the inside.

The unit comes equipped with .030″ and .035″ drive rolls and 4 roll .

INSTALL THE WIRE AND FEED THE GUN.

NOTICE: For most purposes up to 3/16″ thick material you will likely want Once the wire spool has been installed, flip the tensioner lever down and

to use .030″ wire in this unit since it covers the greatest range of metal raise the top drive roll to the upper position. See the illustration below.

thicknesses and amperages within the capability of this unit. .030″ wire Gently guide the wire from the spool over through the wire feeder and into

typically can handle up to about 160A before it transitions to globular

the front section of the gun at least 6 inches. Make sure the wire lays neat-

transfer. For upper range use and materials 3/16″ and over, .035″ is ad- ly in the groove. Hold it with your finger if necessary as you lower the top

visable. Remember, if you change wire size or type, you will need to ei- drive roll down and raise the tensioning lever with your other hand. When

ther flip the lower drive rolls over or completely change the drive rolls to complete the wire should look like the illustration on the previous page.

the correct size and type.

Hint: The wire on the spool is usually bent and threaded through a small

The top drive rolls are actually an idler rollers used to hold tension and keep the wire in the groove and is not changeable. Only the bottom drive roll needs are changed. The bottom drive rolls have two small grooves that are sized for .030″ (.8mm) and .035″ (.9mm) solid wire. Additional sizes and types of drive rolls are available as options. The standard installed drive roll is meant to feed hard (solid) steel wire. The groove on this drive roll has a “V” shape designed for the solid wire. A Flux-Cored drive roll

hole in the side of the spool to lock it in place and prevent de-spooling of the wire. Keep one hand on the wire spool to prevent despoiling and cut the wire loose with a pair of wire cutters. Trim the wire to make sure the end of the wire is straight and able to be threaded through the wire feeder mechanism and gun. After the tensioner is lowered back to the horizontal position, check to confirm the wire is still in the groove and is not riding up on the shoulders of the drive roll.

has a serrated edge to the groove, which grips the softer, cored wire. Viewing a flux-core drive roll from the top, you will see a “zipper” like

Installing the MIG Wire

pattern. This should never be used to feed hard steel, stainless or alumi-

num wire. This will result in damage to the wire, metal flaking and possible

plugging of the MIG gun liner. To determine the exact size of wire and

type you have, look at the side of the drive roll. The size of the drive roll

groove is stamped on the side of the drive roll closest to the correspond-

ing groove. The type of the drive roll will also be stamped with a V if it is

for solid, hard wire. If it is stamped with an “U”, this is a special drive roll

for feeding aluminum wire (Aluminum needs a special polymer type liner

for feeding with the U-groove drive rolls.) “K” or “X” signifies a flux-cored

drive roll.

The drive rolls are held in place by slotted metal thumbscrews. Remove

the screw to expose and change the drive roll. The drive rolls are mounted on bushings. The bushing should be held in place with one finger of

Next, turn the welder on and set to a desired MIG or Flux-Cored mode. Remove the gas nozzle. Twist clockwise to aid removal if needed. Unscrew

one hand while the other hand removes the drive roll. This will prevent the contact tip as shown in the illustration below. Hold the gun cable and

both bushing and drive roll from being removed from the wire feeder drive gun straight as possible. Press and hold the wire jog button. The wire

shaft. When removing,make sure that the square locating key is not dis- should slowly begin to feed through the gun cable and eventually through

mounted. If the key falls out of the keyway, replace it before replacing the the gun. As the wire exits the gun, allow 3 to 4 extra inches of wire to be

Drive Roll Size and Location Info

fed out past the diffusor. Release the wire job button. Re-install the contact tip over the wire and screw it in clockwise until it is tight, but not to the

.6mm =.023″/.025″

point of stripping. Re-install the gas nozzle.

.8mm= .030″

How Do I Disassemble the MIG Gun?

.9mm= .035″

1.2mm= .045″
Size/Type Stamping. The size is stamped on same side as the corresponding groove.

Gas Nozzle

M6 Contact Tip

Diffusor

Contact Tip Holder

Gun Neck

Drive Rolls X 2

Setup Guide

Getting Started

TRIM THE WIRE AFTER INSTALLATION.
Trim the wire sticking out of the nozzle to 1/4″ to 3/8″ (6mm to 9mm) in length with wire cutters. See the illustration below. The gun is now ready for welding. Hint: Always make sure that you re-trim the wire before beginning a new weld if the wire is not already trimmed to this length. This will help to improve arc restarts.
Trim Wire Before Starting a Weld

To Tension the drive roll and check for proper wire feeding:
· Turn the unit on and pull the trigger so that the wire extends approximately 1″ beyond the gas nozzle.
· Find a small block of wood, such as a two by four, and secure it to the welding table or other solid object.
· Caution: Do not test this on the weld metal or on the work table or accidental arc flashing/starting may occur! Do not direct the wire into hand! Injury may occur.

· Hold the gun approximately 2 inches off the wood. Aim the gun at the block of wood so that the nozzle is at a 30 degree angle to the wood.

· Pull the trigger and allow the wire to contact the block.

Trim wire to 1/4″-3/8″ (6mm 9mm)

· Increase wire tension so that the wire contacts the block of wood and is forced to curl up. Continue holding the trigger so that two or three full spirals are made.

· If the wire stops, or stutters during this process, let go of the trigger immediately and increase tension.

PROPERLY TENSION THE WIRE FEEDER.
Test Wire Tension Before Welding

· Adjust the wire until the stuttering or jerking disappears.
· Do not over-tighten the tensioner or use more tension than necessary. When the wire begins to curl without any stoppage, correct tension has been achieved.

4 5
Curl
Wood Block
To feed properly, the wire needs to be tensioned before you begin welding. The tensioning lever has numbers on the dial. To increase tension, rotate the tension lever clock-wise. Different types of wires require different tensions. There is no exact tension that works for all wire types. However, for steel wire, you will generally tension to at least 3 on the dial. For flux-cored wire, and aluminum, it may be only two or three. Wire diameter also plays a small part in the amount of required tension that is needed. Regardless of the wire type or wire diameter, observe the following information and refer to the above illustration.
23

Component Identification and Explanation
Front Panel View
8

7 2

6 3

Number 1 2 3
4 5 6
7
8

Component Identification Protective Cover
Euro-Style Quick Connector Positive Terminal (+) DINSE 35/50 Type
Quick Disconnect Connect Coupling Control Connector Central Connector
Negative Terminal (-) DINSE 35/50 Type
Handle

Component Note Keep cover down and in place during welding activities and in storage. Connect to the MIG gun or Spool Gun. The MIG gun and the spool gun share the same connection. For Stick, connect to the Torch. For MIG, this remains vacant. For Flux-Cored connect the work clamp. For Plasma connect the work clamp. For TIG connect the work clamp. Connect the TIG Argon gas line from the torch directly to this line. For Plasma the torch switch wire connects here. For the Spool Gun, the control circuit wire goes here. Connect the Plasma cutter torch to this connector. This is an all-in-one fitting that provides air, power and pilot arc to the plasma torch. For Stick connect to the work clamp. For MIG, connect to the work clamp. For Flux-Cored, this remains vacant. For Plasma, connect to the torch. Install handle with provided screws. If it is not desired, leave handle off the welder and install provided screws directly to the top.

