Everlast POWER DIGITAL SERIES User manual

1
EVERLAST
EVERLAST
Power ® Series
Combination Tig//Smaw/Plasma Cutter Units
Operator ’ s Manual
Includes AC/DC PowerMaster and DC PowerUltra Units
Safety, Setup and General Use Guide
Rev. 1 0609-09

2
EVERLAST
Thank you for purchasing an everlast product. We ap-
preciate your patronage and hope that you will enjoy
years of use from our product.
Please go directly to the Everlast website to register
your unit and receive your warranty information.
Your unit registration is important should any infor-
mation such as product updates or recalls be issued.
It is also important so that we may track your satis-
faction with Everlast products and services. If you
are unable to register by website, contact Everlast di-
rectly through the consumer department at the main
number. Your unit will be registered and warrantee
will be issued and in full effect.

3
EVERLAST
Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________
EVERLAST
Contact Information
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Main toll free number: 1-877-755 WELD ( 9353 ) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
NOTES:

4
EVERLAST
Table of contents
Section……………………………………………….Page
General ...……………………………………………
Safety Precautions..……………………………….
Introduction and Specifications…………………
Know Your Machine………………………………..
2.1 Panel Face and Functions……………………
2.2 Lower Panel and functions….………………
Getting Started……………………………………..
3.1 General Guidelines……………………………
3.2 Shielding Gas Selection………………………
3.3 Regulator/Flow meter Selection……………
3.4 Regulator Connection………………………...
3.5 Regulator Adjustment………………………..
3.6 Machine Setup………………………………….
3.7 Tungsten Selection……………………………
3.8 TIG Torch………………………………………..
3.9 TIG Welding Principles and Guide…………
3.13 MMA (Stick Welding)…………………………
5.1 Plasma Torch…………………………………...
5.2 Plasma Cutting Principles……………………
5.3 Plasma Cutting Steps…………………………
5.4 Gouging………………………………………….
5.5 Piercing………………………………………….
Trouble Shooting……………………………………
5
6
11
14
14
17
18
18
18
18
18
18
19
19
21
22
23
25
25
25
27
27
29

5
EVERLAST
Everlast is dedicated to providing you with the best possible equipment and
service to meet the demanding jobs that you have. We want to go beyond deliv-
ering a satisfactory product to you. That is the reason we offer technical sup-
port to assist you with your needs should an occasion occur. With proper use
and care your product should deliver years of trouble free service.
Safe operation and proper maintenance is your responsibility.
We have compiled this operator’s manual, to instruct you in basic safety, op-
eration and maintenance of your Everlast product to give you the best possible
experience. Much of welding and cutting is based upon experience and com-
mon sense. As thorough as this welding manual may be, it is no substitute for
either. Exercise extreme caution and care in all activities related to welding or
cutting. Your safety, health and even life depends upon it. While accidents are
never planned, preventing an accident requires careful planning.
Please carefully read this manual before you operate your Everlast unit. This
manual is not only for the use of the machine, but to assist in obtaining the
best performance out of your unit. Do not operate the unit until you have read
this manual and you are thoroughly familiar with the safe operation of the unit.
If you feel you need more information please contact Everlast Support.
The warranty does not cover improper use, maintenance or consumables. Do
not attempt to alter or defeat any piece or part of your unit, particularly any
safety device. Keep all shields and covers in place during unit operation should
an unlikely failure of internal components result in the possible presence of
sparks and explosions. If a failure occurs, discontinue further use until mal-
functioning parts or accessories have been repaired or replaced by qualified
personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves.
These waves may disturb sensitive electronic equipment such as televisions,
radios, computers, cell phones, and related equipment. High Frequency may
also interfere with fluorescent lights. Consult with an electrician if distur-
bance is noted. Sometimes, improper wire routing or poor shielding may be
the cause.
HF can interfere with pacemakers. See EMF warnings in following safety sec-
tion for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.
General

