HTP Revolution 2500 User manual

Revolution™ 2500

1) FOREWARD
Thank you for purchasing an HTP America® Revolution™ 2500—our a vance , multi-process
wel er. The Revolution 2500 is a versatile, high-quality, an feature-rich machine that offers pulse
features in every wel ing process. With the Revolution 2500 you can run the following processes:
SMAW (Stick), SMAW-P (Pulse Stick), GTAW (TIG), GTAW-P (Pulse TIG). All TIG processes
offer both AC an DC options.
In MIG mo e you will fin a manual mo e a well as several synergic programs as well as single
an even ouble pulse programs . These features give you 100% control over the bea appearance
an heat input at any given time.
In the AC TIG mo e, the following wave forms are available: square wave, an triangular wave.
The Revolution 2500 offers the ability to run on single-phase power, from 110Volt* (with output
limitations) an 208 to 240V without output limitations. For crisp arc starts an excellent arc
stability we also recommen the use of 2% ceriate (U.S. Color Co e: Gray; European Color Co e:
Orange) tungsten electro es as our inverter is esigne to work best with them.
2) WARRANTY
It is expressly agree that there are no warranties, expresse or implie , ma e by either the
Salesman, Dealer, or HTP America, Inc. on pro ucts or parts furnishe hereun er, except the
Manufacturer’s Warranty against efective materials or workmanship as follows:
HTP America, Inc. warrants each new wel ing machine to be free from efects in material an
workmanship un er normal use an service for Three (3) Years after elivery to the original
purchaser. HTP America, Inc. will repair or replace, at its factory, any part or parts thereof.
Pro ucts shoul be returne to HTP America, Inc., with transportation charges prepai , an which
its examination shall isclose to its satisfaction to have been thus efective. This warranty being in
lieu of all other warranties, expresse or implie , an all other obligations or liabilities on its part
an it neither assumes nor authorizes any person to assume for it any liability in connection with the
sale of its machines.
This warranty shall not apply to any wel ing machine which has been repaire or altere by
unauthorize service epartments in any way so as, in the ju gment of HTP America, Inc., to affect
its stability an reliability, nor which has been subjecte to misuse, negligence, or acci ent.
HTP America, Inc. shall not be liable in any event, unless HTP America, Inc. receives notice of
allege breach of warranty, actual or constructe , specifying the claime efect within not more
than Thirty (30) Days after iscovery.
HTP America, Inc. has reserve the right to make changes in esign or a any improvements to its
pro ucts, at any time, without incurring any obligation to install the same on equipment.
180 Joey Drive
Elk Grove Village, IL 60007-1304
Ph.: 847) 357-0700 Fax: [phone]
Web: www.usaweld.com

This warranty is voi unless the warranty car is sent to HTP America, Inc. within Fifteen (15)
Business Days from the ate of purchase.
EXCLUSIONS TO WARRANTY:
1) MIG guns an TIG wel ing torches are warrante for a perio of Ninety (90) Days against
efects in material an workmanship.
2) Gas nozzles, contact tips, iffusors etc. as well as tungsten electro es, collet bo ies, collets, an
gas lenses are consumable items, WHICH CARRY NO WARRANTY.
Note: This warranty is to the original purchaser only. The warranty can be transferre to another
owner, with HTP’s approval, for a warranty transfer fee. HTP America, Inc. must be notifie within
Fourteen (14) Days of the sale an must be provi e with the contact information of the original
owner, the contact information of the new owner, an the serial number of the machine.
3) SAFETY SUGGESTIONS
It is forbi en for people with PACEMAKERS to use or come near the machine. When
wel ing near sensitive electronics, for example in hospitals or assiste living homes or aroun
computers or computer control mo ules in vehicles, we STRONGLY recommen turning off
HF (high-frequency arc start). Even an AC arc on a mo ern inverter can be ignite in lift-arc
mo e! HF travels long istances, 10 to 20 feet are very common in some instances, an HF can
interfere with electronics in neighboring buil ings if they are on the same transformer! Unlike
regular wel ing currents, that travel the path of least resistance, HF is unpre ictable.
Electric arc wel ing pro uces ultra-violet rays, which are harmful to skin an eyes.
Ultra-violet ra iation can penetrate lightweight clothing, reflect from light-colore surfaces, an
burn the skin an eyes.
- Wear a heavy, pocket-less, long-sleeve shirt, cuff-less trousers, an high-toppe work shoes.
- Wear a full-face wel ing helmet with a number ten or arker lens an a cap.
Electric arc wel ing pro uces flying sparks an hot material, which can cause fire.
- To avoi fire, o not wel on woo , plastic tile, or carpete floors. Concrete or masonry floors are
safest.
- Do not wel on pressurize containers.
- Do not wel on rums, barrels, tanks, or other containers until they have been cleare an cleane
as escribe in AWS Stan ar A6.01.
- Do not wear flammable materials.
- Wear non-oily/non-greasy, flameproof wel ing gloves; the oil or grease on the gloves may ignite.
- Avoi having any type of fuel, such as cigarette lighters or matches, on your person as you wel .
- Ensure that there is a fire extinguisher in the wel ing area.
Electric arc wel ing pro uces toxic fumes.
- Provi e a equate ventilation in the wel ing area at all times.
- Do not wel on galvanize zinc, ca mium, or lea beryllium materials unless you are POSITIVE
that sufficient ventilation is provi e . These materials pro uce toxic fumes.
- Do no wel in areas close to egreasing or spraying operations. Chlorinate hy rocarbon vapors
may react with the ultra-violet rays an form highly toxic phosphate gas.

