Everlast PowerPro 164Si User manual

Operator’s Manual
Publish Date: Feb. 2020
EVPP164SI2021 Rev. 1
USA/North America
©Everlast Power Equipment
AC/DC
PULSE
160A
DC
130A
120/240V
1 Phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide
FUNCTION: AC/DC TIG with Pulse Function/ DC Stick/ Plasma
PURCHASE DATE:
WELDER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:
DC
40A

2
TABLE OF CONTENTS
SPECIAL NOTICE AND CALIFORNIA PROPOSITION 65 WARNING 3
CUSTOMER GREETING AND EXPLANATION OF PROCEDURES 4
WARRANTY AND CONTACT INFORMATION 5
SAFETY DISCLAIMER AND HF WARNING 6
SAFETY WARNINGS, DANGERS, CAUTIONS AND INSTRUCTIONS 7
GENERATOR OPERATION INFORMATION 10
SPECIFICATIONS, INCLUDING DUTY CYCLE AND INPUT AMPERAGE INFORMATION 11
GETTING STARTED, UNPACKING YOUR UNIT AND INSPECTION 12
CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION 13
SHIELDING GAS INFORMATION AND CONNECTION OF GAS AND AIR COMPRESSOR REGULATORS 14
TUNGSTEN SELECTION AND GRINDING 17
CONNECTING YOUR UNIT AND READYING TO WELD (POLARITY AND PANEL CONNECTIONS) 20
GENERAL TIG SETTINGS AND INFORMATION 23
FRONT PANEL VIEW AND COMPONENT ID 24
REAR PANEL VIEW AND COMPONENT ID 25
CONTROL PANEL LAYOUT AND ID OF TIG FEATURES 26
TIG TORCH PARTS AND ASSEMBLY 33
PLASMA CUTTING OPERATION AND WARNINGS 34
PLASMA CUTTING TORCH PARTS AND ASSEMBLY 40
7 PIN CONNECTOR PINOUT AND INFORMATION 41
TROUBLESHOOTING ERROR CODES 42
TROUBLESHOOTING COMMON WELDING ISSUES 43
TROUBLESHOOTING COMMON PLASMA CUTTING ISSUES 44
MAINTENANCE 45

3
NOTICE:
Product Specications and features are subject to change without notice. While
every attempt has been made to provide the most accurate and current infor-
mation possible at the time of publication, this manual is intended to be a general
guide and not intended to be exhaustive in its content regarding safety, welding,
or the operation/maintenance of this unit. Due to multiple variables that exist in
the welding eld and the changing nature of it and of the Everlast product line,
Everlast Power Equipment INC. does not guarantee the accuracy, completeness,
authority or authenticity of the information contained within this manual or of any
information offered during the course of conversation or business by any Everlast
employee or subsidiary. The owner of this product assumes all liability for its use
and maintenance. Everlast Power Equipment INC. does not warrant this product
or this document for tness for any particular purpose, for performance/accuracy
or for suitability of application. Furthermore, Everlast Power Equipment INC. does
not accept liability for injury or damages, consequential or incidental, resulting
from the use of this product or resulting from the content found in this document
or accept claims by a third party of such liability.
WARNING!
California Proposition 65 Warning:
This product, when used for welding or cutting, produces fumes or gases which
contain chemicals known to the State of California to cause birth defects and, in
some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)
Warning: Cancer and/or Reproductive Harm
www.P65warnings.ca.gov

4
THANK YOU! We appreciate you as a valued customer and hope that you will enjoy years of use from your welder. We work to please the customer by
providing a well supported, quality product. To make sure that you receive the best quality ownership experience, please see below for important infor-
mation and time sensitive details.
What to do right now:
1. Print your receipt from your conrmation email that should have been sent to you after your purchase and put it up for safe keeping. If you do not
have one, contact us at 1-877-755-9353 (US customers) or 1-905-570-1818 (Canadian Customers). You will need this if anything should ever
happen for original owner verication (if bought as a gift, original receipt will still be needed, or explanation sent to Everlast).
2. Read this manual! A large number of tech and service calls are a result of not reading the manual from start to nish. Do not just scan or casually
peruse this manual. There are different features and functions that you may not be familiar with, or that may operate differently than you expect.
Even if you have expertise in the eld of welding, you should not assume this unit operates like other brands or models you have used.
3. Carefully unpack and inspect all items immediately. Look for missing or damaged items. Please report any issues within 48 hours (72 hours on
weekend or holidays) of receiving your product,. Take pictures if you are able and contact us at 1-877-755-9353, ext. 207 if any issue is discov-
ered between 9 am and 5 pm Eastern Time M-F (US customers) or at 1-905-570-1818 (Canadian Customers) between 9am and 4 pm weekdays
except on Fridays when hours are from 9 am to 12pm Eastern. If outside of the US or Canada, contact your in-country/or regional distributor di-
rect at their service number.
What to do within the next 2-3 days:
1. Make sure your electrical system is up to date and capable of handling the inrush and rated current of the unit. Consult and use a licensed and
knowledgeable electrician. If you have downloaded this manual in expectation of delivery, get started now.
2. Make sure this machine is plugged in, turned on, and tested with every process and major feature, checking for proper function. You have a 30
day period to test and thoroughly check out the operation of this unit under our 30 day satisfaction period. If something is wrong, this policy co-
vers shipping on the unit (30 day satisfaction policy applies to the USA only for the 48 lower states and D.C., territories and provinces are exclud-
ed) or any incidental parts that may be needed to resolve any issue. After this 30 day period, if you nd something wrong with the unit, you will not
receive the benet of free shipping back and forth to resolve this issue. Your unit is still covered under the 5 year parts/labor warranty, but ship-
ping is covered by the customer after the 30 day period is over. The rst 30 days of operation with any electronic item is the most critical and if
any issue will happen, it will often happen during this time. This is why it is very important that you put this unit to work as soon as possible. Any
issue should be reported within 48 hours (72 if on the weekend or holiday). Everlast will not be liable for any shipping after that time.
What to do within the next 30 days:
Visit our website (US customers). Go to www.everlastwelders.com. Navigate to the resources tab and to the “product registration” page to register
your product. While keeping your receipt/proof of purpose is still required for verication of ownership, registering will help us keep your details
straight and establish a chain of ownership. Don’t worry, though, your warranty is still valid if you can’t do this. Remember: Always keep your receipt
even if you register. You may want to staple a copy to your manual.
What to do if you have a warranty issue or problem with the unit:
1. Unplug the unit. (Also do this before any maintenance or cleaning is done.)
2. Do not attempt a self-repair until authorized by an Everlast representative. This does not include performing routine maintenance such as point gap
adjustments or regular internal cleaning. Any third party repairs are not covered under warranty, and can further damage your unit.
3. Within 24-48hours, (or by the next working business day) you must contact U.S. tech support at 1-877-755-9353 ext 207(U.S. hours are 9 am to
5pm Eastern for tech support and 9 am to 5 pm Pacic for the business/sales ofce). If you are in Canada contact 1-905-570-1818 (Canada hours
are 9am to 4pm M-Th, 9am to 12pm Fri). Although phone contact is preferred to establish a warranty claim, you may send an email to
[e-mail] (US) or [e-mail] (Canada) along with your contact information and brief explanation of the issue and
ask for a follow up call. If you contact us via phone, and you do not reach a live person, please leave a brief message with the nature of your prob-
lem and your contact information. You should expect a call back within 24 hours. It is also a good idea to follow up the message with an email.
4. Be prepared with as much information as possible when you talk with a tech advisor, including a details of the failure, settings, and application of
the unit. NOTE: A Proof-Of-Purchase (receipt) is required before returning the unit for warranty or before warranty parts can be sent to you.
5. Keep in mind that, you may be asked to check a few basic things. Before you call, having a screwdriver and volt/ohm meter at hand is a good idea
and will save time. Many issues can be resolved over the phone. If the issue cannot be resolved over the phone/email, you may be given an op-
tion to return the unit, or have a part shipped to you, at Everlast’s discretion. Keep in mind, you may be asked questions that seem basic, or ele-
mentary to your knowledge base. These are not meant to question your knowledge, but rather to make sure nothing is overlooked. However the
tech chooses to proceed, please cooperate with the process, even if you think you know what the cause or issue is. You may be asked to check
something or open the unit during the diagnosis. This does not void the warranty! Opening the unit is a part of routine maintenance and cleaning.
This is an important step. The willingness of the customer to work with tech support can save lots of time and accelerate the warranty process. For