Component Identification and Explanation
Rear Panel View

2
1x220V

MIG TIG/PLASMA

6 5

Component Identification

Component Note

1 240V Cooler Plug (Some Models) Do not use unless a cooler is added. This plug should never be used to power any other item than an Everlast Water Cooler. It is a low amperage outlet designed only for water cooler use.

Input Cable and Plug

North America only: The unit may be operated on either 208-240V 1 phase (or on 120V 1 phase with the

included pigtail adapter). North American standards require only 3 wires for 1 phase operation of welders.

NOTICE: Always consult national A neutral is not used or required. For wiring a 1 phase connection to the unit: Use Black for L1, White for

codes and a local licensed electri- L2, and Green for ground (not neutral) use. Red is not typically used in wiring a welder/plasma cutter cir-

cian before service.

wiring

this

welder

any

cuit. This is in accordance with North American codes for welder/plasma cutter wiring (see Article 630 of the NEC for more infoWhen operating on 120V, the white wire (internally) becomes the neutral, and the green still serves as the ground. The supplied NEMA 6-50P is the proper plug used for wiring single

phase 240V welders and plasma cutters in North America. It should not be changed or removed unless

wiring directly into a cut-off switch. Other regions may vary and may have a different plug type or no plug

at all. Use the supplied adapter to convert to 120V operation.

3 Air Regulator Bracket Screw Holes The air regulator bracket supplied in the kit is mounted to these two holes. Mount bracket first.

4 MIG inlet connector (from regulator) 5/8″ CGA.

5 TIG/Air Inlet Connector (from regu- 5/8″ CGA The air for the plasma and the TIG gas are shared. The connection is only able to be used for

lator)

one gas at a time as equipped. An aftermarket inert gas flow valve and 5/8 CGA fittings may be sourced

locally or online to allow both to be connected simultaneously if desired, however Everlast does not supply

these fittings or offer kits to do so.

HF Ground Service Bolt

Used only to mitigate any electrical interference caused by the operation of this unit (if any is found).

Breaker/Power Switch.

This switch doubles as the main power switch and disconnect switch. If this switch trips and the welder

power turns off, a significant internal event or failure of the switch may have occurred. If this occurs, im-

mediately remove from service and mark/tag according to regulations and contact Everlast Tech Support for

further diagnosis and/or repair options.

Component Identification and Explanation
Control Panel Layout

1 2

11 4
10 5

Component I.D.

Component Note

1 Process Selector Use the left and right arrow keys ( ) to select the desired welding or cutting process.

Display

This color LCD display provides all the information relative to setting the machine and indicating set parameters.

Left Adjustment Knob

The left adjustment knob is used change the desired status of a function (i.e. voltage, turn on/off, electrode type, thickness etc.) and to set all adjustable values to the left side of the black dividing hash mark just above the “EVERLAST” logo. If you push in on the knob while adjusting, it will adjust in larger increments, usually in whole numbers or increments of 10.

Left/Right Dividing Mark

This mark divides the functions between left side control functions and right side control functions of the machine. The left side adjustment knob and navigation buttons control the left side of the machine. The right side adjustment knob and navigation buttons control the right side of the machine.

5 Gas Purge

This control activates the free flow of shielding gas/cutting gas to allow the regulator flow rate to be set accurately. This avoids “live” firing the unit with the torch trigger to activate the gas flow.

6 Wire Jog

When this button is selected, the wire is fed wire through the machine to assist in threading the wire through the drive rolls and into gun without pressing the trigger and wasting +shielding gas.

Left Side Navigation

Use the up and down arrow keys ( ) to navigate and select the parameter on the left side of the hash mark that you wish to change or adjust. The actual direction may go either up and down or left and right, depending upon the function level you are adjusting or selecting.

This unit features a programmable memory so programs can be saved and easily recalled. To use, first select the process you wish to save, and

setup the program as desired. When completed, quickly press and release the Program “PRGM” button once to access the save menu. Use

Program/ Save/Recall

the navigation buttons on either side to select the side and program number of the menu that you wish to save. Once selected, press and hold the “PRGM” button for 3 seconds. The program will be saved and the program will automatically be named by the primary settings that distinguish the program. Press the button quickly again to exit, or allow several seconds to pass without adjustment and the machine will automati-

cally return to the settings menu. To access any program, press and release the button, then navigate to the desired program and quickly press

and release the program once again. Don’t forget to Record this program number for your records in a data/log book for easy access.

Right Side Navigation

10 PowerSet

When selected, PowerSet enters a synergic mode which gives automated settings based off of the diameter of electrode, type of metal, type of gas, and thickness you input into the unit. This simplifies operation and reduces the knowledge base needed to make the correct adjustments needed to weld properly. When PowerSet mode is selected, some functions of the machine will be set to automatic and will not be adjustable.

11 Run-in

When selected, the Run-in function feeds the wire slowly until the arc is started. This creates a smoother start, and reduces spatter and arc start stuttering, which is also commonly referred to as “Machine Gunning”.

12 Right Adjustment The right adjustment knob is used change the desired status of a function (i.e. Wire Speed, Amperage, Spool-gun operation etc.) and to set all

Knob

adjustable values to the left side of the black dividing hash mark just above the “EVERLAST” logo. If you push in on the knob while adjusting, it

will adjust in larger increments, usually in whole numbers or increments of 10.

Component Identification and Explanation

Getting Ready To Weld

GENERAL INFORMATION ON SETUP AND USE.

ter selection, the machine automatically defaults back to the main parame-

ter area and the numbers will brighten and will be able to be adjusted. Of

course, if you continue to navigate completely through the left or right side

functions and parameters, you will eventually cycle back to the default

parameter area ( voltage, wire speed, amperage etc.) and the numbers will

brighten to indicate that you have fully cycled through all the parameters

and returned to the default. NOTE: If a parameter or function (4) has a

black background (

) this function or parameter cannot be selected,

changed or adjusted due to the mode or setting you selected (i.e. Pow-

erSet) the function is either not relevant or is automatically set by the ma-

chine.

