Everlast Powertig 325 ext User manual

Operator’s Manual

Publish Date: Dec. 2020

EVPT255EXT2021 Rev. 1

USA/North America

©Everlast Power Equipment

AC/DC

AC/DC PULSE

ADV. AC PULSE

AC WAVE FORM

CONTROL

240V

1/3 Phase

Welders, Plasma Cutters, Multi-Process

Safety, Setup and General Use Guide

FUNCTION: AC/DC TIG with Pulse Function/ DC Stick

PURCHASE DATE:

WELDER SERIAL NUMBER:

OPTIONAL ACCESSORY SERIAL NUMBER:

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 REGULATOR 14

TUNGSEN SELECTION AND GRINDING 15

CONNECTING YOUR UNIT AND READYING TO WELD (POLARITY AND PANEL CONNECTIONS) 18

GENERAL SETTINGS AND INFORMATION 20

FRONT PANEL VIEW AND COMPONENT ID 21

REAR PANEL VIEW AND COMPONENT ID 22

CONTROL PANEL LAYOUT AND ID OF FEATURES 23

TORCH PARTS AND ASSEMBLY 32

7 PIN CONNECTOR PINOUT AND INFORMATION 34

TROUBLESHOOTING ERROR CODES 35

TROUBLESHOOTING COMMON ISSUES 36

MAINTENANCE 37

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

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

tech@everlastwelders.com (US) or mike@everlastwelders.ca (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

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 performance@everlastwelders.com 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: tech@everlastwelders.com

1-877-755-9353 ext. 207

9am-5pm Eastern (Closed holidays)

Monday-Friday

USA Welding Support and General Product Information:

Email: performance@everlastwelders.com

1-877-755-9353 ext 204

9am-6:30 pm Eastern (Closed holidays)

Monday-Friday

USA Sales and Main Ofce:

Email: sales@everlastwelders.com

1-877-755-9353 ext 201

9am-5pm Pacic (Closed holidays)

Monday-Friday

Canada Technical Support:

Email: mike@everlastwelders.ca

905-570-1818

9am-4pm Eastern Monday-Thursday

9am-12pm Eastern Friday

Canada Sales and Main Ofce:

Email: sales@everlastwelders.ca

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.

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.

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

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 poses shock and electrocution risks. Keep this welding equipment 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 weld-

ing. Keep all parts of the body insulated from the part being welded when possible. Do

not touch both terminals or connections at the same time. Consider all welder parts to be

“live” at all times even if no welding is being performed. Do not use frayed welding cables.

CAUTION! Fires are possible but also preventable while welding. Always remove flamma-

ble 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, espe-

cially if pressurized 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.

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. 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).

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.

Important Information: Operating this unit with a generator or other off-grid service.

This welder should only be operated on a generator certied by its manufacturer to produce clean power. Clean power is

equivalent to the quality of household or shop/garage type power. This means the generator must have 5% or less total har-

monic distortion (THD) of the Sine wave. If you are unsure of the power output type of the generator, contact the manufactur-

er 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 13,000 surge Watts. Ideally, it is recommended for use with

14,500 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” generator automatically provides clean power. Price paid does not guarantee a clean power out-

put either. There are multiple brands at various price points capable of producing clean power. Investigate this before pur-

chasing 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 manufacturer 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 gener-

ator R.P.M. has been achieved and the engine is sufciently warmed up. Closely monitor generator fuel level so that the en-

gine R.P.M doesn’t drop or completely shut down with the welder plugged in. For best practice: do not start or stop the gen-

erator 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 alter-

nator 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 ma-

chine and more importantly may cause severe injury or death.

Single Phase and Three Phase Operation:

This unit may be used with single phase or three phase 208 to 240V output. Output and duty cycle should not be greatly af-

fected. Please note that 208V one or three phase power is permissible only if the current does not drop below 205V under

load. Usually, this does not become a concern unless it is being used in older installations or if the unit is operated at some

distance from the power source, or conductors are too small for the distance.

Operating this unit on an extension cord while on 208V may reduce voltage to the machine if it is improperly sized or too long

and can cause IGBT or PCB failure if power drops below 205V under load.

220V and 240V installation on single or three phase power should present no issues if codes are followed and proper sized

conductors are used.

