Everlast CT416 User manual

EVERLAST PRODUCTS
OWNER’S MANUAL
Everlast CT416/518/63 D
DC TIG/MMA Welder
with Plasma Cutter
www.everlastgenerators.com
Email: [e-mail]
Phone: [phone] x201
Support: .everlastgenerators.com

This elding equipment is for industrial and professional use
in conformity ith IEC 60974 International Safety Standard.
We offer a five-year arranty on our elders and cutters
starting on the date of purchase.
Please read and understand the instruction manual carefully
before the installation and operation of this product.
The contents of this manual may be revised ithout prior
notice and ithout obligation. This instruction manual as
issued July 2008.
CONTENTS
- Warning……………………..………………..……………….…..……....………... 2
- General Description………...……….....……...…………………….………...….. 3
- Installation & Operation.……….…... .....……………………………………..….. 4
- Hookup and checks …………….…………………………………………………. 5
- General Operations ……………………………………………………………….. 6
- Caution..………………..…... ........…................. ..………………………………. 8
- Maintenance... .............. ..…………………………………………………………. 9
- Troubleshooting………….…………………………………………………….…… 10
- About Welding………………………………………………………………………. 11
- FAQ ( iring plug, TIG torch info, electrodes, etc) ………………..……….……. 13

WARNING
Welding and plasma cutting is dangerous. Not just to the equipment operator, but people
nearby and the surrounding area ith the sparks and electrical po er. Therefore, the
use of this equipment
must only be under the most strict and comprehensive observance of
all relevant safety rules. Please read and understand this instruction manual carefully before
installing and operating this product.
NOTICE:
S itching bet een functions (TIG/MMA/Plasma) should not be
done hile you are elding or cutting as this can damage the
equipment. Do not disconnect the electrodes-torches or ground
clamp cable from the equipment hile the unit is in use or po -
ered on.
Electric Shock can be fatal
Al ays connect the earth ground clamp to your ork piece.
Avoid “all” contact ith live components of the elding cir-
cuit, electrodes/torches and ires ith bare hands or skin. It
is necessary for the operator to ear dry elding gloves hile
elding or cutting.
The operator should keep the orking
piece insulated from themselves at all time.
Smoke and Gases generated while welding or cutting
can be harmful to your health.
Avoid breathing the smoke and gases hen elding or
cutting. Keep the orking area ell ventilation. Warn
others as ell. Keep pets out of the area as ell.
Arc light-emissions are harmful to people’s eyes and skin.
Wear approved elding helmet, anti-radiation glass and
ork clothes hile elding and cutting. Measures must be
taken to protect people/pets in or near the orking area as
ell.
.
Fire hazards
The elding splash and sparks can cause a fire, remove
flammable materials a ay from the elding and cutting
ork area.
Have a fire extinguisher nearby at all times
and a trained person
ready to use it.
Noise from the unit can possibly harm your hearing.
Surface noise is generated hile elding and cutting, ear
protection is necessary in some cases.
Machine fault or failure
Consult this instruction manual first. Then contact your local
EVERLAST dealer or supplier for further advice.
USERS ’ MANUAL EVERLAST CT-D series - 2 -

USERS ’ MANUAL EVERLAST CT-D series - 3 -
GENERAL DESCRIPTION
The ne ly-developed EVERLAST CT-D series DC TIG, MMA and Plasma cutter al-
lo s elding stainless steel, alloy steel and carbon steel and other nonferrous metals
.
The po er exchange rate of these models are over 85% efficient hich ill save your
po er usage and provide for cleaner elds and cuts.
The design and development of our state-of-the-art Inverter technology used in our
elders and cutters, allo s for the high po er output ith its solid state MOS-FET
(Metal Oxide Semi-conductor Field Effect Transistors). With high quality MOS-FET
output c
omponents, these TIG elding units can function ith a HF (high frequency)
of 100KHz, thus reducing the size and eight of the main components (transformers).
The application of PWM (Pulse Width Modulation) technology enables the concentra-
tion and stability of the output current (AMPS) and ith much more precise and con-
venient current
control. The unique structural design enables the disassembly and
maintenance of these unit and maximizes EMI.
With the exclusive HF Inverter technology of the Everlast CT-D series, in comparison
to traditional elding equipment, you have more advantages, as it is much smaller in
size, lighter in eight,
higher in po er exchange rate; in comparison to the imported
elding equipment. Being a
single phase unit, it can be used through-out the
orld.
Note: An optional foot pedal controller is available, hich allo s the modulation of
your output current hile using your elder. This is available for the Everlast CT-D
series
; improving elding efficiency and performance.
Block Diagram:

