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

I could just stop there, but that would leave a lot of unanswered questions. So I'll tell you why I say this, why I am so impressed with this welder, and why there is not another machine out there like it.

Attachment 11082

So, it's been two weeks since Brown delivered this unassuming package. I've been used to larger machines, so this little box made me wonder what was in it, and when is my welder showing up?!?!

Attachment 11083Attachment 11084Attachment 11085Attachment 11086

Well, it WAS in the box, and it was Perfect, nothing broken, bent, or scratched. This is a nice machine! but looks alone are not enough...

Attachment 11087 Attachment 11088

Here is the Green contingent of the shop, Legacy 250 EXT, 255 EXT, 140 ST. There is nothing to be feared if you are considering a Green machine.

Attachment 11089

Here is the very nice On-line manual printed and bound, plus the spec sheet and inspection record included in the box.

Attachment 11090

Here is a shot of the full DC output showing 251 amps on the panel and over 255 amps on the clampmeter. This one goes to full power!

Attachment 11091

Size comparison between the 255 EXT and the 250 EXT. I am using the 250 as part of the plumbing from my cooler to the old torch, which is plugged into the new 255. I suppose I could get some fittings and put the 250 out of work.

End of Part 1

Really nice update! Impressed by the clamp-on probe DC test and look forward to the next installment in this series. They sure package the machines well now, don't they?

The 250EXT is a really handsome machine but I've got to say that if all else were assumed equal, the more lightweight and compact 255EXT package would be more desirable of the two form factors if space and/or portability were a potential concern / issue.

After unpacking, I wired the cord end and watched for smoke, having seen none, I grabbed the stinger and lit up a few 1/8" 7018's and 6010's. All went well, but I didn't take any pictures.

Attachment 11102Attachment 11103

I then took a look at the pedal in detail. I made the action a little smoother, and adjusted the pot to go full-scale with full travel. I changed out the feet and lowered it another 1/8".

Attachment 11104Attachment 11105Attachment 11106

After locating the best position for my foot on the pedal, I made a heel strap from something like thin mudflap rubber. This works great, as it puts my foot in a position that pivots with my ankle perfectly, and I can scoot the pedal away and toward me almost like I am wearing the pedal.

Attachment 11107Attachment 11108Attachment 11109Attachment 11110

End of Part 2

In this episode, I will begin to demonstrate the excellent low current ability, on some stainless razor blades and, in the next part, some thin aluminum flashing. The razor blades were done using the lowest DC current settings, and some using high-speed pulse.

Attachment 11121

This is one setup to hold the blades, another one had a polished guide to run the cup on, and gave the best results.

Attachment 11122Attachment 11123Attachment 11124

These show how controllable the low-amp capabilities are. In testing, I can actually establish an arc on the side of the blade, and Not melt it. That is certainly low enough.

Attachment 11125

This one was run freehand with .030" 309L add-wire. This is finicky and intricate stuff. Not sure what to use it for, but at least the machine is not the limiting factor.

Next some thin aluminum, then hang on for the ride.

End of Part 3

Quote:

---

Originally Posted by JimMinKent

After unpacking, I wired the cord end and watched for smoke, having seen none, I grabbed the stinger and lit up a few 1/8" 7018's and 6010's. All went well, but I didn't take any pictures.


I then took a look at the pedal in detail. I made the action a little smoother, and adjusted the pot to go full-scale with full travel. I changed out the feet and lowered it another 1/8".


After locating the best position for my foot on the pedal, I made a heel strap from something like thin mudflap rubber. This works great, as it puts my foot in a position that pivots with my ankle perfectly, and I can scoot the pedal away and toward me almost like I am wearing the pedal.

End of Part 2

---

I like the strap idea! These are great submissions. Keep them coming!

Now onto the thin aluminum. This is 0.015" sheet aluminum roofing flashing. The settings were all under about 15 amps, and various AC frequencies, and some with 30hz pulsing. AC frequencies as high as 250hz. All using pedal control.

Attachment 11126

A shot of my more successful samples, I could work harder to make them pretty, but this was a test of the machine's low-end, not me so much.