NOTICE: Do not use this unit with rotary-type or mechanical 1 phase to 3 phase converters or damage may result.

Specifications

*Duty Cycle

Duty Cycle is simply the amount of time out of a

10 minute period in which the unit can operate.

(For this unit, stated duty cycle is at the maximum

intended output of 325A @ 22.8V) For example, if

this unit has a duty cycle of 35% at maximum

output, that means that the unit can be operated

for 3.5 minutes out of 10 minutes. This may be

calculated 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 temperatures with high humidity may

reduce the duty cycle rating. Of course, the duty

cycle may increase somewhat as ambient tempera-

ture 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 exceed-

ed, welding output will stop and an over-

temperature warning light/error code will be dis-

played on the panel. If a duty cycle event is regis-

tered, 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 ma-

chine back on. If the unit does not reset, contact

technical support for further advice and assistance.

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.

NOTICE: Intentionally or repeatedly triggering the

duty cycle protection feature on this unit will short-

en the lifespan of the unit’s electronics and can

weaken internal components. The effect of over-

heating your unit repeatedly takes a cumulative toll

on the unit.

Product Specifications

Construction Type Inverter (IGBT based, Digital Control)

Input Voltage 220-240 V (± 10%) 50/60 Hz (480V 3Ph optional.)

Phase 1 and 3 Ph. 50/60Hz (480V opt. unit is only 3Ph)

I1MAX Current Rating (Inrush Amps) 240V 1Ph: 50A 240V 3Ph: 29A (480V 3ph See panel)

I1EFF Current Rating (Rated Amps) 240V 1Ph: 30A 240V 3Ph: 27A (480V 3ph See panel)

OCV 70V (with VRD <24V)

TIG Duty Cycle @ Maximum Output (Rated at 40° C/104 F) * 35% @ 325A, 60% @ 250A, 100% @ 200A

Stick Duty Cycle @ Maximum Output (Rated at 40° C/104 F )* 35% @ 250A, 60% 200A. 100% @ 160A

TIG Output Range V/A (DC/AC) DC 10.2-22.8V/ 5-325A; AC 10.4-22.8V/ 10-325A

Stick Output Range V/A (Stick output is DC only) 20.8-30V/20-250A

TIG Start Type HF, Remote Lift (with Switch or Pedal Only)

TIG Point Gap Setting (Recommended) .029”-.045” (.035”)

Pre Flow / Post Flow Gas Time PREFLOW: 0-25 Seconds POSTFLOW: 0-25 Seconds

Start Amps (Initial Current); End Amps, AC/DC (Crater Current) START: DC: 5A/ AC: 10A END: DC: 5A / AC:10A

Upslope/ Downslope (Ramp up/Ramp Down Current) Time UPSLOPE: 0-25 Seconds DOWNSLOPE:0-25 Seconds

TIG Pulse Frequency Hz (Standard/Advanced AC Std. Pulse DC .5-500Hz Std. Pulse AC .5-250Hz

Adv. AC Pulse .5-9.9Hz

TIG Pulse Time On (Duty Cycle) 3-100%

TIG Pulse Amps (Background Current) 5-95% of Welding Amp Value

AC Wave Form(s) Adv. Square /Soft Square /Triangular/Sine

AC Frequency 20-250 Hz

AC Balance (Cleaning, % of Electrode Positive) 5-90%

Spot Timer 0-10 Seconds

Stick Arc Force Control 0-100%

Stick Hot Start Intensity 0-100%

Stick Hot Start Time 0-2 Seconds

Setting for Stick E6010 (Cellulose Type Electrodes) No, do not use.

TIG Gun Type/Length/ Connector Type Rigid-Neck 9 Series Air Cooled, 12.5 ft. (4m)

Rigid-Neck 20 Series Water-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 Customer Supplied. For 1ph, use NEMA 6-50P

Cooling Type Full Time, High Volume Fan(s)

Dimensions (Approximate) 18” H X 10” W X 25” L

Weight (Bare Unit) 65lbs.

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.

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. 9 Series Air-Cooled Torch (Rigid/Straight Neck) 12.5 ft.

5. 20 Series Water-Cooled Torch (Rigid/Straight Neck) 12.5 ft.

6. Torch Switches(x2) for 2T/4T use (loose or attached to torch).

7. 250A Stick Electrode Holder (approx. 9.5 ft with cable).

