Everlast POWERCOOL 400 User manual

1
EVERLAST
POWERCOOL 400
Operator’s Manual for the PowerCool 400
GTAW/GMAW
Safety, Setup and General Use Guide
TIG/MIG 400A WATER COOLER
Rev. 1 0 2020704-19
everlastwelders.com
1-877-755-9353 Specications and Accessories subject to change without notice.
329 Littleeld Ave. South San Francisco, CA 94080

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Table of Contents
Secon……………………………………………………………..Page
Leer to the Customer ………………...………………….
Everlast Contact Informaon…………………………….
Safety Precauons…………………………………………....
Unit Specicaons…………………..………………………..
Introducon……………..………………….……………………
Know Your Machine…………………………………………..
Addional Warnings and Notes………………………….
3
4
5
9
10
11
13
NOTE: Product Specications and features are subject to change without no-
tice. While every attempt has been made to provide the most accurate and cur-
rent information 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 prop-
er safe operation/maintenance of this unit. Everlast Power Equipment LLC, does
not guarantee the accuracy, completeness, authority or authenticity of the infor-
mation contained within this manual. The owner of this product assumes all lia-
bility for its use and maintenance. Everlast Power Equipment LLC, 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 LLC does not accept liability for damages, consequential or
incidental, resulting from the use of the product or of the content found in this
document or accept claims by a third party of liability.

3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast. We appreciate you as a custom-
er and hope that you will enjoy years of use from your welder.
Please go directly to the Everlast website to register your unit and receive your warranty information.
Your unit registration is important should any information such as product updates or recalls be is-
sued. It is also important so that we may track your satisfaction with Everlast products and services.
If you are unable to register by website, contact Everlast directly through the sales department
through the main customer service number in your country. Your unit will be registered and warran-
ty will be issued and in full effect. Keep all information regarding your purchase. In the event of a
problem, as a rst step, you must contact technical support before your welder can be a candidate
for diagnosis and warranty service. The unit cannot be returned for repair until authorization is
given by technical support. Units returned without contacting tech support and attaching an au-
thorization repair form may incur repair charges and/or denial of claim. The reason you must rst
contact technical support is because it allows proper diagnoses and can remedy many issues over
the phone, preventing needless delays and returns.
Please review the current online warranty statement and information found on the website
of the Everlast division located in or nearest to your country. Print it for your records and
become familiar of its terms and conditions.
Everlast offers full technical support, in several different forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interaction.
Technical advisors are active on the forum daily. We also divide our support into two divisions: tech-
nical and welding performance. Should you have an issue or question concerning your unit, please
contact performance/technical support available through the main company headquarters available in
your country. For best service call the appropriate support line and follow up with an email, particu-
larly if off hours, or you cannot reach a live person. In the event you do not reach a live person, par-
ticularly during heavy call volume times, holidays, and off hours, leave a message and your call will
normally be returned within 24 hours. Also for quick answers to your basic questions, join the com-
pany owned forum available through the website. You’ll nd knowledgeable, helpful people and staff
available to answer your questions, and perhaps nd a topic that already addresses your question at
http://www.everlastgenerators.com/forums/.
Should you need to call or write, always know your model name, purchase date and welder manu-
facturing inspection date. This will assure the quick and accurate customer service.
REMEMBER: Be as specic and informed as possible. Technical and performance advisors rely
upon you to carefully describe the conditions and circumstances of your problem or question.
Take notes of any issues as best you can. You may be asked many questions by the advisors to
clarify problems or issues that may seem very basic. However, diagnosis procedures MUST be
followed to begin the warranty process. Advisors can’t assume anything, even with experienced
users, and must cover all aspects to properly diagnose the problem. Depending upon your issue,
it is advisable to have basic tools handy such as screwdrivers, wrenches, pliers, and even an inex-
pensive test meter with volt/ohm functions before you call.
Let us know how we may be of service to you should you have any questions.
Sincerely,
Everlast Customer Service