6
EVERLAST
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. Therefore ob-
serve the following to minimize potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even
under welding helmets to protect your eyes from flying sparks and debris. When chip-
ping slag or grinding, goggles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct
shade of filter installed. Always use a welding helmet in good condition. Discard any
broken or cracked filters or helmets. Using broken or cracked filters or helmets can
cause severe eye injury and burn. Filter shades of no less than shade 5 for cutting
and no less than shade 9 for welding are highly recommended. Shades greater than 9
may be required for high amperage welds. Keep filter lenses clean and clear for maxi-
mum visibility. It is also advisable to consult with your eye doctor should you wear
contacts for corrective vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless
fully protected by a filter screen, protective curtains or equivalent protective equip-
ment. If no protection is available, exclude them from the work area. Even brief expo-
sure to the rays from the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy.
Ear protection is necessary to prevent hearing loss. Even prolonged low levels of
noise has been known to create long term hearing damage. Hearing protection also
further protects against hot sparks and debris from entering the ear canal and doing
harm.
Always wear personal protective clothing. Flame proof clothing is required at all
times. Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose
clothing is tucked in neatly. Leather aprons and jackets are recommended. Suitable
welding jackets and coats may be purchased made from fire proof material from
welding supply stores. Discard any burned or frayed clothing. Keep clothing away
from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for ade-
quate foot protection. Canvas, polyester and other man made materials often found
in shoes will either burn or melt. Rubber or other non conductive soles are necessary
to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient.
Gauntlet type welding gloves are available from your local welding supply companies.
Never attempt to weld with out gloves. Welding with out gloves can result in serious
burns and electrical shock. If your hand or body parts comes into contact with the
arc of a plasma cutter or welder, instant and serious burns will occur. Proper hand
protection is required at all times when working with welding or cutting machines!

7
EVERLAST
SAFETY PRECAUTIONS
continued
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.
While the effects of EMF radiation are not known, it is suspected that there may be
some harm from long term exposure to electromagnetic fields. Therefore, certain pre-
cautions should be taken to minimize exposure:
Lay welding leads and lines neatly away from the body.
Never coil cables around the body.
Secure cables with tape if necessary to keep from the body.
Keep all cables and leads on the same side the body.
Never stand between cables or leads.
Keep as far away from the power source (welder) as possible while welding.
Never stand between the ground clamp and the torch.
Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible
need for respiratory equipment while welding or cutting. Always weld with adequate
ventilation. Never weld in closed rooms or confined spaces. Fumes and gases re-
leased while welding or cutting may be poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
Stop immediately and relocate work if necessary until adequate ventilation is ob-
tained.
Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, cop-
per, cadmium, lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product when used for welding or cutting produces fumes and
gases which contains chemicals known to the State of California to cause birth de-
fects and in some cases cancer. (California Safety and Health Code §25249.5 et seq .)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas.
Release of Phosgene gas can be deadly. Consider all chemicals to have potential
deadly results if welded on or near metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain
regulations regarding high pressure cylinders can be obtained from OSHA or local
regulatory agency. Consult also with your welding supply company in your area for
further recommendations. The regulatory changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and
closed. Store chained so that overturn is not likely. Transporting cylinders incorrectly
can lead to an explosion. Do not attempt to adapt regulators to fit cylinders. Do not
use faulty regulators. Do not allow cylinders to come into contact with work piece or
work. Do not weld or strike arcs on cylinders. Keep cylinders away from direct heat,
flame and sparks.

8
EVERLAST
SAFETY PRECAUTIONS
continued
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 weld-
ing 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. Turn machine on or off only
with gloved hand. Keep all parts of the body insulated from work, and work tables.
Keep away from direct contact with skin against work. If tight or close quarters ne-
cessitates standing or resting on work piece, insulate with dry boards and rubber
mats designed to insulate the body from direct contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their location and
make sure all personnel in area are advised of their location. Taping or securing ca-
bles with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodi-
cally check work area for smoldering embers or smoke. It is a good idea to have
someone help watch for possible fires while you are welding. Sparks and hot metal
may travel a long distance. They may go into cracks in walls and floors and start a fire
that would not be immediately visible. Here are some things you can do to reduce the
possibility of fire or explosion:
Keep all combustible materials including rags and spare clothing away from area.
Keep all flammable fuels and liquids stored separately from work area.
Visually inspect work area when job is completed for the slightest traces of smoke
or embers.
If welding or cutting outside, make sure you are in a cleared off area, free from
dry tender and debris that might start a forest or grass fire.
Do not weld on tanks, drums or barrels that are closed, pressurized or anything
that held flammable liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling
hot pieces of metal. Remember to place hot metal on fire-proof surfaces after han-
dling. Serious burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death.
Proper maintenance is your responsibility. Make sure all equipment is properly main-
tained and serviced by qualified personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding
parts. Touching uncovered parts inside machine can cause discharge of high
amounts of electricity. Do not allow employees to operate poorly serviced equipment.
Always check condition of equipment thoroughly before start up. Disconnect unit
from power source before any service attempt is made and for long term storage or
electrical storms.
Further information can be obtained from The American Welding Society (AWS) that
relates directly to safe welding and plasma cutting. Additionally, your local welding
supply company may have additional pamphlets available concerning their products.
Do not operate machinery until your are comfortable with proper operation and are
able to assume inherent risks of cutting or welding.

