CC CV GMAW SMAW GTAW IGBT AC/DC PULSE 1 PHASE DV 120/240V Operator’s Manual for the Lightning MTS 275 Safety, Setup and General Use Guide Rev. 1 everlastwelders.com 1-877-755-9353 329 Littlefield Ave. South San Francisco, CA 0 11220-19 Specifications and Accessories subject to change without notice.
TABLE OF CONTENTS CUSTOMER GREETING 3 EVERLAST CONTACT INFORMATION 4 SAFETY INSTRUCTIONS 5 PERFORMANCE/DESIGN SPECIFICATIONS 9 ELECTRICAL INPUT/OUTPUT/DUTY CYCLE 10 GENERAL PRODUCT AND USE INFORMATION 11 DUTY CYCLE AND WARNINGS 12 SUMMARY OF FEATURES 13 GENERAL MIG/FLUX-CORED/DRIVE ROLL INFORMATION 14 MIG GUN AND WIRE SPOOL INSTALLATION 18 CONNECTING GAS AND REGULATOR INFORMATION 20 GAS SELECTION AND GAS FLOW RATE 22 CABLE CONNECTIONS AND POLARITY 23 MIG CONNECTION 24 FLUX-CORED
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Safety Precautions Everlast is dedicated to providing you with the best possible equipment and service to meet the demanding job requirements that you may have. We want to go beyond delivering a satisfactory product to you. That is the reason we offer free technical and basic welding support to assist you with your needs, should an occasion occur where it is needed. With proper use and care your product should deliver years of trouble free service.
Safety Precautions These safety precautions are for protection of safety and health. Failure to follow these guidelines may result in serious injury or death. Be careful to read and follow all cautions and warnings. Protect yourself and others. Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can cause severe skin burn and damage. There are other potential hazards involved with welding such as severe burns and respiratory related illnesses.
Safety Precautions WARNING! Persons with pacemakers should not weld, cut or be in the welding area until they consult with their physician. Some pacemakers are sensitive to EMF radiation and could severely malfunction while welding or while being in the vicinity of someone welding. Serious injury or death may occur! Welding and plasma cutting processes generate electro-magnetic fields and radiation.
Safety Precautions WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground clamp. Do not stand in water or damp areas while welding or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain or in extremely humid conditions. Use dry rubber soled shoes and dry gloves when welding or cutting to insulate against electrical shock.
Section 1 Introduction and Specifications General Performance Specifications Lightning MTS 275 MIG/TIG/Stick Amp Range 120V: MIG 30-150A/ TIG DC: 10-150A, AC: 15-150A / Stick 10-120A 240V: MIG 30-250A/ TIG DC: 10-250A, AC: 15-250A / Stick 10-200A MIG Output Type Standard, non-pulse, with Flux-Cored Capability. Spool gun ready. (Spool gun is optional) Volt Adjustment Range MIG 120V: 15.5-22V 240V: 15.
Section 1 Introduction and Specifications Electrical Specifications EVERLAST LIGHTNING MTS 275 MODEL: Lightning MTS 275 1~ f1 Serial No. EN/ IEC60974.1 f2 240V; DC: 30-250A; 15.5-26.5V S U0 V 74V X 60% 100% 35% 60% 100% I2 250A 200A NA 150A 90A U2 26.5V 24V NA 21.5V 20V 240V; DC: 10-250A; 10.4-20V AC: 15A-250A; 10.6-20V S U0 V 74V 1~ 50/60 Hz PROTECTION CLASS IP21S U0 V 74V 120V; DC: 10-150A; 10.4-16V AC: 15-150A; 10.
Section 1 Introduction and Specifications General Product and Use Information NOTICE: This manual has been compiled to give an overview of operation and is designed to offer information centered around safe, practical use of the welder and its functions Welding operations are inherently dangerous. Only the operator of this welder can ultimately ensure that safe operating practices are being followed, through the exercise of common sense practices and training.
Section 1 Introduction and Specifications General Product and Use Information DUTY CYCLE AND ERROR CODES This Multi-Process welder features a self-diagnosing feature, which will display an error and a numeric error code that corresponds to a known fault or error, when a problem has occurred. This unit has a duty cycle rating of 60% @ 250 Amps while welding in MIG and TIG mode. The duty cycle rating for stick is 60% @ 200 Amps.
Section 1 Introduction and Specifications Discussion of Welder Features and Operation SUMMARY OF FEATURES GMAW Process (MIG) and F-CAW (Flux-Cored) The digitally controlled components of this welder precisely control wire feeding and arc quality. It also gives real-time feed back about the welding output parameters. The welder is also spool gun (gun optional) ready for economical welding of Stainless and Aluminum wires if needed.