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Serial Number: __________________________
Model Number: ____________________________
Date of Purchase:___________________________
Everlast US:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [email protected]
Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am-5pm PST M-F
Technical Support: 1-877-755-WELD (9353) Ext. 207 9am-5pm EST M-F
Welding Support: 1-877-755-WELD (9353) Ext. 204 9am-5pm EST M-F
Everlast Canada:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [email protected]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Austrailia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
After hours support: 0413 447 492
Everlast Technical Support: [e-mail]

5
Everlast is dedicated to providing you with the best possible equipment and service to meet the
rigorous welding demands that you have. We want to go beyond merely delivering a satisfacto-
ry product to you. We want to offer products that meet and exceed expectations, in both per-
formance and service. That is the reason we offer free technical support to assist you with your
needs and questions should the occasion occur. With proper use and care your product should
deliver years of trouble free service. Safe operation is a partial key to achieving long life and
optimum performance from your unit.
Any product designed to meet safety standards can be operated in an unsafe manner. No
amount of safety apparatuses can ultimately prevent accidents in every situation if the product is
used in an unsafe manner. Ultimately, safe operation and proper maintenance is your responsi-
bility. Safe operation also requires the operator to have basic welding knowledge and practice
common sense and caution during use.
We have compiled this operator’s manual, to instruct you in basic safety, operation and mainte-
nance of your Everlast product to give you the best possible experience. Much of welding and
cutting is based upon experience and common sense. As thorough as this welding manual may
be, it is no substitute for either. Exercise extreme caution and care in all activities related to
welding or cutting. Your safety, health and even life depends upon it. While accidents are never
planned, preventing an accident requires careful planning.
Please read this manual carefully before you operate your Everlast unit. The purpose of this
manual is not only to instruct the operator in the basic use of the machine, but also to assist
the operator in obtaining the best performance from the unit Do not operate the unit until you
have read this manual and you are thoroughly familiar with the safe operation of the unit. If you
feel you need more information please contact Everlast technical or welding support.
The warranty does not cover improper use, maintenance or consumables. Do not attempt to
alter or defeat any piece or part of your unit, particularly any safety device. Keep all shields
and covers in place during unit operation should an unlikely failure of internal components result
in the possible presence of sparks and explosions. If a failure occurs, discontinue further use
until malfunctioning parts or accessories have been repaired or replaced by qualied personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves. These waves may
disturb sensitive electronic equipment such as televisions, radios, computers, cell phones, and
related equipment. High Frequency may also interfere with fluorescent lights. Consult with an
electrician if disturbance is noted. Sometimes, improper wire routing or poor shielding may be
the cause.
HF can interfere with pacemakers. See EMF warnings in following safety section for further in-
formation. Always consult your physician before entering an area known to have welding or
cutting equipment if you have a pacemaker.
Safety Precautions

