Everlast PowerArc 200STi User manual

EVERLAST
POWERARC 200ST i
Operator’s Manual for the PowerARC 200STi
Safety, Setup and General Use Guide
Rev. 2. 1 00-181215– Jan. 2019
DC Stick/DC TIG Inverter Welder
CC
GTAW
SMAW
IGBT
1
~
PHASE
DC
everlastwelders.com
1-877-755-9353
380 Swi Ave. South San Francisco, CA 94080 USA
Specicaons and accessories subject to change without noce.
120V
240V

2
Table of Contents
Section…………………………………………………….Page
Letter to the Customer ………………...…………………..
Everlast Contact Information……………………………….
Safety Precautions……………………………………….…
Section 1: Specications…….……………………………..
Section 2: General Setup and Operation………………….
General Description, Purpose and Features……………...
Front Panel..…………………………………….………......
Rear Panel …….…………………………………………....
Stick Welding Conguration………..……………………...
TIG Torch Conguration.…………………………………..
Wire Connection…………………………………………....
Stick Operation Technique/Information…………………...
Basic TIG Operation…………………..……………………
TIG ARC Start and TIG Tips………...……………………..
Tungsten Preparation…………….………………………...
Kit Contents…..……………………………………………..
TIG Torch Assembly………………………………...……..
Trouble Shooting……………………………………………
3
4
5
9
10
10
14
15
16
17
18
19
20
22
23
24
25
26
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 US:
Everlast consumer sasfacon email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Welding Support: performa[email protected]
Everlast Support Forum: hp://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353)
Sales: Ext 201 9am—5pm PST M-F
Tech Support: Ext 207 9am—5pm EST M-F
Welding Support: Ext 204 9am—5pm EST M-F
FAX: [phone]
Everlast Canada:
Everlast consumer sasfacon email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
Telephone: [phone]am-4:30pm EST M-F
FAX: [phone]
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
Aer hours support: 0410 661 334
Everlast Technical Support: [e-mail]
Other Numbers (Please record here for your records):

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 delivering a sasfactory product to
you. That is the reason we oer technical support 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 operaon and proper maintenance is your responsibility.
We have compiled this operator’s manual to instruct you in basic safety, operaon and
maintenance of your Everlast welder to give you the best possible experience. Much of the
welding related acvies you will encounter are based upon experience and common sense.
As thorough as this welding manual may be, it is not a substute for either. Exercise extreme
cauon and care in all acvies related to welding. Your safety, health and even life depends
upon it. While accidents are never planned, prevenng an accident requires careful planning.
Please carefully read this manual in its enrety before you operate your Everlast unit. This
manual is not only intended to outline the funcons of the machine, but to assist you in ob-
taining the best performance out of your unit. Do not operate the unit unl you have read
this manual and are thoroughly familiar with the safe operaon of the unit. If you feel you
need more informaon about operang your unit, please contact Everlast Support.
The warranty does not cover improper use, maintenance or consumables. Do not aempt to
alter or defeat any piece or part of your unit, parcularly any safety device. Keep all shields
and covers in place during unit operaon should an unlikely failure of internal components
result in the possible presence of sparks and explosions. If a failure occurs, disconnue fur-
ther use unl malfunconing parts or accessories have been repaired or replaced by qualied
personnel.
Note on High Frequency electromagnec disturbances:
Certain welding and cung processes generate High Frequency (HF) waves. These waves may
disturb sensive electronic equipment such as televisions, radios, computers, cell phones, and
related equipment. High Frequency may also interfere with uorescent lights. Consult with
an electrician if disturbance is noted. Somemes, improper wire roung or poor shielding
may be the cause.
HF can interfere with pacemakers. See EMF warnings in following safety secon for further
informaon. Always consult your physician before entering an area known to have welding or
cung equipment if you have a pacemaker.