5
warranty to be honored, you will need to make sure that you follow these guidelines. Units that are returned without an RMA (issued by the tech
support department) may not be repaired under the warranty agreement and you may be charged for the repair and can result in a delayed repair
as well.
What to do if you need setup help, guidance, weld issue diagnosis or have general product compatibility questions.
Call us at 877-755-9353 ext. 204 for welding guidance and general welding issue diagnosis. Or email [e-mail] with the basic
issue you are having, along with your specic settings, and welding application.
Hey...wait, what is my warranty?
Warranties and service policies and procedures vary from country to country and are maintained and supported by the region-
al or in country distributor of Everlast welding equipment.
USA Customers Only: For full details on the 5 year parts and labor warranty, 30 day satisfaction policy, terms of sale, and how to proceed with a war-
ranty claim, please visit: https://www.everlastgenerators.com/standard-warranty. Accessories are covered by a separate warranty and detailed infor-
mation can also be found at the link above.
Canada Customers Only: For full details on the 3 year parts and labor warranty, terms of sale, and related policies and procedures, please visit: https://
www.everlastwelders.ca/terms.php.
Who do I contact?
USA Technical Support:
Email: [e-mail]
1-877-755-9353 ext. 207
9am-5pm Eastern (Closed holidays)
Monday-Friday
USA Welding Support and General Product Information:
Email: [e-mail]
1-877-755-9353 ext 204
9am-6:30 pm Eastern (Closed holidays)
Monday-Friday
USA Sales and Main Ofce:
Email: [e-mail]
1-877-755-9353 ext 201
9am-5pm Pacic (Closed holidays)
Monday-Friday
Canada Technical Support:
Email: [e-mail]
905-570-1818
9am-4pm Eastern Monday-Thursday
9am-12pm Eastern Friday
Canada Sales and Main Ofce:
Email: [e-mail]
905-570-1818
9am-4pm Eastern Monday-Thursday
9am-12pm Eastern Friday
Other Countries and Regions:
Visit the U.S. Website @ www.everlastwelders.com and click on the flag of the country or region represented that is closest to you. If your country or
region is not found, call the U.S. ofce at 1-650-588-8588 between the hours of 9am to 5pm Pacic, Monday through Friday.

6
Safe operation and proper maintenance is your responsibility.
Everlast is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and
maintenance of your Everlast product, it is no substitute for observing safe welding practices and behavior. Safe welding and related cutting
operations require basic knowledge, experience and ultimately the exercise of common sense. Welding does signicant hazards to your health
and life! Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even life depends upon it.
WARNING! If you do not have proper knowledge or capability to safely operate this machine, do not use this machine until proper
training has been received!
While accidents are never planned, preventing an accident requires careful planning. Stay alert!
Please carefully read this manual before you operate your Everlast unit.
The warranty does not cover damage or harm created by improper use. neglect of the machine or failure to follow safe operating practices.
NOTICE:
Welding and cutting operations may generate undesirable High Frequency (HF) and EMF
energy. This can interfere with surrounding electronic equipment such as computers,
routers, CNC equipment, televisions, radios, fluorescent lighting etc. If disturbance in
surrounding electrical and electronic equipment is noted, consult a licensed electrician to
help properly ground surrounding equipment to limit the interference. This machine may
cause GCFI and ground fault outlets to malfunction. This unit is designed to be operated
on a dedicated, properly grounded circuit.

7
Safety Warnings, Dangers, Cautions and Instructions
NOTICE. This unit manual is intended for users with basic knowledge and skillset in weld-
ing. It is your responsibility to make certain that the use of this welder is restricted to per-
sons who have read, understand and follow the warnings and instructions in this manual. If
you or the operator needs further instruction, contact Everlast welding support at 1-877 755
-9353 ext. 204 or seek qualied professional advice and training.
WARNING! High Frequency (HF) energy can interfere with the operation of pacemakers and
can damage pacemakers. Consult with your physician and pacemaker manufacturer before
entering an area where welding and cutting equipment is in operation and before using this
welder. Some pacemakers have limited shielding. Alert any users or customers of this po-
WARNING! Use approved safety glasses with wrap around shields and sides while welding
and working in the weld area or serious eye damage or loss of vision may result. Use a
grinding shield in addition to the safety glasses during chipping and grinding operations.
WARNING! When welding always use an approved welding helmet or shielding device
equipped with at least an equivalent of a shade 9 or greater. Increase the shade number
rating as amperage increase over 100 amps. Inspect helmet for cracks in lenses and in the
helmet. Keep lens covers in good condition and replace as necessary.
WARNING! Welding/cutting operations carry inherent risks which include but not limited to
possible cuts burns, electrical shocks, lung damage, eye damage and even death. Take all
appropriate measures to use proper Personal Protective Equipment (PPE). Always use
leather welding gloves, closed toe (preferably reinforced or steel toe leather shoes, and long
-sleeved flame resistant clothing (i.e. denim). Do not wear Poly/Nylon blend materials.
DANGER! Welding/cutting poses shock and electrocution risks. Keep this welding equip-
ment dry. Do not weld in the rain or where moisture accumulates. Use dry, rubber soled
shoes, gloves and clothing when welding. Do not rest or contact work clamp (ground) when
welding. Keep all parts of the body insulated from the part being welded when possible. Do
not touch terminals or connections while the unit is on. Consider all parts to be “live” at all
times even if no live work is being performed. Do not use frayed welding cables.
CAUTION! Fires are possible but also preventable while welding. Always remove flammable
rags, papers, and other materials from the weld area. Keep rags stored in an approved flame
proof canister. Keep a fully charged re extinguisher at hand. Remove any fuels, oils,
paint, pressurized spray cans, and chemicals from the weld area. Make sure any smoke/re
detectors are function properly. Do not weld on tanks, drums or barrels, especially if pres-
surized or sealed. Do not weld on any container that previously held fuel or chemicals.
Make sure the weld area is clear of flammable materials such as grass or wood shavings
solvents and fuels. Do not wear frayed or loose clothing. Visually inspect and recheck the
work area after welding looking for smoldering debris or flames.
WARNING! Welding gas cylinders are under high pressure. Keep all gas cylinders upright
and chained to a cart or held safely in a safety holding pen. Never transport gas cylinders
in an enclosed car van or other vehicle. Transport gas cylinders securely. Keep all cylin-
ders capped while not in use or during transport. Replace the cap on the cylinder when it
is going to be more than 24 hours before use. Do not use or attempt to repair faulty regu-
lators. Never weld on gas cylinders. Keep gas cylinders away from direct sparks.