Changing the Functions and Adjusting the Parameters.

Selecting the Process.

At the top of the panel (1) the process selector is used to select the de-

sired welding or cutting process. Use either the right or left arrow

(

) buttons to advance to the next process. Pressing the left or right

arrow button rapidly will require the button to be pressed twice to move to

the next process. The initial press of the arrow button will display the

polarity screen for the next process. A rapid second press abbreviates the

polarity screen (see next page) and allows you to enter directly into the

setup screen for the process selected. A third rapid press advances to the

next process polarity screen. However, if you advance slowly or decide to

move to the next process after the machine has had time to automatically

advance to the setup screen, it will only require one press to advance to

the next process. If you accidentally pass the process you wanted, instead

of cycling back through all the processes, simply use the opposite arrow

button to scroll back to the process you desire.

Navigating the Menu.

To change the status of a function or adjust the value of a parameter, use the left or right up and down arrow keys ( ) to navigate and highlight the desired function or parameter. Then, use the left or right control knob (6) to make the change in function status (change from OFF to ON, or change torch type, etc.) or change in parameter value (increase or decrease the amount of seconds or percentage etc.). As a default, without navigating to the desired function or value, the left and right control knobs will be used to adjust the Voltage, IPM, or Amperage. NOTE: When in Stick mode, the left display will display voltage, but due to the nature of constant current stick welding, voltage is not adjustable and is controlled by the arc length.
Observing the Important Information.
At the top center of the machine (7), the welder will display important reminders to change gas, or which process is being used. It will also tell you, in case you forget, whether you are in manual or PowerSet mode. The input voltage is displayed as a confirmation and reminder of the correct input voltage. Run-in status is also displayed as “Run-in On” or “Runin Off”.

The panel is divided in half by a black hash-mark (2) below the screen and a green vertical bar down the middle of the screen. This divides the

Why Are Some Settings Limited or Blocked?

control region in half. The left side up and down (3) arrows ( ) con- There are two basic reasons some settings are limited in adjustment or

trols the left half of the screen and the right side up and down arrows

completely blocked from adjustment. The first is that the unit is being

( ) controls the right half of the screen. Both functions (items that

used on 120V and output is limited. With limited output, the machine

may change in status, such as ON/OFF, or Gun Selection), and parameters must limit certain range of adjustments to protect itself from malfunc-

(items that change in value in a range such as inductance percent) are

tion. In PowerSet mode this is obvious by the limit on selecting elec-

selectable with the arrow buttons. The arrows are used to scroll through

trode or thickness sizes. The second reason is that the machine is in

and highlight the selected function or parameter. When a function or pa-

PowerSet mode and is automatically presetting the unit for you. In

rameter is selected and available for adjustment, it will be highlighted and manual mode, most all functions are available for adjustment with the

change color, turning from gray to green (3). In some modes, to avoid

exception of stick mode which does not allow electrode selection.

confusion, the general area that is navigated to will flash as well. Default

selection will always be the main adjustment on that side (Volts/Amps/Wire Saving a Program.

Feed Speed etc.) (5). When navigation is in default mode, the main pa- To save a program, the welder should be set to desired parameters. Once

rameter will be brightly lit in white (or green for voltage in stick, see stick setup section). When navigating away from the default parameter area, the

desired parameters are set, press and release the PRGRM/SAVE/RECALL buttton (8). When the save screen opens, use the corresponding left or

large white numbers will appear to dim. After 4 to 5 seconds if you haven’t made another selection or made an adjustment to the function or parame-

right up and down arrow keys ( ) to navigate up and down to the desired program number. When the desired number is highlighted, press

Component Identification and Explanation
Getting Ready To Weld
PRGRM/SAVE/RECALL button to return to the program screen. Use the navigation buttons to highlight the desired program. Quickly press and release the PRGRM/SAVE/RECALL button to recall and open the program. If the program needs to be fine tuned, the settings may be adjusted or changed while in use. However, if changes are made to the program, unless the program is resaved, these settings will not be automatically saved to the program. To save the changes, repeat the save program steps. IMPORTANT: When recalling a program, do not press and hold the button or the program may be erased or saved over with the current settings of the machine. Simply press and release the button quickly.
NOTICE:
The unit is designed with several features and functions in common between welding processes. The principles of setup and operation carry over from one process to another. In this case, information may not be repeated in as much detail in this manual if it has been discussed previously in another process.
28

Component Identification and Explanation

Setting the Unit Up for Welding/Cutting Manually

The Welcome/Boot Screen

sure to wait until this screen is present before you attempt any change of the welding process. Any time you change processes, the screen will reappear briefly to remind you to make any required changes to polarity.

THE MAIN CONTROL SCREENS (MANUAL MODE)

The MIG/Flux Cored Manual Screen

When you first turn the unit on with the rear power switch, this screen will greet you as the machine begins the boot process. Simultaneously, all the

process selection LED’s should be lit on the control panel.

The Polarity Screen

9 10 11 12

13 14 15 16

1. Welding Voltage. Adjust with Left adjustment knob. Select with left up and down arrow keys. When the Voltage is selected for adjustment, the numbers will brighten in color. This is the default setting of the left side. After 5 seconds of no input or adjustment of other parameters or functions, the selected setting will default back to the Voltage.

After the boot process (2 to 3 seconds) completes, the unit will briefly

display a polarity reminder screen (4 to 5 seconds) as depicted above.

Simultaneously, the welder should highlight the last process used by light- 3. ing one corresponding red LED at the top of the panel in the process se-

lection area. NOTE: In the left column of the screen, during any wire feed-

ing mode, the unit also reminds you to check and change your polarity

connections of your wire feeder, indicated by the terminal lug and blank

terminal. A reminder to use gas (MIG), or not to use gas (Flux-Cored) is also displayed for wire feeding modes. MIG will also display a “Run-In”

indicator for slow wire start for improved starting if selected. For Stick, a

similar polarity reminder appear as well. It’s especially important to check

and change your torch and work clamp polarity or improper operation and

even damage to the machine may occur. As a best practice, keep the

torches disconnected until the polarity screen displays to prevent damage 5. to the machine. Also be sure to remove the torch before changing polari-

ties. Do not try to operate the machine with more than one torch connect-

ed at a time. 6.
If desired, at this point you may change the process by using the up/right