Section 1 Introduction and Specifications Discussion of Welder Features and Operation SUMMARY OF FEATURES Pulse TIG Mode The pulse TIG feature can be employed to control heat, wicking of the puddle and reduce the arc cone diameter, improving the directability of the arc. The Pulse TIG mode has three components: Pulse Amps, Pulse Frequency, and Pulse Time-On. Each feature works together with the others to change the shape of the welding arc, average heat, puddle control, wet-in and penetration.
Section 1 Introduction and Specifications Discussion of Welder Features and Operation SUMMARY OF BASIC FEATURES Foot Pedal/Finger Amp Control (located with the 2T/4T function) The foot pedal function setting controls AC and DC TIG functions. It starts and ends the arc. It also allows the welding Amperage to be controlled within the range from minimum start/end amps to the maximum welding Amperage selected on the panel.
Section 2 Setup Guide General Product and Use Information MIG/FLUX-CORED WIRE, DRIVE ROLL AND GUN INFORMATION This unit is designed for multiple types and sizes of MIG and Flux-Cored wire. Recommended wire sizes range from .30” to .045” (.6 to 1.2mm), with the standard equipped 36 series MIG gun. Keep in mind that you may need to purchase optional drive rolls and/or another gun or gun liner to fully utilize and weld with all wire types.
Section 2 Setup Guide General Product and Use Information MIG/FLUX-CORED WIRE, DRIVE ROLL AND GUN INFORMATION For smooth wire feeding, free of jamming and slipping, the drive rolls must be sized correctly. You must select the proper type and size of drive roll for the size and type of wire used. The size of the wire and the type of drive roll is marked on the side of each drive roll. On this welder, the groove on the same side of the printed size is the groove that corresponds to the marked size.
Section 2 Setup Guide General Product and Use Information MIG/FLUX-CORED WIRE, DRIVE ROLL AND GUN INFORMATION The MIG gun has a Euro-style quick connect that is used to connect the gun to the welder.
Section 2 Setup Guide General Product and Use Information MIG/FLUX-CORED WIRE, DRIVE ROLL AND GUN INFORMATION 1. 2. 3. 4. 5. 6. 7. 8. Install the MIG gun as instructed in “To install the MIG gun (torch)” on the previous page. Loosen the top idler roller tensioner, rotating the black tensioner knob counter-clockwise. Flip the tensioner down, toward you, releasing the carrier arm that holds the top drive rolls. Raise the drive roll arm up.
Section 2 Setup Guide General Product and Use Information NOTICE: The Lightning MTS 275 uses two gas connections. One connection is for MIG operation and the other is for TIG operation. Two cylinders may be connected at the same time. Only one regulator is supplied, but an additional regulator may be purchased. If only one cylinder is used, or no connections are being used, the open fitting(s) should be plugged or covered to prevent dirt and debris from entering the fittings.
Section 2 Setup Guide General Product and Use Information Gas and Electrical Connections ADJUSTMENT VALVE FLOATING BALL FUSE 580 CGA 1x2 5/8”-18 RH INERT CYLINDER PRESSSURE GAUGE TIG GAS MIG GAS NEMA 6-50P 50A 240V 1 PHASE NOTICE: The unit is shipped with only one regulator. However the unit does have separate gas inlets for MIG and TIG. An additional regulator may be purchased and both may be connected at the same time.
Section 2 Setup Guide General Product and Use Information GAS SELECTION Gas selection for different processes can be confusing. The unit has preset selections for gas type and recommendations for gas in the reminder screen that pops up for a few seconds when a new process is selected. These guides help you remember which gases should be used. However, for MIG, they are not absolute. This is particularly true of the MIG Steel C25 and MIG Stainless Mode, unless it is being used in Pro-Set mode.
Section 2 Setup Guide CONNECTIONS AND POLARITY STOP! IMPORTANT! Read the information on this page and the following pages carefully. It contains important information on correct polarity of your torches and guns for all processes. Failure to follow these directions can lead to damage to your welder. Damage occurring from improper polarity may not be covered under warranty. CAUTION! Pay attention to the separate DC and AC TIG connections.
Section 2 Setup Guide CONNECTIONS AND POLARITY MIG (GMAW) WORK - GUN + NOTICE: For MIG, the polarity connection for the gun is located under the spool cover. It must be connected to the positive terminal. MIG requires that the gun be positive polarity and the work clamp be negative polarity.
Section 2 Setup Guide CONNECTIONS AND POLARITY Flux-Cored (F-CAW) WORK + GUN - NOTICE: For Flux-Cored, the polarity connection for the gun is located under the spool cover. It must be re-located to the negative terminal. Flux-Cored requires that the gun be negative and the work clamp be positive polarity.