8
Safety Warnings, Dangers, Cautions and Instructions
DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these
hazards are immediate while others are cumulative in their effect. Do not weld in enclosed
spaces or in areas without adequate ventilation. Fumes and gases released in the welding
and cutting operations can be toxic. Use fans or respiration equipment to insure adequate
ventilation if you are welding in a shop or garage area. Do not weld on galvanized metal
under any circumstance. You may develop metal fume fever. Symptoms are similar to lu-
like symptoms. Seek medical advice and treatment if you are exposed to galvanized weld-
ing fumes.
If you experience any eye burning, nose or throat irritation while welding, these are signs
that you need more ventilation.
If you feel these symptoms:
• Stop work immediately and relocate work area with better ventilation.
• Wash and clean your face and hands.
• Stop work completely and seek medical help if irritation persists
DANGER! Never use brake cleaner or any chlorinated solvent to clean or degrease metal
scheduled to be welded or other related equipment in the area being welded. The heating
of this cleaner and its residue will create highly toxic phosgene gas. Small amounts of
this vapor are harmful and can lead to organ failure and death. If degreasing of a part is
necessary, use Acetone or an approved pre-weld cleaner. Use the proper personal protec-
tive equipment (PPE) when handling any cleaners/solvents.
DANGER! People with pacemakers should consult a physician and pacemaker manufactur-
er before welding. There is a potential for damage or serious malfunction resulting in
death. High Frequency energy (HF)/Electromagnetic Fields generated during welding can
interfere with pacemaker signals, even permanently damaging it. Some pacemakers offer
some shielding, but restrictions regarding amperage and HF starting of TIG arcs may be
placed upon the individual. Warn all potential bystanders that they should exit the work
area if they have a pacemaker or similar medical equipment before welding. Severe electri-
cal shock leading to injury or death may occur while using the plasma cutter if the user
becomes part of the circuit path. While the Amp output of the plasma cutter is limited, the
unit may produce an OCV of 300V or greater. Consult with a Physician if a pacemaker is
expected to be implanted.
DANGER! Never defeat or modify any safety guards or shields. Keep all safety covers and
shields in place.
Never place your ngers in or near a fan shroud or insert any object into the fan(s).
DANGER! Do not supply more than 100 PSI to the air-pressure regulator supplied with
this machine. If you do, the regulator may leak or explode, causing severe injury or
death. Use a separate regulator mounted at the air-compressor to control supply air pres-
sure. Never use an air compressor without a separate compressor mounted air regulator!

9
Safety Warnings, Dangers, Cautions and Instructions
CAUTION! Trip Hazards exist around welders. Cords, cables, welding leads and hoses pose
a trip hazard. Be aware of their location and inform others of their location. Tape and se-
cure them so they will stay out of high trafc areas.
CAUTION! Welded metal can stay hot long after welding is completed. Burns may occur.
Always wear gloves or use tongs/pliers when handling welded or cut metal. Remember
the heat from the metal may catch other material on re. Always have a re-proof area
ready to place welded components until they fully cool. Use soap stone or a metal marking
marker to label the metal as “HOT” to serve as a reminder to all present in the area.
CAUTION! Welding and cutting operations generate high levels of ultraviolet (UV) radiation
which can burn and damage skin and eyes. The intensity is so high that exposed skin and
eyes can burn in a few minutes of exposure. Minimize direct skin and eye exposure to this
intense form of radiation by using proper PPE and sun screen where appropriate.
CAUTION! Do not allow bystanders. Do not allow others without proper Personal Protec-
tion Equipment (PPE) suitable for welding to stand in the welding area or to observe weld-
ing and welding related activities. If protection is not readily available, use a welding
screen to separate the welding area from the rest of the area. If no protection or screen is
available, physically exclude them from the welding area by a wall or other solid divider.
Keep all pets and young children away from the welding area.
CAUTION! Electromagnetic Fields can be generated by this welder and radiate into the work
place. The effect of EMF is not fully known. Exercise caution when welding by: NOT drap-
ing welding leads (guns/cables) over your shoulders or arms, NOT coiling them around
your body, NOT inserting yourself directly between the cables, and by NOT contacting the
unit while welding. DO keep the work clamp connected as close as possible to the area of
the weld and directly to the object being welded whenever possible.
DANGER! Never touch connectors or ttings while this machine is turned on. Keep all
safety covers in place when not in use. Never remove or replace the plasma consumables
while the machine is turned On. Even though the torch is equipped with a “parts-in-place”
safety disconnect, it is possible that overheating of the torch, excessive wear or damage to
the consumables may cause this feature to malfunction. Make sure the brass safety cut out
pins on the torch head remain in good repair and that the spring loaded function remains
operational and keeps them fully extended when the torch cap is removed. The Open Cir-
cuit Voltage (OCV) while in plasma mode may exceed 300V. This is enough to cause
burns, injury severe electrical shock, injury and instant death.

10
Important Information: Operating this unit with a generator or other off-grid service.
This welder/plasma cutter multi-process unit should only be operated on a generator certied by its manufacturer to produce clean pow-
er. Clean power is equivalent to the quality of household or shop/garage type power. This means the generator must have 5% or less
total harmonic distortion (THD) of the Sine wave. If you are unsure of the power output type of the generator, contact the manufacturer of
the generator for verication. Do not operate on square wave or modied square wave generators or converters/inverters or damage or
malfunction may occur. Damage caused by running this welder off of “dirty” power or modied sine waves may not be readily apparent
and can be cumulative in nature. However, damage may present itself immediately. The damage caused by running this welder on “dirty”
power usually leaves internal tell-tale signs and damages specic parts.
When operating on 240V 1 phase, you will need a minimum of 7,000 surge Watts. Ideally, it is recommended for use with 8,000 watt
generators or larger. Operating the unit on under-powered generators and/or on generators not rated with 5% or less THD can damage
your unit. The generator manufacturer determines this rating, not Everlast. Do not assume that a name brand generator, or a “new” gen-
erator automatically provides clean power. Price paid does not guarantee a clean power output either. There are multiple brands at vari-
ous price points capable of producing clean power. Investigate this before purchasing a generator. The manufacturer will usually state
that a unit is clean power in the advertising information and will state actual THD. If the manufacturer does not state it, contact the manu-
facturer directly for actual THD.
NOTICE! Operation of this unit with generators not rated by its manufacturer as providing clean power (5% or less THD) is prohibited and
will void the warranty. Operation with modied sine wave, or square wave generators and inverters/converters/UPS that do not produce
“sine wave” output is prohibited and doing so will also void the warranty. Use only with generators/inverters/converters that produce an
equivalent type of sine wave used in shops, homes and “shore” type systems.
WARNING! Do not start or stop the generator with the welder switched on. Never use the generator in ECO mode or an auto-idle mode.
Even with a clean power rated generator, this action can damage the unit. Turn on the welder only after full generator R.P.M. has been
achieved and the engine is sufciently warmed up. Closely monitor generator fuel level so that the engine R.P.M doesn’t drop or com-
pletely shut down with the welder plugged in. For best practice: do not start or stop the generator with this welder plugged in, even if it
is turned off. Unplug the welder before shutting down the generator.
If using with a welder generator, make sure the manufacturer has determined that the generator portion produces a clean sine wave.
Many older models do not. Some newer models use “divided” power between welding and generating and cannot supply the full power
to the welder unless the ne current control knob is turned to maximum. Do not use this unit with such welder/generators unless the
Power/ne current control is turned to 100%. Some welder generators do have a separate alternator for generating power. If this is the
case, just be sure not to weld or load the machine while this unit is in use.
WARNING! Always make sure any generator or welder generator is properly grounded, according to local code. Ground the machine per
the generator manufacturers instructions to meet code. Improperly grounded generators may damage the machine and more importantly
may cause severe injury or death.
Single Phase 240V Operation:
This unit should be used with single phase 220/240V output. However, the unit may be used with single phase 208V if the voltage does
not drop below 205V. If using this unit on 208V, duty cycle and display accuracy may be affected. Rated and Inrush Amperage will rise
proportionately as well. If you decide to use this machine on 208V, before installing permanently, have an licensed electrician monitor
voltage fluctuations, particularly under load and during peak use times. If the voltage remains constant, and steady without dropping be-
low the 205V threshold, this unit may be used. Damage caused by using on undervoltage power sources is not covered by the warranty.
Long arcing of the plasma may also increase amp demand.
WARNING!
Never use the electrical power outlet on the back of this machine for anything other than powering an Everlast brand water cooler. This is
a special outlet designed to produce 240V with limited amperage draw. No other device or brand should be used in conjunction with this
unit’s outlet. This outlet is designed to supply 240V only. Do not attempt to modify, or change this outlet for use with anything else other
than an Everlast brand water cooler designed for 240V operation. Severe damage, re or injury may occur if other devices or other brand
equipment is connected.

