Everlast CT416, CT518, CT630D Owner's Manual

EVERLAST PRODUCTS

OWNER’S MANUAL

Everlast CT416/518/630D

DC TIG/MMA Welder

with Plasma Cutter

www.everlastgenerators.com

Email: [e-mail]
Phone: [phone] x201
Support: www.everlastgenerators.com

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 (wiring plug, TIG torch info, electrodes, etc) ………………..……….……. 13

This welding equipment is for industrial and professional use
in conformity with IEC 60974 International Safety Standard.

We offer a five-year warranty on our welders 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 without prior
notice and without obligation. This instruction manual was
issued July 2008.

WARNING

Welding and plasma cutting is dangerous. Not just to the equipment operator, but people
nearby and the surrounding area with the sparks and electrical power. Therefore, the
use of this equipment
all relevant safety rules. Please read and understand this instruction manual carefully before
installing and operating this product.

NOTICE:

Switching between functions (TIG/MMA/Plasma) should not be
done while you are welding or cutting as this can damage the
equipment. Do not disconnect the electrodes-torches or ground
clamp cable from the equipment while the unit is in use or pow­ered on.

Electric Shock can be fatal

Always connect the earth ground clamp to your work piece.
Avoid “all” contact with live components of the welding cir­cuit, electrodes/torches and wires with bare hands or skin. It
is necessary for the operator to wear dry welding gloves while
welding or cutting.
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 when welding or
cutting. Keep the working area well ventilation. Warn
others as well. Keep pets out of the area as well.

must only be under the most strict and comprehensive observance of

The operator should keep the working

Arc light-emissions are harmful to people’s eyes and skin.

Wear approved welding helmet, anti-radiation glass and
work clothes while welding and cutting. Measures must be
taken to protect people/pets in or near the working area as
well.

.

Fire hazards

The welding splash and sparks can cause a fire, remove
flammable materials away from the welding and cutting
work area.
and a trained person

Noise from the unit can possibly harm your hearing.

Surface noise is generated while welding 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.

USERS’MANUAL EVERLAST CT-D series - 2 -

Have a fire extinguisher nearby at all times

ready to use it.

GENERAL DESCRIPTION

The newly-developed EVERLAST CT-D series DC TIG, MMA and Plasma cutter al­lows welding stainless steel, alloy steel and carbon steel and other nonferrous metals
The power exchange rate of these models are over 85% efficient which will save your
power usage and provide for cleaner welds and cuts.

The design and development of our state-of-the-art Inverter technology used in our
welders and cutters, allows for the high power output with its solid state MOS-FET
(Metal Oxide Semi-conductor Field Effect Transistors). With high quality MOS-FET
output c
of 100KHz, thus reducing the size and weight of the main components (transformers).
The application of PWM (Pulse Width Modulation) technology enables the concentra­tion and stability of the output current (AMPS) and with much more precise and con­venient current
maintenance of these unit and maximizes EMI.

With the exclusive HF Inverter technology of the Everlast CT-D series, in comparison
to traditional welding equipment, you have more advantages, as it is much smaller in
size, lighter in weight,
welding equipment. Being a
world.

Note:

your output current while using your welder. This is available for the Everlast CT-D
series

Block Diagram:

omponents, these TIG welding units can function

control. The unique structural design enables the disassembly and

higher in power exchange rate; in comparison to the imported

single phase unit, it can be used through-out the

An optional foot pedal controller is available, which allows the modulation of

; improving welding efficiency and performance.

with a HF (high frequency)

.

USERS’MANUAL EVERLAST CT-D series - 3 -

INSTALLATION AND OPERATION

1. Power Cord : The power cord is attached to the unit, however you will be required to provide a power plug and power outlet.

This is to accommodate different countries and setups. Please contact an electrician if you are not qualified or not sure how to
attach an AC plug. See FAQ for more information on wiring.

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 clockwise.
2b: TIG torch, also plug the seven pin plug connector 2c from the TIG torch or the “optional” foot pedal into its socket, attach/

screw the TIG torch to ”GAS” outlet. Fasten the collar nuts, see the diagram below.
2b: Plasma torch will connect the same as the TIG just using the Plasma torch rather than the TIG torch.

Make sure you connect COMPRESSED AIR for Plasma operation OR Argon for TIG operation. 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 clockwise direction. Then the ground clamp connects to your work piece.

SWITCHES

3. Main power switch: The power switch. When “ON”

troubleshooting section.

4. MMA/TIG/Plasma mode switch:

5. AIR FLOW DELAY: This switch sets the pre and post argon gas or air flow delay.

6. AMP settings: This control sets the welding amperage (outer scale) and Plasma cutter amperage (inner scale)

7. Machine/Pedal switch: This switch tell the welder if you are using the torch on/off switch or optional foot pedal.

MMA is for stick/MMA welding.

INDICATORS

8. O.C./Over Current: This light will 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” welding/cutting but leave the unit “ON” for the fans to cool it. Wait
for the light to go “off” before you continue welding. If it does not go off please contact the manufacturer for help.

this switch will light up

and you will hear the fans turn on. If not see

TIG is for

DC TIG welding and Plasma for cutting.

USERS’MANUAL EVERLAST CT-D series - 4 -