Everlast PowerTig 255 EXT - Performance beyond expectation, exceptional machine...

Mark, soon I will explain it, nobody yet has asked how I did it, though. I will say this, all the information to figure it out is contained in the specs that Duncan sent from his room overseas in the other EXT thread. It was after I saw those specs, and a few follow up questions to you, that the idea came to me. It actually worked exactly as I hoped, only much better.

Guys, let's have some guesses as to how you think it's done. The 255EXT and 210EXT fans will have an advantage guessing.

I'm not too concerned with the skeptics.

Stay tuned...

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Originally Posted by fdcmiami

great thread. i think the photo that grabbed my attention the most (though they were all good) was the one of the perfectly formed dollop of aluminum sitting below the hole in the plate above it. how the heck did that happen. lol

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Seeing that hole WAS pretty impressive. Mind you, the whole review was impressive. I'm going back to the other thread to look at Duncan's specs to see if I can figure out the settings.

Jim, nice work. That is very intersting effect on the thick plate melt-through. Haven't seen anything like it.

Can you add how long it took to get a puddle on those thick pieces? If you say "right away as fast as can be, I wasn't even flooring it", for pure argon, I will be VERY impressed (although that is probably not a realistic expectation).

Eventually, I'd like to know or see how the 255EXT with your "magic settings" might work on a truly large weldment. Here is the massive flatbed alumium trailer that kicked my Super 200P's butt:
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It's the biggest and thickest aluminum "thing" I ever tried welding. I think those cast side rails (with a cast-in beam shape) had upper and lower flanges about 2"x1.5" (you can see the 2" dimension being measured above). But the massive size weldment really made it impossibe to pre-heat or even really to sit there with the arc letting the heat build up, even. The massive weldment just conducted the heat away too fast for anything to work. (This was before I got Helium, and I still wonder if even with Helium I could have done it with the Super200P.)

Do you think your 255EXT could have done it with pure argon?

I'm curious if you've thought of a way to test the 255EXT's different A/C waveforms to make sure they're working properly? I tried them (only briefly and once, so far) on my 255EXT, and my first reaction was, I didn't notice the softening in the AC arc sound qualities that I was expecting. (I've welded a transformer machine and it definitely had a softer arc sound, but it wasn't running 120Hz so maybe I'm just not used to the higher frequency yet.) My Super200P that I'm most used to is a 60Hz inverter. On my first run on my 255EXT, I was using the default 120Hz and 25% (I think?) EP. Short beads, relatively low power since I'm still getting my torch setup sorted out on this new machine and don't yet have aircooled or a watercooler going. I did notice that the triangle wave needed more current to run a puddle in same material than the other waveforms did. So I do believe they are doing something. I was just surprised the sine wave wasn't more "mellow" sounding. (And to a lesser degree, also the soft square)

Initially, I found all the different 2T/4T/footpedal/nopedal options of the 255EXT to be quite dizzying. And I was surprised setting the "footpedal" didn't take off the downslope. (But it was nothing that couldn't quickly be fixed, just adds a bit to the initial learning curve of this particular machine design.)

I still have very little arc time on my 255EXT. (I've just been busy with other stuff!) But hope to get more time to focus on it soon. Thanks for the best 255EXT review on the Web yet, though (takes some pressure off of me from having to get mine done so quickly ;) ).

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Originally Posted by performance

PFC or not, these units are not recommended for use on phase generators. Use 220 1 phase, and you won't see a lot of difference.

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I suspect Kempy was asking not for the 255EXT but for the 325EXT!

A Phase Perfect digital unit can deliver better than power company 3 phase. All leg voltages within 1%, close to zero harmonic distortion, pure sine wave, 97% efficient. But at over $3000 for their smallest 36 amp unit, it's not what you would call a cheap date. But if you have no other options...

Jakeru, the 1/2" plate took only about 30 seconds to start, run across the plate, AND melt through. The 3/4" T-joint took about a minute for each side from a cold start. So, it gets going right away, and I only have argon.

It would be interesting to see how it handles your trailer work. Where exactly does it need welding? Does it break, or wear down?