9
EVERLAST
Introduction and SpecificationsSection 1
PowerTig DX, LX and EX Models, I-Tig Models
PowerMaster Series
Includes 164, 205, 226
PowerUltra Series
Includes164, 185, 205

10
EVERLAST
Introduction and SpecificationsSection 1
Power Series TIG
(GTAW) WP 18/28 Torch
Power Series TIG (GTAW)
Foot Pedal Assembly
Power Series Deluxe Stick (SMAW, MMA)
Electrode Holder And Work Clamp Power Series TIG (GTAW)
Torch Accessory Pack
Ever last
Everlast
Power Series
Plasma Torches
P-series, S–Series
Everlast
Everlast
Everlast

11
EVERLAST
1.1 This manual has been compiled to give
an overview of operation and is designed to
offer information centered around safe,
practical use of the machine. It is not in-
tended to teach welding technique. All
suggestions and techniques given are ap-
proximations and should be used as a gen-
eral guide only.
1.2 To ensure that your Everlast product is
in top condition, carefully inspect unit for
damage upon opening the box, looking for
damage on the surface of the unit and to
the machine itself and all its accessories.
Do this immediately upon receipt of prod-
uct. Any damage issues must be resolved
right away. It is further recommended that
the product be tested at the same time for
proper operation, even if it is to be stored
for a while. Check to make sure all pas-
sages, connections and fittings are clear of
any packing material or other obstruction.
Record the serial number on the page pro-
vided in this manual. Include purchase date
for warranty reference. Serial numbers are
located on the rear of the machine.
1.3 The Power® Series Combination units
are used daily in the industry performing
day to day fabrication and repair activities.
The exceptional arc characteristics are
provided by the inverter based technology
that employs the use of reliable IGBT tran-
sistors technology from Germany. Light-
weight inverters allow a machine to be
finely tuned for precise arc characteristics,
while consuming less power than the lar-
ger transformer based machines. Ever-
last’s Power Series combination units al-
low non-contact starts, eliminating the
problem of tungsten contamination. De-
pending upon the unit, precise control of
the welding arc is allowed through the ad-
justments available on the panel face. The
independent controls allow for a virtually
limitless number of configurations to suit
every type metal and weld condition en-
countered. The use of High Frequency arc
starting in the TIG mode, greatly simplifies
the TIG(GTAW) process. The incorporation
of the advanced Pilot Arc in the Plasma
Mode eliminates the need for contact starts
and greatly improves consumable life.
1.4 Be careful to observe duty
cycles of the machine posted in
this manual and on the machine
itself. A duty cycle is a rating of percent-
age of time out of 10 minutes the machine
can be used at the rated power setting .
Overheating may occur if the duty cycle is
exceeded. On multi-voltage, multi-phased
machines, note that the rated duty cycle
will change.
1.5 The unit should be stored in a dry
place for long term storage. Humid/wet
conditions can contribute to the eventual
decay of the circuitry in the machine. For
safety reasons, do not use this machine
directly in the rain or with soaked clothing
or protective gear.
1.6 Use only the provided handles to lift the
unit. Do not suspend by cables or chains
or use fork trucks to lift the units. If neces-
sary, use two people to carry the unit.
1.7 Make sure that the units cooling fan
and exhaust vents are kept free of obstruc-
tion. Before every operation, inspect the
unit for unexpected obstructions such as
insect and rat nests. From time to time, a
cleaning of the machine with low pressure
air and a small plastic bristle brush is nec-
essary to ensure long life. On these occa-
sions only, unplug unit and remove cover
to access interior. Concentrate efforts on
aluminum heat sinks and panel vents to
remove dust and dirt.
1.8 Refer to the following pages to locate
your particular unit and its specifications.
Note that product specifications are sub-
ject to change without notice due to prod-
uct improvements. If any additional infor-
mation is needed contact Everlast. Sche-
matics are not offered due to the proprie-
tary information that they contain. How-
ever, simple wiring diagrams may be ob-
tained for basic diagnosis and may be ob-
tained from technical support.
Introduction and SpecificationsSection 1