11
Specifications
*Duty Cycle
Duty Cycle is simply the amount of time out of
a 10 minute period in which the unit can
operate. For example, if this unit has a duty
cycle of 35% at maximum output on plasma
(or other modes), that means that the unit can
be operated for 3.5 minutes out of 10 minutes.
This may be continuously, or intermittently
during the 10 minute period of time. This
rating standard (United States) is based on a
maximum ambient temperature of 40 C.
Operating above this point, or at lower temper-
atures with high humidity may reduce the duty
cycle rating. Of course, the duty cycle may
increase somewhat as ambient temperature
drops. Regardless, this unit’s duty cycle is not
controlled by a timer. Rather, this unit is
equipped with a heat sensor located on a heat
sink near the critical power components of the
welder. If the operating temperature of the unit
is exceeded, welding output will stop and an
over-temperature warning light/error code will
be displayed on the panel. If a duty cycle
event is registered, do not turn the unit off!
Allow the welder to continue to run at idle for
at least 10-15 minutes until the temperature
has fallen enough to reset the sensor and over
-temperature warning light. Even if the unit
resets, allow the unit to cool for a full 15
minutes, or the duty cycle will be more quickly
triggered since the unit resets just below the
heat threshold. The fan(s) must continue to
run for a full 15 minutes to cool the unit
properly after the duty cycle shut down has
occurred. After 15 minutes of cooling, you
may switch the unit off if you are nished
welding. If the unit does not automatically
reset after 15 minutes, turn the unit off. Wait
for 15 seconds before turning the machine
back on. If the unit does not reset, contact
technical support for further advice and assis-
tance. As a best practice, when you have
completed welding and have been welding
continuously for extended periods of time,
keep your unit on for 10 additional minutes
without welding to allow it to cool.
The intentional and/or repeated triggering of
the duty cycle protection feature on this unit
will shorten the lifespan of the unit’s electron-
ics and can weaken internal components. The
effect of overheating your unit repeatedly takes
a cumulative toll on the unit.
Product Specifications
Construction Type Inverter (IGBT based, Digital Control)
Input Voltage 120;240 V (± 10%) 50/60 Hz
Phase 1 Phase 50/60Hz
I1MAX Current Rating (Inrush Amps) 120/240V 28.5A/24.8A
I1EFF Current Rating (Rated Amps) 120/240V 23A/20A
OCV 85V TIG/ Stick . 300V Plasma.
TIG Duty Cycle @ Maximum Output (Rated at 40° C/104 F) * 120V: 60% @ 100A 240V: 60% @ 160A
Stick Duty Cycle @ Maximum Output (Rated at 40° C/104 F )* 120V: 60% @ 90A 240V: 60% @ 130A
Plasma Duty Cycle @ Maximum Output (Rated at 40° C/104 F )* 120V: 35% @ 25A 240V: 35% @ 40A
TIG Output Range V/A (DC/AC) 120V: DC 10.2-14V/ 5-100A; AC 10.8-14V/ 20-100A
240V: DC 10.2-16.4V/5-160A; AC 10.8V-16.4V/ 20-160A
Stick Output Range V/A (DC Output Only) 120V: 20.2-23.6V/ 20-100A 240V: 20.2-25.2V/20-130A
Plasma Output Range V/A (DC Output Only) 120V: 88V-90V/20-25A 240V: 88V-96V/20-40A
TIG Start Type HF, Remote Lift (with Switch or Pedal Only)
TIG Point Gap Setting (Recommended) .029”-.045” (.035” target)
Plasma Start Type Blow-back style, with Pilot Arc. (Non High frequency)
Recommended Plasma Air Pressure 65 to 75 PSI while cutting. Max. supply pressure: 90PSI
Recommended Minimum Compressor size 30 Gallon with 4.0 CFH or greater @ 90 PSI
Pre Flow / Post Flow Gas Time PREFLOW: Fixed (.5 Seconds) POSTFLOW: 0-10 Seconds
Start Amps (Initial Current); End Amps, AC/DC (Crater Current) Fixed @ Minimum Value
Upslope/ Downslope (Ramp up/Ramp Down Current) Time UPSLOPE: Fixed DOWNSLOPE: 0-10 Seconds
TIG Pulse Frequency Hz Choose either 1Hz or 25Hz
TIG Pulse Time On (Duty Cycle) Fixed @ 50%
TIG Pulse Amps (Background Current) Fixed @ 50%
AC Wave Form(s) Adv. Square
AC Frequency 20-250 Hz
AC Balance (Cleaning, % of Electrode Positive) 10-90%
Stick Arc Force Control Auto
Setting for Stick E6010 (Cellulose Type Electrodes) No. Use 6011. (6011 performance may be limited)
TIG Gun Type/Length/ Connector Type Rigid-Neck 17 Series Air-Cooled, 12.5 ft. (4m) DINSE
35/50 (1/2 nom. dia.)
300A Work Clamp with Cable Length 6.5 ft (2m) DINSE 35/50 (1/2 nom. dia.)
250A Stick Electrode Holder Length 9.5 ft (3m) DINSE 35/50 (1/2” nom. dia.)
Power Cable Length 6.5 ft (2m)
Power Plug Type for Single Phase 240V Operation NEMA 6-50P (Standard 240V Welder Type)
Cooling Type Full Time, High Volume Fan(s)
Dimensions (Approximate) 18” H X 10” W X 25” L
Weight (Bare Unit) 62lbs.
Ingress Protection Rating IP21S
Breaker Sizing and Wiring Requirements
Before installation of this unit in any facility, always consult a licensed local electrician familiar with the requirements of properly wiring a welder into the electrical supply. Refer to
the National Electric Code (NEC) and local codes. If needed, refer the electrician to Article 630 of the NEC during consultation to determine proper application and wiring needs.
Use the I1MAX and the I1EFF ratings listed above to determine the proper breaker and conductor (wire) sizing required. Everlast welders are designed around use in industrial
wiring applications and are intended to be used with modern electrical systems. Household wiring may need to be upgraded before this welder may be installed. Additional HF
protection and isolation may be needed if this welder interferes with the operation of electrical/electronic equipment. WARNING! Do not modify welder wiring. This unit meets the
standards for conductor sizing on the power cable and takes into account power cable length, duty cycle and rated current.

