Everlast POWERARC 140ST User manual

EVERLAST
POWERARC 140ST
Operator’s Manual for the PowerARC 140ST
Safety, Setup and General Use Guide
Rev. 2 0 00618-14
Analog dc Stick/DC TIG inverter welder
CC
GTAW-P
SMAW
IGBT
1
~
PHASE
DC
everlastwelders.com
1-877-755-9353
329 Lileeld Ave. South San Francisco, CA 94080 USA
Specicaons and accessories subject to change without noce.

2
Table of contents
Section…………………………………………………….Page
Letter to the Customer ………………...……………….
Everlast Contact Information………………………….
Safety Precautions………………………………………
Section 1: Specifications…….…………………………
Section 2: General Setup and Operation……………
General Description, Purpose and Features……….
Front Panel..…………………………………….………...
TIG Torch and Gas Configuration…………………….
Stick Configuration……………………………………...
Rear Panel and Wiring…………………..………………
Arc Starting Methods (Stick)…….……..……………..
Lift TIG Arc Starting Method…….……………….…….
Tungsten Preparation…………….…………………….
Trouble Shooting………………………………………...
Kit Contents…..…………………………………………..
Notes………………………………………………………..
3
4
5
9
10
10
12
13
14
15
16
17
18
19
20
21
NOTE: Product Specicaons and features are subject to change without noce. Every aempt has been
made to ensure this manual’s contents is accurate at me of publicaon. However, certain descripons, quan-
es, appearance and specicaons of the product in this manual are subject to change without noce or up-
date of this manual. This manual is intended to be a general guide and not intended to be exhausve in its
content regarding safety, welding, or the operaon/maintenance of this unit. Everlast Power Equipment INC.
does not guarantee the accuracy, completeness, authority or authencity of the informaon contained within
this manual. 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 parcular purpose, for per-
formance/accuracy or for suitability of applicaon. Furthermore, Everlast Power Equipment INC. does not
accept liability for injury or damages, consequenal or incidental, resulng from the use of this product or re-
sulng from the content found in this document or accept claims by a third party of such liability.

3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast. We appreciate you
as a customer 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 infor-
maon. Your unit registraon is important should any informaon such as product updates or re-
calls be issued. It is also important so that we may track your sasfacon 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 regis-
tered and warranty will be issued and in full eect. Keep all informaon regarding your purchase.
In the event of a problem you must contact technical support before your welder can be a candi-
date for warranty service and returned.
Please review the current online warranty statement and informaon found on the web-
site of the Everlast division located in or nearest to your country. Print it for your records
and become familiar of its terms and condions.
Everlast oers full technical support, in several dierent forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interacon.
Technical advisors are acve on the forum daily. We also divide our support into two divisions:
technical and welding performance. Should you have an issue or queson 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, parcularly if o hours, or you cannot reach a live person. In the event you do not reach a
live person, parcularly during heavy call volume mes, holidays, and o hours, leave a message
and your call will normally be returned within 24 hours. Also for quick answers to your basic ques-
ons, join the company owned forum available through the website. You’ll nd knowledgeable,
helpful people and sta available to answer your quesons, and perhaps nd a topic that already
addresses your queson at hp://www.everlastgenerators.com/forums/.
Should you need to call or write, always know your model name, purchase date and welder manu-
facturing inspecon 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 condions and circumstances of your problem or queson. Take notes of
any issues as best you can. You may be asked many quesons by the advisors to clarify prob-
lems or issues that may seem very basic. However, diagnosis procedures MUST be followed to
begin the warranty process. Advisors cannot assume anything, even with experienced users, and
must cover all aspects to properly diagnose the problem. Depending upon your issue, it is advisa-
ble to have basic tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive
test meter with volt/ohm funcons before you call.
Let us know how we may be of service to you should you have any quesons.
Sincerely,
Everlast Customer Service

4
Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________
EVERLAST
Contact Information
Everlast US:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD ( 9353 ) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
Everlast Canada:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [email protected]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
( 0 2 ) 9999 2949
Port Macquarie: 2B Pandorea Place Port Macquarie
( 0 2 ) 6584 2037
After hours support: 0410 661 334
Everlast Technical Support: [e-mail]

