Everlast CT416 User manual

EVERLAST PRODUCTS
OWNER’S MANUAL
Everlast CT416/518/63 D
DC TIG/MMA Welder
with Plasma Cutter
www.everlastgenerators.com
Email: [e-mail]
Phone: [phone] x201
Support: .everlastgenerators.com

This elding equipment is for industrial and professional use
in conformity ith IEC 60974 International Safety Standard.
We offer a five-year arranty on our elders and cutters
starting on the date of purchase.
Please read and understand the instruction manual carefully
before the installation and operation of this product.
The contents of this manual may be revised ithout prior
notice and ithout obligation. This instruction manual as
issued July 2008.
CONTENTS
- Warning……………………..………………..……………….…..……....………... 2
- General Description………...……….....……...…………………….………...….. 3
- Installation & Operation.……….…... .....……………………………………..….. 4
- Hookup and checks …………….…………………………………………………. 5
- General Operations ……………………………………………………………….. 6
- Caution..………………..…... ........…................. ..………………………………. 8
- Maintenance... .............. ..…………………………………………………………. 9
- Troubleshooting………….…………………………………………………….…… 10
- About Welding………………………………………………………………………. 11
- FAQ ( iring plug, TIG torch info, electrodes, etc) ………………..……….……. 13

WARNING
Welding and plasma cutting is dangerous. Not just to the equipment operator, but people
nearby and the surrounding area ith the sparks and electrical po er. Therefore, the
use of this equipment
must only be under the most strict and comprehensive observance of
all relevant safety rules. Please read and understand this instruction manual carefully before
installing and operating this product.
NOTICE:
S itching bet een functions (TIG/MMA/Plasma) should not be
done hile you are elding or cutting as this can damage the
equipment. Do not disconnect the electrodes-torches or ground
clamp cable from the equipment hile the unit is in use or po -
ered on.
Electric Shock can be fatal
Al ays connect the earth ground clamp to your ork piece.
Avoid “all” contact ith live components of the elding cir-
cuit, electrodes/torches and ires ith bare hands or skin. It
is necessary for the operator to ear dry elding gloves hile
elding or cutting.
The operator should keep the orking
piece insulated from themselves at all time.
Smoke and Gases generated while welding or cutting
can be harmful to your health.
Avoid breathing the smoke and gases hen elding or
cutting. Keep the orking area ell ventilation. Warn
others as ell. Keep pets out of the area as ell.
Arc light-emissions are harmful to people’s eyes and skin.
Wear approved elding helmet, anti-radiation glass and
ork clothes hile elding and cutting. Measures must be
taken to protect people/pets in or near the orking area as
ell.
.
Fire hazards
The elding splash and sparks can cause a fire, remove
flammable materials a ay from the elding and cutting
ork area.
Have a fire extinguisher nearby at all times
and a trained person
ready to use it.
Noise from the unit can possibly harm your hearing.
Surface noise is generated hile elding and cutting, ear
protection is necessary in some cases.
Machine fault or failure
Consult this instruction manual first. Then contact your local
EVERLAST dealer or supplier for further advice.
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USERS ’ MANUAL EVERLAST CT-D series - 3 -
GENERAL DESCRIPTION
The ne ly-developed EVERLAST CT-D series DC TIG, MMA and Plasma cutter al-
lo s elding stainless steel, alloy steel and carbon steel and other nonferrous metals
.
The po er exchange rate of these models are over 85% efficient hich ill save your
po er usage and provide for cleaner elds and cuts.
The design and development of our state-of-the-art Inverter technology used in our
elders and cutters, allo s for the high po er output ith its solid state MOS-FET
(Metal Oxide Semi-conductor Field Effect Transistors). With high quality MOS-FET
output c
omponents, these TIG elding units can function ith a HF (high frequency)
of 100KHz, thus reducing the size and eight of the main components (transformers).
The application of PWM (Pulse Width Modulation) technology enables the concentra-
tion and stability of the output current (AMPS) and ith much more precise and con-
venient current
control. The unique structural design enables the disassembly and
maintenance of these unit and maximizes EMI.
With the exclusive HF Inverter technology of the Everlast CT-D series, in comparison
to traditional elding equipment, you have more advantages, as it is much smaller in
size, lighter in eight,
higher in po er exchange rate; in comparison to the imported
elding equipment. Being a
single phase unit, it can be used through-out the
orld.
Note: An optional foot pedal controller is available, hich allo s the modulation of
your output current hile using your elder. This is available for the Everlast CT-D
series
; improving elding efficiency and performance.
Block Diagram:

INSTALLATION AND OPERATION
1. Power Cord : The po er cord is attached to the unit, ho ever you ill be required to provide a po er plug and po er outlet.
This is to accommodate different countries and setups. Please contact an electrician if you are not qualified or not sure ho to
attach an AC plug. See FAQ for more information on iring.
2. Connecting the Torches and Cutter (front of unit):
2a: MMA clamp, connect the MMA stick torch/clamp to the 2a fast-plug and turn it clock ise.
2b: TIG torch, also plug the seven pin plug connector 2c from the TIG torch or the “optional” foot pedal into its socket, attach/
scre the TIG torch to ”GAS” outlet. Fasten the collar nuts, see the diagram below.
2b: Plasma torch ill connect the same as the TIG just using the Plasma torch rather than the TIG torch.
Make sure you connect COMPRESSED AIR for Plasma o eration OR Argon for TIG o eration. Not doing so could damage
the unit or consumables.
2c: Torch on off control or optional foot pedal control.
2d: IN ALL modes mentioned above the fast-plug on the black ground clamp cable needs to be plugged into 2d socket on
the front panel, and turn it in the clock ise direction. Then the ground clamp connects to your ork piece.
SWITCHES
3. Main power switch: The po er s itch. When “ON” this s itch ill light up and you ill hear the fans turn on. If not see
troubleshooting section.
4. MMA/TIG/Plasma mode switch:
MMA is for stick/MMA elding. TIG is for DC TIG elding and Plasma for cutting.
5. AIR FLOW DELAY: This s itch sets the pre and post argon gas or air flo delay.
6. AMP settings: This control sets the elding amperage (outer scale) and Plasma cutter amperage (inner scale)
7. Machine/Pedal switch: This s itch tell the elder if you are using the torch on/off s itch or optional foot pedal.
INDICATORS
8. O.C./Over Current: This light ill turn on in the event the units overheats due to long periods of use at high current. It is
there to protect the unit. If you see this light “on”, “stop” elding/cutting but leave the unit “ON” for the fans to cool it. Wait
for the light to go “off” before you continue elding. If it does not go off please contact the manufacturer for help.
USERS ’ MANUAL EVERLAST CT-D series - 4 -

Hookup and checks
1) With automatic voltage fluctuation control, this elder ill function despite the input voltage exceeding
15% of the nominal voltage or a loss of up to 15% of nominal voltage.
2) If you increase the length of the leads, be a are that possible machine damage can occur ith exces-
sively long leads.
3) Make sure the gas/air supply is al ays available for the operation (plasma or TIG) you are orking
ith. Connect the Argon gas supply for TIG or compressed air for plasma. Make certain the connec-
tion and pressure is correct (see about elding for more information).
4) Ground the unit ith 6mm
2
(10 gauge) ire to the earth ground.
5) Connect the po er cord, torch and earth ground clamp (see dra ing belo ).
6) If you’ve follo ed all e have ritten, you should be ready to eld. Weld safely please…
Thank you for your time and support, Everlast Products.
USERS ’ MANUAL EVERLAST CT-D series - 5 -