12
Setup Guide
Getting Started
UNPACK YOUR UNIT.
Upon arrival, you will need to completely unpack your unit, and check
things over. This is a time sensitive matter. Do not delay or hold the
welder unopened in the box. First, make sure the unit is opened from
the top. Be careful with using knives and sharp objects so you won’t
cut cords and cables inside the boxes. Lay all items out and inspect
them.
You should have the following in your box:
1. Welder.
2. Foot Pedal (Deluxe Style Standard, NOVA Style Optional).
3. Floating Ball Type Brass Argon Regulator with Tubing.
4. Air-Regulator with built in water trap/particulate lter.
5. 17 Series Air-Cooled Torch (Rigid/Straight Neck) 12.5 ft..
6. 250A Stick Electrode Holder (approx. 9.5 ft with cable).
7. 200A Work Clamp (approx. 9.5 ft with cable).
8. Consumable Starter Kits for TIG. Tungsten not included.
9. Consumable Starter Kit for Plasma. (50-60A rated Tips)
10. S45 Plasma torch.
11. 240V to 120V adapter
When you receive your package, inspect the unit for damage. Check for
the presence and general condition of the accessories. Some slight
rubbing or chafng of some of the accessories may be present, but this
is considered normal. If any item is damaged or missing, please inform
Everlast within 72 hours of product receipt. See pages 4 and 5 for
more details. Assemble the front, middle and rear handles with the
supplied screws. Do not overtighten the screws.
POWER UP AND TEST YOUR UNIT.
You will need to fully test the unit as soon as possible. Within 72 hours
after receipt of the unit, be sure to have every thing you need at hand
to test the unit. Make sure the correct input power, wiring, and plug
conguration is being used. Then, power up your machine without any
accessories installed. Allow the unit to idle for 15 minutes. Check and
observe operation of knobs, controls and buttons, cycling through each
as required. Make sure the fan is running at full speed. After the test
NOTICE:
The foot pedal may arrive with the top separated from the bottom. This is not dam-
age. The top can easily be installed on the bottom, by aligning the pivot pins with the
corresponding holes for the pins located in the top. The pins are spring loaded and
can be squeezed so that the top slides down onto the pins. The pins will pop out into
the holes and allow the top to pivot once the pins and holes are properly aligned.
You may need to make sure the pressure return spring is flipped so that it pushes
back against the pedal as it is assembled. Similarly, the foot pedal may be disassem-
bled simply by pressing in on the ends of the pins on both sides to remove the top.
is completed, turn the unit off, connect the accessories, shielding gas
(customer supplied) and conduct live testing of all the functions and
features of the machine. For testing and welding make sure work
clamp is connected directly to the part being welded (work). Check
for arc starting and stability. If problems are observed, contact Ever-
last. See page 5 for more information. NOTICE: Cosmetic damage
claims after 30 days will not be accepted, unless Everlast is contacted
and informed of such delay and reason for such a required delay (i.e.
Overseas in deployment).
CHECK FOR GAS LEAKS.
Be sure to check for gas leaks before attempting to weld or cut. For
TIG operation, you can test this by installing both back caps into the
TIG torch head (from both sides). Next install the regulator and
tighten to both cylinder and unit (see section on regulator installa-
tion). After the regulator is secured, set post flow time to maximum.
Trigger a false start with either the foot pedal or torch switch by tap-
ping and releasing so that post flow can flow. Observe the ball on the
regulator. It will briefly float before settling back down. If it continues
to float or rattle, you have a leak. For the Plasma Cutter, connect all
the lines and tighten and recheck any related clamps, plugs and t-
tings. If you hear or suspect leaks either while congured to TIG weld
or while congured to Plasma cut, use warm, soapy water (or a dedi-
cated leak testing solution available from welding suppliers) and
spray on all connections, including the torch connections at the head
and handle. If any leaks are present, bubbles will form around the
area of the leak. Tighten any clamps or ttings found to be leaking.
If the problem cannot be remedied, contact Everlast.
DISTANCE YOUR WELDER FROM YOUR WORK.
As a best practice technique, be sure to locate your welder away from
the immediate area you are welding. The fan(s) found in your unit
are powerful enough to create strong air turbulence in the weld area.
This will disrupt the smooth, even flow of shielding gas around your
weld creating unstable arcs, porous welds, and dull nish on the
weld. If possible the welder should be located at least 6 feet away
from the weld area and should be on a different level to prevent weld
porosity and defects being created by the welder’s fan system. Keep
in mind the fan draws air in from the rear and exhausts out the front
and the sides of the unit. This information also pertains to the water-
cooler, if used.
GIVE YOUR WELDER SPACE TO COOL.
The welder needs room to cool itself. Place the unit in a place that
will allow 18” from all sides to allow for proper cooling. The welder
pulls air in from the rear, and pushes it through the unit’s heat sinks
to cool the electronics. The air is then exhausted through the front
panel and side louvers of the unit. If any of sides is blocked or re-
stricted, the duty cycle will be reduced, and overheating will occur,
leading to possible damage if the restriction is severe enough. Never
1
2
4
5
6
8
7
9
10
3
11

13
attempt to restrict air flow by attaching lters to the vents or by modi-
fying your fans for “on demand” service.
CONNECT YOUR UNIT TO THE OUTLET.
Your unit has been shipped with a NEMA 6-50P welder plug. This is
the standard for 240V 1 Phase welders in North America. For single
phase 240V connection, select a NEMA 6-50 Receptacle for opera-
tion with this unit. (Other regions/countries vary). A neutral is not
used. For a dedicated circuit, the wire wires supplying power (the
conductors and ground) are black, white and green. A red wire,
which is traditionally the “hot” leg of power is not present in the three
wire 240V wire circuit of a welder. For welders, from the panel box,
the Black wire serves as L1(Hot), White serves as L2 (Hot) and Green
NOTICE:
There are special rules centered around wiring an outlet for service
with a welding machine. The National Electric Code under Article
630 has developed specic regulations for wiring electrical service
for welding equipment. These are different than for other types of
service such as a stove or dryer in a household or even in a com-
mercial application. You need to consult and/or employ a locally
licensed electrician before installing this unit to make sure all nation-
al and local codes are followed. If you are not qualied to make
these connections, don’t. Everlast is in no way liable for any damag-
es caused by improper connection of your welder. Your welder
should be on a dedicated branch circuit not far from an electrical
disconnect box. Importantly, it should not share circuits with other
shop or household items. Do not attempt to “adapt” existing circuits
because conductor (wire) colors are different for welders with 3 wire
operation than for a dryer or range with 4 wire operation. (Unless
adapting with an approved adapter when being powered with a
“clean power” generator.) No neutral is used in a welder circuit. The
white wire is a conductor in a single phase welder service. The red
wire is not used. The input power cable conforms to North American
standards for size, length, with consideration given to inrush amper-
age, rated amperage and duty cycle. Do not modify, or attempt to
rewire your unit.
Standard Plug Conguration 1 Phase 240V
.
NEMA 6-50P
Setup Guide
serves as G (Ground). Red will not typically be used as a conductor
(on a dedicated welder circuit). There is no need for a neutral, so white
is used as the other “hot” conductor in this instance. It is recommend-
ed to either install the receptacle as close to the main panel as possible
or install a subpanel cutoff as close as possible to the outlet and weld-
er. Follow local code to determine best arrangement.
If you are using this unit in conjunction with a 240V air compressor,
you must supply a separate, dedicated circuit for both. Do not share or
piggy-back a circuit with this welder/cutter unit.
This welding unit is also designed to operate on 120V power. While
operating on 120V, the output will be reduced. To adapt the unit for
120V operation, the unit has been supplied with a 240V to 120V pigtail
adapter. When operation on 120V is required, simply plug this NEMA
6-50R to 5-15P adapter to any standard type wall outlet with either a
slow blow fuse, or delayed trip breaker protecting the circuit. The in-
rush current of this unit can exceed the limits of a typical 15A 120V
circuit when used at or near maximum output of this welder while oper-
ating on 120V. For best results, use this unit with a slow blow fuse, or
a delayed trip breaker on a dedicated 120V 20 or 30 Amp circuit to
avoid nuisance fuse blowing or breaker tripping. There is no need to
alter or change any wiring or switching required to be able to operate
on 120V. The unit automatically senses the input power and adjusts
the maximum output of the welder.
Getting Started
Selecting A Breaker and Wire Size
Select a breaker based off of the I1MAX rating of this unit. This is the
maximum inrush current of the unit. The inrush is not a sustained
current. The I1EFF rating of the unit is the maximum “rated” current of
the machine. When combined with the length of the run from the
main panel, his determines the conductor size needed to supply the
welder, Refer your electrician to Article 630 and the specication page
of this manual (or the specication grid printed on your unit) when
selecting the correct breaker and wire size. A delayed trip breaker, or
slow blow fuse should be used with this unit.
240V to 120V Pigtail Adapter (Supplied)