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

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

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

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

9
Specicaon: PowerARC 140ST
INVERTER TYPE ANALOG CONTROLLED IGBT
INPUT VOLTAGE ±10%;PHASE/
FREQUENCY 110/220V; 1PH/50-60Hz
MAXIMUM INPUT AMPS (I₁MAX) 3O.7 A @110V/ 25.5 A @ 220V
MAXIMUM INPUT RUNNING AMPS (I₁e) 18.3 A @ 110V/ 15.7 A @ 220V
DUTY CYCLE % @ AMPS
35% @ 80 A (110V)
60% @ 65 A (110V))
100% @ 50 A (110 V)
35%@ 140 A (220V)
60% @ 100 A (220V)
100% @ 85 A (220V)
OUTPUT A 10-80 A, 20.4-23.2 V (110V)
10-140 A, 20.4-25.6 V (220V)
OPEN CIRCUIT VOLTAGE 70 V
LIFT /HF TIG FEATURE LIFT START TIG ONLY
LIFT START TIG PACKAGE 17V TORCH (GAS VALVE)
CONSTANT CURRENT (CC) OUTPUT TYPE DC (±)
CELLULOSE ROD CAPABLE 6010,6011 6011 ONLY (DC+)
INCLUDES WELDER, WORK CLAMP WITH CABLE (5FT),STICK TORCHWITH CABLE (5FT),
TIG TORCH, CARRY CASE, CONSUMABLES AND BRUSH (NO REGULATOR)
DINSE CONNECTOR TYPE 25/35mm²
HOT START (SURGE CURRENT) AUTO
ARC FORCE CONTROL ADAPTIVE
MAXIMUM SUGGESTED ROD DIAMETER 110V: 3/32” 220v: 1/8”
PROTECTION CLASS IP21S
INSULATION GRADE F
PERFORMANCE AND FEATURE COMPARISON
specificationsSection 1

10
3.1 General Descripon, Purpose and Features.
PowerARC 140 ST:
The PowerARC 140ST is a compact inverter welder
that provides DC sck and DC TIG welding capability.
The welder is ideal for welding tasks where portability
and performance are required. With 120V/240V capa-
bility, the unit can be operated almost anywhere a
power outlet is found, and can be used with small
clean powered generators. (USA/Canada models)
In sck mode the arc is smooth and stable. The auto-
mac hot start in sck mode reduces rod scking
while striking an arc by providing a controlled surge of
amps. Similarly, the auto arc force control adapts to
the arc length and provides extra current to the arc
when the arc length is shortened and voltage begins to
fall. This prevents the arc from exnguishing and
helps to improve overall arc performance in out of
posion welds. The welder is suitable for welding with
iron powder, stainless and low hydrogen class rods
including 7018, 6013, 7014, and 309). It also is able to
perform well with 6011.
NOTE: This unit is not designed to weld with 6010.
Addionally the unit is equipped with a li start TIG
funcon and is excellent for almost DC TIG applicaon
requiring less than 140 amps (240V). The li start
funcon provided in the TIG mode provides a clean,
interference free start for electronically sensive areas
where High Frequency arc starng is restricted or pro-
hibited. (Unit does not have HF start capability.)
NOTE: This unit does not support operaon with a
foot pedal, torch mounted amptrol or remote.
NOTE: This unit is DC output only. This unit is not
designed to TIG weld aluminum or magnesium. How-
ever, the unit can be used to sck weld aluminum
with specially designed aluminum sck welding elec-
trodes (rods). Flux-coated aluminum sck welding
rods are expensive and other than occasional use for
emergency repair are not generally considered a eco-
nomically viable alternave to AC TIG welding or MIG
welding aluminum. While DC+ and DC– TIG have
both been used to weld aluminum in the past, both
have technical issues that can create problems. AC
TIG is generally considered to be far superior, and the
correct method of welding aluminum.
3.2 Basic Overview and operaon.
PowerARC 140ST :
The PowerARC 140 ST package includes a basic TIG
torch with a manual gas valve, sck electrode holder
with cable, and a work clamp. The oponal regulator
may be purchased from Everlast (recommended: EV
200UW) or can be sourced from other suppliers. Cus-
tomers must supply only pure argon (or a combinaon
of argon and Helium while operang in TIG mode.
TIG:
NOTE: This unit is not foot pedal capable.
The welder does not have a gas solenoid circuit so it
does not provide automac ow control of the gas.
Rather it’s equipped with a manually controlled valve
mounted on the torch. See page 13. Twisng the
valve located on the neck of the torch opens and clos-
es the gas ow. This gas valve manually controls pre-
ow and poslow of shielding gas , and must be
opened before striking an arc. This is a common type
of setup found throughout the welding industry.
When using a manual gas valve setup, care must be
taken to shut the gas o each me to prevent wasng
argon.
The torch must be connected directly to the regulator
for TIG use. Most regulators come with a 5/8” CGA
ng. Some, such as the regulator available from
Everlast, may be supplied without ngs, designed
for use with barbed ngs. You will need to join the
regulator and torch by adapng the 5/16” torch gas
hose to the regulator. This is easily accomplished with
a minimal amount of standard hose, a hose barb and
CGA ngs available at any welding supply store.
To use the TIG li arc, ip the switch toward the TIG
icon on the welder. Ensure the torch cable is located in
the negave terminal of the welder and the work
clamp cable is located in the posive terminal. Adjust
welding current with the Amp control knob to desired
amp level. Make sure the tank is open and the regula-
tor is adjusted for 10-20 CFH (5-10 lpm). Lightly
touch the tungsten to the metal, and quickly li up to
a distance of 1/8” or less. See page 18 for li arc strik-
ing method.
NOTE: the tungsten will be electrically live (hot) all
the me. Do not allow it to contact the weldment or
any conducve area that is directly or indirectly in
contact with the work clamp or arc ashing and/or
injury may result. Use a protecve sleeve or torch
GENERAL SETUP AND OPERATIONSection 2