12
EVERLAST
Introduction and SpecificationsSection 1
PowerMaster Combination Units
Table 1.1
MODEL PowerMaster 226 PowerMaster 205
INPUT Voltage AC220/230/ 240V 50Hz
Open Current Voltage 60 - 80V
AC
Base Current Range 20~220A 20~200A
AC balance Control
30%~70 %
TIG
AC Frequency Control 20~100Hz
Rated Duty Cycle 60%
Pulse Current Range 5~220A 5~200A
Rated Duty Cycle 60%
DC
Current Down-slope Timer 0~10S
Base Current Range 5~220A 5A~200A
Pulse Width Ratio 0.1~0.9
TIG
Pulse Frequency 0.5~25Hz
After Flow Time 1~25s
Arc Starting Method High Frequency
Open Current Voltage 60 - 80V
DC
Base Current Range 5~180A 5~160A
MMA
Rated Output Current 180A 160A
Rated Duty Cycle 60%
CUT
Cutting Current Range 20A~60A 20~50A
Rated Duty Cycle 60%
Arc Starting Method Pilot Arc
Efficiency
≥ 80%
Mass 55 lbs (25kg)
Protection Class of enclosure IP21S
Dimensions 17x8x11.5 inches (430x200x290 mm)

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EVERLAST
Introduction and SpecificationsSection 1
PowerUltra Combination Units
DC Output Only
Table 1.2
Model
PowerUltra205
Power Supply Voltage AC 220/230/240V 50/
60Hz
Open Current Voltage 60-80V
Rated Output Current
200A(TIG/MMA)
50A(CUT)
Rated Duty Cycle 60%
Current Adjusting Range
10 ± 5-200A(TIG)
10 ± 5-200A(MMA)
20 ± 5-50A(CUT)
TIG Arc/ Plasma Starting Method High Frequency/ Pilot Arc
Post Flow Timer 1S~25S
Weight 33lbs (15kg)
Protection Class of enclosure I P21S
Dimensions
17x8.5x12.25 inches (30 × 210 × 310 mm)

14
EVERLAST
Section 2 Know Your machine
3
2.1 Panel Face. The following is a unit panel
face from an EX series unit. Depending upon
your unit, the panel face may vary with regard
to quantity and location of controls and fea-
tures. Use the appropriate referenced num-
ber to refer to equivalent features on your
unit. Names or designation of control features
may slightly vary. Some numbers are omitted
on each panel because the function does not
apply to that unit.
1. Power lamp. This light illuminates while
the unit is powered on.
2. Over Current/Overheat lamp. This lamp
illuminates when the duty cycle has been ex-
ceeded or the machine has overheated due to
improper ventilation. Discontinue use until
lamp goes out. Allow the fan to continue to
run. Once lamp goes out, you may resume
using the unit. If frequent or continuous over-
heating is encountered, contact Everlast.
3. Digital Display. The display posts the ap-
proximate welding amps.
4. Base Current Control. This is the primary am-
perage control. Base amperage is set with this
knob. If the pulse function is desired, first select
your base (low amperage) with this control to
attain you minimum amperage requirements for
the pulse cycle. The amperage change will be
reflected on the digital display. Since the
Power Ultra has no pulse unit, its sole function
is to set the Tig and cut currents (main amper-
age).
5. Pulse Current. This sets the peak (high)
amperage of the pulse cycle. Select the Peak
amperage with this control to achieve the maxi-
mum amperage requirements for the pulse cy-
cle. The amperage change will be reflected on
the digital display. Turn the pulse off by turning
the pulse current control to lowest setting and
use only the base amps to select main amper-
age without the pulse function.
6. Pulse Frequency. The pulse frequency con-
trols the number of pulse cycles per second
(Hz). By defining the pulse frequency, this di-
rectly sets the duration of each pulse cycle.
This allows for fine control of heat input into the
base metal.
7. Pulse Width. This allows the relative amount
of time that the pulse spends in the base (low)
current stage during a cycle length determined
by the pulse frequency control to be adjusted.
For example: A control knob setting of 90%
or .9 will signal the pulse function of the ma-
chine to spend 90% as long in the base (low)
current stage as spends in the peak (high) cur-
rent stage of the pulse cycle. Note: The Pulse
Width does not control the overall length of the
pulse. The pulse frequency setting sets the cy-
cle length, thereby determining the overall
length of each leg of the cycle. Within each cy-
cle length, there is a certain amount (ratio) of
time that the pulse spends in the base (low) am-
perage stage of the cycle and in the peak (high)
amperage stage of the cycle. As the cycle fre-
quency (Hz) increases, overall cycle length is
shortened, thereby compressing the exact
amount of time that the cycle spends in each
stage. However, the pulse ratio continues to
function within the compressed cycle propor-
tionately.
8. Arc Force. This controls the dig of the arc.
The dig is a term used to describe the intensity
1
1
2
2
3
3
4
4 5
6 7 8 9 10 11
12 13 14
14
11
15
15 16
17
Images 2.1.1 a, b