Section 2 Setup Guide CONNECTIONS AND POLARITY MIG (GMAW) with Spool Gun GUN + CONTROL WORK - NOTICE: The polarity connection for the Spool gun is located under the cover. The gun polarity should be positive. If welding Flux-Cored wire with the spool gun, use the negative terminal, and configure for Flux-Cored use.
Section 2 Setup Guide CONNECTIONS AND POLARITY DC TIG ONLY! (GTAW-DC) NOTICE: The water cooler is optional and must be purchased separately. Water cooled torches must be used with water coolers and cannot be used dry. GAS TO COOLER FROM COOLER TORCH - CONTROL SWITCH PEDAL WORK + NOTICE: The foot pedal and the torch switch cannot be connected at the same time.
Section 2 Setup Guide CONNECTIONS AND POLARITY AC TIG ONLY! (GTAW-AC) NOTICE: The water cooler is optional and must be purchased separately. Water cooled torches must be used with water coolers and cannot be used dry. GAS WORK (AC TIG ONLY) TO COOLER FROM COOLER TORCH - CONTROL SWITCH PEDAL NOTICE: The foot pedal and the torch switch cannot be connected at the same time.
Section 2 Setup Guide CONNECTIONS AND POLARITY Stick (SMAW) WORK - TORCH+ NOTICE: This is the typical setup for stick welding. Most all welding electrodes use electrode positive as the preferred polarity. Some rods are designated for both polarities. Consult the electrode manufacturer’s recommendations for applications of EN or EP. Operation with old or improperly kept welding electrodes will affect performance.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS PANEL CONTROLS AND NAVIGATION GENERAL OVERVIEW OF MANUAL SETUP This welder has an user interface that has been carefully designed to reduce needless steps and eliminate hidden menus where ever it is possible. The key feature that was most important during the design process, was to mimic the feel of an analog machine, where most all settings are visible at a glance.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS PANEL CONTROLS AND NAVIGATION GENERAL OVERVIEW OF POWER-SET FUNCTION The Power-Set function has been designed to be a predictive setting guide for the beginner and professional seeking easy, straight forward, no-hassle setup for many welding applications. The Power-Set function can be used to suggest useful settings for DC TIG (Steel/Stainless, Titanium etc.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS POWERING UP THE WELDER BOOT SCREEN MENU When the unit is turned on, the unit will display a boot screen similar to the one above while it is powering up and determining the input voltage. All the LEDs should be lit as well. This will take a few seconds, and then it will default to indicate the last used process in the vertical LED array.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS PANEL CONTROLS AND NAVIGATION NAVIGATION AND ADJUSTMENT SUMMARY Although it may take a little practice at first, the navigation of the screens and menu are fairly straight forward. The left and right (arrow) buttons located below the screen will always navigate around the pin wheel menu or 4-way menu Screen. In Power-Set mode, arrow buttons are used to select filler size/ type, or metal thickness and only navigate the X segment closest to the button.
Section 2 Setup Guide TIG STEEL/STAINLESS (DC TIG) 34
Section 2 Setup Guide UNDERSTANDING DC TIG FUNCTIONS TERMS RELATED TO DC TIG FUNCTIONS Arc Start Type. There are two basic forms of Arc starting that may be selected in manual mode, The user may select from either High Frequency (touchless) arc starting or Lift Start (Lift Arc) . High Frequency start sends an HF impulse to the torch tip to jump the gap between the Tungsten and the workpiece which establishes a circuit path for the welding arc to follow and ignite.
Section 2 Setup Guide UNDERSTANDING DC TIG FUNCTIONS TERMS RELATED TO DC TIG FUNCTIONS Pre-Flow Time. Pre-flow time is the amount of time that the shielding gas flows before the start of the weld. This is used to help provide clean arc starts and prevent oxidation of the weld metal by forming a pocket of shielding gas around the weld area before the arc starts. It also preserves the point on the Tungsten. Typical Pre-Flow times range from .5 to 1.5 seconds. Pulse.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS DC TIG FUNCTIONS AND PARAMETER SELECTIONS TIG STEEL/STAINLESS (DC TIG) SELECTION To begin, select the TIG Steel/Stainless option by scrolling through the left menu array of LEDs. The LED will light and the following screen will display briefly. Pay attention to the shielding gas reminder, and make sure you have the shielding gas connected and turned on. SELECTION AND ADJUSTMENT OF TIG STEEL/STAINLESS (DC TIG) PARAMETERS 1. 2.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SELECTION AND ADJUSTMENT OF DC TIG (TIG STEEL/STAINLESS) IN POWER-SET MODE Important! Before entering the Power-Set mode, be sure to select and adjust all basic settings such as pre-flow, control method etc. (except Amps). The Power-Set mode does not set these functions for you. If at any time an adjustment needs to be made to the basic functions such as pre-flow, control type, start Amps etc.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS DC TIG FUNCTIONS AND PARAMETER SELECTIONS TIG STEEL/STAINLESS (DC TIG) SELECTION OF ARC STARTING 1. 2. 3. 4. To select the arc start type, press and release the right arrow button one time to highlight the right square box that indicates arc start type. (This assumes the unit is in the default highlighted position: Amps) Press and release the settings button to bring up the 4 way secondary menu to access the start types.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS DC TIG FUNCTIONS AND PARAMETER SELECTIONS TIG STEEL/STAINLESS (DC TIG) SELECTION OF 2T/4T/PEDAL/FINGER OPERATION 1. 2. 3. 4. To select the type of control function, press and release either one of the arrow buttons several times until the Control segment of the pinwheel is highlighted. Press and release the settings button to bring up the 4 way secondary menu to access the control selections.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS DC TIG FUNCTIONS AND PARAMETER SELECTIONS TIG STEEL/STAINLESS (DC TIG) SELECTION AND ADJUSTMENT OF PULSE 1. 2. 3. 4. 5. To turn on and adjust the parameters of the pulse function, press and release either one of the arrow buttons several times until the pulse segment of the pinwheel is highlighted. Press and release the settings button to bring up the 4 way secondary menu to access the pulse on/off and pulse parameters.