6
These safety precautions are for protection of safety and health. Failure to fol-
low these guidelines may result in serious injury or death. Be careful to read
and follow all cautions and warnings. Protect yourself and others.
Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can
cause severe skin burn and damage. There are other potential hazards involved with welding
such as severe burns and respiratory related illnesses. Therefore observe the following to
minimize potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even under
welding helmets to protect your eyes from flying sparks and debris. When chipping slag or
grinding, goggles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct shade
of lter installed. Always use a welding helmet in good condition. Discard any broken or
cracked lters or helmets. Using broken or cracked lters or helmets can cause severe eye
injury and burn. Filter shades of no less than shade 5 for cutting and no less than shade 9 for
welding are highly recommended. Shades greater than 9 may be required for high amperage
welds. Keep lter lenses clean and clear for maximum visibility. It is also advisable to consult
with your eye doctor should you wear contacts for corrective vision before you wear them
while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless fully
protected by a lter screen, protective curtains or equivalent protective equipment. If no
protection is available, exclude them from the work area. Even brief exposure to the rays
from the welding arc can damage unprotected eyes. If necessary, use a welding screen.
Always wear hearing protection because welding and cutting can be extremely noisy. Ear
protection is necessary to prevent hearing loss. Even prolonged low levels of noise has been
known to create long term hearing damage. Hearing protection also further protects against
hot sparks and debris from entering the ear canal and doing harm.
Always wear personal protective clothing. Flame proof clothing is required at all times.
Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose clothing is
tucked in neatly. Leather aprons and jackets are recommended. Suitable welding jackets and
coats made from re proof material may be purchased from welding supply stores. Discard
any burned or frayed clothing. Keep clothing away from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for adequate foot
protection. Canvas, polyester and other man made materials often found in shoes will either
burn or melt. Rubber or other non conductive soles are necessary to help protect from elec-
trical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or han-
dling metal. Simple work gloves for the garden or chore work are not sufcient. Gauntlet
type welding gloves are available from your local welding supply companies. Never attempt to
weld with out gloves. Welding with out gloves can result in serious burns and electrical
shock. If your hand or body parts comes into contact with the arc of a plasma cutter or weld-
er, instant and serious burns will occur. Proper hand protection is required at all times when
working with welding or cutting machines!
Safety Precautions

7
WARNING! Persons with pacemakers should not weld, cut or be in the welding area until
they consult with their physician. Some pacemakers are sensitive to EMF radiation and
could severely malfunction while welding or while being in the vicinity of someone welding.
Serious injury or death may occur!
Welding and plasma cutting processes generate electro-magnetic elds and radiation. While
the effects of EMF radiation are not known, it is suspected that there may be some harm from
long term exposure to electromagnetic elds. Therefore, certain precautions should be taken
to minimize exposure:
• Lay welding leads and lines neatly away from the body.
• Never coil cables around the body.
• Secure cables with tape if necessary to keep from the body.
• Keep all cables and leads on the same side the body.
• Never stand between cables or leads.
• Keep as far away from the power source (welder) as possible while welding.
• Never stand between the ground clamp and the torch.
• Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any guidelines
from your chosen consumable and electrode suppliers regarding possible need for respiratory
equipment while welding or cutting. Always weld with adequate ventilation. Never weld in
closed rooms or conned spaces. Fumes and gases released while welding or cutting may be
poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
• Stop immediately and relocate work if necessary until adequate ventilation is obtained.
• Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, copper, cadmi-
um, lead or zinc without proper respiratory equipment and /or ventilation.
WARNING! This product may contain products known to the State of California to cause birth
defects and in some cases cancer and/or reproductive harm. The use of this product may cre-
ate by-products with the same effects. (California Safety and Health Code §25249.5 et seq.,
Prop. 65)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas. Release of
Phosgene gas can be deadly. Consider all chemicals to have potential deadly results if welded
on or near metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain regula-
tions regarding high pressure cylinders can be obtained from OSHA or local regulatory agency.
Consult also with your welding supply company in your area for further recommendations. The
regulatory changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and closed.
Store chained so that overturn is not likely. Transporting cylinders incorrectly can lead to an
explosion. Do not attempt to adapt regulators to t cylinders. Do not use faulty regulators. Do
not allow cylinders to come into contact with work piece or work. Do not weld or strike arcs on
cylinders. Keep cylinders away from direct heat, flame and sparks.
Safety Precautions