INSTALLATION AND OPERATION
1. Power Cord : The po er cord is attached to the unit, ho ever you ill be required to provide a po er plug and po er outlet.
This is to accommodate different countries and setups. Please contact an electrician if you are not qualified or not sure ho to
attach an AC plug. See FAQ for more information on iring.
2. Connecting the Torches and Cutter (front of unit):
2a: MMA clamp, connect the MMA stick torch/clamp to the 2a fast-plug and turn it clock ise.
2b: TIG torch, also plug the seven pin plug connector 2c from the TIG torch or the “optional” foot pedal into its socket, attach/
scre the TIG torch to ”GAS” outlet. Fasten the collar nuts, see the diagram below.
2b: Plasma torch ill connect the same as the TIG just using the Plasma torch rather than the TIG torch.
Make sure you connect COMPRESSED AIR for Plasma o eration OR Argon for TIG o eration. Not doing so could damage
the unit or consumables.
2c: Torch on off control or optional foot pedal control.
2d: IN ALL modes mentioned above the fast-plug on the black ground clamp cable needs to be plugged into 2d socket on
the front panel, and turn it in the clock ise direction. Then the ground clamp connects to your ork piece.
SWITCHES
3. Main power switch: The po er s itch. When “ON” this s itch ill light up and you ill hear the fans turn on. If not see
troubleshooting section.
4. MMA/TIG/Plasma mode switch:
MMA is for stick/MMA elding. TIG is for DC TIG elding and Plasma for cutting.
5. AIR FLOW DELAY: This s itch sets the pre and post argon gas or air flo delay.
6. AMP settings: This control sets the elding amperage (outer scale) and Plasma cutter amperage (inner scale)
7. Machine/Pedal switch: This s itch tell the elder if you are using the torch on/off s itch or optional foot pedal.
INDICATORS
8. O.C./Over Current: This light ill turn on in the event the units overheats due to long periods of use at high current. It is
there to protect the unit. If you see this light “on”, “stop” elding/cutting but leave the unit “ON” for the fans to cool it. Wait
for the light to go “off” before you continue elding. If it does not go off please contact the manufacturer for help.
USERS ’ MANUAL EVERLAST CT-D series - 4 -

Hookup and checks
1) With automatic voltage fluctuation control, this elder ill function despite the input voltage exceeding
15% of the nominal voltage or a loss of up to 15% of nominal voltage.
2) If you increase the length of the leads, be a are that possible machine damage can occur ith exces-
sively long leads.
3) Make sure the gas/air supply is al ays available for the operation (plasma or TIG) you are orking
ith. Connect the Argon gas supply for TIG or compressed air for plasma. Make certain the connec-
tion and pressure is correct (see about elding for more information).
4) Ground the unit ith 6mm
2
(10 gauge) ire to the earth ground.
5) Connect the po er cord, torch and earth ground clamp (see dra ing belo ).
6) If you’ve follo ed all e have ritten, you should be ready to eld. Weld safely please…
Thank you for your time and support, Everlast Products.
USERS ’ MANUAL EVERLAST CT-D series - 5 -