11
holder to prevent accidental tungsten contact with
the conducve surfaces of the work area.
Sck:
The sck funcon is fairly simple and straight forward.
Be sure to ip the torch switch towards the sck icon
before starng to weld, or poor performance may
result. Arc striking can be done quite easily with prac-
ce and the hot start reduces scking. As with any
type of welding, this takes pracce. Be sure to double
check (especially aer TIG welding) that the electrode
holder cable is located in the posive terminal, and the
work clamp is located in the negave terminal. See
page 16 for arc striking technique and general rod size
selecon. Rod size while operang on 120V volt is gen-
erally limited to 3/32” max diameter electrode. Rod
size while operang on 240V is generally limited to
1/8” diameter electrode. Oversizing a rod will increase
scking and can create undesirable cold lap.
3.3 Handling and general maintenance.
Duty Cycle and Overcurrent.
Be careful to observe the duty cycle of the welder.
Overheang may occur if the duty cycle is exceeded.
Overheang will cause the unit safety cutout to en-
gage, subsequently interrupng output. Allow the unit
to rest while remaining switched on for 10 –15 minutes
if the safety cut out has triggered. Aer that, reset the
unit by cycling the main power switch on the rear.
High heat and humid condions will also aect the
duty cycle of the welder. If the unit overheats or an
overcurrent condion is experienced, the duty cycle
light will light as well. Welding will resume once the
duty cycle light is cleared. If the light is red, this is usu-
ally indicates an over/under current condion. An over
current or under current condion is usually caused by
dirty power condions, over/under voltage power sup-
ply or an internal fault. If the light is green or yellow
green, this a duty cycle issue. In either case, if the
light does not clear and the unit does not resume
welding output, by cycling the power switch aer the
required amount of rest, contact Everlast.
Note: The duty cycle is 35% at the maximum output
of 140 amps while operang on 240V. Maximum amp
output will be reduced to 80(±) amps while operang
on 120V to limit current draw. The Duty cycle is re-
adjusted to 35% at 80 amps while operang on 120V.
The unit should be stored in a dry place for long term
storage. Humid/wet condions 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 protecve gear.
The service rang for this unit is IP21S, and is not de-
signed for wet environment use.
Use the carry strap or handle provided to li the
welder. Do not suspend the unit in the air by the
strap or handle.
Make sure that the unit’s cooling fan and exhaust
vents are kept free of obstrucon. Before every oper-
aon, inspect unit for unexpected obstrucons such as
insect and vermin nests. Once a month, or as needed,
clean the machine thoroughly inside and out with com-
pressed air. Before removing the covers however, un-
plug the welder for 30 minutes to allow the internal
capacitors to discharge to prevent shock, injury and
even death. Aerwards, open the units by removing
the rear plasc cover and the metal cover only. Do not
remove the front cover. Do not remove and circuit
boards unless authorized. Check all plugs and connec-
ons for ghtness before replacing the covers. Do not
pinch any wires when reinstalling the covers. Wear
safety glasses to prevent eye injury from ying par-
cles that may get dislodged while cleaning with com-
pressed air. Do not concentrate compressed air on the
skin or injury may occur.
GENERAL SETUP AND OPERATIONSection 2

12
- +
DIGITAL AMP METER
AMP/CURRENT CONTROL
LIFT START TIG/STICK SELECTOR SWITCH
ON INDICATOR
OVERCURRENT/DUTY CYCLE
INDICATOR
TORCH AND WORK CLAMP CONNECTORS
POLARITY:
TIG MODE: TORCH NEGATIVE (-), WORK POSITIVE (+)
STICK MODE: TORCH POSITIVE (+), WORK NEGATIVE (-)
PowerARC 140ST
Front Panel View
GENERAL SETUP AND OPERATIONSection 2

