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

[JimMinKent]

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.



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?!?!



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...



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.



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



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!



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

[jakeru]

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.

[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

[JimMinKent]

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.



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



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.



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

[Mr120]

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!

[JimMinKent]

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.



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.



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.



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

[JimMinKent]

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!




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.



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



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



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



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

[JimMinKent]

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...
































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...

[JimMinKent]

So, What are the Limits?!?

Where are the Boundaries?!?











Someone Stop the Madness!!!

Or is it?

[performance]

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.

[DaveO]

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!

[Kempy]

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.

[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.

[JimMinKent]

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.

[Mr120]

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.

[Kempy]

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?

[JimMinKent]

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.

[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

[Rambozo]

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?

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.

[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.

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.