GENERAL OPERATION
DC TIG INSTRUCTIONS (Steel and Stainless)
1. Set the operation mode s itch (s itch 4 on page 4) to TIG.
2. Set your amperage (s itch 6 on page 4) to your desired elding amperage.
3. Set the argon regulator (15-20cfh).
4. Set the pre/post flo s itch to 2.5 seconds or 5 seconds. 5 seconds for thicker steel.
5. Hook your ground clamp to the ork piece.
6. S itch ON the elding unit (s itch 3 on page 4).
7. Press the torch s itch or optional foot pedal, am electromagnetic valves ill click on, HF electricity should
be auditable and gas output presents.
Note: When starting ith a ne TIG session, press the s itch on the elding torch for several seconds to
completely fill the hose ith argon gas (purging any air out). At this point you are ready to eld. After eld-
ing; the post gas output continue for several seconds to protect the eld.
8. If using the optional foot pedal controller. Adjust the elding AMPS on the front panel to 0. The elding
amperage ill be adjustable ith the pedal controller.
9. The distance bet een tungsten and ork pieces should be in the range of 2mm to 4mm (1/8” to 1/4”).
Press the s itch of elding torch, you ill hear and see HF electricity bet een the tungsten and ork pieces.
Start your puddle and use your filler rod to fill it.
MMA/Stick welding (AC or DC)
1. Set the mode to MMA.
2. Connect the MMA torch as mentioned on page 4 section 2
3. Set your AMPS as desired (for the thickness of your ork pieces)
4. Turn on the MAIN po er, no other settings are required, you are ready to stick eld. See the “about elding” sec-
tion for more details and learning ho to strike your arc.
USERS ’ MANUAL EVERLAST CT-D series - 6 -

USERS ’ MANUAL EVERLAST CT-D series - 7 -
GENERAL OPERATION (continued)
PLASMA CUTTER INSTRUCTIONS
1. Set the operation mode s itch to CUT (see page 4 for a diagram).
2. Connect the Plasma torch as sho n on page 4 section 2 (same as MMA just a different torch)
3. Set your AMPS as desired (for the thickness of your ork piece) AND AIR PRESSURE (65 PSI)
4. Turn on the MAIN po er, no other settings are required, you are ready cut.
Note: There are many ays to plasma cut. Al ays use extreme caution and the proper protection. Al ays blo the
melted metals a ay from you. You can either get close to the ork piece ith the torch tip to start the arc or
drag the side of the torch tip for dragging and cutting. The internet has many ebsites that ill explain
Plasma cutting as this is an instructional manual, be sure to search the internet for methods and example
projects.
CAUTIONS
1. Working Environment
1.1 The location in hich this elding equipment is installed should be of little dust, corrosive chemical gas,
flammable gas or materials etc, and of maximum 80% humidity
1.2 Avoid the operation of elding in the open air unless the orking area is sheltered from the sunshine, rain
ater and sno etc; the temperature of orking environment should be maintained ithin -10°C to +40°C;
1.3 Keep this cutting equipment 2’ or more from the all or obstacle .
1.4 Only ork in a ell ventilated area.
Safety Tips
2.1 Ventilation: This cutting equipment is small-sized, compact in structure, and has excellent performance in amper-
age output. The fans are only to extract heat generated by its internal electronics. Make sure your cutting area is
ell ventilated and use proper protection (breathing protection if required).
Cautions: Make sure the louvers (vents) on the equipment as al ays clear of obstructions. Good ventila-
tion is critical for the proper performance and service life of this cutting equipment.
2.2 O.C. Overload
If a sudden halt occurs hile cutting or elding and the O.C. (over current) light comes one, simply stop
elding.
Do not turn off the unit or restart it either. Leave the unit ON and allo the internal fans to bring
do n the temperature inside the equipment. Continue hen the O.C. light goes out.
2.3 Over-voltage
Regarding the po er supply voltage range of the equipment, refer to the Main
parameter tables (page 6
and 7). This cutting equipment has automatic voltage compensation in the po er supply, hich al-
lo s it to operate
ithin the given ranges listed there. In case that the voltage exceeds the stipulated
value, it is possibly damaging to the components of this equipment.
2.4 An earth terminal ground should be used if required and available. Connect the earth ground cable to
avoid the static and electric shock.
2.5 DO NOT ever contact the output terminals (torch and ground) hen elding or cutting. An electric
shock ill occur.
Keep SAFETY as number one, you are working with voltage, high amperage, sparks and gas.