Section 2 Setup Guide CAUTION! When changing over from DC TIG (Stainless, Steel and other metals except Aluminum and Magnesium), to AC TIG (Aluminum and Magnesium), you must remember to change the location of the work clamp over to the red terminal marked “AC”. If you do not, damage and incorrect operation may occur.
Section 2 Setup Guide UNDERSTANDING AC TIG FUNCTIONS TERMS RELATED TO AC TIG FUNCTIONS AC Balance. This refers to the amount of time that the AC wave form stays at either positive or negative polarity. In simple terms the amount of time that the unit spends in either positive or negative polarity can be skewed one way or the other to favor more Electrode positive, or more Electrode negative as the AC wave form cycles. This is the “balance” of the wave form.
Section 2 Setup Guide UNDERSTANDING AC TIG FUNCTIONS TERMS RELATED TO AC TIG FUNCTIONS Crater. The weld crater is the sunken area left at the end of the weld where the weld pool solidified. This divot is detrimental to welds and cause cracking or create a point of weld stress as the weld metal tends to shrink at this point. The crater should be filled before terminating the arc. In best practice, this is done during the down-slope stage of the weld cycle. Down-Slope.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS AC TIG FUNCTIONS AND PARAMETER SELECTIONS TIG ALUMINUM SELECTION To begin, select the TIG Aluminum option by scrolling through the left menu array of LEDs. The LED will light and the following screen will display briefly. Pay attention to the shielding gas reminder, and make sure you have the shielding gas connected and turned on. SELECTION AND ADJUSTMENT OF TIG ALUMINUM PARAMETERS 1. 2.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SELECTION AND ADJUSTMENT OF AC TIG (TIG ALUMINUM) IN POWER-SET MODE Important! Before entering the Power-Set mode, be sure to select and adjust all basic settings such as pre-flow, control method etc. (except Amps). The Power-Set mode does not set these functions for you. If at any time an adjustment needs to be made to the basic functions such as AC wave form, pre-flow, control type, start Amps etc.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS AC TIG FUNCTIONS AND PARAMETER SELECTIONS TIG ALUMINUM (AC TIG) SELECTION OF ARC STARTING 1. 2. 3. 4. To select the arc start type, press and release the right or left arrow button until the arc start pinwheel segment is highlighted. Press and release the settings button to bring up the 4 way secondary menu to access the start types. Press one of the arrow buttons to highlight the desired start type.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS AC TIG FUNCTIONS AND PARAMETER SELECTIONS TIG ALUMINUM (AC TIG) SELECTION OF 2T/4T/PEDAL/FINGER OPERATION 1. 2. 3. 4. To select the type of control function, press and release one of the arrow buttons until the control segment of the pinwheel is highlighted. Press and release the settings button to bring up the 4 way secondary menu to access the control selections. Press and release one of the arrow buttons to highlight the desired type of control.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS AC TIG FUNCTIONS AND PARAMETER SELECTIONS TIG ALUMINUM (AC TIG) SELECTION AND ADJUSTMENT OF PULSE AND ADVANCED PULSE To turn on and adjust the parameters of the pulse OR advanced pulse (mixed TIG) function: 1. Press and release either one of the arrow buttons several times until the pulse segment of the pinwheel is highlighted. 2.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS AC TIG FUNCTIONS AND PARAMETER SELECTIONS TIG ALUMINUM (AC TIG) WAVE FORM SELECTION AND ADJUSTMENT OF AC FREQUENCY AND BALANCE To select the wave form and adjust the AC Frequency and Balance: 1. Press and release one of the arrow buttons until the AC segment of the Pinwheel is highlighted. 2. Press and release the settings (gear icon) button to access the 4-way menu. The AC wave form is selectable from this menu.