8
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded.
Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on
ground clamp. Do not stand in water or damp areas while welding or cutting. Keep work sur-
face dry. Do not use welder or plasma cutter in the rain or in extremely humid conditions.
Use dry rubber soled shoes and dry gloves when welding or cutting to insulate against electri-
cal shock. Turn machine on or off only with gloved hand. Keep all parts of the body insulated
from work, and work tables. Keep away from direct contact with skin against work. If tight
or close quarters necessitates standing or resting on work piece, insulate with dry boards and
rubber mats designed to insulate the body from direct contact.
CAUTION! All work cables, leads, and hoses pose trip hazards. Be aware of their location and
make sure all personnel in area are advised of their location. Taping or securing cables with
appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep re extin-
guishers close by and additionally a water hose or bucket of sand. Periodically check work
area for smoldering embers or smoke. It is a good idea to have someone help watch for possi-
ble res while you are welding. Sparks and hot metal may travel a long distance. They may go
into cracks in walls and floors and start a re that would not be immediately visible. Here are
some things you can do to reduce the possibility of re or explosion:
• Keep all combustible materials including rags and spare clothing away from area.
• Keep all flammable fuels and liquids stored separately from work area.
• Visually inspect work area when job is completed for the slightest traces of smoke or em-
bers.
• If welding or cutting outside, make sure you are in a cleared off area, free from dry tender
and debris that might start a forest or grass re.
• Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held
flammable liquid or material.
CAUTION! Metal is hot after welding or cutting! Always use gloves and or tongs when handling
hot pieces of metal. Remember to place hot metal on re-proof surfaces after handling. Seri-
ous burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper mainte-
nance is your responsibility. Make sure all equipment is properly maintained and serviced by
qualied personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding parts.
Touching uncovered parts inside machine can cause discharge of high amounts of electricity.
Do not allow employees to operate poorly serviced equipment. Always check condition of
equipment thoroughly before start up. Disconnect unit from power source before any service
attempt is made and for long term storage or electrical storms.
Further information can be obtained from The American Welding Society (AWS) that relates
directly to safe welding and plasma cutting. Additionally, your local welding supply company
may have additional pamphlets available concerning their products. Do not operate machin-
ery until your are comfortable with proper operation and are able to assume inherent risks of
cutting or welding.
Safety Precautions

9
POWER COOL 400 Specication
Processes GTAW/GMAW
Input Voltage/Hz 240V, 50/60 Hz
Maximum Input Amps (I1MAX) 1.1 Amps
Coolant Flow Rate (Unrestricted Flow) 8.5 lpm/ 2.2 gpm
Cooling Capability @ 40° C (104° F) 1.7 Kw
Operating Pressure .3-.39 MPa/45-57 psi
Suggested Maximum Cooling Amperage 400 A
Water Ingress Protection Rating IP21
Pump Construction Type Stainless Housing/Impellor/ Italy
Motor Construction Type Sealed Industrial/ Italy
Fan Motor Pump Construction Direct Drive beltless construction
Radiator/Heat Exchanger Type Copper Construction with
Protectively Coated Cooling Fins
Coolant Connection Type 9mm quick connect
Coolant Capacity 2.3 gallon (nominal, may vary slightly)
Coolant Type Distilled Water or or Coolant (non-
automotive type) designated as TIG/
MIG water cooler coolant.
Reservoir Construction Type Durable Plastic
Dimensions 12”WX10”HX24”L
Weight 33 lbs.
Section 1 Introduction and Specications