15
EVERLAST
of the arc. It determines how hard the arc
penetrates the metal when the arc is held
short. This is an exceptionally helpful fea-
ture in MMA (SMAW) operation. It helps
hold the molten metal in place in out-of-
position welds by providing a crisp, force-
ful arc. Or, it can provide a soft, buttery
arc that easily washes the metal into the
toes of the weld. This is a matter of opera-
tor preference. Rotating the knob clock-
wise increases dig. There are no recom-
mended settings regarding this feature.
Skill, operating styles and electrode selec-
tion are controlling variables that help de-
termine the optimum setting of the arc
force. Holding the arc close activates the
arc force control and a increase of amps
can be observed. With a little experimenta-
tion, the proper setting can be found for
each task.
9. AC Frequency Control. This control nar-
rows the welding arc and helps to control
penetration and weld shape.
Image 2.1.9 Frequency effects on weld puddle.
200 AC Hz 20 AC Hz
10. AC Balance. This control determines
the amount of time the AC cycle spends in
DCEN (-) or DCEP (+). More DCEN is pre-
ferred for cleaning oxidation, particularly
in aluminum. More DCEP is preferred for
better penetration. A 50% setting equal-
izes the time spent in both. Try this setting
first as a starting point for adjustment.
11. Post Flow. This timer controls the flow
of shielding gas after the weld arc is termi-
nated. Too little post flow time can cause
weld contamination or torch overheating
12. Up Slope. This controls the time that
the machine takes to ramp up the current
from the start current to the normal weld-
ing current. This provides for excellent
Section 2 Know Your machine
continued
control over the welding puddle after it is
developed and allows the operator to ad-
just manipulation techniques as the puddle
warms up.
13. Down Slope. This controls end cycle
of the weld by slowly ramping down the
welding current. As the end of the weld is
reached, the down slope helps prevent
weld cracking and hole formation in the
crater by.
14. TIG/Cut/MMA rocker switch. This
switch allows you to select the use of ei-
ther TIG , plasma cutting or the conven-
tional arc welding features (stick). It is
not recommended to weld with the stick
setup while switched in TIG mode. How-
ever, scratch start TIG welding may be
done in the ARC mode. This discontinues
the HF in sensitive areas. Not all models
are capable of this feature. Be sure to ob-
serve the lower duty cycles of the Arc set-
ting if using TIG in Arc mode.
15. 4T/2T or Remote/Local Rocker
Switch. This switch selects for control
of the TIG weld cycle via the TIG torch
trigger. In the 2T /local mode, simply
touch and hold the trigger to start the
arc and continue holding while welding.
The machine will cycle automatically
according to the settings selected on
the machine. Release the trigger to
finish.
Image 2.1.15 4t/2t operation