arrows (

) at the top of the panel to select the desired process. Be

Voltage Input Confirmation. This confirms which voltage the machine is being supplied. This also serves as a diagnostic tool. If the machine does not show 240V while operating on 240V, then the power supply to the welder is likely faulty. NOTE: Maximum output of the machine is governed by the input voltage. Some selections may not be possible on reduced input power.
Gas/Process Reminder. This reminds the user which gas or process has been selected. It will display either C25 (75/25 Ar/CO2 for Steel), C100 (100% CO2 for Steel), Mix Gas ( 98/2 Ar CO2 for Stainless/Inox), Ar Gas (100% Argon for Aluminum), or No Gas (For Flux -Cored on Steel) in wire feeding modes.
Manual/PowerSet Mode. This indicates which mode the machine is operating in, whether in full manual mode or in PowerSet mode which is a synergic, more automated mode. In PowerSet, many functions may not be available for adjustment. (See the MIG PowerSET section).
Run-In On/Off. Run-in provides a low speed start for the wire until after the arc is started. This improves the arc starting ability. This indicator reminds you whether you have it selected or not.
Wire Feed Speed Indicator. Adjust with Right adjustment knob. This indicates the wire feed speed in both Inches Per Minute (IPM) and in Meters Per Minute (m/Min). This is the default setting for the right

Component Identification and Explanation

Setting the Unit Up for Welding/Cutting Manually

side. After 5 seconds of adjustment or no input being made, When the Wire Feed Speed is selected for adjustment the display will brighten in color. This is the setting. After 5 seconds of no input or adjustment of other parameters or functions has ceased, the selected setting will default back to the Voltage setting.

also serves to provide gun cooling. However, the user may opt to turn down this setting if desired Use the left Up and Down navigation keys to navigate and highlight (turn green) this setting. Use the left adjustment knob to turn the setting on or off. In Flux-Cored mode, this feature will be unavailable and be listed as N/A.

7. Up-Slope and Down Slope. These two functions are linked in func- 11. Inductance. This improves the wet in of the weld. A low setting will

tion. Up Slope provides a time duration for wire speed to accelerate

result in a very poor arc, with a high pitch. The result will be a raised

from the Start Wire Feed Speed (Start WFS). This can be used to

ridge in the middle and poor wet-in. Excess spatter may be observed.

further improve arc starting when used with run in and should exag-

The result of too high of a setting will result in a very fluid, flat pud-

gerate the hot start feel. The Down Slope provides a time duration

dle. The pitch will be raspy and not smooth. Starts will not be as

for the wire speed to ramp down to the preset End Wire Feed Speed

smooth Generally a setting of 65 to 75% is a good starting point on

( End WFS). This provides time for the welder to fill the crater instead

Steel with C25. With Steel and C100, 70 to 80% is a good starting

of the arc abruptly terminating and leaving a crater at the end of the

point. Generally pure CO2 is not very smooth on many welders, but

weld. In 2T, the arc will start slow and accelerate up to the welding

with inductance control, high quality welds can be achieved. Stainless

wire feed speed automatically. In 4T, the trigger should be depressed requires the highest inductance with 90% or greater. Aluminum can

and released quickly, as soon as the arc starts, to allow the Up Slope

range depending upon the wire from 60 to 80% or so. Flux-Core

to function and accelerate the wire speed. If the trigger is held the Up

behaves a little differently with a 40 to 50% starting point. Of course,

-Slope will be delayed until the trigger is released. Note that Down

different weld positions, joint designs and thicknesses of metal can

Slope will keep the wire feeding briefly after the trigger is let go in 2T

affect the inductance requirement slightly. Use the left Up and Down

if a time value is set more than 0.0 seconds. In 4T the trigger is

arrow keys to navigate and highlight (turn green) the Burn Back con-

depressed and held to control the actual arc termination, or is de-

trol. Use the left side control knob to change the value.

pressed and let go quickly to automatically allow the wire to decelerate to the End WFS. If one or both of these functions are not desired, select 0.0S. In PowerSet mode these functions are managed automatically and will be non- adjustable. If manually rapid tacking or spot welding select 0.0S for both.

Burn Back. This is the amount of time the arc stays on after the wire stops feeding. It is used to help prevent the wire from sticking in the weld and to reduce the need for constant trimming of the wire before restarting. Use a setting of .1 to .3 seconds to begin with for most applications. Smaller diameter wires need less burn back time. Use

8. Start and End Wire Feed Speed (WFS). The Start and End Wire Feed

the left Up and Down navigation keys to select and highlight (turn

functions (Start WFS, End WFS) allow the user to set a pre-

green) the Burn Back feature. Use the left adjustment knob to adjust

determined wire feed settings at the start and end of the weld. At the

the duration of the Burn Back.

Start of the weld, if being used, a lower setting creates a smoother start with less popping and spattering typical of cold starts. The reduction of the sputtering (also known as “machine gunning”) will be noticeable at lower settings than used to weld. End wire feed speed is designed to be used to fill the crater at a lower Amperage/WFS to help prevent stress in the weld. If in doubt about the best setting for either, always start at the minimum Start and End WFS setting for the smoothest starts. Or, for general purpose welding set both to 60% to 75% of welding wire feed speed and fine tune it as desired.

13. Spot Timer. This is a timer that can be set to automatically shut off the weld when the trigger is held down. This allows you to make repeatable and perfectly sized tack welds or short seams. Use the Right side Up and Down navigation keys to navigate and highlight (turn green) the Spot Timer. Use the right side adjustment knob to turn the Spot Timer on and set the duration of the spot timer. NOTE: Keep in mind that If the spot timer is turned on accidently, the wire feed will stop suddenly soon after the trigger is pressed. In fact it may barely feed and just seem to quit if the time is set low. This is

9. Pre-Flow. The unit has an adjustable pre-gas flow setting. This auto-

normal, but often a source of tech support calls. If your wire feeder

matically times the flow of gas before the weld, improving overall

stops feeding unexpectedly after the trigger is pressed, check this

weld quality at the critical start of the weld. However, the user may

function first.

opt to turn down this setting if desired Use the left Up and Down navigation keys to navigate and highlight (turn green) this setting. Use the left adjustment knob to turn the setting on or off. In FluxCored mode, this feature will be unavailable and be listed as N/A.

14. Stitch Timer. This function works only in conjunction with the Spot timer. This provides a continuous “on/off” action of the spot timer, allowing the user to move smoothly and evenly space spot welds along a seam or around a part, providing “stitches”, or a series of tack

10. Post Flow. The unit has an adjustable post-gas flow setting. This is

welds. The time set is the length of “OFF” time between the Spot

complimentary to the Preflow setting and also serves to improve the

cycles. The trigger will be held down and the spot/stitch cycle will

weld quality and prevent oxidation after the weld is terminated and

continue until the trigger is released unless the unit is being used in

Component Identification and Explanation

Setting the Unit Up for Welding/Cutting Manually

4T mode in which case the trigger will be pressed and released and

Amperage setting after 4 to 5 seconds.

the cycle will begin. A second press of the trigger will be required to terminate the cycle. (See next item for 2T/4T explanation.)