14
Setup Guide
Getting Started
Connecting Argon shielding gas for versus
connecting compressed air.
This unit is equipped with only one inlet in the rear for gas supply.
This means that both shielding gas for TIG welding and the Air sup-
ply for plasma cutting uses the same tting.
With that said here are some things to keep in mind.
1) Never, under any circumstance run the shielding gas through
the air regulator. Gas flow will be inconsistent and difcult to
regulate.
2) As equipped, you will need to disconnect the air regulator at the
bottom rear inlet on the unit and reconnect the shielding gas
cylinder tting to the bottom inlet and vice versa when you
change between processes.
3) Since the connection TIG connection and Air Compressor con-
nection is shared at the bottom rear of the unit, and the same
solenoid and tubing govern the delivery of both gases to the
torches, special care should be exercised to keep the compres-
sor air dry. Any residual moisture in the lines while welding TIG
can create contamination problems. This is also true for oil
from worn compressors getting into the line. Make sure that
Air compressors and dryers are drained or serviced regularly to
eliminate the possibility of contaminating the lines with both oil
and water.
4) Install a separate air dryer before the air reaches the regulator
on the unit. It is best to place it 2 or 3 feet away and use a
short jumper hose between the air dryer and the regulator. If
this cannot be done, then install a dryer directly at the compres-
sor.
5) Use a dedicated air hose intended for use only while plasma
cutting. This will reduce the change of cross contamination
when automatic tool oilers are used in the system.
6) You may install a Y valve, or a ball valve and T tting at the rear
of the unit if you do not want to switch ttings back and forth
when changing processes. If a valve is desired to switch gases
more quickly, consider using an inert gas Y valve, such as a
Western #411 or similar model valve.
7) The pressure gauge on the front of the welder may register-
some pressure while in TIG welding mode with the shielding
gas connected. The presence of, the absence of, or the amount
of pressure registered is not relevant or of concern while TIG
welding. Use only the flow meter included with this unit to
measure and regulate the actual shielding gas flow rate. The
pressure gauge on the regulator only registers cylinder pres-
sure and is used to determine a relative amount of cylinder
contents remaining.

15
Setup Guide
Getting Started
CONNECT YOUR UNIT TO TIG SHIELDING GAS.
Always wear safety glasses when changing a cylinder. Before installing
any cylinder, stand to the site of the valve, away from the discharge,
and quickly open the cylinder to give it a quick blast. This will dis-
lodge any dirt or particles stuck in the valve or the connection seat.
This will help reduce the chance of dirt particles making its way into
the solenoid valve, causing sticking issues later on.
Connecting your cylinder will require a cylinder wrench(1 1/16”)to
connect the regulator to the cylinder (North American Cylinders with a
580 CGA valve). If you do not have a cylinder wrench, an adjustable
type wrench will work, but make sure it is properly adjusted to prevent
What Shielding Gas Should Be Used?
Selecting shielding gas for MIG is straightforward. For all metals,
whether using in AC or DC, use 100% Argon. Never use a gas mix
mixed with CO2. CO2 will rapidly consume the tungsten and intro-
duce porosity into the weld even at low concentrations.
With that said, if you are welding at or near the maximum capability
of the unit, you may also wish to use an Argon/Helium mix. This
will increase the overall heat going into the weld. No more than
25% Helium mix should be used with this unit, or Arc starting ef-
ciency will be reduced (hard to start arc). Arc stability will also be
affected at higher percentages. Helium is expensive and the cost
versus benet of adding it must be weighed carefully as a cylinder or
two of high percentage Helium may approach the cost difference of
upgrading to a larger unit! If a high Helium content is used, expect
some trade-offs. Arc starting may be improved slightly by readjust-
ing the point gap.
There are a few new gas mixes (blends) on the market with promise,
but as of publication they have not been thoroughly evaluated for
use with this welder. Exercise caution when using a new mixture
(often marketed with Nitrogen or Hydrogen) as the application is very
specic. Pure 100% Argon is the most economical and best for
nearly every application, and having multiple gases should not be a
concern for even the most advanced user.
BE AWARE: It is increasingly common for users to get cylinders of
“bad gas,” creating mysterious and difcult to identify issues. An
Argon cylinder is the same type of cylinder as an Argon/CO2 cylinder
used for MIG and sometimes times can get mixed in and relabeled
as pure argon. Another increasingly common issue is that a gas mix
cylinder gets relled with Argon with residual Ar/CO2 mix without
using proper purging techniques. Usually this occurs in “batches”
and complete lots of cylinders can be affected. Sometimes swapping
with another cylinder from the same supplier will not correct the
problem. Also it has been found that a customer to specify “Argon”
and receive a cylinder marked as Argon/CO2 mix. Always check your
cylinder label below the cap area for proper labeling before accept-
ing the cylinder.
rounding of the tting shoulders. Do not use pliers, or a serrated jaw
wrench such as a pipe wrench or basin wrench to tighten the tting.
The design of the tting means that no thread sealing tape or com-
pound needs to be used.
Connect the regulator tubing to the regulator. The regulator may
have either a hose barb connection, or a threaded connection. If the
regulator supplied has a hose barb, make sure the hose barb tting is
tight on the regulator. Tighten with a 3/4” (19mm) wrench. If it is a
threaded connection, use two 3/4” (19mm) wrenches to hold both
the regulator and the tubing connection at the same time. Hold
counter pressure on the regulator connector while tightening the
hose tting to prevent damage to the regulator and to ensure maxi-
mum sealing. After connecting the tubing to the regulator, connect
the other end of the tubing to the 5/8” CGA tting on the unit. Hold
the tting on the unit with one 3/4” (19mm) wrench rmly while
tightening the hose tting with another 3/4”(19mm) wrench. Im-
portant! Do not use thread tape or pipe sealant on any cylinder, regu-
lator or unit connection. The residue and debris may get into the gas
solenoid and cause operational issues.
Connect Regulator To Cylinder And Unit.
CAUTION!
Do not tighten the rear unit connection without holding the female
5/8 CGA tting on the unit with a wrench, or damage may occur to
the bezel and the tting as the tting may turn in the plastic housing
while the hose tting is being turned.