Section 2 Setup Guide NOTICE: The sections on MIG and Flux-Cored adjustment and operation have been combined since setup and adjustment is similar. Where there are exceptions, it will be noted.
Section 2 Setup Guide UNDERSTANDING MIG FUNCTIONS TERMS RELATED TO MIG/FLUX-CORED SETUP Amps. (A) Amps are directly related to wire feed speed in MIG and Flux-Cored operation. The type of wire, the diameter of the Wire and the Wire feed speed govern the amount of current that flows as wire is fed. This is comparable to the rate of “flow” of water. While Amps aren’t shown on the panel, WFS controls the Amp output of the unit. Burn-Back.
Section 2 Setup Guide UNDERSTANDING MIG FUNCTIONS TERMS RELATED TO MIG/FLUX-CORED SETUP Start. This is the initial wire feed speed (WFS) that helps start the weld. Expressed in Inches per Minute, this can be used interchangeably with the term run-in, which is designed to slow the run-in of the welder so that the wire doesn’t tend to stutter (machine-gun) when you start the weld. Or the wire speed can be set a bit higher if desired than the wire feed speed used when welding.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS MIG/Flux-Cored Functions and Parameter Selections MIG/FLUX-CORED FUNCTION SELECTION To begin, select the desired MIG or Flux-Cored option by scrolling through the left menu array of LEDs. The LED will light and the following screens will display briefly. Pay attention to the shielding gas reminder, and make sure you have the shielding gas connected and turned on for MIG. Flux-Cored requires no gas.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SELECTION AND ADJUSTMENT OF MIG/FLUX-CORED PARAMETERS 1. 2. 3. Once the process has been selected, use the right or left arrow button to select the desired parameter for adjustment. The selected parameter on the pin wheel will be highlighted in red, indicating this parameter is ready for adjustment. Rotate the top right knob to increase or decrease the parameter value.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SELECTION AND ADJUSTMENT OF MIG/FLUX-CORED PARAMETERS In all MIG and Flux-Cored wire modes, use both top and bottom knobs to control both Wire Feed Speed and Voltage. The top knob controls Wire Feed Speed and the bottom knob controls Voltage, when in the default position. When the right or left arrow button is pressed, and a segment in the pinwheel is highlighted, the WFS will not longer be highlighted red and adjustment of the WFS will not be possible.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SELECTION AND ADJUSTMENT OF MIG/FLUX-CORED PARAMETERS IN POWER-SET MODE Important! Before entering the Power-Set mode, be sure to select and adjust all basic settings such as pre-flow, control method etc. (except WFS and Voltage). The Power-Set mode does not set these functions. It only sets the Wire Feed Speed and Voltage. If at any time an adjustment needs to be made to the basic functions such as pre-flow or wire start speed (run-in) etc.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SELECTION OF 2T/4T CONTROL AND SPOOL GUN OPERATION To change the way the torch trigger functions and/or select Spool gun operation: 1. Press and release the left arrow button one time to highlight the Control function. 2. Press and release the settings button (gear icon) to access the 4-Way menu. 3.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SELECTION OF SPOT/STITCH CONTROL To activate the spot/stitch timer and adjust the settings: 1. Press and release one of the arrow buttons until the Spot/Stitch Timer segment of the pinwheel menu has been highlighted. 2. Press the settings button (gear icon) to access the 4-way secondary menu. 3. Press and release one of the arrow buttons to highlight and select either “Spot/Stitch On” or “Spot Off”.
Section 2 Setup Guide NOTICE: This unit operates multiple classes and sizes of electrodes, including E6010. There are basic differences in how a transformer welder and an inverter welder handle E6010. Inverters, including this one, typically prefer a tight arc for E6010. In fact, the action of the arc force control encourages this type of welding. Where a long arc is used to add extra heat in a weld with a transformer based Stick welder, the opposite is true with an inverter Stick welder.