Arc Force %. The arc force function only works in Stick mode. Arc force is used to offset the loss of overall wattage (VxA=W) as arc

15. Torch Trigger Function. This controls how the welder reacts to the

length is shortened and voltage begins to drop while stick welding. It

torch trigger. In 2T, the trigger is pressed and held to weld. In 4T,

offsets the drop in voltage by injecting extra amps into the weld when

the trigger is pressed briefly to start the arc, then released to continue

voltage drops below 20V. This enables the amperage to react aggres-

to weld. The weld is continued without the torch trigger being held

sively or mildly, depending upon settings, to prevent arc outages, and

down. The trigger is once again pressed, held and then released to

allowing the user to hold a tight arc and maintain better control.

terminate the arc.

7. Hot Start %. This adjusts the intensity of the start. When welding

16. Torch Type. Select between the main MIG gun or Spool Gun func-

this helps to prevent electrode sticking and helps to eliminate porosi-

tion.

ty at the start of the weld. . Hot start intensity is the percentage over

The Manual Stick Screen

the set amps at which the Amps will be boosted during the arc start. 8. Hot Start Time (S). This sets the amount of time the hot start stays

engage at the beginning of the weld.

3 4

9. VRD. This is called the Voltage Reduction Device. It is a safety feature designed to help reduce chance of shock or electrocution. This

lowers the OCV of the machine helping to reduce the chance of acci-

dental shock or electrocution while welding where the user may become a part of the circuit path of the weld. This may be required in

some situations by regulations. This will increase arc starting difficul-

ty on some rods. If this is not required, or the conditions exist where

6 7

the user is perfectly insulated from the work and the possibility of becoming a part of the circuit path is low or eliminated, it may help to

turn this setting to “OFF”. To help start the arc while the VRD is on, a

quick double tap will help to strike the arc instead of the single

scratch or tap.

Welding Voltage. In Stick Mode, the Voltage is not adjustable due to the nature of stick (Constant Current) welding. The voltage varies according to the length of the arc. The Voltage displayed while idling is the Open Circuit Voltage (OCV) of the machine. While welding this changes to reflect the actual arc voltage.

10. Standard Mode. This mode is to be used with all stick electrodes except electrodes with a cellulose-based flux, i.e. 6010, 7010, 6011 etc. It provides a softer arc, with low spatter and a smooth bead appearance.

Voltage Input Confirmation. This confirms which voltage the machine is being supplied. This also serves as a diagnostic tool. If the does not display 240V, then the power supply to the welder is likely faulty. NOTE: Maximum output and accuracy of the machine is affected by voltage lower than 220V.

11. Cellulose Mode. This mode is to be used with welding electrodes including 6010, 7010, 8010, 6011. It provides a more forceful, penetrating arc. When combined with hot start and arc force, this setting will make the arc more aggressive and help with maintaining a key hole in root pass welds. As a general rule, keep the arc short as possible to prevent arc outages and increase the arc force to 65% or

3. Process Reminder. The process reminder displays “Stick” when stick

more to maintain the arc and digging characteristics of the rod.

mode has been selected.

The Manual Plasma Cutting Screen

Manual/PowerSet Mode. This indicates which mode the machine is operating in, whether in full manual mode or in PowerSet mode which is a synergic, more automated mode. In PowerSet, many functions may not be available for adjustment. (See the Stick PowerSET section).

Remember the Plasma cutter uses compressed air. The air pressure, though it is reflected on the front of the unit, is adjusted on the rear at the regulator. The air pressure will not be adjustable through the front control knobs. Air pressure is subject to change while cutting due to changes in supply air pressure. Always set the air pressure while the gas is flowing. It

5. Amperage. The Amperage is adjusted by the right side adjustment. is normal to drop 3 or 4 PSI while cutting. Recommended pressures are

This is the default setting. If no adjustment is made to selected func- always cutting pressures, and not static pressures. If the air pressure

tions or parameters, the machine will automatically default back to the drops by more than 5 psi when cutting from the static pressure reading,

Component Identification and Explanation
Setting the Unit Up for Welding/Cutting Manually
increase supply hose diameter. Do not supply more than 90 psi to the rear regulator from the air compressor. If needed, the plasma cutter may be operated with Nitrogen gas with a high flow regulator.
5

1. Air Pressure. The air pressure is set and adjusted on the rear of the unit by the air pressure regulator that you previously installed. The display reflects the air pressure that you have set, or the air pressure that is present in the system while cutting. The left adjustment knob cannot be used to adjust the air pressure. This side of the display only reflects air pressure and is not controlled by any front panel control or button. However, it still serves as the default area for navigation purposes. If air pressure drops below acceptable safe levels for the torch operation, an error code screen will be displayed and the plasma setup screen will not reappear until the air pressure is at the suitable pressure required for operation. This may also happen if air pressure is too high. Upon startup, if the Cut function is selected, and no air is connected, the error screen will appear automatically.
2. Amps. Set amps with the right side control knob. Be sure to change consumable size with the change in Amps. Use the plasma torch parts and breakdown page in this manual, or use the PowerSet function to determine the correct consumable size to use.
3. Post Flow. This sets the amount of time the air will continue to flow after the arc has stopped. This is used to cool the torch and extend consumable life. Set this for at least 3 to 5 seconds unless making very short cuts. Typically 1 to 2 seconds for every 10A is sufficient.
4. Tip Saver. By setting this function to “ON” the unit will only initiate the pilot arc one time, at the beginning of the cut. Once the pilot arc has shut off once the arc is established, the arc will go out if continuity is lost. The Pilot arc will not relight unless the trigger is pulled again and held to reset. If the Tip Saver is “OFF”, then the pilot arc will automatically relight when continuity is lost if the trigger is kept held down. Keep the Tip Saver “OFF” if cutting, painted, rusty or expanded metal where continuity could be lost. NOTE: The pilot arc will eventually time out in either mode. Keep pilot arc on time to a minimum. Do not pull the trigger to light the pilot arc unless you are ready to cut. Using the pilot arc greatly affects consumable life.
32

Component Identification and Explanation
Setting the Unit Up for Welding/Cutting Manually

The Manual AC/DC TIG Screen 2

welded with DC unless it is an Aluminum or Magnesium, or an alloy thereof. Stainless, Bronze,

1 7

3 4 6
5
11 12 13 14 8

8. Up and Down Slope. Up and Down Slope provide a ramping up or down of the welding Amperage from the Starting or Ending Amp Setting. This is not used with the standard Pedal setting. But with settings such as 2T or 4T the unit can be programmed to slowly or rapidly (depending upon the length of time selected) to increase or decrease the Amperage to the preset Welding Amperage. In some cases where the Start Amperage is set above the welding amperage for a “Hot Start” effect, the Up Slope will actually slope “down” to the welding Amperage. Technically, the Down Slope could slope “up” if

the End Amperage value was set above the Welding Amperage,

though this would rarely be the case.