8. 400A Bronze Work Clamp (approx. 9.5 ft with cable).

9. TIG Consumable Starter Kit (x2) Tungsten not included.

10. Argon Regulator, floating ball type.

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 but-

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.

tons, cycling through each as required. Make sure the fan is running

at full speed. After the test 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 prob-

lems are observed, contact Everlast. See page 5 for more infor-

mation. 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. You can

test this by rst installing both back caps into the torch head (from

both sides). Next install the regulator and tighten to both cylinder

and unit (see section on regulator installation). After the regulator is

secured, set post flow time to maximum. Trigger a false start with

either the foot pedal or torch switch by tapping and releasing so that

post flow can flow. Observe the ball on the regulator. It will briefly

float before settling back down. If the ball continues to flow, or if you

hear or suspect leaks, use warm, soapy water (or a dedicated 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 prob-

lem 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

attempt to restrict air flow by attaching lters to the vents or by modi-

fying your fans for “on demand” service.

Setup Guide

Getting Started

CONNECT YOUR UNIT TO THE OUTLET.

You’ll notice that your unit has been shipped without a power plug. This is

because the welder will operate on either single phase or three phase 240V

voltage and the wiring is different for single phase service than it is for three

phase service. You’ll also notice that this unit is equipped with 4 wires. The 4

wire conguration is not used with single phase 240V operation. Only 3

wires are used (black, white, and green in color). The remaining fourth wire

(red color) is to either to be snipped off and taped over with electrical tape,

or it is to be bent back, and taped against the cable sheathing (if used inter-

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

changeably between single and three phase service). For single phase 240V

connection, select a NEMA 6-50 Plug and Receptacle for operation. This is

the standard plug used when wiring welders for 240V single phase operation

in North America. (Other regions/countries vary). A neutral is not used. If

you inspect the NEMA 6-50 Plug closely (most brands) that the plug is

stamped where each color wire should go. If you do not see a stamp, the

Black wire serves as L1(Hot), White serves as L2 (Hot) and Green serves as

G (Ground).

For three phase 240V service (or for the optional 480V service congura-

tion), the plug conguration is different for various applications. It is recom-

mended to either install the line direct into an electrical cutoff box, or wire a

3 phase receptacle and cutoff (disconnect) close to where the unit will be in

use.

Wire Conguration 1 Phase 240V

NEMA 6-50P

Wire Conguration 3 Phase 240/480V

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.

Using with 208V 1 or 3 Phase

This unit may be operated with 208V service (1 or 3 phase). How-

ever voltage should be checked under load before allowing perma-

nent installation. Voltage should not fall below 205V or damage may

occur to the unit. Most modern 208V service runs several volts

above 208V and is not usually a concern. Older installations where

service wiring may be degraded or not up to code may produce sub

standard voltage not suitable for use with this unit. Additionally,

some accuracy/calibration issues may be observed while on 208V.

480V is a special order option,

however wiring conguration is

the same as 240V.

Setup Guide

Getting Started

CONNECT YOUR UNIT TO THE SHIELDING GAS.

Always wear safety glasses when changing a cylinder. Before in-

stalling 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 dislodge 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

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.

a 580 CGA valve). If you do not have a cylinder wrench, an adjusta-

ble type wrench will work, but make sure it is properly adjusted to

prevent rounding of the tting shoulders. Do not use pliers, or a

serrated jaw wrench such as a pipe wrench or basin wrench to tight-

en the tting. The design of the tting means that no thread sealing

tape or compound 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.

CAUTION! Do not tighten the rear unit connection without holding

the female tting on the unit with a wrench, or damage may occur to

the bezel as the tting may turn in the plastic housing while the hose

tting is being turned..

Connect Regulator To Cylinder And Unit.

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

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!

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.

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.

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.

Where Do I Connect The Torch?

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 left. This

is whether it is welding in DC or in AC. Once the TIG torch is in the

negative terminal, never 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 posi-

tive (+) terminal on the right.

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

Water-Cooled TIG Torch

Work Clamp

TIG Torch

Argon Line

Control Cable

Water

From

Cooler

Water

Cooler

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.

NOTICE: Choose between the torch switch operation (2T/4T) or

the foot pedal operation. Both cannot be used at the same time.