Section 2 Setup Guide UNDERSTANDING DC STICK FUNCTIONS TERMS RELATED TO DC STICK FUNCTIONS Amps. This is the measure of the “ flow” of the welder current. Arc Force Control. In stick mode, as arc length drops, so does voltage due to the manual process design. A weld isn’t made with only Amperage, Voltage is also involved. Using the formula of VxA=Watts, the output of a welder and total heat drops if either volts or amps are affected. In reality, wattage is a better measure of heat input into a weld.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS STICK FUNCTIONS AND PARAMETER SELECTIONS STICK SELECTION To begin, select the STICK option by scrolling through the left menu array of LEDs. The LED will light and the following screen will display briefly. Since there is no shielding gas involved with Stick, the unit reminds the user that the electrode has become live with “OUTPUT ON”. SELECTION AND ADJUSTMENT OF STICK PARAMETERS 1. 2.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SELECTION AND ADJUSTMENT OF DC TIG (TIG STEEL/STAINLESS) IN POWER-SET MODE Important! Before entering the Power-Set mode, be sure to select and adjust all basic settings such as pre-flow, control method etc. (except Amps). The Power-Set mode does not set these functions for you. If at any time an adjustment needs to be made to the basic functions such as pre-flow, control type, start Amps etc.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SELECTION OF VRD To activate the VRD (Voltage Reduction Device): 1. Press and release one of the arrow buttons of the main menu until the VRD segment is highlighted. 2. Press and release the settings button (gear icon) to access the secondary menu. 3. Press and release one of the arrow buttons to select either ON or OFF. 4. Press and release the home button (house icon) to return to the main menu.
Section 2 Setup Guide PROGRAM/MEMORY 65
Section 2 Setup Guide SETTING UP WELDING PARAMETERS SAVING PROGRAMMED SETTINGS This welder provides a programmable memory function, which allows up to 16 individual, customized programs to be saved. Any process can be saved. To save settings: 1. Make any necessary adjustment to the desired program. 2. Press the Program (Pgm) button to access the program menu. 3. Use one of the arrow keys to select a number where the program can be saved. (Default saved programs can be saved over.
Section 2 Setup Guide SETTING UP WELDING PARAMETERS RECALLING SAVED PROGRAMMED SETTINGS This welder provides a programmable memory function, which allows up to 16 individual, customized programs to be saved. Any process can be saved. To recall previous settings: 1. Press and release the Program (Pgm) Button to enter the program mode. 2. Press and release one of the arrow buttons to highlight the desired program number. 3. Press and release the Program button to recall the saved program.
Section 2 Setup Guide FRONT PANEL LIGHTNING MTS 275 7 2 4 6 1 CONTROL AC GAS OUTLET 3 68 5
Section 2 Setup Guide FRONT PANEL LIGHTNING MTS 275 FRONT PANEL FEATURES 1. 2. 3. 4. 5. 6. 7. AC Connector. The DINSE 35 Style connector is an industry standard sized connector. This terminal has one use only. It is designed to be used only in AC TIG mode. When AC TIG welding mode is selected, the work clamp should be relocated to this terminal. The TIG torch will remain in the negative.
Section 2 Setup Guide SIDE ACCESS PANEL LIGHTNING MTS 275 - 2 1 3 4 70
Section 2 Setup Guide SIDE ACCESS PANEL LIGHTNING MTS 275 SIDE PANEL FEATURES 1. Spool Carrier. The spool carrier is designed to carry full-size spools of wire 12” in diameter, and up to 44 lbs. It can also be used with the supplied adapter to carry 8” diameter spools with the supplied adapter. Hint: With some brands of smaller 8” rolls the adapter locating pin may be too long to fit properly.
Section 2 Setup Guide REAR PANEL LIGHTNING MTS 275 FUSE + 4 1x220V 7 2 4 6 5 1 72
Section 2 Setup Guide REAR PANEL LIGHTNING MTS 275 REAR PANEL FEATURES 1. 2. 3. 4. 5. 6. 7. Gas Supply. The Lightning MTS series unit is equipped with dual gas inlets. The top should be connected to pure Argon for TIG. The bottom should be connected to the appropriate MIG gas. This is a standad 5/8 CGA inert gas female fitting. The unit is supplied with one regulator, but the two inlet setup allows for installation of 2 regulators at the same time. One is for MIG, and the other for TIG.
Section 2 Setup Guide 36 SERIES MIG TORCH Expanded View NOTICE: Over time, pressure on the drive rolls causes metal fragments from the filler wire’s surface to find its way to the gun cable liner. If the wire guide is not cleaned, it can gradually clog up and causes wire feed malfunctions. If feeding difficulty is observed, clean the liner in the following manner: 1. Remove the welding gun’s gas nozzle, contact tip and contact tip’s adapter. 2.
Section 2 Setup Guide EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) 11 1 2 10 9 3 4 5 6 7 12 8 13 5/8” 17 9 15 14 16 NO.
Section 3 Basic Theory and Function MIG OPERATION AND THEORY General Setup of Amps and Volts. When welding in standard with the Lightning MTS, the two main functions that require adjustment are Voltage and Wire feed speed. The function of voltage in MIG welding is to control the overall width and to a great extent, the height of the weld bead. In other words, voltage controls the bead profile. The wire feed speed directly controls the amps, and in turn amps control penetration.
Section 3 Setup Guide MIG OPERATION AND THEORY All MIGs have a preset inductance that is inherent in the machine’s design. However, few MIGs have an adjustable inductance. Inductance is part of the personality of a MIG welder. It’s one reason that some people prefer the arc of one brand over the other as people develop personal preferences in arc performance.