- If you evelop eye, nose, or throat irritation uring wel ing, stop wel ing imme iately. This is an
in ication that ventilation is not a equate. Do not continue to wel until ventilation is improve .
ELECTRIC SHOCK CAN KILL.
Expose , electrically hot con uctors, other bare metal in the wel ing circuit, or ungroun e ,
electrically hot equipment can fatally shock a person whose bo y becomes a con uctor. Do not
stan , sit, lie, lean on, or touch a wet surface when wel ing.
- Disconnect the power supply before working on the wel ing machine.
- Do not work with eteriorate or amage cables.
- Frequently inspect cables for wear, cracks, an amage. Replace those with excessively worn
insulation to avoi a possible lethal shock from bare cable.
- Do not touch bare electrical parts.
- Ensure that all of the panels covering the wel ing machine are firmly secure in place when the
machine is connecte to the power supply.
- Insulate yourself from the workbench an from the floor (groun ); use insulating footwear an
gloves.
- Keep gloves, footwear, clothes, the work area, an the wel ing equipment clean an ry.
- Check the machine power cable frequently; the power cable must be free from amage to the
insulation. BARE CABLES ARE DANGEROUS. Do not use the machine if the power cable is
amage ; a amage power cable must be replace imme iately.
- If it is necessary to open the machine, first isconnect the power supply an then wait Five (5)
Minutes to allow the capacitors to ischarge. Failure to take this precaution may expose you to the
angerous risk of electric shock.
Noise can amage your hearing. Protect yourself suitably to avoi hearing amage.
The wel ing arc can cause burns. Keep the tip of the wel ing gun/torch far from your bo y an
from other persons.
For more information, refer to the following stan ar s an comply as applicable.
1) ANSI Stan ar Z49.1 SAFETY IN WELDING AND CUTTING, obtainable from the American
National Stan ar s Institute, 1430 Broa way, New York, NY 10018.
2) ANSI Stan ar Z87.1 SAFE PRACTICE FOR OCCUPATIONAL AND EDUCATIONAL EYE
AND FACE PROTECTION, obtainable from the American National Stan ar s Institute, 1430
Broa way, New York, NY 10018.
3) AWS Stan ar A6.0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable from the American Wel ing Society, 2051 NW 7th St., Miami, FL
33125.
4) NFPA Stan ar 51 OXYGEN-FUEL GAS SYSTEMS FOR WELDING AND CUTTING,
obtainable from the National Fire Protection Association, 470 Atlantic Ave., Boston, MA 02210.
5) NFPA Stan ar 51B CUTTING AND WELDING PROCESSES, obtainable from the National
Fire Protection Association, 470 Atlantic Ave., Boston, MA 02210.
6) CGA Pamphlet P-1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS,
obtainable from the Compresse Gas Association, 500 Fifth Ave., New York, NY 10036.
7) OSHA Stan ar 29 CFR, Part 1910, Subpart Q, WELDING, CUTTING, AND BRAZING.