Safety Precautions

6
These safety precauons are for protecon of safety and health. Failure to follow
these guidelines may result in serious injury or death. Be careful to read and follow all
cauons and warnings. Protect yourself and others.
Welding and cung processes produce high levels of ultraviolet (UV) radiaon that can cause se-
vere skin burn and damage. There are other potenal hazards involved with welding such as severe
burns and respiratory related illnesses. Therefore, always wear Proper Personal Protecve Equip-
ment (PPE) and observe the following to minimize potenal accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even under weld-
ing helmets to protect your eyes from ying sparks and debris. When chipping slag or grinding, gog-
gles and face shields may be required.
When welding or cung, always use an approved shielding device, with the correct shade of lter
installed. Always use a welding helmet in good condion. 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 cung and no less than shade 9 for welding are highly recommend-
ed. 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 con-
tacts for correcve vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cung operaon unless fully protected
by a lter screen, protecve curtains or equivalent protecve equipment. If no protecon is availa-
ble, exclude them from the work area. Even brief exposure to the rays from the welding arc can
damage unprotected eyes.
Always wear hearing protecon because welding and cung can be extremely noisy. Ear protec-
on is necessary to prevent hearing loss. Even prolonged low levels of noise has been known to cre-
ate long term hearing damage. Hearing protecon also further protects against hot sparks and debris
from entering the ear canal and doing harm.
Always wear personal protecve clothing. Flame proof clothing is required at all mes. Sparks and
hot metal can lodge in pockets, hems and cus. Make sure loose clothing is tucked in neatly. Leather
aprons and jackets are recommended. Suitable welding jackets and coats may be purchased made
from re proof material from welding supply stores. Discard any burned or frayed clothing. Keep
clothing away from oil, grease and ammable liquids.
Leather boots or steel toed leather boots with rubber booms are required for adequate foot pro-
tecon. Canvas, polyester and other man made materials oen found in shoes will either burn or
melt. Rubber or other non conducve soles are necessary to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cung or handling met-
al. Simple work gloves for the garden or chore work are not sucient. Gauntlet type welding gloves
are available from your local welding supply companies. Never aempt 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 cuer or welder, instant and serious burns will occur.
Proper hand protecon is required at all mes when working with welding or cung machines!
Safety Precautions

7
WARNING! Persons with pacemakers should not weld, cut or be in the welding area unl they
consult with their physician. Some pacemakers are sensive to EMF radiaon and could severely
malfuncon while welding or while being in the vicinity of someone welding. Serious injury or death
may occur!
Welding and plasma cung processes generate electro-magnec elds and radiaon. While the
eects of EMF radiaon are not fully known, it is suspected that there may be some harm from long
term exposure to electromagnec elds. Therefore, certain precauons 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 cung processes pose certain inhalaon risks. Be sure to follow any guidelines from
your chosen consumable and electrode suppliers regarding possible need for respiratory equipment
while welding or cung. Always weld with adequate venlaon. Never weld in closed rooms or con-
ned spaces. Fumes and gases released while welding or cung may be poisonous. Take precauons
at all mes.
Any burning of the eyes, nose or throat are signs that you need to increase venlaon.
• Stop immediately and relocate work if necessary unl adequate venlaon is obtained.
• Stop work completely and seek medical help if irritaon and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, tanium, copper, cadmium,
lead or zinc without proper respiratory equipment and or venlaon.
WARNING! This product when used for welding or cung produces fumes and gases which con-
tains 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 Phos-
gene gas can be deadly. Consider all chemicals to have potenal 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. Unchained cylinders
may be damaged in fall and can cause damage, injury or death. Certain regulaons regarding high
pressure cylinders can be obtained from OSHA or local regulatory agency. Consult also with your weld-
ing supply company in your area for further recommendaons. The regulatory changes are frequent so
keep informed.
All cylinders have a potenal explosion hazard. When not in use, keep capped and closed. Store
chained so that overturn is not likely. Transporng cylinders incorrectly can lead to an explosion. Do
not aempt 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, ame and sparks. Do not transport without safety caps in place.