13
- +
POLARITY:
TIG MODE: TORCH NEGATIVE (-), WORK POSITIVE (+)
ARGON ONLY!(Ar)
CO2
REGULATOR
Optional. May need to sup-
ply additional fittings for
connection, depending
upon regulator.
Recommended:
EV200UW regulator from
Everlast
EVERLAST
EVERLAST
WORK (+)
TIG TORCH (-)
IMPORTANT: The PowerARC 140ST is DC output only. DC TIG is not recommended for welding aluminum or magnesium The li start process is a
low maintenance start type for DC TIG, and High Frequency is not usually needed for high quality welds in steel, stainless or chrome moly steel.
PowerARC 140ST
TIG TORCH AND GAS CONFIGURATION
SWITCH LEFT FOR LIFT TIG
MANUAL GAS VALVE
GENERAL SETUP AND OPERATIONSection 2

14
GENERAL SETUP AND OPERATIONSection 2
PowerARC 140ST
STICK WELDING CONFIGURATION
- +
POLARITY:
STICK MODE: TORCH POSITIVE (+), WORK NEGATIVE(-)
WORK (-)
TORCH (+)

15
IMPORTANT: WHILE USING THE POWERARC 140 ST WITH 120V POWER, BE SURE TO MAINTAIN POLARITY AND USE THE WHITE WIRE AS THE COM-
MON/NEUTRAL, THE BLACK AS THE HOT, AND THE GREEN AS THE GROUND OR MALFUNCTION/DAMAGE MAY OCCUR.
SWITCH ON/OFF
GREEN GROUND (120/240v)
L1,BLACK; HOT(240V)
BLACK; HOT (120V)
L2,WHITE; HOT (240V)
WHITE; NEUTRAL (120V)
50 AMP
EVERLAST
RECEPTACLE SIDE
CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE WIRING YOUR UNIT!
EVERLAST IS NOT RESPONSIBLE FOR DAMAGE OR INJURIES RESULTING FROM IMPROPER WIRING.
Use a 240V to 120V connector/adapter available from
Everlast when operating with 120V power supply.
Fe, Cu
Even though the unit is grounded by the main ground
wire to the chassis, an additional bonded ground may be
necessary in some locations to comply with code. Con-
sult a locally licensed electrician concerning the use of
this ground and its application.
GENERAL SETUP AND OPERATIONSection 2
PowerARC 140ST
Rear Panel View and Wiring Connection

16
STICK OPERATION TECHNIQUE
Tapping Method Scratch/Match Method
STARTING METHODS
METAL THICKNESS ELECTRODE SIZE WELDING AMPS
< 1 mm/.040”1.5 mm/ 1/16” 20-40
2 mm/.080”2 mm/3/32”40-90
3 mm/ 1/8” 3.2 mm/1/8”80-150
DC STICK (SMAW) OPERATION GUIDE
GENERAL SETUP AND OPERATIONSection 2

17
Note: This method takes some pracce to master to iniate the arc on the rst try. However, an arc can usually be struck fairly easily by the beginner, though it
may take 2 or 3 mes to get one to iniate properly. Aer it is mastered, arc striking can be done with a light, seamless moon on the rst try. The tungsten
will always be live, so be sure to protect the p from accidental contact with the surface of the metal when not welding. If a torch holder isn’t available to store
the torch when not in use, a protecve boot can be made from heat resistant hose, tubing or other similar material that will slide onto the torch cup so it
protects and insulates the tungsten from direct contact.
METAL THICKNESS WELDING AMPS (A) TUNGSTEN DIA. Ar FLOW RATE
1-3 mm/.040”-1/8” 5-80 1-2 mm/.040”-3/32” 8-15 CFH /4-7 lpm
3-6 mm/ 1/8”-3/16” 80-140 2-3 mm/ 3/32”-1/8” 15-25 CFH/ 7-14 lpm
5. Leave 1/8” or less gap between the tungsten tip and the metal.
1. Position the edge of the ceramic cup on the metal. Do not touch the tungsten to the metal until ready. The tip is always live.
2. Quickly rotate the cup so that the tungsten comes in brief contact (< .2 seconds) with the metal.
3. After contact with the metal, quickly rock the torch back so that the tungsten breaks contact with the metal.
<1/8”
Note: A Lift TIG start should be done with a nearly seamless motion. Use a light touch and a quick motion for best results.
1
23
4
5
LIFT START TIG OPERATION
4. An arc should form. As the arc grows, raise the cup up off the metal and slowly rotate the torch into welding position.
6. Poor starts and welding of the tungsten to the surface can be a result of a rapid “double tap” or quick bounce off the surface
of the metal and back down. This inadvertently signals the inverter to put out full power until the continuity or arc is broken.
If this occurs, fully break the arc by quickly snapping the torch up and away from the weld, and re-sharpen the point if neces-
sary, then allow the point to stop glowing and attempt the start again. Do not scratch start in Lift TIG mode, or the tungsten
may stick fast. Performing a scratch start instead of a lift start can also trigger this as the tungsten “skips” along the surface.
GENERAL SETUP AND OPERATIONSection 2