16
Setup Guide
Getting Started
CONNECT THE AIR COMPRESSOR
What do I need to be able to plasma cut?
The unit comes with everything you need as far as a basic starter kit
for consumables, torch and regulator. However, you will need to
supply a few things on your own.
1. You will need a suitable air-compressor and at least 3/8” supply
line hose. By suitable, we mean one of at least 30 gallon capac-
ity, with at least 5.3 CFM @ 90 PSI. This size air-compressor
usually is available as an oil type which has a oil sump for
lubrication for long life and improved cooling. 6CFM @ 90PSI
and a 60 gallon tank is even better, but not required. A 30
gallon compressor is usually 120V, but larger compressors are
240V. If it uses 240V, you will need a separate circuit for your
air compressor. Your welder and air-compressor should not
share the same circuit, or be “piggy backed” at the panel or
receptacle. Get a licensed electrician to assess your needs, to
make recommendations and to install the circuit if needed.
2. You will need to be able to regulate your air at the air compres-
sor. Do not use the pressure switch on the air compressor to
control the air pressure. A gate or ball valve installed on the air
compressor is not enough either. You will need an adjustable
regulator which will control the air pressure at the tank. The
regulator that you install on the unit is to be used to regulate
actual cutting pressure. You need to be able to regulate the
supply pressure down to 90PSI at the air-compressor. If you
supply more than 100PSI to the cutter’s regulator, you may
damage the regulator.
3. You will need a separate air-dryer. Moisture is the enemy of
any plasma system and destroys consumable life and eventually
torches themselves. The regulator/lter included with the unit
is not sufcient to remove moisture from the system. It is de-
signed to trap particulates and slugs of water created by the
coupling/decoupling process. A refrigerated system is not
necessary. We recommend you look at the cartridge type sys-
tems that have replaceable elements for a budget alternative. If
these are not available, consider at least having a replaceable
paint gun dryer mounted inline and monitor the moisture it
traps and replace it often.
4. You may need additional consumables with different sizes to
match the cut Amperage. The stock consumables are designed
for use at the maximum amperage of the machine. The orice
in the plasma tip is specically designed for a range of Amps.
To see that range, check the plasma torch page of this manual,
and each tip diameter corresponds to a specied amp range.
Lowering air pressure to try to compensate for lower Amps
results in poor quality cuts and inconsistent arc behavior. Al-
ways match the consumable size to the Amperage being used.
IMPORTANT:
Do not reverse air flow direction! Make sure the arrow stamped on top
of the regulator coincides with the direction of air flow.
Connect Regulator To Cylinder And Unit.
1
2
3
4
0
5
Tubing connect to lower rear of the unit. Air Dryer
Regulator

17
Setup Guide
SELECT THE PROPER TUNGSTEN TYPE.
Getting Started
What Type of Tungsten Do I Use?
Selecting the correct tungsten for your welder is important. Modern
Inverters no longer use Pure (Green band) Tungsten for welding AC.
In fact pure Tungsten used with an inverter can created problems
with arc stability, arc starting and excessive balling. While Thoriated
2% Tungsten can be used in an inverter for DC, and even for AC
welding, it is falling out of favor in the industry due to the slight
radioactive nature of it, and it does present some issues while weld-
ing in AC than other choices. But it is still an industry standard.
For welding in AC and DC consider the following types.
• Lanthanated 2% (Blue Band). Overall this is one of the best
choices for TIG welding and can be used for AC and DC weld-
ing. It has great arc starting characteristics, and its point hold-
ing capability is excellent.
• Ceriated 2% (Gray Band or Orange Band, depending upon
brand and country of origin). This is a good choice for welding
with both AC and DC, but doesn’t hold up as well and starts to
erode faster than Lanthanated at higher amperages. But arc
starting is excellent.
• Lanthanated 1.5% (Gold Band). Holds up nearly as well as
Lanthanated 2% and can be used for AC or DC welding. In
some tests it has rivaled Lanthanated 2% performance.
• Tri-Mix/Rare Earth (Purple Band or Turquois Band). Still rela-
tively new. Some swear by it, and is being marketed as a re-
placement for Thoriated 2%. Overall, it does perform fairly well
and even excels in many circumstances. But some problems
have been seen with quality control. The primary metal oxide
used is lanthanum 1.5%. Usually it also includes a small per-
cent of Zirconium and Cerium to complete the mix. Some use
Yttrium. But the balance of the composition blend are usually
stated to be around .06 to .08%, but can be allowed to vary up
or down from .04% to .01%, making he blend prone to incon-
sistency in quality control.
• Thoriated 2% (Red Band) Still considered the best for DC,
works ok for AC, but has been banned in many markets outside
the US due to a small radiation risk posed as an alpha emitter.
Do not use the following types of Tungsten.
• Pure Tungsten (Green Band). This will create arc instability.
The tungsten will not stand up well to the more intense arc
created by an inverter welder.
• Zirconiated Tungsten (White Band). This was created as an
alternative for Pure Tungsten for Transformer welders. Similar
issues welding issues are presented as with Pure Tungsten.
Purchasing Tungsten can be difcult. Local suppliers tend to put a
premium price on Tungsten, and may be three times an online price
direct from a distributor. In many areas, the choice of tungsten may
be limited. However, many local welding suppliers are stepping up
and offering competitive prices and range of selection, so don’t rule
them out until you have checked. Also, there are some companies
that may send you free samples to test, so be sure to investigate their
product, and give them a chance as well.
GRIND THE TUNGSTEN CORRECTLY.
An improperly ground tungsten is a cause of many issues with arc
stability, arc directability, and penetration. A bench grinder and a ne
stone dedicated only for tungsten sharpening is all you need to put a
point on the Tungsten. This is the age old standard. This does take
practice to master. However, there are hand held special grinders that
feature diamond stones with guided slots, designed to hold the tung-
sten at the proper angles. . A chemical sharpener is available and is
relatively inexpensive, and does an excellent job in seconds. An
added bonus of it is that it can be done without getting up from the
bench top without removing the tungsten from the cup. The tung-
sten should be hot before attempting as this activates the chemical.
How Do I Grind My Tungsten?
• Grip the Tungsten rmly. Grind with the tungsten secured.
• Grind the Tungsten perpendicular to the wheel face. Allow tung-
sten to grind slowly without much pressure.
• Rotate the Tungsten quickly as it is being ground to keep the
point even and symmetrical.
• Do not grind the Tungsten parallel to wheel face or an unstable
arc will result.
WARNING!
Wear safety glasses and leather gloves while grinding tungsten or
serious injury may occur. On occasion tungsten may split or shatter.
Do not breathe or inhale tungsten dust. Do not use angle grinders!
!

18
Setup Guide
Getting Started
Choosing the proper grind angle is important to achieving the weld
penetration, bead appearance, and arc cone width that you desire.
While there is no true “one size ts all” angle, there are some general
rules of thumb to observe:
• Always grind in-line with the length of the tungsten. Never make
radial grind (in the direction of the circumference) marks on the
tungsten which will cause arc instability. Never grind with the
tungsten held parallel to the stone face.
• For most applications, grind a point that is 2 –2.5 times in length
than the tungsten is wide. This will create an angle of about 30
to 35 .
• For AC, a more blunt angle may be used (around a 60 degree)
for best penetration. However, the 2 to 3 times in length rule will
still work for many circumstances.
• For higher amperages, you will want to put a slightly truncated tip
on the tungsten.
• Grip the tungsten rmly and slowly rotate it while grinding.
What Type of Grind Works Best?
• Never use a radial grind pattern. This can be caused by grinding
at the wrong angle, or spinning the tungsten too fast while
grinding at the proper angle. The arc will be unstable.
• Grind the angle so that the length of the grind measures 2 to 2.5
times the wide of the tungsten (For general purpose use this
should form about a 30 to 35 angle.) A slightly blunted end
(truncated) may be used if the amperage is over 50A to prevent
the tungsten from breaking off into the metal while welding.
• AC welding may require a blunter point for some applications
where greater penetration is desired. It may seem counter-
intuitive, but this will create a narrower arc cone and provide
more penetration.
<50 A
2.5 – 3 X Ø (DIAMETER)
>50 A
As you use the tungsten (depending upon the type you have select-
ed) you will notice that the tungsten will gently form more of a point-
ed dome as it is used, especially on AC. This is normal and the arc
will remain stable. Depending upon what arc properties you are look-
ing for, you may periodically want to regrind your tungsten to main-
tain optimal arc characteristics.
AC
IMPORTANT! Don’t Ball The Tungsten.
If you’ve ever operated an older transformer welder, or an early invert-
er, you were probably balling the tungsten when welding on AC. In
fact tons of literature exist about proper size ball, how to ball etc. In
fact, well meaning instructors and seasoned welders (who have never
worked with an inverter) may even insist you weld this way today.
However this is no longer true with an inverter. In fact, if you insist
on balling tungsten with an inverter, you are going to create an unsta-
ble arc, and in general hate the way it will weld. Be warned. Don’t
blame the machine. Blame the ball.
Why? The old “Green” tungsten is considered to be pure tungsten.
This meant that it did not handle heat as well at higher temperatures
as with the more modern tungsten blended with rare earth metal ox-
ides, and would even ball on its own as it was used. But it was also
needed to hold a certain type of arc cone. An intentional ball would
help the tungsten handle the arc better on a transformer.
Modern inverters treat green tungsten rather roughly, and you’ll
quickly end up with a huge, molten liquid ball dangling at the end of
the tungsten on AC. This is in part due to the short off time between
polarity change from + to - and back to + during the AC cycle. In fact
this time is so short, that inverters do not need High Frequency Stabi-
lization (HF) while welding AC, and do not have it. In fact HF is only
used for establishing the arc, then the HF shuts off automatically. The
extra “time on” of the arc means the tungsten is hotter, and pure
tungsten (green) isn’t able to handle the heat and will over-ball. That
is why rare earth metal-oxide blends are recommended. They do
handle the heat better and actually conduct electricity better. So they
do not need a ball. If given enough heat at the high end of their
operating range (for the diameter of the tungsten) they will form a
slight, but neatly elongated dome. But this dome still isn’t a ball.
If you think about it, the big ball at the end is really a large “target” for
the arc to jump to as it reverses polarity. When the electrons begin to
flow from the plate to the tungsten, that is a bigger target for the elec-
trons to hit, so the arc could end up anywhere along that balled sur-
face. The bigger the target, the more room for the arc to oscillate
around the ball, creating a randomly wandering arc. This is why
pointed tungsten is recommended with inverters.