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 cung. Keep work surface dry. Do not
use welder or plasma cuer in the rain or in extremely humid condions. Use dry rubber soled shoes
and dry gloves when welding or cung to insulate against electrical shock. Turn machine on or o
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 ght or close quarters necessitates standing or resng
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 locaon and make sure all
personnel in area are advised of their locaon. Taping or securing cables with appropriate restraints
can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cung. Always keep re exnguish-
ers close by and addionally a water hose or bucket of sand. Periodically check work area for smol-
dering embers or smoke. It is a good idea to have someone help watch for possible res while you are
welding. Sparks and hot metal may travel a long distance. They may go into cracks in walls and oors
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 combusble materials including rags and spare clothing away from area.
• Keep all ammable 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 cung outside, make sure you are in a cleared o 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 amma-
ble liquid or material.
• Keep cylinders turned o when not in use.
• Turn o all cylinders and remove regulators when the machine is expected not to be used for
more than 24 hours. Do not transport cylinders uncapped.
Metal is hot aer welding or cung! Always use gloves and or tongs when handling hot pieces of
metal. Remember to place hot metal on re-proof surfaces aer handling. Serious burns and injury
can result if material is improperly handled. Immediately label all recently welded or cut material as
“Hot” with soapstone or a marker suitable for marking metal, when le unaended.
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 em-
ployees to operate poorly serviced equipment. Always check condion of equipment thoroughly
before start up. Disconnect unit from power source before any service aempt is made and for long
term storage or electrical storms. The warranty does not cover lightening strike damage.
Further informaon can be obtained from The American Welding Society (AWS) that relates directly
to safe welding and plasma cung. Addionally, your local welding supply company may have addi-
onal pamphlets available concerning their products. Do not operate machinery unl your are com-
fortable with proper operaon and are able to assume inherent risks of cung or welding.
Safety Precautions

9
PERFORMANCE AND FEATURE COMPARISON
SpecificationsSection 1
Specification PowerARC 200ST i
Inverter Type Digitally Controlled IGBT
Input Voltage (±10); Phase/Frequency 120/240V; 1PH/50-60Hz
Maximum Inrush Amps(I1max) 39.2A @120V/ 36.8A @ 240V
Maximum Eecve (rated running) Amps (I1e) 24A @ 120V/ 22A @ 240V
Duty Cycle @ Rated Amps/Volts
120V:
35% @ 120A/ 24.8 V
60% @ 90A/ 23.6 V
100%@ 55A/ 22.8 V
240V:
35%@ 200A/ 28V
60% @ 160A/26.4V
100%@130A/25.2V
DC Output Range
120V:
5-120A, 20.2-24.8V
240V:
5-200A, 20.2-28V
Open Circuit Voltage 70 V
Li TIG/ HF Start Feature Live Li use with manual gas valve torch. No gas solenoid. No HF Start.
TIG Pulse No Pulse
Welding Accessory Package INCLUDES: Electrode holder (sck) with 10 cable and connector work
clamp with 10  cable and connector. Regulator and Foot Pedal oponal.
Current Output Type DC (±)
Cellulose Electrode Capable (6010,6011) Yes, selectable buon for E6010 operaon.
DINSE Connector Type 35/50mm² (DINSE 35 STYLE)
Hot Start Adjustable Intensity (0-100%) and Duraon (0-2 Seconds).
Arc Force Control Adjustable (0-100%)
Voltage Reducon Device (VRD) for Sck Not Equipped.
An-Sck Funcon Not Equipped.
Maximum Rod Diameter (Sck Electrode) 120V: 3/32” -1/8” 240: 5/32”-3/16” (depending on electrode type.)
Dimensions 6.5”W x 11.5”H x 16.5”L (165mm W x 292mm H x 420mm L)
Weight 26 Lbs. (11 KG) Bare Unit Weight.