15 16 17 18

9. Start and End Amps. The Start and End Amps determine the Amper-

1. Welding Voltage. TIG welding voltage will always be displayed in green. The welding voltage for TIG is not adjustable since the voltage is controlled by the arc length. The default voltage displayed when no welding activity is occurring is the Open Circuit Voltage (OCV). When welding, the OCV will drop to reflect the actual welding voltage.

age at which the weld begins and ends. Starting Amperage helps to establish the arc and can be used to create a gentle or harsh start depending on the weld conditions. Typically the Start Amps will be set lower for an easy start and transition to welding Amperage. However, for use with the torch switch, occasionally a Hot start higher than the set welding Amperage may be required to establish a pud-

2. Input Voltage Confirmation. This confirms which voltage the machine

dle. A low Amp start is desirable so that the Tungsten life is improved

is being supplied. This also serves as a diagnostic tool. If the ma-

and less contamination occurs when the arc is struck, and it also

chine does not show 240V while operating on 240V, then the power

prevents burn through on thin metals. However, the Tungsten size

supply to the welder is likely faulty. NOTE: Maximum output of the

will dictate the minimum stable start the unit can perform. For best

machine is governed by the input voltage. Some selections may not

results with 3/32 and 1/8″ Tungsten, set the Start Amps to 15 to 20A

be possible on reduced input power.

higher than the minimum setting allowed. End Amp settings will be

3. TIG Process Reminder. This reminds the user which process is in use. In any TIG process, the shielding gas used is 100% Argon.

similar to Start Amps, especially when using the foot pedal to provide a gentle taper off of the arc so the weld crater can be properly filled

There is no gas reminder since Argon is always assumed for TIG. 10. Pre and Post Flow. The Pre and Post Flow settings provide a timed

4. Manual/PowerSet Mode. This indicates which mode the machine is operating in, whether in full manual mode or in PowerSet mode which is a synergic, more automated mode. In PowerSet, many functions may not be available for adjustment. (See the MIG PowerSET section).
5. AC/DC Mode Indicator. The unit displays the TIG mode. DC TIG is generally used for all metals except Aluminum and Magnesium and related alloys. AC is generally used for both Aluminum and Magnesium alloys.

flow of gas before the weld starts (Pre) and after the weld ends (Post). Shielding gas flow before the weld is important to providing a pocket of gas to displace the atmosphere and to provide an easily ionizable gas between the tip of the Tungsten and the work piece to help establish the welding arc. Post Flow provides after weld cooling and protection of both the weld and the Tungsten. In general, .5 seconds of Pre Flow time is enough gas flow to establish the arc properly. Post Flow is generally determined by the amount of Amperage used and the amount of time the weld takes to make. At a minimum, consider using 3 seconds for any weld. But figure as a general

6. Amperage. The Amperage is adjusted by the right side adjustment. This is the default setting. If no adjustment is made to selected functions or parameters, the machine will automatically default back to the

rule, dividing your amperage by 8 or 10 to determine the number of seconds of Post Flow time required. For short welds use 8. For long or heavy welding, use 10.

Amperage setting after 4 to 5 seconds.

11. Pulse. The Pulse is used in both AC and DC modes with this ma-

7. Start Type. The unit features different start types for TIG, which include both Lift TIG and High Frequency (HF) start types. HF is a touchless start. Lift TIG requires the torch tip to touch the metal briefly before the torch is lifted up to create an arc. Usually, all metals are

chine. Pulse helps to average “down” the Amperage, while maintaining penetration and travel speed. This helps to heat wicking and the subsequent warping often experienced on thinner metals. The pulse is composed of two parts. The first part of the Pulse is the Welding

Component Identification and Explanation
Setting the Unit Up for Welding/Cutting Manually

Amp stage of the pulse. This is the highest Amperage stage of the pulse. This is also referred to as the “Peak” Amperage. The second part of the Pulse cycle is the Pulse Amperage stage. This is also referred to as the “Base” Amperage, or sometimes technically referred to as the “Background Current”. At low frequencies, below 10Hz, and usually between .5Hz and 2 Hz, the pulse is also used to improve weld appearance by created a stacked, or neatly rippled puddle. At higher frequencies, it can be used to decrease arc cone width and focus the arc. Generally, pulse is not used for welding thicker metals unless warping is a concern.

will cycle on and will ramp automatically to the Welding Amp Selection set on the machine. Releasing the trigger will down slope and terminate the arc. 4T gives more control over the weld cycle. To use, press down and hold to start the Preflow and the arc. Once the Preflow time is over and the arc is established, release the torch trigger to weld. When the weld is done and the arc is ready to be terminated, press and hold the trigger until the machine fully down slopes and the down slope cycle has reached the end. When this happens, release the trigger and the arc will terminate and the timed post flow period will begin.

12. Pulse Frequency (Hz). Pulse Frequency is the number of times per 16. AC Balance % (For AC applications only. Not used for DC). The AC

second that the pulse cycle occurs. Low pulse frequencies common-

balance controls the balance between Electrode Positive and Elec-

ly used around .5 to 2 Hz allow the user to create a rippled, or de-

trode Negative during the AC cycle. This is expressed as a percent of

fined puddle and allows time to add filler before the next cycle occurs

100% Electrode Positive (+). The Electrode positive portion of the

and freezes the puddle. High pulse frequencies are useful for con-

AC wave form provides cleaning. The Electrode Negative portion of

stricting the welding arc cone and improving arc directability and

the AC wave form provides weld penetration. If too much cleaning

control of the welding heat.

percent is used, the Tungsten may ball, or the cleaned/etched area

13. Pulse Amps. Pulse Amperage is sometimes referred to as “base” amperage and is the low amperage stage of the pulse. This is the “freezing” stage of the pulse where the weld puddle begins to cool at low frequencies. At higher frequencies, the Pulse Amps help bring down the overall average Amperage input. This helps to control heat input. Pulse Amps should not be confused with “Peak” welding Amps, which are actually set with the main welding Amp setting.

running parallel to the weld will be excessive. Typically set the cleaning for 30% EP+ for sufficient cleaning to occur. Less EP+ may be used to lessen the width of the cleaning lines that parallel the weld. Using a setting of more than 40 to 45%, the Tungsten will begin to ball and the arc may begin to wander. At 50% EP+ the tungsten will begin to be consumed rapidly. If 50% EP+ is required to provide adequate cleaning on dirty or impure aluminum, step up the size of the Tungsten to be able to hold the heat without over-melting.