Attachment 11127Attachment 11128Attachment 11129

This is a very small autogenous edge weld joining these two "L" shaped pieces. Amazing control that can do that without a total meltdown through that thin edge.

Attachment 11130Attachment 11131

This is both sides of the same piece. I have flipped over from bottom to top. As you can see, I was able to lay a bead on just the top surface of the right-hand side of this 0.015" thin sheet. That's good and low.

That concludes the low-current testing. The PowerTig 255 EXT excels in this department, and puts tremendous control and capability into the hands of the operator. But that's not the real story here.

In the next episode, we leave charted territory behind, reality will never be the same. Follow me, now, down the rabbit hole...

End of Part 4

Welcome Fellow Explorers,

We now go where mere mortals have never been allowed to go. A place reserved for only the elite of the elite, it could be called a dynasty of sorts. We can now join their ranks, because of this machine. The place I speak of is the land of Thick Plate, yes, Thick Aluminum Plate. Are you ready for this? Well Hang On!


Attachment 11132

After running some high-power AC beads, using various AC frequencies, I played around a bit and found I could actually make a dent in 1/2" 6061 plate.

Attachment 11133Attachment 11134

Not only could I make a dent in it...but that lump on the bottom is where it dropped out the bottom!

Attachment 11135Attachment 11136

I put on my stick gloves and fire jacket, as this was going to get hot!

Attachment 11137Attachment 11138

The Everlast 255 EXT can puddle 1/2" plate! Using only Argon! No other gases are needed.

Attachment 11139Attachment 11140

So if it can puddle 1/2" plate, what More could it do?!?

I'll show you, Let's travel even Deeper down the rabbit hole...

End of Part 5

Here is where reality distorts, and common sense is of little use. Where capability is affordable, and compact is powerful, and other topsy-turvy paradigms are in play.

What follows is my personal journey exploring the capabilities of this amazing new machine, enjoy the ride...


Attachment 11141


Attachment 11142


Attachment 11143


Attachment 11144


Attachment 11145


Attachment 11146


Attachment 11147


Attachment 11148


Attachment 11149


Attachment 11150


So you see, a new world awaits each of us. One without limits, small or great. Jump on board, we don't yet know where this journey ends, but I for one, do like the ride!

End of Part 6

But Could There Be Even More...

So, What are the Limits?!?

Where are the Boundaries?!?


Attachment 11152


Attachment 11151


Attachment 11153


Someone Stop the Madness!!!

Or is it?

Imagine what a little preheating could do. Thanks Jim. People wouldn't believe it unless you show them, and then some may think the results are faked...but that 3/4" stuff says it all. It looks like from the depth of penetration, a little different torch angle may have gotten the penetration all the way through the joint.

Dayum.

Very enjoyable post, well written. Going through the pictures in post #8 I was thinking, 'means nothing if he doesn't cut the weld to show penetration... hope he cuts the weld to show penetration... is this the one where he cuts the weld to show penetration?!' and then there it was. Cool!

Nice job on testing the New Everlast PowerTig 255EXT Jim, from the top end to bottom end can't wait till mine comes in now, it will be some time in Nov.
Jim good luck with the new 255EXT so far everyone is very happy with them.

Jim for the last photo set, you might need the new compliment, the 325ext for that one. Same features, more power, but 3 phase.

Quote:

---

Originally Posted by performance

Jim for the last photo set, you might need the new compliment, the 325ext for that one. Same features, more power, but 3 phase.

---

I've got my money on the 255! Perhaps it will take a little pre-heating. The point is that the 255 EXT is More machine than most guys, or companies even, will ever need. My local fab shop owner dropped his jaw, and two of his welders just stared at the 3/4" T-joint in awe. He wants one, and they run on single phase power.

Here we can get in the game without another mortgage payment, or buying the power company another wind turbine.

This is the machine for us mortals.

Quote:

---

Originally Posted by JimMinKent

I've got my money on the 255! Perhaps it will take a little pre-heating. The point is that the 255 EXT is More machine than most guys, or companies even, will ever need. My local fab shop owner dropped his jaw, and two of his welders just stared at the 3/4" T-joint in awe. He wants one, and they run on single phase power.