CAUTIONS
1. The Working Environment
1.1 The location in hich this elding equipment is installed should have little dust,
corrosive chemical fumes, flammable gas, and of maximum 80% humidity .
1.2 Avoid elding in the outside unless the orking area sheltered from the sunshine,
rain and sno ; the temperature of orking environment should be maintained
ithin –50°F to +120°F;.
1.3 Keep this equipment 12 inches from any alls or obstructions.
1.4 Keep the orking environment “ ell” ventilated.
2. Safety Tips
2.1 Ventilation of equipment
This equipment is compact and can produce high output amperage. The fans are to
extract the heat generated by this equipments internal circuits hile in operation.
Maintain good ventilation of the louvers of this equipment. The minimum distance
bet een this equipment and any other objects in or near the orking area should be
no less that 12 inches. Good ventilation is of critical importance for the normal per-
formance and service life of your unit.
2.2 If you ever over heat!
If a sudden ever occurs hile using this equipment and the O.C. light turns one.
Stop cutting or elding and allo the fans to cool the unit until the O.C. light
turns off. Do not turn the unit off, as the fan ill help cool it faster.nt.
2.3 Input voltage!
Make sure you provide a 240vac 50-60Hz input ith 30 amps of po er to this unit.
This equipment has automatic voltage compensation, hich enables the unit to
ork given proper voltage, current and frequency if provided. If improper in-
put po er is not used,
it is possible to damage the components of the unit.
2.4 Make sure the green ground ire on the po er line and plug are connected to
ground, the other t o are to connect to 120vac hot legs for 240vac operation.
There is no neutral in this case. Connecting the earth ground is to avoid the electri-
cal shock.
2.5
NEVER contact the output terminals hen the elding. An electric shock can pos-
sibly occur if you are in contact a ground ith another part of your body (bare feet
as ell makes a great ground).
USERS ’ MANUAL EVERLAST CT-D series - 8 -

MAINTENANCE
Exposure to extremely dusty, damp, or corrosive air can be damaging to this equipment. In order
to prevent
a future possible failure, clean any dust on regular intervals ith clean, dry compressed air of a rea-
sonable pressure.
On the plasma torch, keep the nozzle clean/clear. Check and make sure the internal electrode is not
orn, if so replace it. Everlast sells large packs of consumables at a very lo price.
On the TIG, check and sharpen your tungsten as needed (see about elding).
Be careful not to drop the torches as the ceramic cups can crack or break.
Keep the unit out of direct sunlight as the Sun’s UV can fade the paint and knobs.
Please note: The lack of reasonable maintenance/care can void your arranty.
The arranty of this equipment
ill be cancelled if the unit has been abused or opened ithout the consent of an Everlast Products technician.
Circuit Diagram
USERS ’ MANUAL EVERLAST CT-D series - 9 -

USERS ’ MANUAL EVERLAST CT-D series - 10 -
TROUBLESHOOTING
Caution: For safety reasons only qualified technicians are allo ed to ork on this unit if there’s an electrical failure.
Belo is a trouble shooting matrix . If the scope is a elding issue, you can use these tables to assist you in your trou-
bleshooting. We recommend under all circumstance you should contact your authorized Everlast dealer or take this
manual and your unit (if out of arranty) to a certified professional and have them diagnose the unit.
Troubleshooting matrix chart
Symptoms Possible Causes Corrective Action
Main po er s itch is on, no po er
light or display.
1. No AC po er to the unit from
the all outlet
2. Insufficient po er to the unit
3. Internal po er supply failure or
blo n fuse
1. Make sure you have voltage
going to the units po er cord.
2. Correct voltage issue
3. Contact your Everlast dealer
Can not eld or cut but the po er
light is on and display is orking.
1. Lo voltage on the main
po er .
2. HF circuit is not running right
1. Check the po er and make
sure it is ithin specs.
2. Call for tech support
O.C. light on hen s itched on 1. Electrode is shorted 1. Remove and clean or replace
the electrode and nozzle(s)
Po er s itch ill not turn on OR
po er s itch ill not turn off
1. Bad po er s itch 1. Call Everlast for a replacement
s itch. Note the ire colors
hen you replace the s itch
No air sound hen using plasma
or TIG elding modes
1. Gas or air compressor is not
getting to the unit, check regula-
tor or gas/air supply
2. Bad gas s itch in the unit
1. Correct gas flo to the unit, air
on, tank on and regulator set-
tings
2. Call Everlast for instruction
Torch s itch orks, foot pedal
does not
1. Foot pedal is not plugged in or
pedal knob is not set
2. Foot pedal controller is bad
1. Reconnect and set the knob on
the pedal
2. Call Everlast