16
EVERLAST
Section 2 Know Your machine
continued
4T/ Remote operation allows full control of the
welding cycle. By touching and releasing the
trigger once, the preflow, start current and
up slope are initiated. By touching and re-
leasing again, the down slope, crater current,
and post flow are initiated. Only a momentary
pause between touching and releasing is
necessary to activate the up or down cycle.
*Note: The use of the foot pedal overrides
these functions. Place the setting in the 2T
position to use the foot pedal. The foot pedal
is used to manually control the cycle. To con-
necting the foot pedal to the pin connector is
done in lieu of connecting the torch control to
the pin connector.
16. AC/DC Rocker Switch. This switch selects
the use of either AC or DC current. AC cur-
rent is used primarily when TIG welding alumi-
num. Certain stick electrodes can be welded
in this mode to prevent arc blow and increase
penetration.
17. Pressure Gauge. Identifies the correct
pressure setting for use in plasma mode. Set
plasma for minimum of 60 psi.
2.2 Lower Panel. The lower front panel is de-
picted below. Each terminal or lug should be
kept free of dirt or obstructions. Actual layout
of items may vary.
1. Workpiece or positive(+) lug. For TIG, use
the work clamp (ground) in the positive lug.
(Some units use a positive or negative sign for
reference only.) Mate the work clamp cable
lug into the hole by aligning the raised tab.
Give a slight clockwise twist to lock the cable
onto the machine. When using MMA/Stick,
either terminal may be used for the work
(ground). However, most stick electrodes
require the use of Direct Current Electrode
Positive ( DCEP, or commonly known as re-
verse polarity). In the case of the elec-
trode positive requirement, connect the
electrode holder cable to this side of the
panel. For Plasma cutting, , be sure to
only use this lug terminal for the work
clamp.
2. Fuse. This fuse is used to protect the
pilot arc circuit from overloading. If
blown, the pilot arc will not work. Only
replace the fuse with the same amperage
fuse if blown.
3. Gas Outlet. To secure the TIG torch the
outlet, unscrew the outer ferrule and
slide it onto the TIG torch gas hose. Slide
the hose onto the barb protruding from
the panel until it is completely seated.
Slide the ferrule up the hose and lightly
tighten it on the machine with a small
wrench. Be careful not to over tighten the
nut or hose as breakage or stripping may
occur. Check for leaks.
4. Torch Control. Plug either the foot
pedal or the torch trigger lead directly
into this plug. Tighten the collar to secure
the plug onto the machine. The use of the
foot pedal substitutes for the use of the
torch trigger. For Plasma , the torch
switch must be used. Do not use the foot
pedal for plasma torch operation.
5. Pilot Arc. The plasma torch switch is
connected to this terminal. The torch wll
not operate properly without this at-
tached. Unscrew thumbscrew to attach.
6.Torch or negative (-) lug. For TIG opera-
tion, connect the TIG torch to this side in
the same manner as described for the
positive lug. Direct Current Electrode
Negative (DCEN or Straight Polarity) is
generally the best setting for TIG opera-
tion. For most MMA/Stick welding situa-
tions, connect the work clamp to this
side. For plasma, insert torch lug into this
side.
*Note: For proper use of DCEN and DCEP
while stick welding, consult enclosed in-
formation usually supplied with stick elec-
trodes.
1 2 3 4 5 6
Image 2.2