TIG Torch Switch

2T/4T

Foot Pedal

DINSE 35/50

Adapter

Where Do I Connect The TIG Torch?

Air-Cooled TIG Torch

Argon Line

Control Cable

TIG Torch

Work Clamp

NOTICE: Choose between the torch switch operation (2T/4T) or the

foot pedal operation. Both cannot be used at the same time.

TIG Torch Switch

2T/4T

Foot Pedal

DINSE 35/50

Adapter

DINSE 35/50

Adapter

DINSE 35/50

Adapter

Work

Setup Guide

Getting Started

GET A COOLER IF YOU HAVE A WATER-COOLED TORCH

OR WELD OVER THE AMP LIMIT OF YOUR AIR-COOLED

TORCH.

The new design of the PowerTIG units features an improved, seam-

less pairing of the welder and the water-cooler. The new PowerCool

series of water coolers are designed to stack under the units, with a

matched sheet metal and front and rear fairings. These will interlock

and provide a slip free connection.

For cooler connection, stacking of the welder over the cooler and

general information on using a water cooler with your unit, see the

water cooler manual. This unit is designed to stack with the new

PowerCool cooler. If you have any questions about purchasing the

correct cooler and assembly for your welder, contact Everlast.

SELECT THE PROPER STICK POLARITY.

The electrode holder, or stick torch (sometimes called a stinger) will

almost always be connected to the right terminal of the machine

( positive+). The work clamp will be connected to the negative. This

is known as DCEP (DC, Electrode Positive), Although it is an older

term, this is sometimes this is known as “reverse polarity” Most all

welding rods weld primarily in DCEP. DCEN (DC, Electrode Nega-

tive), although an older term is sometimes called “Straight Polarity”.

There are a few rods like E6011 which can operate either way, but

the preferred polarity is DCEP. Reasons for welding with DCEN are

usually to provide a softer arc, or reduce burn through.

Where Do I Connect The Stick Torch?

Stick Torch

Work Clamp

Stick Torch

WARNING!

This unit is not designed for Air Carbon Arc Gouging or Cutting. Do

not this unit for this application. It is not designed to sustain the

high volt and long arc characteristics needed for Carbon Arc use.

IMPORTANT!

This unit is designed to operate with most welding rods. However,

this unit is not designed for use with E6010. This unit should oper-

ate with E6011, however, which is considered to be a similar rod in

characteristics. When welding with E6011, some brands may weld

differently than others. Always select a good quality brand for best

arc stability. If instability is observed with E6011, switch brands.

This unit operates best with a short arc, so either drag the rod, or

hold a very short arc length so that arc outages with E6011 are not

experienced. A dragging motion, or a slight weave is recommend-

ed, but increasing the arc length may result in arc outages. Rods like

E7018, and E7014 are highly recommended for use.

Setup Guide

Getting Started

If you are needing basic help getting started, here are some general settings and selections to get you started. This guide is intended to be only a start-

ing point, not a completely exhaustive source. Keep in mind that no guide is a substitute for practice and experience. You may nd that your nal set-

tings may be different from the ones listed. The following guide does not represent the maximum capability, or even the recommended capability of

the unit. However, it demonstrates what is considered to be a practical capability limit of multiple variables when factored together. It is possible to

weld thicker materials with the same amp range. However, as a best practice, the industry does not recommend heavy passes, rather thinner “stacked”

passes on thicker plate. Multi-pass welds are typically stronger, have less defects and require less amperage. On heavy gauge plate, such as 3/8” up

to 3 to 5 passes may be required. Additionally beveling of the joint is required for complete joint penetration, even at higher amperages. The thickness

rating takes into account the “heat sink” capability of the metal, and the power of the amperage to overcome the conductivity of heat of the metal used

using multiple passes. The position of the weld also influences the amperage, cup size, gas flow rate and tungsten size used. For the following recom-

mendations, these are all in “flat” position. Modify your settings accordingly. Vertical will require less amperage the more you weld “up hill”.

Amp Range Electrode Dia. Cup Number Flow Rate (CFH)

Standard Lens

Flow Rate (CFH)

Gas Lens

Metal Thickness

Aluminum (AC)

Metal Thickness

Steel/Stainless (DC)