Section 3 Basic Theory and Function MIG OPERATION AND THEORY weld as already mentioned. The gun should have no more than 15 degrees lean pointed into (push) or pointed away from (pull) the direction of travel. In most cases a push motion is desired. However, a lot of texts offer conflicting information on whether to push or to pull the gun. In reality, both are correct if used correctly and with each having particular strength and weakness.
Section 3 Basic Theory and Function MIG OPERATION AND THEORY welds should not exceed 1/4” even with the heaviest wire the welder is capable of handling. A thick pass may also begin to cool before contaminates and gas pockets have the time to float out to the surface. It’s far better to make multiple smaller passes to complete a plate weld for a higher quality result. For best results, this requires that most joints 1/4” and over be prepared with a grinder to accept multiple weld passes.
Section 3 Basic Theory and Function MIG OPERATION AND THEORY V-GROOVE (60-80°) DOUBLE V-GROOVE U-GROOVE DOUBLE U-GROOVE BEVEL GROOVE J-GROOVE DOUBLE BEVEL GROOVE DOUBLE J-GROOVE Besides a butt joint and lap joint which are often used for thinner metal gauges, consider using one of these groove joints for best welding results. When grinding or cutting the bevels, especially with a single V-groove, it may be beneficial to leave a small land with a gap between the joint to achieve full penetration.
Section 3 Basic Theory and Function MIG OPERATION AND THEORY NO VERTICAL GUN YES OK PULL ≤15° Problem: Gun is not being held vertical from side to side. Wire is not being directed to the center of the puddle. This concentrates heat on one side of the joint and results in poor fusion on the neglected side. It also can create more buildup on one side of the joint than the other. Correction: Hold the gun so that the angle of the neck stands perpendicular from side to side.
Section 3 Basic Theory and Function MIG OPERATION AND THEORY NO NO NO YES Characteristics: Concave weld, poor filling, possible undercutting resulting in weak weld. Possible Causes: Voltage too high, not enough wire speed, too short of wire stick out, wrong gun angle. Remedy: Decrease voltage, use push motion, increase wire speed. Characteristics: Small Convex weld possibly with bulging sides/cold lap and/or an inconsistent arc. Possible Causes: Not enough Voltage or Amperage.
Section 3 Basic Theory and Function MIG OPERATION AND THEORY Special Notes Concerning Operation. 1. Shielding Gas Selection for MIG and TIG. While welding aluminum with the Spool gun or MIG gun you must use 100% Argon. You cannot use a mix as you would with steel or stainless. For Steel or Stainless, there are a variety of gases that are used. The type of gas used with Steel or Stainless depends upon whether you are using short-circuit transfer, or spray transfer.
Section 3 Basic Theory and Function MIG OPERATION AND THEORY 3. Spool Gun Selection. When using the optional spool gun, the wire speed control is controlled on the spool gun. You must purchase a MTS version of the spool gun to operate correctly. You may purchase a compatible spool gun directly from Everlast for your unit. For the best matchup, we recommend the Parker DSP-360. 4. Flux-Core Operation. Flux-Core welding requires the use of serrated drive rollers.
Section 3 Basic Theory and Function STICK OPERATION AND THEORY STICK ARC STARTING METHODS 1. 2. 3. 4. 5. 6. Make sure the unit is turned on and the boot cycle has finished. Select the Stick Process on the Selector. Make sure the electrode holder is in the Positive connector and the work clamp is in the negative connector. Select the Amp level desired. No voltage adjustment is available. Select Hot Start Time and Hot Start Amps % (Intensity) to improve starting reliability.
Section 3 Basic Theory and Function TIG OPERATION AND THEORY General Setup. The process to set up the welder for the basic TIG mode is much less involved than for basic MIG. TIG voltage is not conventionally adjustable and is a product of the arc length. This is not to say voltage is not important to TIG welding, but it is not something that can be adjusted on the unit. In practical terms, voltage is not a concern to the user as it is self regulating. Amperage however, is adjustable.
Section 3 Basic Theory and Function TIG OPERATION AND THEORY cillated in a figure 8 pattern. This will require a forehand grip typically, and a good bit of motion of your forearm to accomplish. The filler metal should be moved from side to side to provide an evenly filled puddle under the Tungsten. This method requires much practice and effort, but yields beautiful welds when performed correctly.
Section 3 Basic Theory and Function TIG OPERATION AND THEORY TIG Pulse. The TIG pulse creates two amp values, a high and a low value that cycle back and forth between each other while welding. The upper amperage is called the “TIG Pulse Amps” (sometimes referred to as “Peak” current.) The lower amperage is called “TIG Pulse Base Amps “ (sometimes called “background” or “base“ current).
