PowerTig 255EXT got CODE 805

[JimMinKent]

I'll add the following and let you continue to cogitate...

As I said above, I am working with a difficult material, thin-walled home-store satin anodized aluminum tubing. Cannot use bumping method due to the near blow-through at about the point the anodizing breaks up. I need to grind every weld area and take special care on the work clamp contact point to achieve the best esthetic results.

Until this project, I have never seen Code 805. I do use the pedal in 2T, and also of course in Pedal mode. What I get is the Pedal mode gives me current control, and the 2T gives me instant panel amps. Great feature, use it often. The way the pedal is built, there is a slight disconnect between the switch and the pot. The first 3/8" of travel touch the switch, and after that the gear sector moves the pot shaft. This is better than the older style when you needed to fine tune the switch point, as the belt was already changing the pot value. Not the case with the new pedal, it works very nicely as a foot operated torch switch.



I have set the AC start amps to 5 (the default lowest value) and then to 25, and get about the same results, which are: In Pedal mode, HF buzzes, enough to trigger my AD helmet (Balder lens), but no arc initiation. Let off pedal, post flow timer runs out, then next time nothing, no click, no pre-flow, no HF, etc. it seems that when it does this it will come back to normal after maybe 15-20 seconds. Then all is fine until it decides to do it again. It acts like an un-grounded work piece.

If it was my Syncrowave 250 I would bump up the HF intensity, but I'd rather that it work at this level than jolting me through the filler rod running right past my neck and ear.

So here are some more data points, keep them coming in so we can make a perfect machine out of a fantastic machine.

[Kempy]

I have seen something like that before on a different machines. Where it needs a little more start to get a reliable arc and build some heat in the tungsten, but then it can go down and weld at an even lower setting, especially on DC. There is also the actual arc initiation start pulse setting that is probably a little higher. I'm not sure I remember any way to adjust that on this model, though. I think there was a hidden menu for the 210EXT for that. I would be curious to know what that is, if it's a published spec or if someone will measure it. On other machines, I recall the start pulse being around 10-20 amps to get a reliable start.

It does make it sound odd to "upslope" from 5 to 3, but it makes perfect sense.

They should call it the Up/Down Slope.

[JimMinKent]

Thanks on the green lineup. On page 14 of the online manual it shows the welders 220/240V plug is your not connected to the water cooler so when you turn the welder on it turns the cooler on. The Canadian one has it.
Attachment 11370

I may have to set up an outlet and wire my pump for 220. My machine is the early release with no rear outlet and the incorrect accessory package, (which should be on their way to us soon). It is such a capable machine, though, these teething pains are just that.

[Rambozo]

Thanks for the pics, Jim. Now that makes a little more sense, and I see the reason to split off the 2T and pedal settings. I can see that being real useful for speed tacking things up, using the pedal as just a switch. Like the older Miller's where they split off contactor and amperage with two remote/panel switches. Now they just need to add a spot timer, and Bob's your uncle. It sounds like that project is tricky, for sure. Maybe the error checking is just a little too sensitive. At least all that can be tweaked later in firmware. I hear you about cranking up the HF. It's amazing what path it will take when you turn it up. Gloves can become pretty good conductors. One thing I remember with Syncrowaves for real thin AL was that you could crank up the craterfill setting, then it would continue in most of the postflow time. So by tapping the pedal and getting postflow going you could bring the torch up to the material and the craterfill flavor of HF would be going with no arc current. Then you could press the pedal to slowly bring in the arc current without having the initial start pulse. It was a super soft start as long as the tungsten was still warm enough. You could start an arc on foil that way without blowing a hole in it.
This machine sounds like a lot of fun. Keep the info coming.

[JimMinKent]

Oh boy, you just got me thinking...

With all the timers on board the EXT, a guy should be able to spot weld, And We Can!

For a say, 60 amp 2 second spot weld do this:

2T mode
AC or DC your choice,
Pre-flow = 0.5 (my standard setting)
Start amps = 60
Upslope = 0
Welding amps = 60
Downslope = 2.0 sec
End amps = 60

Bingo, just let off the switch as soon as she lights off, and you've got a burn time the duration of your Downslope setting.

These machines are SOOOO cool

I had never known of that trick on the Syncrowave crater fill/HF operation, nice little trick. Now had you been able to set the target ending amperage with the crater fill, you'd have had spot welding there, too. That option is not installed on my SW, and always made me want to get it just so the panel had all the knobs! But not so much any more.



Here she is on display in my shop, hasn't had any use since my Legacy EXT showed up.

Onward and Upward!

[Kempy]

Oh boy, you just got me thinking...

With all the timers on board the EXT, a guy should be able to spot weld, And We Can!

For a say, 60 amp 2 second spot weld do this:

2T mode
AC or DC your choice,
Pre-flow = 0.5 (my standard setting)
Start amps = 60
Upslope = 0
Welding amps = 60
Downslope = 2.0 sec
End amps = 60

Bingo, just let off the switch as soon as she lights off, and you've got a burn time the duration of your Downslope setting.

These machines are SOOOO cool

I had never known of that trick on the Syncrowave crater fill/HF operation, nice little trick. Now had you been able to set the target ending amperage with the crater fill, you'd have had spot welding there, too. That option is not installed on my SW, and always made me want to get it just so the panel had all the knobs! But not so much any more.

Here she is on display in my shop, hasn't had any use since my Legacy EXT showed up.

Onward and Upward!

Well that a good trick to know for spot welding with the 255EXT, the 250EX has it built in.

The forum should have a section on TRICKS of the TRADE then we put in thing like Jim’s Spot welding with a 255EXT or TOOLS made to hold parts, Plasma Cutting, Stick Welding, Tig Welding and Mig Welding thing people have found.

[everlastsupport]

Well that a good trick to know for spot welding with the 255EXT, the 250EX has it built in.

The forum should have a section on TRICKS of the TRADE then we put in thing like Jim’s Spot welding with a 255EXT or TOOLS made to hold parts, Plasma Cutting, Stick Welding, Tig Welding and Mig Welding thing people have found.

We have an off-topic tips and tricks. http://www.everlastgenerators.com/fo...as-and-Reviews