ABOUT WELDING
At this point you should have read the previous pages, kno ho to hook up the torches and ground, set the operat-
ing mode, and hookup the right gas or air. We cannot possibly teach you to be a elder or all the options you have
ith the Everlast unit, but here e ill offer some tips in each area to get you started.
NOTE AGAIN: Smoke from metals, flux and gases are simply bad for your health. Galvanized and zinc plated metals
should not be used at all. If you need these type metals elded, take them to a local professional elding shop. As-
suming that you’ve read about the eye protection, clothing, fire and electrical hazards, let’s move on. Please read all
the sections here as they may have little tips that might not be in the others.
Plasma cutting:
The Plasma torch. This torch has an electrode inside, cup and air nozzle. The torch comes assembled, so take it
apart and you can see ho to replace parts later, they just scre in. Get them on snug but do not over tighten them.
Inspect the electrodes each use, if it is ever pitted or orn, replace it. If your electrode is pitted, you ‘re probably
touching the ork piece hile cutting. Practice ill prevent this as you learn to keep the cutter just off the ork piece.
There are a couple methods of plasma cutting, one is called the drag cut and this can all be googled for as ell as the
others (thank you google.com). So e ill spend very little time on technique for plasma cutting as it is quite simple.
Always make sure you have com ressed air connected when cutting, 60-70 PSI at 3CFM should be connected to the
rear of the units air input nipple. If you do not supply the compressed air it can damage the cutter. Do a test cut and
make sure the melted metal is blo ing through your ork piece. If the cut is too ide, lo er your current. You can
use other thick steel and a C-clamp, as a straight edge to make your cuts straight and nice.
Make sure you aim the cutter a ay from you as you cut to blo the molten metal a ay from you. And last on all
these areas make sure you ear the proper long sleeves, gloves, leathers, shoes and shield.
General items for welding:
General tools you ill need, slag/chipping hammer for MMA, a stainless steel ire brushes, a grinder, files, C clamps.
You ill find other tools you need as you learn. You ill need flux coated rods for MMA elding, rods and tungsten
electrodes for the DC TIG elding.
For TIG, the tungsten is not included ith the elder and is “not a consumable” ( ell as you start elding for the first
time, it might be). So you ill need to go to a local elding store for these items. After e cover MMA and TIG e
ill outline some rods you might ant to start ith and tungsten types/sizes, also ho to sharpen your tungsten.
NOTE: With MMA AND TIG it is VERY IMPORTANT to clean the joints ( ork pieces) before you eld. All rust/
oxidation and paint must be removed. I like to ipe everything do n ith denatured alcohol after ard. If it is not
clean, the eld ill be eak and can break, and you do not ant this on your kids bike, a trailer, a car, etc.
MMA/Stick welding:
The MMA clamp/torch has 0/45/90 degree slot to hold your elding rod. Just clamp in the rod at the angle that ill
be easiest to use for the position you need to eld. Set the amperage, lo er for thin steel, higher for thick. You can
order good books on elding ith charts on rods, pressures, and amperage. We are just giving you a kick start, this is
not a elders manual by any means.
With MMA you must strike the rod to start the elding process. This takes practice. So do not plan on elding some-
thing important until you have gathered some small scrap steel and have practiced. There is no gas required, the flux
on the rod acts as the gas to protect the metal. Just the torch/clamp, ground clamp and filler rod.
Do not turn the elder on until you are ready to eld. Then strike the arc like a match on the ork piece, after the arc
is going you have to keep the rod 1/8” to 1/4” over the area to be elded or the arc ill stop. This type elding ill
take a lot of practice, but hen proficient, you ill be able to do a lot ith MMA. MMA is quick and requires no gas.
You can go to a local elding shop for 6010 or 6013 rod to start elding steel. And 308 rod for stainless steel. Your
local elding shop ill steer you right, do not demand hat I say, this is hat orks ell for me.
USERS ’ MANUAL EVERLAST CT-D series - 11 -