Here we can get in the game without another mortgage payment, or buying the power company another wind turbine.

This is the machine for us mortals.

---

Jim, I think some of us are questioning whether you are mortal. You have done us all a great service with your highly entertaining and informative pursuit of what your welder can do. I was literally on the edge of my seat waiting to see the next picture, the next paragraph, the next installment. Very impressive and thank-you.

Quote:

---

Originally Posted by performance

Jim for the last photo set, you might need the new compliment, the 325ext for that one. Same features, more power, but 3 phase.

---

Mark
Do the welder need to be on a true 3 phase or will a Phase converter work I have one running my CNC machine the voltage is T1or(L1)-237V, T2or(L2)-239V, T3or(L3)-229V under load? No load L1-240V, L2-241V, L3-258V, L3 is the inverter leg or do I need a L3 (T3) leg stabilizer?

Gentlemen, Thank You all for the kind words, I am glad that you enjoyed the report.

Jakeru - I did find the new packaging to be impressive, too. I was really surprised how clean and straight it was upon arrival.
The 250 EXT is indeed a really great looking machine, and is impressive in size and weight. I wondered if the smaller size of the 255 would be any detriment to performance, but as you can see, it lacks nothing. This compact machine is the new workhorse of the shop.

DaveO - I am glad that I finally Did answer your question. I laughed reading about you going through the pictures, wondering if "the next one" would provide your answer.

Kempy - Thanks for the nice comments, I also look forward, on your behalf, for yours to arrive, too. You will not regret your purchase, good luck with it.

Mark - You can imagine the amount of molten material involved here. It looks like this will be a flat position process for the time being. I do think if I orient the plates, a little flatter for the vertical piece, those weld nuggets will indeed touch in the middle. I'll try that soon, these are just my first experiments. I'll try a little pre-heat, too, but I will stick to my single-phase process, Thank You!

Mr120 - I am glad you liked the pedal mod, it really does work well now. Thanks also for the very kind comments, I'll try to keep the future updates up to the caliber you have come to enjoy :) Truly though, just a mere mortal. ;)

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

Great review Jim. I know what model I want next, now. I wonder when the next batch with the cooler outlet and proper torch package are due in the US?

Quote:

---

Originally Posted by Kempy

Do the welder need to be on a true 3 phase or will a Phase converter work I have one running my CNC machine the voltage is T1or(L1)-237V, T2or(L2)-239V, T3or(L3)-229V under load? No load L1-240V, L2-241V, L3-258V, L3 is the inverter leg or do I need a L3 (T3) leg stabilizer?

---

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.

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.

Jim,
I think we should let the cat out of the bag about exactly how you achieved this...before people accuse us/you of lying and going to a high end machine shop and picking up a drop off the floor. LOL.

These welds were achieved with using the advanced pulse, correct? This is a product of the DC side of the pulse achieving greater penetration, as the AC cleans in front of the weld pool for the next DC half pulse. Not only does the Advanced pulse work well for controlling heat on aluminum sheet, and freezing the puddle, it also works well on the high end, but with different effect if adjusted properly.

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...

Quote:

---

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

---

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:
Attachment 11155 Attachment 11156
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 ;) ).

Quote:

---

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.

---

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.

Quote:

---

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.

---

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.

Quote:

---

Originally Posted by Rambozo

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

---

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.

Quote:

---

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.

---

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".

Attachment 11179Attachment 11180

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

Attachment 11181

"The Package"

Attachment 11182

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

Attachment 11183

Attachment 11184

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.

Attachment 11185

Attachment 11186

Attachment 11187

Attachment 11188

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.

Attachment 11189

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

Attachment 11190

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

Attachment 11191

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

Attachment 11192

Attachment 11193

Another perspective of both sides of the stack.


Attachment 11194

Attachment 11195

These are paired to show the mating surfaces.

Attachment 11196

Attachment 11197

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

Attachment 11198

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!

Quote:

---

Originally Posted by Mr120

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

---

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 .

Quote:

---

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 .

---

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.
Attachment 11363Attachment 11364Attachment 11365

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.

Attachment 11418Attachment 11420Attachment 11421Attachment 11422Attachment 11423