18
1. Use a dedicated grinding
wheel or contaminaon may re-
sult. Do not breath grinding dust!
Wear eye protecon and gloves.
2. Hold Tungsten rmly.
3. Grind perpendicular to grind-
ing wheel face. Allow tungsten to
grind away slowly, creang point.
4. Rotate tungsten quickly as it is
being ground to keep point even
and symmetrical.
DO NOT GRIND TUNGSTEN
PARALLEL TO WHEEL FACE OR
AN UNSTABLE ARC WILL RESULT.
Use a point for low amp use to
help control arc. Create a slight
truncaon on the p for higher
amp use for best arc stability.
Grind the p so that it is 2.5- 3
mes longer than the tungsten is
wide (Diameter).
DO NOT BALL TUNGSTEN WHILE
USING AC. ERRATIC ARC WILL RE-
SULT. MAKE SURE GRINDING
MARKS RUN PARALLEL TO TIP.
CONCENTRIC MARKS WILL CAUSE
AN ERRATIC ARC.
<50 A
>50 A
2.5 – 3 X Ø (DIAMETER)
TUNGSTEN PREPARATION

NEVER USE PURE (GREEN) TUNGSTEN IN AN INVERTER WELDER.

GENERAL SETUP AND OPERATIONSection 2

19
TROUBLE: CAUSE/SOLUTION
Machine will not turn on Check cords and wiring in the plug. Check cir-
cuit breaker. Contact Everlast Technical Sup-
port to check and replace main unit fuse.
Machine runs, but will not weld in
either mode. Red LED is on.
Check for sound work clamp connection.
Make sure work/Torch cable is securely fas-
tened to DINSE connector. Reset main power
switch if overcurrent light is on after cool down
period. Contact Technical Support.
Arc has difficulty establishing,
welding rod sticking
Wet welding rods. Too low of amperage. Too
high of amperage. Use fresh rods. Adjust
amps. Wrong polarity.
Welding rod is rapidly consumed. Too small of welding rod. Too high of amper-
age setting. Wrong polarity.
Tungsten is rapidly consumed. No/low gas flow. Wrong torch polarity (+).
Open gas valve, readjust flow meter.
Change polarity so torch is in negative (-).
Scratch starting. For 140ST use only lift start
technique. 200/300 results in more wear be-
cause lift sta
Porosity of the Weld. Discolored
weld color. Too much spatter.
Additional TIG symptom: Tungsten
is discolored.
Stick: Too long of arc length. Too high of
amps.
TIG: Same as above/ Low flow rate of shielding
gas. Too short of post flow period. Wrong TIG
cup size.
Weld quality is poor, unstable arc.
Weld is dirty/oxidized.
Clean paint/rust from weld. Make sure work
clamp has good contact. Too low of amps/Too
large of tungsten. Incorrect wiring of welder.
Tungsten (TIG) is poorly ground/contaminated.
LED illuminates yellow/green or
red. Machine runs, but no weld
power.
Duty cycle exceeded. Allow machine to cool.
Reset main power switch after full cool down
period. Make sure fan is not blocked. Overcur-
rent (red). Check circuits for over/under volt-
age. Dirty power from generator. Internal fault.
Slight whine or squeal to arc or to
welder while turned on.
Normal. Sound may vary.
Circuit breaker trips. Internal
Fuse blown.
Wiring fault. Too small of wire or circuit break-
er. Welder internal short. Contact Everlast
Technical Support before resuming use.
Trouble shootingSection 3

20
Kit contentsSection 4
PowerARC 140ST Kit Contents
Qty. Description
1Impact resistant carry case
1Tong style Stick electrode holder and cable, 10 ft
117V Economy gas valve torch and cable, 10 ft
1Steel work clamp and cable, 10 ft
1PowerARC 140ST DC Stick/DC TIG Inverter welder
1 Manual
NOTE: Kit contents, appearance, size and quanty are subject to change without noce.