GENERAL OPERATION
DC TIG INSTRUCTIONS (Steel and Stainless)
1. Set the operation mode s itch (s itch 4 on page 4) to TIG.
2. Set your amperage (s itch 6 on page 4) to your desired elding amperage.
3. Set the argon regulator (15-20cfh).
4. Set the pre/post flo s itch to 2.5 seconds or 5 seconds. 5 seconds for thicker steel.
5. Hook your ground clamp to the ork piece.
6. S itch ON the elding unit (s itch 3 on page 4).
7. Press the torch s itch or optional foot pedal, am electromagnetic valves ill click on, HF electricity should
be auditable and gas output presents.
Note: When starting ith a ne TIG session, press the s itch on the elding torch for several seconds to
completely fill the hose ith argon gas (purging any air out). At this point you are ready to eld. After eld-
ing; the post gas output continue for several seconds to protect the eld.
8. If using the optional foot pedal controller. Adjust the elding AMPS on the front panel to 0. The elding
amperage ill be adjustable ith the pedal controller.
9. The distance bet een tungsten and ork pieces should be in the range of 2mm to 4mm (1/8” to 1/4”).
Press the s itch of elding torch, you ill hear and see HF electricity bet een the tungsten and ork pieces.
Start your puddle and use your filler rod to fill it.
MMA/Stick welding (AC or DC)
1. Set the mode to MMA.
2. Connect the MMA torch as mentioned on page 4 section 2
3. Set your AMPS as desired (for the thickness of your ork pieces)
4. Turn on the MAIN po er, no other settings are required, you are ready to stick eld. See the “about elding” sec-
tion for more details and learning ho to strike your arc.
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USERS ’ MANUAL EVERLAST CT-D series - 7 -
GENERAL OPERATION (continued)
PLASMA CUTTER INSTRUCTIONS
1. Set the operation mode s itch to CUT (see page 4 for a diagram).
2. Connect the Plasma torch as sho n on page 4 section 2 (same as MMA just a different torch)
3. Set your AMPS as desired (for the thickness of your ork piece) AND AIR PRESSURE (65 PSI)
4. Turn on the MAIN po er, no other settings are required, you are ready cut.
Note: There are many ays to plasma cut. Al ays use extreme caution and the proper protection. Al ays blo the
melted metals a ay from you. You can either get close to the ork piece ith the torch tip to start the arc or
drag the side of the torch tip for dragging and cutting. The internet has many ebsites that ill explain
Plasma cutting as this is an instructional manual, be sure to search the internet for methods and example
projects.
CAUTIONS
1. Working Environment
1.1 The location in hich this elding equipment is installed should be of little dust, corrosive chemical gas,
flammable gas or materials etc, and of maximum 80% humidity
1.2 Avoid the operation of elding in the open air unless the orking area is sheltered from the sunshine, rain
ater and sno etc; the temperature of orking environment should be maintained ithin -10°C to +40°C;
1.3 Keep this cutting equipment 2’ or more from the all or obstacle .
1.4 Only ork in a ell ventilated area.
Safety Tips
2.1 Ventilation: This cutting equipment is small-sized, compact in structure, and has excellent performance in amper-
age output. The fans are only to extract heat generated by its internal electronics. Make sure your cutting area is
ell ventilated and use proper protection (breathing protection if required).
Cautions: Make sure the louvers (vents) on the equipment as al ays clear of obstructions. Good ventila-
tion is critical for the proper performance and service life of this cutting equipment.
2.2 O.C. Overload
If a sudden halt occurs hile cutting or elding and the O.C. (over current) light comes one, simply stop
elding.
Do not turn off the unit or restart it either. Leave the unit ON and allo the internal fans to bring
do n the temperature inside the equipment. Continue hen the O.C. light goes out.
2.3 Over-voltage
Regarding the po er supply voltage range of the equipment, refer to the Main
parameter tables (page 6
and 7). This cutting equipment has automatic voltage compensation in the po er supply, hich al-
lo s it to operate
ithin the given ranges listed there. In case that the voltage exceeds the stipulated
value, it is possibly damaging to the components of this equipment.
2.4 An earth terminal ground should be used if required and available. Connect the earth ground cable to
avoid the static and electric shock.
2.5 DO NOT ever contact the output terminals (torch and ground) hen elding or cutting. An electric
shock ill occur.
Keep SAFETY as number one, you are working with voltage, high amperage, sparks and gas.

CAUTIONS
1. The Working Environment
1.1 The location in hich this elding equipment is installed should have little dust,
corrosive chemical fumes, flammable gas, and of maximum 80% humidity .
1.2 Avoid elding in the outside unless the orking area sheltered from the sunshine,
rain and sno ; the temperature of orking environment should be maintained
ithin –50°F to +120°F;.
1.3 Keep this equipment 12 inches from any alls or obstructions.
1.4 Keep the orking environment “ ell” ventilated.
2. Safety Tips
2.1 Ventilation of equipment
This equipment is compact and can produce high output amperage. The fans are to
extract the heat generated by this equipments internal circuits hile in operation.
Maintain good ventilation of the louvers of this equipment. The minimum distance
bet een this equipment and any other objects in or near the orking area should be
no less that 12 inches. Good ventilation is of critical importance for the normal per-
formance and service life of your unit.
2.2 If you ever over heat!
If a sudden ever occurs hile using this equipment and the O.C. light turns one.
Stop cutting or elding and allo the fans to cool the unit until the O.C. light
turns off. Do not turn the unit off, as the fan ill help cool it faster.nt.
2.3 Input voltage!
Make sure you provide a 240vac 50-60Hz input ith 30 amps of po er to this unit.
This equipment has automatic voltage compensation, hich enables the unit to
ork given proper voltage, current and frequency if provided. If improper in-
put po er is not used,
it is possible to damage the components of the unit.
2.4 Make sure the green ground ire on the po er line and plug are connected to
ground, the other t o are to connect to 120vac hot legs for 240vac operation.
There is no neutral in this case. Connecting the earth ground is to avoid the electri-
cal shock.
2.5
NEVER contact the output terminals hen the elding. An electric shock can pos-
sibly occur if you are in contact a ground ith another part of your body (bare feet
as ell makes a great ground).
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