17
EVERLAST
Section 2 Know Your machine
continued
2.3 Rear Panel. Reference the following im-
age for guidance on rear panel setup and
function.
1. Air regulator/filter/water trap. To adjust
air pressue, pull up slightly on the control
knob on the top of the regulator until a click is
heard. Twist clockwise to increase pressure
or counter clockwise to decrease pressure.
Note: Do not exceed 80 psi. When installing
observe directional arrow for air flow. A step
down regulator at the tank is highly recom-
mended as well as a air dryer. A tank side air
filter/dryer will increase consumable life and
help keep moisture out of air lines.
2. Gas Inlet. This port is a dual pupose port
to provide the unit with either Argon or com-
pressed air. As configured in the picture, it
is set up for compressed air. To use Argon,
you must remove air line (5) and install the
line from the argon regulator. Alternately,
you may install a T-fitting with two shut off
valves at the inlet to eliminate the need to
change out the plumbing when switching
functions. Do not attempt to operate plasma
cutter with argon connected and do not
operate TIG with air pressure connected
unless a suitable shut-off mechanism is in
place and the lines have been sufficiently
purged.
3. High Frequency Ground. This unit pro-
vides a separate ground for the high fre-
quency to help control interference that high
frequency may cause. This ground must be
connected to a separate 12 gauge wire that is
grounded to a metal stake driven into the
ground. It is strongly recommended that you
connect this ground as prescribed. This will
also help prevent shock from the high fre-
quency while it is in operation. Temporary
operation of the unit without the ground may
lead to a High Frequency shock when touch-
ing the unit with bare skin while the high fre-
quency is in operation. If the unit must be op-
erated without HF ground, extreme care
must be taken. Do not operate this unit if you
have a pacemaker until you have consulted
your doctor due to HF interference.
4. Specifications and Serial number. Be-
cause product design and improvement is
continuous, the specifications on this panel
face overrides any specifications found in this
manual. Be sure to record the serial number
in this manual and on the Everlast website.
This will help track any problems and war-
ranty issues should they occur.
5. Air line. Secure the air line with the hose
clamps provided. Make sure the air line does
not bulge or have leaks in it. Occasionally,
stray sparks may burn a hole in the line.
Keep it checked for proper operating condi-
tion. If needed, source extra hose clamps
and tighten onto air line if air is leaking
around the connection.
6. Fan guard. Keep fan away from objects
that could block air flow. Keep away from
walls, and other objects a distance of at least
12 inches.
7. Power cord. The power cord must not be
kept in a strain or the unit pulled by the cord
at any time. Notice that you will have 3 wires
coming from the cord. You will see a green
wire. This is the ground connection. A white
wire and a black wire. These are your two
hot connections. Follow the wiring connec-
tion directions for your type of welding power
plug.
1
2 3
4
6
5
7
Image 2.3

18
EVERLAST
Section 3 Getting started
3.1 These are general guidelines for use
and maintenance for your Power Series
unit. Take into account all safety rules and
recommendations first before operation
and service. Do not let untrained person-
nel operate or service equipment in any
way.
3.2 Shielding gas selection.
Do not attempt to operate theTIG func-
tion with out the proper shielding gas!
Proper shielding gas selection is crucial to
satisfactory operation of your TIG machine.
Shielding gas is a special gas or mixture of
gases designed to cover and protect your
weld from contamination from the atmos-
phere while welding and as it cools. Oxy-
gen and other gases from the atmosphere
can infiltrate the weld and make it unserv-
iceable. Do not be fooled by the weld’s ap-
pearance, because many defects are con-
tained inside the weld without the use of
proper shielding gas. The most economi-
cal and available gas is 100% Argon. He-
lium and Argon/Helium mixes are also
available. Helium offers faster weld rates
while Argon offers a more focused cone
and better cleaning action. Do not attempt
to use common shielding gases designed
for MIG welders. These will melt the tung-
sten and contaminate the weld. If you have
never developed a working relationship
with your local welding supplier, then it is
time to make a visit to purchase or lease a
tank of shielding gas. Many sizes of tanks
are available. Choose the size that best fits
your long term needs.
3.3 Regulator/ flow meter selection. You
will need a flow meter/ regulator designed
to be fitted onto your shielding gas tank. It
controls the flow rate of shielding gas into
your Power Series. There are two styles
generally available. The first has two
gauges, one for pressure the other for
flow. The best regulator has a pressure
gauge and a flow meter with a ball that
floats when gas flows. Certain flow meters
can regulate Helium, Argon or Helium/
Argon mixes equally well. However, oth-
ers cannot. It is advisable that a flow meter
be selected that can regulate both.
Always be sure to select the correct
flow meter for the type of shielding
gas that is in use. Never substitute oxygen
or acetylene regulators!
Image 3.3a Ball type flow meter
Image 3.3b Ball type flow meter
3.4 Regulator/Flow meter connection. Af-
ter connecting regulator safely to tank,
attach hose end to shielding gas inlet .
(see 2.3.5) Firmly clamp and secure hose
end to the unit. Depending upon the flow
meter manufacturer, you may have to cut
and remove the pre-crimped hose fitting to
attach the hose to the shielding gas inlet
barb. Open the tank valve slowly and
gradually increase the regulator flow to
check for leaks.
3.5. Regulator /Flow meter adjustment.