14. Pulse Time On. Pulse Time On is a time adjustment (expressed in %

If AC balance is set to 30% and the cleaning area is too wide, that is

that allows you to set and change the amount of time the pulse

a good indication of too slow of travel speeds. In this case, set the

spends in the “Peak” welding Amp stage of the Pulse and the “Base”

unit for more Amperage, and increase travel speed.

Pulse Amp stage of the pulse. Sometimes this is referred to as the Pulse “Duty Cycle”. As a percent of welding Amps, the amount of time can be split 50/50, 60/40 or any amount you desire up to the setting range limit of the machine. In this case, the Pulse Time On refers specifically to the percent of time that Welding Amp stage is “on” during one pulse cycle. General purpose welding will usually use a configuration such as 60% Pulse Time On, or at least 50%. If the pulse frequency is high or low, a 60% setting means the total amount of time in one second is spent in the Peak welding Amp stage. But these are just beginning points and the user can experiment with finding the best balance to meet the requirements. The

17. AC Frequency (Hz) (For AC applications only. Not used for DC). AC frequency helps to control the arc focus when welding in AC mode. Frequency refers to the number times per second the AC cycle occurs. Increasing the frequency narrows the arc cone and creates a more pinpoint and directable arc. However, when a higher frequencies are used, the puddle does not wet in as quickly. For a good starting point, start with a frequency between 90 to 120Hz. This range offers a good, consistent result while providing good arc control and an acceptable arc cone for most situations in daily welding. Note that at high frequencies, the pitch of the arc will be higher and louder.

higher the Pulse Time on is, the faster the travel speed will be and 18. Wave Form Control (For AC applications only. Not used for DC). This

the greater the wet in of the puddle will be. But average heat will be

unit features multiple wave forms to provide better welding control.

increased as well.

The wave forms featured in this unit are Advanced Square, Soft

15. Remote. This function provides a choice of control over how the welding arc is started/ended and how the Amperage is controlled. The 2T and 4T selections use the torch switch to start and end the arc and allows the programming on the machine to cycle the programming and control the slope functions as well as specific arc termination times. 2T is simply a “press and hold” function. The arc

Square and Triangular. Advanced Square is typically used for most default applications. It provides an excellent puddle wet-in and best travel speed. Soft Square provides a more rounded feel, with a softer arc and works well with people used to transformer style square wave. The Triangular Wave form is normally used for welding thin materials. The design of the wave form provides the least amount of heat input and will often feel “cold” if used for thicker materials.

Component Identification and Explanation

Setting the Unit Up in The PowerSet Mode

UNDERSTANDING POWERSET.

Using PowerSet Mode.

The PowerSet mode, regardless of process selected is designed to help the user make accurate settings without the aid of complicated charts or calculators. This helps both new welders and professionals to set the machine easily without an extensive trial and error process.
The synergic nature of PowerSet mode requires the user to input certain basic information (depending upon the process) such as metal thickness, electrode diameter, wire type, and gas type. Once entered, the machine takes over from there and presets a setting that is determined mathematically from the information given.

4 3
1

4 3
2

While PowerSet is a useful tool, not ever possible scenario can be predict-

ed. It does a good job at getting close to the right setting (in most case, it

will be very accurate). But things like weld position, joint design, and

even certain welding styles can create a situation where the provided setting is not perfect. In these cases, the PowerSet allows the user to fine tune the settings. However, there is a limit to adjustment that is allowed in the PowerSet mode to prevent an unworkable setting. This is usually a sufficient amount of adjustment allowed to allow the user to find the perfect adjustment. However, in the event the user cannot find the perfect setting in PowerSet mode or is unhappy with limitations placed on other

Keep in mind that if you don’t enter the correct information into the machine, the machine will operate correctly. The machine is dependent upon correct inputs for accuracy. Always review the information you’ve put into the machine before deciding the unit isn’t working correctly or there isn’t enough adjustment to provide the proper setting. This machine cannot sense wire diameter or plate thickness.

functions or modes, the user should leave PowerSet mode and use it in the manual configuration.

Regardless of the Process, the PowerSet mode essentially functions the same. The above image is the PowerSet mode as it appears in the MIG

USING POWERSET MODE. Starting PowerSet Mode

C25 process. Each process is slightly different with which functions and parameters are allowed to be set, but otherwise setup procedure is nearly identical. Begin the setup process by using the up and down arrows

To use the PowerSet mode, first select the process you wish to use, pay- ( ) on the left side to navigate to the “Work Thickness” (1) level. Rotate

ing attention to the type of gas/metal you are welding. Then, once you the left side adjustment knob to select the thickness of the metal you are

have properly set the process, select the Power Set Button at the bottom welding, or the closest thickness/gauge if not listed. Continue the setup

right side of the panel by pressing the button briefly. The LED above the process by using the up and down arrows ( ) on the right side to

PowerSet button will illuminate. This will activate the PowerSet Screen for navigate to the “Wire Diameter” (2) (Each mode varies whether its elec-

the process you are using. (Each process allows the use of PowerSet.) trode size or wire diameter that is to be selected). Use the right side ad-

Once activated you will be ready to begin entering the information. Be sure justment knob to select the correct size. NOTICE: If operating on 120V,

the information is accurate to achieve the best recommended setting.

some sizes and diameters will be not be allowed to be selected as it is

considered beyond the capacity of the machine. In some cases, selections

may be limited because it is beyond the capacity of the electrode size or

wire diameter to properly weld or cut.