ABOUT WELDING (continued)
TIG welding in general:
TIG elding requires an inert gas, 100% Argon or an Argon mix (start ith 100% Argon if you are ne to elding). So
you ill need a tank of Argon to hook to the gas inlet on the back of the unit. Put a fitting so you can s ap the air com-
pressor for your Plasma cuts and Argon tank. Hint, get one size bigger on the argon tank as it costs about the same to
get t ice as much on the refill.
TIG also requires a tungsten electrode (not included). The argon and electrode are not parts you ould get ith any
elder. So you “ ill” need to visit the elding store before you TIG. TIG elding ill give you the best control over your
elds, keep the heat right on the area you ant to eld (reduces arping), and probably give you the strongest eld if
done right (ok all elds are strong if done right). TIG ill look nicer over all electrical elding methods. Even as a nov-
ice you can make a nice bead ith some practice.
As far as the tungsten electrodes, there are t o general types and a fe different sizes (diameter). The first type is the
(green tip) ”pure tungsten” for aluminum TIG AC elding and the (red tip) “tungsten 2% thoriated” for TIG DC or pulsed
steel and stainless steel elding. I ill list hat I use here shortly, but let’s get back to the Everlast Super series TIG.
With your supplies you ill see you have 1/16, 3/32, 1/8 inch collets to allo for different electrode sizes. You might
have larger in your set. I keep 1/16 and 1/8 inch for steel (thoriated/red; steel DC elding;). 3/32 and 1/8 inch pure
tungsten for aluminum (green). They are 7” long.
Before you install the tungsten electrode you ill need to sharpen the tips. The point taper should be 2.5 time the diame-
ter on the electrode tip as a general rule. The steel tungsten electrodes (red tip) should be sharpened to a very sharp
point on the end and sharpened ith the length of the rod not across the point. Aluminum you ant a ball on the end (if
it ’s not a perfect ball, it ill be after you use it, so that is not so critical). And it should be sharpened ith the length as
ell. No let’s see ho to put the electrode in the torch.
On the top (back side ) of your torch you ill have the short black “back” cap and in the accessory bag you ill see a
longer black “back” cap, hich is for the 7” electrodes you picked up at the elding store. Along ith the longer back
cap, there are ceramic cups (pink) of varying sizes 5-7 to output the shielding Argon gas. The larger the cup the better
(unless you are doing small gauge flat metals). The smaller cups and short back cap are for elding in tight areas so
you can get the torch in tight spots. (you ill need to cut an electrode do n to use the short back cap). On the bottom of
the torch you have the cup (pink ceramic). This sends the gas out to protect the metal from oxidation as you eld (heat)
the metals. Also in the bag there are collets for the different size diameter tungsten electrodes you can use.
If you have sharpened your tungsten electrode, unscre the short back cup shipped on the torch (and get the larger long
back cap from the bag). Take out the collet inside the torch (under the back cap; the cap pushes the collet to lock your
tungsten electrode in place). Match your electrode ith the correct collet size. Insert the collet and tungsten electrode
and put on the long back cap and start to tighten. Make sure you have from 1/8 to 1/4 inch of the tungsten electrode
sticking out belo the bottom of the (pink) cup. At this point you have the gas hooked up, the torch ready for steel or
aluminum. You ill ant to set your Argon gauge from 10-25 cfh (cubic feet per hour). I normally shoot for 20.
To set the gas pressure gauge you ill have to press the torch s itch or pedal and aste a little gas, but you need to
purge the air from the line any ay..
TIG DC
If you reference page 7 (TIG DC) of this manual, it has the setup information for DC TIG. Use this to set your control
panel. DC TIG is good for steel, stainless and carbon steel. Your tungsten electrode (red tip; thoriaded) should have a
sharp point. With a longer point, you have a more precise and narro TIG arc. As mentioned above, set your gas to
20cfh, the controls, prep (clean) your ork pieces, clamp them together and connect the ground clamp. At this point you
are ready to TIG. Start by evenly heating the t o parts you ant to eld. Watch for a pool of metal to form. When you
see the pool and glo , you are ready to dip the rod in the pool and remove it. You then move the torch and repeat this
operation. You might ant to tack eld each end first so you can remove the clamps and then run your bead.
If you are right handed, use the torch in your right hand and the left to dip the (308 stainless steel or W-1200 steel) filler
rod you purchased in the type ork piece you are elding.
USERS ’ MANUAL EVERLAST CT-D series - 12 -