Protecon Class IP21S
Insultaon Grade F
Input Cable Length 6 .
Minimum Recommended Generator Surge Was 9000 Was. Must be clean power output rated by the generator manufac-
turer. (clean power is considered ≤5% THD) or warranty is void.
IMPORTANT:
This unit is DC output only. Although technically possible, DC TIG is not recommended for welding aluminum or magnesium.

10
2.1 General Description, Purpose and Features.
PowerARC 200STi:
The PowerARC 200STi is a digitally controlled inverter welder
that provides DC stick and DC TIG welding capability (DC
SMAW/DC GTAW)wrapped up in a completely portable design.
The new digital design has allowed the incorporation of extra
features and improve overall performance. It has also im-
proved serviceability and reliability of the unit by reducing
internal circuitry and discrete structures. The welder is ideal
for welding tasks where portability and commercial perfor-
mance are required. With 120V/240V single phase capability,
the unit can be operated almost anywhere a power outlet is
found, and can be used with small clean powered generators
rated for at least 9000 surge watts (240V). (USA/Canada mod-
els only. Other regions may vary.)
Stick Features.
The improved Stick arc performance of the PowerARC 200STi
still includes the ability to weld with E6010/Cellulose rod type
as well as the ability to weld with almost any other type of
welding rod with a simple touch of a button. The smooth and
stable Stick welding characteristics of the PowerARC series are
well known, particularly with iron powder type rods. The
PowerARC 200STi no longer requires a separate work clamp
connector to select E6010 welding performance. However,
activation of the E6010 function on this welder only requires a
simple touch of a button to attain the crisper, more driving arc
performance that is needed to weld with cellulosic rods such as
the E6010, E6011, etc. The addition of adjustable arc force
control, hot start intensity and duration further renes the per-
formance of the machine with all welding rods. Adjustable Hot
start in stick mode reduces rod sticking while striking an arc by
providing a controlled surge of amps to temporarily increase
welding wattage. Similarly, the adjustable arc force controls
the intensity of the amp reaction to the arc length and by
providing extra current to the arc when the arc length is short-
ened and voltage begins to fall below 20 volts. This prevents
the arc from extinguishing and helps to improve overall arc
performance in all position welds by increasing amps to main-
tain a level welding wattage (Remember: Volts x Amps =
Watts).
TIG Features.
Additionally the unit has been improved in TIG function. The
low contamination Live lift function provides a continuously live
arc and allows the arc to be struck without the use of a foot
pedal or torch switch. With the version of live lift that the
PowerARC 200STi uses, the torch will always remain live, and
when contact is sensed, the current is lowered to allow an
easier time of lifting the torch without the tungsten sticking fast
in the target weld area. The torch is simply placed on the met-
al and lifted up to start the arc. Then the current automatically
increases to the set welding amperage once contact is broken.
The disadvantage is that the Tungsten is live all the time and
an arc could be accidentally struck, causing eye flash, burn or
serious injury. Careful attention to placement of the torch after
the arc has been terminated is required. The new improved
Live Lift TIG Start function provides a relatively clean, interfer-
ence free start for electronically sensitive areas where high
frequency (HF) arc starting is restricted or prohibited.
NOTE: This unit is DC output only. This unit is not intended to
TIG weld aluminum or magnesium. However, the unit can be
used to stick weld aluminum with specially designed aluminum
stick welding electrodes (rods). Flux-coated aluminum stick
welding rods are expensive. Other than occasional use for
emergency repair, are not generally considered a economically
viable alternative to AC TIG welding or MIG welding aluminum.
While DC+ and DC– TIG have both been used to weld alumi-
num in the past, both have technical and practical issues. AC
TIG is generally considered to be far superior, and is generally
considered by professionals the best method of welding alumi-
num.
2.2 Basic Overview and operation.
Basic Welding Package. The PowerARC 200STi package in-
cludes a basic stick welding package as standard equipment.