Once the information has been entered, the machine will automatically set your welding or cutting parameters for you and will be indicated by the center adjustment bar in the stair stepped indicator below the parameter (3). The bar will have a 4 pointed star to indicate this is the target setting and will be highlighted green. If you need to fine tune the setting, the location of the green bar will move left or right down the “stairs” to the next lower level, (depending upon whether you are increasing or decreasing the value). If you move further than is recommended, the bar and numbered value (4) will turn red. If you find that you have moved too far off the suggest setting of the machine, all you will need to do is turn the adjustment knob until you are back at the center, tallest bar. Once you are

Component Identification and Explanation
Setting the Unit Up PowerSet Mode
back at the suggested setting, the white 4 pointed star will reappear. Keep in mind these are suggested setting only. The unit is designed so the user can adjust the functions up or down freely until the limit is reached to achieve desirable results. If a setting is too hot or too cold, adjust the settings to the desired result is achieved. Even though the settings may be in the “red” this will not harm the welder. It is simply suggesting the setting is out of the range that is typically recommended by the industry for general purpose welding. If the PowerSet setting does not allow enough adjustment, switch to Manual mode and create your own settings and save them under a program number for easy recall.
If you need to make any changes to the functions, use the up and down navigation arrows to navigate to the bottom of the menu and to the function. Most parameters will be on a black background and display either “AUTO” or “N/A” above them. These will be blocked from access and will be automatically set for you. If you desire control of these settings, then deselect the PowerSet mode and use the manual mode. HINT: If you are concerned about loosing the PowerSet mode to access and control things such as Pre/Post Flow or Inductance, simply copy from the PowerSet mode and then use the suggested settings into manual mode. You are then free to make any adjustment you need to any parameter or function permitted.
In Stick PowerSet mode, you will notice different restrictions on rod size selections that are allowed with different rod types, especially in 120V mode. This is normal. The welder’s programming takes into the account the normal min/max range of each class and size of welding rod and it’s respective capability at any given amperage.
Similarly in TIG PowerSet mode, some functions will be restricted or placed in Auto mode and will be preset or controlled based off the user inputs. In PowerSet, Pre and Post Flow functions are selectable for adjustment. The user may also select the type of arc start and the remote type used. Everything else will be preset for the user.
In Plasma PowerSet mode, the settings are very basic. However, remember to change your cutting tip based off the amperage suggested. Using too large or too small of a tip will cause malfunction of the cutting arc. If the tip is too small, the consumable will wear very quickly. If the consumable is too big, the arc will be unstable. The amp range for each size cutting tip is found on the Plasma torch parts page in this manual. This unit comes equipped with 40A tips. Most all items can be cut at 40A, regardless of the PowerSet suggested settings. The biggest difference between using a 20A rated tip and a 40A rated tip is the kerf width and the cut speed needed to keep the cut blown out and clean. On thin metals, the 40A tip may cause weld back after the sheet metal has been cut, or some extra dross may appear.
36

Component Identification and Explanation
NOTICE: The following sections cover MIG, TIG, Stick, and Plasma terms, definitions, and basic operation. Some of the terms overlap from process to process and serve essentially the same functions. Take note that some terms will repeat from process to process, but will be described in a way that is specific to the process being used. In some cases where function is identical or so similar to the same function found relating to another process it may not be repeated or redefined. For example, the 2T/4T torch switch function applies to both MIG and TIG, and it behaves similarly for each. However, there are slight differences to what it controls The general description under MIG and TIG will describe it slightly differently to accommodate the operational differences, but in the main drawing and discussion, the function will be more generic to accommodate both processes.
37

Component Identification and Explanation

Using The Trigger/Torch Switch Remote Functions

Operating the 2T/4T Remote Function
The Remote Torch Trigger function works with both the MIG and TIG processes. The Trigger function is designed to allow the user to program the welder so that the stages of the weld cycle can be controlled via operation of the torch switch. This should not be confused with a Remote Amp control like a Foot Pedal or a Spool Gun Amp control wheel. The switch itself provides no adjustable control. It is only designed to cycle a stage or stages of the weld cycle. Both TIG and MIG processes behave similarly in 2T and 4T modes since there are very similar controls in both processes.
2T function controls all of the weld cycle with a simple press-and-hold and release action. This is the conventional “pull the trigger” mode that is familiar to most users, but it involves controlling more functions than a simple “on and off” of the weld arc. This is also called a 2 step function. The torch trigger moves in two directions, each change of direction signals the welder to advance to another part of the weld cycle
4T function controls each stage of the weld cycle by multiple press and hold actions of the torch trigger. This is used to retain manual control over the slope stages and start and end portions of the weld cycle through each movement of the torch trigger. Press the trigger and hold to start the Pre- flow cycle and start the weld. Once the arc has started release the trigger to upslope and weld at the normal set Amperages. Pull and hold the trigger to allow the down slope cycle to occur. Once the down slope cycle has completed and the weld crater is adequately filled, release the trigger to end the weld. The arc will terminate and the Post Flow cycle will begin. A common error is to simply click the torch trigger rather than hold the trigger during the down slope. The only time the trigger should be clicked is in the middle of the down slope cycle to toggle the weld back to the welding cycle Amperage. If the cycle has fully reached the bottom of the down slope the cycle cannot be restarted and the arc will terminate when the trigger is released. This is useful for managing the weld heat once it begins to get hot. This toggling feature can be repeated during the weld. It’s not meant to be a adjustable amp substitute, but it is useful to help manage heat temporarily when a weld gets too hot to manage.
When using the TIG foot pedal, the Up and Down Slope functions are irrelevant because the user’s foot is controlling that function manually. It’s important to select only the “Pedal” function for the unit when the foot pedal is plugged in.
For the Spool Gun in MIG mode, the selection of the torch type automatically gives you control over the Amperage, but it still cycles all of the 2T/4T programming through the separate trigger pulls. The Wire Speed/ Welding Amps are adjusted on the gun, while the max amperage is set on the screen.
See the next column for a visual explanation of 2T and 4T function in TIG and MIG. Notice that the arrow buttons indicate an up (in or press) or down (out or release) movement of the torch trigger.

= UP ON SWITCH = DOWN ON SWITCH = UP ON SWITCH = DOWN ON SWITCH = UP ON SWITCH = DOWN ON SWITCH = UP ON SWITCH = DOWN ON SWITCH

Component Identification and Explanation

Explanation of MIG Functions and Terms

EXPLANATION OF WELDER FUNCTIONS

References

Read User Manual Online (PDF format)

Read User Manual Online (PDF format) >>

Download This Manual (PDF format)

Download this manual >>

Hurricane 220 MTS-C Stick Welder

Specifications

Product Usage Instructions

1. Getting Started

2. Connecting to Power Source

3. Air Compressor Connection

4. Torch Setup

5. Wire Installation

6. Welding Preparation

7. Welding Setup

8. Power Mode Configuration

FAQ

Q: What should I do if I encounter an error code?

Q: How do I shape the tungsten electrode for TIG welding?

Q: What is the duty cycle of the Hurricane 220 MTS-C?

2 Phillips

Component Identification

References

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Related Manuals