4) SPECIFICATIONS
Revolution 2500 Specifications
Input Voltage ( volts ) Single Phase : 115 – 240 V
Electronic Overloa Protection YES
Wel ing Mo es STICK ( an Pulse Stick )
TIG ( an Pulse Tig )
MIG MANUAL
MIG 2T ( an Pulse Mig )
MIG 4T ( an Pulse Mig )
MIG 4TS ( an Pulse Mig )
Hot-Start Stick ( % ) 0 to 50
Arc-Force Stick ( % ) 0 to 500
Wave Forms TIG Square , Triangular
AC Frequency ( Hz ) 20 to 400 ( Up to 100 Amps )
20 to 200 ( Over 100 Amps )
AC Balance ( % ) 10 to 90
Pre-Flow ( Secon s ) TIG : 0,3 – 2
MIG : 0,1 - 2
Post Flow ( Secon s ) TIG : 0,1 - 15
MIG : 0,5 – 15
Initial Amps ( % ) 10 to 90
Final Amps ( % ) 10 to 90
Wire Diameter
*Depen s on the material being wel e ( not all
wire can be wel e in all sizes )
.023” to .045”
Wire Fee Rate ( In/Min.) 55 to 629
Wire Spool Capacity 8”
Pulse Parameters
Pulse/Secon (PPS) Stick
Pulse/Secon (PPS) TIG
DC Peak Time (%)
Backgroun Amps (%)
0,4 to 5,0
0,4 to 999,9
10 to 90
10 to 90
Dimensions 300 x 420 x 535
Weight ( lb ) 77,6

DATA PLATE

FRONT PANEL CONNECTIONS
Z – central connector for MIG gun
U – connector for tig torch or electro e hol er
N – gas for tig torch (outlet)
Y – remote control receptacle
W – WORK (groun ) clamp, automatic polarity reversal epen ing on wel ing process
Z
U
N
Y
Z
W
USB PORT . This USB port i
s used only for
software update
Fig. 1
Fig. 2

BACK PANEL CONNECTIONS
P – power switch
Q – connector for tig torch or electro e hol er
R – port for TIG an Spool Gun shiel ing gas
S – port for MIG shiel ing gas
T – ata plate
Fig. 3
P
Q
R
S
T

ELECTRICAL CONNECTIONS
Your REVOLUTION 2500 operates to its full capacity on single-phase, 230V power (208V-240V). IT can
be run on 110/120 volt with re uce output. The machine raws 30 amps (230 volts) from of the wall when
operating at maximum output. We recommen a 30 Amp breaker for maximum performance. If you operate
the machine on a generator, it nee s to be a clean power generator with a minimum of 7500 watts. 7500
watts must be the “continuous” rating or “running watts” rating of the generator, NOT the “peak” rating or
“starting watts” rating of the generator. If you operate the machine on an extension cor , the wire size of the
cor nee s to be at least 10AWG an shoul not excee a length of 100’ regar less if you operate the
machine on 110/120 or 220/240 volt.
The machine is from the factory equippe with a NEMA6-50 plug an will plug into a matching receptacle
an is “rea y to be powere on”. For the first few secon s you will see the message PF0 flashing in the
isplay, the machine is now evaluating which voltage is supplie to the machine an will make internal
a justments. After this PF0 message flashes a few times it will go away, an the machine will go to the
regular operating screen. The machine is rea y to wel now.
To operate the machine on 110/120 volt please use a apter plug (HTP part number 5 5P650R 8) to a apt
to 110/120 volt. To operate the machine on 110/120 Volt simply plug machine into the wall outlet, wait for
the PF0 message to clear an the machine is rea y to be use now. There are no switches to switch, no
mo ifications nee e the machine will automatically i entify the input voltage an work properly.
When operating this machine on 110/120volt please use a e icate circuit (no other lights or grin ers or any
other appliances shall share the circuit with the wel ing machine). The REVOLUTION 2500 can be operate
on a 15amp 110/120volt circuit but with even more limitations in regar on maximum output an uty cycle,
for best results wel ing on 110/120 volt a e icate 20amp circuit is recommen e . On a 120volt 20amp
circuit the maximum output of the machine is 120A MIG, 110A Stick an 150A Tig. For more etaile specs
please refer to the ata plate on your machine.