19
Setup Guide
SELECT THE PROPER TUNGSTEN SIZE.
The key to obtaining good, picture perfect arc starts is to use proper-
ly sized tungsten. A properly sized tungsten, combined with correct
sharpening technique will display the best arc characteristics. An
undersized tungsten will tend to ball at higher amperages, especially
if the tip is too sharp for the application. An oversized tungsten will
be more difcult to start at lower amps.
Getting Started
What Size of Tungsten Do I Use?
Everlast advertises low arc start capability on their units. Surge Am-
perage to establish the arc are quite low. When starting an arc,
some brands have a high surge in amperage to start the arc, lasting
just a fraction of a second. This surge isn’t usually reflected in the
display. This surge ensures good arc starting, but can blow through
thin materials before the arc is established and welding begins at a
lower amperage. Everlast has kept the surge to a minimum. Howev-
er, when welding with thicker tungsten like 1/8”, arc starts may ap-
pear “soft” and not forceful enough to start cleanly. For best results,
when low amp starts are needed, use a 1/16” or .040” tungsten.
Arc starts will be clean and crisp. The adjustable HF point gap can
be further adjusted to improve starting with larger diameter tungsten,
but simply dropping down a size in tungsten to operate at low am-
perages is the best solution.
The tip angle and grind preparation will ultimately affect amperage
carrying capability of the tungsten. Machine wave form can also
affect it. Each type of Tungsten blend will vary in amperage handling
capability, but in general, consider the following for selecting your
tungsten diameter. The list below is not the absolute maximum
range of the tungsten, but recommended range. Absolute range is
up to 30% higher. However, it is a good practice when you ap-
proach the maximum limit of the tungsten’s capability in terms of
amperage, that you switch to the next size up for best point retention
and arc characteristics. AC operation can reduce tungsten amperage
capability. The setting of the AC balance and AC frequency has an
effect on tungsten point holding capability. Too much cleaning (over
40% EP) will over heat the tungsten and ball it. Lower frequencies
tend to places more heat on the tungsten as well. But in general, for
AC and DC operation, consider the following:
• .040” (1mm) 3-30A
• 1/16” (1.6mm) 5-70A
• 3/32” (2.4mm) 10-200A.
• 1/8” (3.2mm) 20-250+A
NOTE: Starter kit does not include .040”(1mm) collets.)
NOTICE.
A tungsten such as a 1/8” diameter or larger may not start as cleanly
at the minimum capable start amp of this unit. If arc wander or dif-
culty establishing a stable arc exists and you need to operate and
weld at a much higher amperage, increase the Start Amps to 25 to 30
Amps. A higher start amperage may be selected if needed for more
rapid puddle development, but usually is not used with a foot pedal.

20
Setup Guide
Getting Started
SELECT THE PROPER TIG POLARITY AND CONNECTIONS.
Selecting polarity for TIG is quite simple. The torch will always be
connected to the negative (-) output terminal located on the right.
This is whether it is welding in DC or in AC. Once the TIG torch is in
the negative terminal, there is no need to ever change it. Selecting
the wrong polarity with TIG will quickly consume your tungsten. It
will ball up and draw back to the collet body after only a few seconds
when the arc is initiated, especially when higher amperages are used.
Many times the arc will even be hard to start, since the HF starting
energy would be flowing the wrong way. Of course that means the
work clamp is in the positive (+) terminal on the left
The TIG torch switch or the Foot Pedal is connected to the 7 pin
control connector. This allows you to select 2T or 4T control with
the torch switch OR foot pedal control. Since there is only one con-
nector, you will need to determine which operation you will use and
select either the TIG torch switch or the Foot Pedal and plug it in.
KNOW THE DIFFERENCE BETWEEN AN AIR COOLED AND
WATER COOLED TORCH.
An air-cooled and water-cooled torch connects differently. An air
cooled torch for this unit will have one line exiting from the DINSE
Connector. This is the gas/argon line. The water cooled torch will
have 3 lines. Two descending from the torch, and one exiting from
the DINSE type connector. Traditionally, the black line descending
down from the torch will be the argon line. (Some brands vary
WARNING!
A water-cooled torch must be operated with a water-cooler or per-
manent damage will occur to the torch. Any operation without water
can damage the torch. There is no safe amp limit for operation with-
out water. If you have a water cooled torch and no cooler, you must
order a cooler before you use the torch, or purchase a separate air-
cooled torch. If an air cooled torch is purchased, observe the amp
limits of the torch. The largest air-cooled torch (26 series) maximum
amperage at 60% duty cycle is 200A DC, and 175 AC. If Amperages
are to be welded over that, you must purchase a water cooler. Torch-
es operated without water, or sustained amperage over their rating
and duty cycle, are not eligible for warranty replacement. Always
match the torch to the job. Usually most users nd that one torch is
not enough and several torches may need to be purchased to suit
different welding applications. Each torch size/class has different
amp limitations. Know these limitations before using!
in color coding, so match the color codes of the torch to the cooler
couplings for best results). The line exiting from the DINSE connect-
or is no longer a gas line but a water line. Traditionally this line is
the return line to the water cooler. The remaining line will be the
input line from the water cooler. If in doubt, blow through the torch
lightly with compressed air to determine torch flow through the hos-
es. Some NOVA torches use the line from the DINSE connector as
the input. Follow the color coding used by NOVA.
Where Do I Connect The TIG Torch?
Air-Cooled TIG Torch
NOTICE: Choose between the torch switch operation (2T/4T) or the
foot pedal operation. Both cannot be used at the same time.
Argon
Line
Control Cable
TIG Torch
Work Clamp
TIG Torch Switch
2T/4T
Foot Pedal
Work
DINSE 35/50
Adapter
Where Do I Connect The TIG Torch?
Air-Cooled TIG Torch
NOTICE: Choose between the torch switch operation (2T/4T) or the
foot pedal operation. Both cannot be used at the same time.
TIG Torch
Work Clamp
TIG Torch Switch
2T/4T
Control Cable
Foot Pedal
Work
DINSE 35/50
Adapter
Argon Line
To Cooler
To Cooler