USERS ’ MANUAL EVERLAST CT-D series - 13 -
FAQ (frequently asked questions)
(Q) How do I wire my units power cord and plug?
(A) All EVERLAST units ork ith 220volts AC (it’s al ays recommend using 220VAC), some units
ill ork ith 110VAC. Make sure you have a 110VAC unit before trying to run your unit on
110VAC. It’s VERY HARD to miss- ire your unit as long as you hook the green or green/yellow
GROUND ire to the ground terminal on your po er plug first. See the diagram that came with
your ower lug and P EASE make sure the power its OFF. After you connect the GROUND
ire to the ground terminal, connect the t o remaining hot ires to the t o remaining terminals,
one ire to one terminal, the other ire to the other terminal.
Note: Be sure to checked the unit s ecs for ower and am erage of your ower lug, outlet and
circuit breaker size. If you use a 4 terminal 200VAC lug (for generator com atibility), NEUTRAL
is NEVER used on 220VAC lugs and o eration.
If you’re not qualified to wire the unit, please hire an professional electrician.
When wiring for 22 VAC, first connect the ground ire to the ground terminal (see the diagram that
came ith your plug), then connect the t o hot ires to the other t o remaining terminals (you can
connect either ire to either terminal).
When wiring a 11 VAC unit for 11 VAC operation, ire the ground first (as ith the 220VAC), then
the other t o ires to the remaining t o terminals on the 110VAC plug. The unit ill automatically
adjust for neutral as there is a neutral prong on a 110VAC plug.
An example of a 4 prong 22 VAC/3 AMP twist lock plug wired for 22 VAC ( e ill not use neu-
tral; 4th prong (W)). Only the X and Y (hot mains) and GROUND (GREEN). If you use a three prong
220VAC plug, a neutral ill not be present or needed. Start by iring GREEN GROUND ire to the
ground terminal after sliding on your cap and seal (see belo right).
Make sure there are no frayed wires and the plug terminals are tight.
Above left is a 4 prong male plug (250VAC/30AMP), plug cap, rubber cap seal and the cord from the elder.
Use this same procedure on 3 prong (250VAC) plugs (there’s no neutral on the 250VAC “three” prong plugs).
The above right picture sho s the seal and cap on the cord and the ground ire connected to the ground ter-
minal, note the green on the ground terminal (green ire goes there).
Above left is a 4 prong male plug (250VAC/30AMP), plug cap, rubber cap seal and the cord from the elder. Use this
same procedure on 3 prong (250VAC) plugs (there’s no neutral on the 250VAC “three” prong plugs). The above right
picture sho s the seal and cap on the cord and the ground ire connected to the ground terminal, note the green on the
ground terminal (green ire goes there).