Section 3 Basic Theory and Function TIG OPERATION AND THEORY through and speed up welding on thin materials. It can also help maintain a proper bead profile on a thin edge weld or prevent burn through on extremely thin metal. A fast pulse speed will make fine ripples in the weld while a slow pulse speed will give a much more coarse, but visually appealing result. There are limitless ways to adjust the pulse.
Section 3 Basic Theory and Function TIG OPERATION AND THEORY desired, particularly on thin aluminum. Total heat output is affected regardless of the amperage selected. In the Triangular wave form maximum output will seem colder with less aggressive wet in and colder fusion. Using the triangular wave form at the same amperage of the Advanced Square wave form will demonstrate the stark difference. You should notice a colder puddle with a different bead profile.
Section 3 Basic Theory and Function TIG OPERATION AND THEORY switch to a larger sized tungsten that can handle the increased heating level. Signs of too little cleaning action while welding aluminum are sooty, black or dull looking welds. (In MIG some soot is normal while welding aluminum.
Section 3 Basic Theory and Function TIG OPERATION AND THEORY NOTICE: • • • • • • • • • Due to the rapid switching of the inverter, High Frequency (HF) is not used for anything except starting the arc. The HF TIG only refers to the initial arc start, and can be used for DC as well. In a transformer welder, the HF could be switched to continuous to stabilize the AC arc, but in an inverter, this is not necessary. So, the HF switch refers only to the Start of the arc, and not to AC operation.
Section 3 Basic Theory and Function TIG ARC STARTING LIFT START OPERATION NOTICE: When using the TIG lift start function, the lift start should be performed using a light touch and a quick, seamless motion. Lift Start is often used anywhere HF use is restricted, particularly in hospitals, or where computers are in close proximity. Steel or Stainless are good candidates for Lift Start operation. Aluminum is generally not used with Lift Start due to contamination of the Tungsten.
Section 3 Basic Theory and Function TUNGSTEN SELECTION AND SHARPENING TUNGSTEN SHARPENING • • • • • Use a dedicated grinding wheel or contamination may result. Do not breath grinding dust! Wear eye protection and gloves. Grip the Tungsten firmly. Grind the Tungsten perpendicular to the wheel face. Allow tungsten to grind slowly without much pressure. Rotate the Tungsten quickly as it is being ground to keep the point even and symmetrical. Alternatively you may use a drill to hold the Tungsten.
Section 4 Trouble Shooting IF YOU SEE THIS SCREEN…. STOP! OVER-TEMPERATURE SCREEN An Over Temperature means that the Duty Cycle has been exceeded and the unit is over heated. This can be caused by: • Welding past the 60% rating of the welder. • Dirty components, failure to service. • Blocked Air Flow. • Damaged/Broken Fans What to do: • Allow the unit to continue to run. DO NOT TURN OFF! • Inspect unit for lack of air flow on all sides.
Section 4 Trouble Shooting IF YOU SEE THIS SCREEN…. STOP! OVERCURRENT SCREEN An over current can be caused by several things. • Running on undersized extension cord, or too long away from power source. • Insufficient power source. • Running on a generator that isn’t rated for wattage or for clean power. • Internal fault has been caused by an external condition • IGBT or PC board failure. What to do: • Turn off unit immediately. • Investigate cause, remedy if possible. • Try again.
Section 4 Trouble Shooting IF YOU SEE THIS SCREEN…. STOP! STUCK TRIGGER SCREEN A Stuck Trigger Screen can occur for several reasons. • Primarily, the trigger on the torch has been held for too long without starting an arc (more than 3 seconds) and is caused by the following. • The trigger has broken, stuck or torch contacts have been accidentally bridged. • The foot pedal is stuck down, or foot switch is damaged. • Point gap is dirty or incorrect. • No or bad work clamp connection.
Section 4 Trouble Shooting NO. Trouble 1 Unit is switched on, but the power light isn’t on 2 After welding machine is overheating and the fan does not work 3 When torch switch is pressed, no gas flows Wire reel does not turn 4 Wire-feeder does not work Wire reel turns Possible Cause Solution Switch damaged. Unit Fuse damaged. Power breaker tripped. Fan damaged. Replace. Replace. Reset. Check fan housing and fan. Replace if necessary. Fan power connector is loose.
Section 4 Trouble Shooting NO. Trouble Possible Cause Solution 18 Arc will not start unless lift started. Points misadjusted, worn or dirty. HF not selected Check HF point gap. Clean and set to .035” Contact Technical Support for details. Make sure unit is set to HF 19 Tungsten is rapidly consumed. Inadequate gas flow. Too small of tungsten. Wrong shielding gas. Use only Ar. Using green tungsten. Wrong polarity. Possible contamination of shielding gas from gas supplier. Check gas flow.