10
This manual has been compiled to give an overview
of operation and is designed to offer information cen-
tered around safe, practical use of the water cooler.
Only YOU, the operator, can ensure that safe operating
practices are followed, through the exercise of com-
mon sense and training. Do not operate this machine
until you have fully read the manual.
1. To ensure that your Everlast Power Cool 400 is
in top condition, carefully inspect it for damage
upon opening arrival, looking for damage on the
surface of the unit and to the cooler itself and all
its accessories. Note: A very small amount of
residual water from testing may still be present in
the tank, or may have leaked from the tank. Re-
move the box and plastic and fully check the unit
immediately upon receipt of product. Any damage
issues must be resolved right away through tech
support. The product should also be tested at the
same time for proper operation, even if it is to be
stored for a while. Check to make sure all passag-
es, connections and ttings are clear of any pack-
ing material or other obstruction. Failure to test
and check the unit may result in denial of shipping
damage and warranty claims. Record the serial
number on the page provided in this manual. In-
clude purchase date for warranty reference. Serial
numbers are located on the top, side or rear of
the machine, wherever the specication sticker is
located (may vary). Be sure to register your unit
online as well. Please locate, download and read
your current warranty statement found online at
www.everlastgenerators.com listed under “terms
and policy”.
2. The Power Cool 400 is designed for industrial
fabrication and repair chores. Overall function
and design has been geared toward simple, trou-
ble free operation. The units offers fast and easy
connection of the TIG or MIG torch. The connect-
ors are 9mm quick connect male couplings availa-
ble from Everlast and many other sources found
in welding stores and online sources.
3. The unit should be lled only with distilled water
or with an approved antifreeze that is rated for
TIG/MIG water cooler use (ethylene glycol). The
antifreeze designed for TIG/MIG use has algae
growth preventers which keep the small passages
in a TIG or MIG torch clear. Use of automotive-
type antifreeze can cause other long term damage
to the cooler. It also creates an electrically con-
ductive circuit which can make starting the arc
difcult while the HF start is in use. Some water
cooler coolants are listed as “MIG Only”. Be sure
to evaluate the claims of the product before pur-
chase and use. The warranty does not cover
freezing, clogging or corrosion of components due
to improper antifreeze. Do not use MIG only rated
coolant if it is to be used with TIG or poor arc
starting may result.
4. The unit should be stored in a dry place for long
term storage and drained of coolant. Humid/wet
conditions can contribute to the eventual decay of
the circuitry in the machine. For safety reasons,
do not use this machine directly in the rain or with
soaked clothing or damp protective gear. The ser-
vice rating for this unit is IP21, sufcient for drip-
ping water protection, but is not recommended for
wet environment use.
5. Make sure that the cooling fan and exhaust vents
are kept free of obstruction. Before every opera-
tion, inspect the unit for unexpected obstructions.
From time-to-time (at least quarterly) cleaning of
the machine with low pressure air and a small
plastic bristle brush will be necessary to ensure
long life and efcient cooling. On these occasions
only, unplug the water cooler and remove the main
cover to access the interior. Do not remove the
front panel. A dirty or blocked radiator will lower
the cooling capability because it reduces the air
flow and heat exchanging capability of the unit.
Keep a minimum of 12 inches distance from any
obstruction on the front, rear and sides of the
unit during operation. If the unit does not seem
to spin up and run normally, turn off the unit im-
mediately. Then, unplug the cooler. Remove the
top cover and inspect the fan and radiator. Make
sure the radiator has not shifted into the fan during
shipping. If the fan is clear from obstruction, turn
it gently and make sure the fan/pump assembly
spins smoothly and freely. If it does not, contact
tech support immediately. In any case, where the
fan does no seem to start or spin properly, imme-
diately turn the unit off.
6. The cooler is designed to run continuously while
it is switched on. The cooler flow is not activated
by the foot pedal or torch switch. Flow through
the torch should be continuous. Failing to turn
the unit on while welding with a water-cooled
torch can result in damage to the TIG torch. The
receptacle found on the rear of your Everlast weld-
er is designed to be used with the PowerCool 400
cooler. Power will flow to the plug when the weld-
er is switched on. If the cooler switch is left
switched in the on position, the welder will turn the
cooler on and off as the power is cycled.
7. This unit is 220/240 V only. Do not use it with
110/120 V circuits! If this cooler is to be used with
units other than Everlast TIG machines tted with
the IEC 60320-1 c-13/14 setup, the plug must be
removed and a new one installed. Consult a li-
censed electrician and local electrical codes be-
fore attempting any modication of the wiring of
the water cooler or power circuit.
8. Refer to the following pages for specications.
Note that product specications are subject to
change without notice due to product improve-
ments. If any additional information is needed
contact Everlast. As with any product, some
changes in specications do occur that do not af-
fect overall scope and function of the machine.
Section 1 Introduction