USERS ’ MANUAL EVERLAST CT-D series - 14 -
FAQ ( frequently asked questions continued )
Still not sure ho to ire the plug? Let’s cover more on AC iring and the type ires
and plugs. This is not to make anyone an electrician. If you are unsure of the iring,
hire a professional and be safe.
Standard US 110volts AC is normally 3 ires, a black (hot), hite (neutral) and green
(ground). EVERLAST elders have a bro n (hot), blue (neutral) and green (ground).
On the dual voltage units, the bro n is the black and blue is the hite. But make sure
you have a dual voltage unit if you ant to run on 110volts AC. Also, note the current
your elder/cutter ill pull. Again, e recommend 220volts AC iring, and 30 AMPs,
but if you ant to ork ith hat you have you must be responsible for the po er you
dra from the outlet. After this is said.
DO NOT USE 11 VAC UNLESS YOU KNOW
WHAT YOU’RE DOING!
11 volts AC wiring (not recommended, 22 vac 3 amp minimum)
22 volts AC wiring

FAQ ( frequently asked questions continued )
(Q) How do I setup my TIG torch?
(A) The TIG torch comes ith shield cups (pink), collets (copper) and caps (black scre in
plugs ith o-ring). You ill need to provide the argon gas tank (and 20cfh) and the tung-
sten electrode (from a local elding store). The t o caps, a short cap (flat cap) for close
tight ork (you ill have to cut an electrode do n for it) and a long cap (7” standard elec-
trodes, you ill use to start your TIG elding). Collet sizes are labeled on the collet as to
hat size electrodes they ill lock in the torch. Again, use the largest shield cup hen
you can. Small collets and electrodes are for thin narro elds and larger ones for
thicker/ ider elds. Read the “About elding” to learn the red (steel/stainless) type tung-
sten electrode and ho to sharpen the end of the electrode.
USERS ’ MANUAL EVERLAST CT-D series - 15 -
This is ho the torch looks
once you have it assembled.
The tungsten is about 1/8” to
1/4” out from the shield cup.
Sharpened as per the “About
Welding” section for the metal
you ish to eld ith the 2%
Thoriated tungsten. The
points and taper on the point
ill affect your idth of your
eld.
This is a breakdo n of the TIG
torch. The tungsten (non-
consumable) is not included
and the type tungsten is based
on the type metal you ish to
eld.
This vie sho s ho the
parts insert into each other
and the torch handle. The
tungsten size should match
the collet size, cup ide as
you can go (I like 7) for good
gas flo (lo oxidation). The
shield cup scre s on rounded
side up and the cap (short or
long) scre s in the top to lock
the tungsten electrode tight.
Short cap is not pictured but it
is a flat cap for tight elding
spots, you should start off
ith the long cap.

FAQ ( frequently asked questions continued )
(Q) What type Tungsten Electrodes do I need for what type metal and how to I sharpen it?
(A) Read “About Welding” again for the details, here are pictures of the brand I use and sizes.
You can ask your local Welding store hat they like.
USERS ’ MANUAL EVERLAST CT-D series - 16 -
With this unit, you ill use the RED tips (2% thoriated) for steel and stainless. The green in the
picture are for use ith the Super P series elders.
Red tip (2% thoriated) need a very sharp point for steel and stainless (DC TIG). The longer the
points, the finer the arc. So sharpen the Tungsten to a shape point and the taper length should be
2.5 time the diameter of the electrode.

A note from Everlast Products.
This is a ne manual for the Super160/200/250P and ACDC TIG 160/200 products. It can be used
ith the TIG product line if you ignore the plasma cutter sections.
We hope you like the ne version. The “About Welding” section is ne as ell as the FAQ that ill
gro as questions come into our technical support group. We ill make updates to it on an on going
bases. We ill have updates on the everlastgenerators.com ebsite via a link.
Please send any recommendations or corrections (as e kno some professionals use our units).
Thank you for your purchase, and spread the ord about Everlast products.
Email: [e-mail]
Phone: [phone] x201
Support: everlastgenerators.com
USERS ’ MANUAL EVERLAST CT-D series - 17 -