Don't feel bad about your Super 200P, neither my Syncrowave 250 or the legacy 250EXT could stand a chance against that size material. That's another clue about the 255, it does something other welders do not do. But I think you will have some success on that large stuff with your 255, I think I could make a repair on it, and yes using argon.

I did try all the waveforms, and think they are working fine. Try the sine wave at 40-50hz, 30%ep, and 120 amps on 1/8" 6061. It should run soft and wet in nicely. I'll try that tomorrow, too. The triangle is for thin stuff, where you want to get in and out of the peak current quickly on each cycle.

I used all options of 2T/4T/Pedal/2TPedal/4TPedal. They run as I had hoped for. For a simple example, Set amps to 200, in 2T the pedal switch is used to start the arc at the panel amps setting, useful for hot tacking. Push the button to Pedal mode and now you control the amps from 0 - 200 by the pedal, without needing to swap out the 7-wire connector for the torch switch.

So, keep at it, we'll be getting our proper accessories pretty soon, and thanks for the interesting post of your own.

Judging from the grind marks, it looks like jakeru was aiming to weld the inside corner where the side rail meets the bed(?) That's one massive heatsink but given the really small and well formed hole that Jim put into that block of aluminum with the 255ext, I think jakeru could have done that job with his new 255ext on Argon. The 255ext seemed to be able to put down a lot of localized heat quickly which is exactly what jakeru needed.

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Originally Posted by Rambozo

If the welder has PFC it will be a lot more tolerant of phase issues. Is your phase converter static or rotary? You can also add some PFC caps to clean up your home made 3ph.
I would not expect a static phase converter to work well if at all, but a rotary might be ok, but far from ideal. The best would be a digital phase converter rated to run welders, but they are not cheap.

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I see the new 255EXT and the 325EXT have PFC (Power Factor Correction) and I do have a rotary phase converter out put 10.7 KVA so with a little more research I found that if you want the voltage more equal on each leg you run it thru a 240V in and 240V out 10 KVA transformer. I also found out that true 3 phase can very up to 10% between legs (L1,L2&L3) the new style rotary phase converters now also have electronic voltage control at 1 to 3% also with fully programmable MicroSmart controller and out put of 12 KVA for less then $1800.00. could run the everything in my shop and the welder but not all at the same time.

The phase angles on a rotary phase converter are more of a smeared 180° rather than a true 120°. No idea of the impact that will have on anything but an inductive load. One thing that I know from using them on CNC machines is that you want the two true legs going to any single phase control circuitry.
Yeah, power companies only guaranty 10% voltage, on 3 phase. You have to pitch a bitch to get them to set a new transformer if you are too far out of spec. Been there, done that.

I take it there is no practical way to get 3 phase service in your shop?

One thing to keep in mind is that rotary phase converters waste a fair bit of power, so a digital converter will pay for itself given enough hours of operation. Much like running a VFD instead of a rotary.

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Originally Posted by Rambozo

I take it there is no practical way to get 3 phase service in your shop?

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Hydro One will put it in for a around $12,000.00 or so. I will what and see how the New 255EXT works so far it looks like it will do what I need. Duncan said it will be in around the end of Nov.
And for a Phase Perfect Digital Phase Converters would be to run the shop $4200.00.

The major issue with having three phase is simply the expense involved, and in some areas you pay higher commercial rates. Here, if you are using it for farm use, power isn't so bad. A lot of farms have it for running the drive motors on the center pivot irrigation systems. Most is 240 Delta. Our EMC's provide really good power to most locations. Here, my voltage reads 244-247 Volts consistently. The 3 phase systems I have checked on Delta, the high leg reads about 270. We have 480 around, but all systems are delta, not wye.

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Originally Posted by performance

The major issue with having three phase is simply the expense involved, and in some areas you pay higher commercial rates. Here, if you are using it for farm use, power isn't so bad. A lot of farms have it for running the drive motors on the center pivot irrigation systems. Most is 240 Delta. Our EMC's provide really good power to most locations. Here, my voltage reads 244-247 Volts consistently. The 3 phase systems I have checked on Delta, the high leg reads about 270. We have 480 around, but all systems are delta, not wye.

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For me the 3 phase startup price is high but the operating cost is a lot lower. My Phase converter is a Delta type manufactured leg is 256 to 260V no load and 229 to 231V under load. I will stick with single phase till I find a good used digital phase converter.