19
EVERLAST
Section 3 Getting started
continued
Adjust the flow meter per manufacturer’s
recommendations. Generally, the flow
should be set around 15-25 CFH indoor for
Argon. Helium settings are usually at least
twice the flow rate of Argon. You will have
to increase the flow of gas if weld porosity,
sootiness, or weld discoloration is encoun-
tered. If a draft is present or welding is
done outdoor, additional flow may be
needed. Increase flow meter output until
symptoms disappear.
3.6. Machine set up .
1. Plug installation. The Power Series com-
bination unit may or may not be equipped
with a service plug. Due to the lack of
standards concerning 220V wall plug con-
figurations, Everlast may choose to ship
the unit without a plug for wall service and
to allow for permanent connection by a li-
censed electrician to the shop circuit
panel. However, if you do not desire per-
manent connection o f your unit, purchase
of a 220V plug may be necessary. May
types and styles of 220V plugs may be pur-
chased. Select a plug rated for at least 40-
50 amps. Also determine plug prong pat-
tern of the existing 220V outlets in your
shop or garage. Make sure both plug and
receptacle match perfectly. Do not force
plugs to mate .
Since Everlast seeks to stay up to date
with ever changing electrical manufactur-
ing standards, the exact wire color may
vary from time to time. Generally , a green
wire may be recognized as the ground and
the black and white wires as the “hot” legs.
To make a 220V circuit work, two “hot”
wires must be used. Attach the two re-
maining wires to the remaining two
prongs. Three phase uses 3 “hot” wires
with the red wire being the 3rd “high” leg. If
a dual phase unit is to be used in single
phase, simply ignore the red wire and cap
it off with a wire connector or tape.
Although Everlast offers broad information
for your consideration, all local codes
must be followed and it is recommended
that you consult with a local licensed elec-
trician if you are unsure of making the
proper connection. Under no circum-
stances does Everlast encourage im-
proper wiring techniques. If you have fur-
ther questions, contact Everlast Support.
Image 3.7a Painted Tips
3.7 Tungsten Electrode Se-
lection. Currently there
are many choices available
for tungstens. Tungstens
are generally referred to by a colored band
painted on the end of each electrode. Each
color represents a certain alloying element
that is present with the tungsten that helps
to extend tungsten life. Sizes also vary.
Each size tungsten is capable of handling a
certain current range. Not all tungstens
are alike. Pure tungsten (Green) is not rec-
ommended for use in any Everlast Power-
Tig machine. Pure tungsten is not capable
of handling the heat and stress placed
upon it by an inverter based welder. Al-
though pure Tungsten is the most afford-
able, it forms a large ball that makes the
arc erratic and difficult to control in in-
verter based machines. Old style trans-
former welders are better suited for pure
tungsten.
The most widely used tungsten is
thoriated (Red). It withstands
the heat of inverter based weld-
ing quite well and retains its
shape without over-melting. Red
(thoriated) tungsten may pose a health risk
as it is slightly radioactive. Inhalation of
the grinding dust or microscopic particles
is possible. Although it is suited for weld-
ing use in an Everlast machine, many peo-
ple choose not to risk their health. Red
tungsten has been available for a long time
and is the standard tungsten in the industry
today. However, as concerns rise, more
companies are looking for alternatives.
The most favored alternatives have be-
come either a Ceriated (Orange) tungsten
or Lanthanated (Gold) tungsten. Both are
suitable for use in an Everlast PowerTig
unit. Costs for these electrodes are con-
siderably higher than pure or thoriated
types of tungsten. Many welders experi-
ment with several types, eventually finding
one that they favor in all situations.

20
EVERLAST
Section 3 Getting started
continued
The following table supplies basic information
about Tungsten selection and suitability.
Note: Use only recommended sizes in Tig
torches unless you purchase additional col-
lets to fit the electrodes snugly. Loose fitting
electrodes quickly ruin TIG torch parts.
NOTES:
NR
NR
O
K
O
K
NR
Table 3.7.1
Not
Recommended