Gentlemen, I trust you are all up for another "day hike" on our journey into the Unbelievable, so come along.

As you will remember, I have been exploring the upper and outer limits of the 255 EXT's capabilities. But I have not yet found them. I thought this test would reveal them, but I actually got into a dangerous situation and had to abort the test without conclusive results. So, here is Part 1 of that latest exercise, I call "Deep Fusion".

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More of the 3/4" 6061, cleaned and prepped, tape shown for scale.

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"The Package"

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CK Pyrex gas lens setup with sharpened 3/32" 2% Lanthanated tungsten. Argon at 20 CFH.

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This process gets Hot, goes Deep, and the reason I didn't crater out is because it went Sideways! TOWARD MY SIDE! I got off the pedal just before the puddle melted through the side walls! This generates a LOT of molten aluminum, and I punched out at the last split second. I don't yet see how this could be done other than in the flat position, surface tension will not keep a cubic inch of molten aluminum in place.

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There is much here to polish and etch, so we will look at all that in Part 2...

Part 2 of "Deep Fusion"

Alright, let's have a look.

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I preheated with a MAPP gas torch, started in Section #1 and moved to the left. Filler is 1/8" 4043.

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The view 'through' the stack from the start to end.

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The view 'through' the stack from the end to the start.

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Another perspective of both sides of the stack.


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These are paired to show the mating surfaces.

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These are of section #4 showing how wide the puddle got.

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Here is the deepest penetration achieved, just before I bailed out, about 0.680". Total weld time was about 2 minutes.

So what IS the deepest we can go? This got pretty close, but as you can see, it was still going deeper when I stopped. So we don't quite know yet. I'm not sure when I'll be able to find out the true limits, as I need to get back the Real world and do some work!

But, there is One More EXT test I plan to perform, so I'll be back with that before too long.

In the mean time stay safe, and Expect the Unexpected.

Glad you weren't hurt. That must have been some molten puddle!

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Originally Posted by Mr120

Glad you weren't hurt. That must have been some molten puddle!

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Thank You, yes it was indeed a Grand molten puddle! These are really surprising discoveries. The "T" joint was a first try and so was this deep fusion. I'm just beginning to understand how this process behaves. How long it takes to go so deep, how to handle that amount of liquid metal, etc.

So, here is what you need to try this at home or at work. You need an Everlast EXT-Class machine! Nothing else will do it because nothing else has 'The Feature'. The Feature is Advanced Pulse . This alternates from AC welding current to DCEN pulse current. This is only available in a Green box, and if you only need one reason to buy Green, This Is It!

The other guys have Amplitude control, and that's nice, but is no way in this league of heat and penetration. My guess is that it would take their 700-class machine to do this in AC alone. What we get is the cleaning action of AC with the deep penetration of DCEN.

I did think of three test to perform before I call this experiment complete. Another "T" joint, a 3/4' plate butt joint, and a 1/2" test plate with my 255 set to 210amps, to simulate a 210 EXT.

So, stay tuned for a few more pix, keep thinking about how I set the welding parameters and post your guesses, and I'll be back real soon.

Hey Jim,

I have watched the video on the advanced pulse and thought I finally wrapped my head around how it would be useful for thin metal welding. Now with this deep penetration demonstration I've gotta watch it again and see how this all works. Great idea about simulating the 210EXT and how it would perform. Cheers and thanks for all of the really good information.

would like to see how many people have purchased these units and what they think of them over the 250 ex as i am thinking of selling mine to get the 255.the 250 ex has been a great machine but i am liking what i am seeing so far with 255 ext .

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Originally Posted by johnson697

would like to see how many people have purchased these units and what they think of them over the 250 ex as i am thinking of selling mine to get the 255.the 250 ex has been a great machine but i am liking what i am seeing so far with 255 ext .

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Well I got one and still have the 250EX will keep testing both but the 255EXT is out front at the moment. The thing I like best of all so far is the save it and recall it just wish it had more memory numbers 1 to 9 is not enough.
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Welded up some transmission cases with the 255EXT. The cases are very thin and keep cracking after welding so I just weld them to keep the pieces in place and the transmission shop uses Fel-Pro Aluminum epoxy to seal it up.

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