This is not a complete TIG and stick package. The TIG torch
and regulator will need to be purchased separately. The TIG
torch, if purchased from Everlast, will need to be congured to
work with the optional Regulator. The additional connector(s)
are not provided. The TIG torch can be connected via a 5/8” RH
female to female CGA coupling which is standard in the USA
and Canada. An additional male 5/8” CGA male to 1/4” hose
barb tting will need to be tted to the the torch to couple the
torch to the coupling. This will mean that the user will need to
remove and replace the existing tting on the torch. The ttings
are not supplied to do this. However, the ttings needed are
available from most local welding supply stores and online
welding supply sources. If this is not available, the same thing
may be accomplished with similar brass gas ttings available
from most hardware stores, but will also require retting the
regulator tting to match up. Some other brands may include a
5/8” RH male tting on the torch. In this case, only the cou-
pling will need to be purchased. If a TIG torch is required, the
suggested TIG torch is a 17V series for best combination of
flexibility and heat handling ability. A 26V torch is recom-
mended if you expect to regularly weld over 150 Amps. A TIG
torch with 12.5 ft. cables and DINSE 35/50mm² connector and
built-in gas valve is required for use regardless of series or
amp handling capability. Any of the 17, 26, or 18 series con-
sumables are compatible across the industry and are not
“special” or exclusive to Everlast. The gas regulator is optional
as well. The unit also includes a pigtail adapter for adapting the
unit to operate on 120V. No changeover other than the pigtail
adapter is needed to operate on 120V power.
The PowerARC 200STi package includes a stick welding pack-
age as standard equipment with an additional TIG torch and
accessory package available as an option. The stick package
includes a stick electrode holder with cable, and a work clamp
with cable. Work clamp and electrode cables are approximately
10 ft. in length. Longer cables lengths can be added to the
electrode holder and work clamp and accompanying 35/50mm²
connectors, if desired. These can be readily sourced at almost
any local welding supply store. Do not surpass 50 ft. lengths
General Setup and OperationSection 2

11
on welding cables for best arc behavior and starting. If the TIG
function is going to be used, we recommend ordering a NOVA
torch from Everlast, the NOVA 17V TIG torch with 12.5 ft cables
and DINSE 35/50mm² connector. This torch features a built-in,
manually controlled gas valve and includes cables and DINSE
adapter for use. Any 17V or 26V series torch will be compati-
ble, but cables and DINSE adapters are usually sold separately
from other manufacturers which can increase the torch cost. All
17, 26 and even 18 series torches use interchangeable con-
sumables. These consumables are “universal” and will t
across brands of torches as long as the torches have similar
numeric designations. Note: Customer supplied pure argon
must be used while operating in TIG mode.
The stick package includes a stick electrode holder with cable,
and a work clamp with cable. Work clamp and electrode cables
are approximately 10 ft. in length. Longer cables lengths can
be added to the electrode holder and work clamp and accompa-
nying Heavy duty DINSE 35/50mm² connectors, if desired. To
change the cable, slide the rubber boot back from the brass
lug. (This may require clamping the brass pin lightly in a vice
and vigorously pulling the boot back while twisting back and
forth.) Welding cable can readily sourced at almost any local
welding supply store. Do not surpass a total of 100 ft. length on
the welding leads for best arc behavior and starting.
Basic TIG Operation Information:
Attention: This unit does not include remote operation capability
with torch switches, torch amptrols, or foot pedals. For this
type of operation, see our PowerARC 210STL. This unit uses a
“Live-type” lift start and variable amp control is not used. Amp
control during welding is only able to be made on the panel.
The welder features a version of Live Lift TIG operation. No gas
solenoid is provided on this unit making it necessary to use a
manually controlled gas valve torch to control flow of shielding
gas. Gas flow is manually actuated by twisting the torch mount-
ed knob counter-clockwise to provide a flow of gas a “pocket”
of shielding gas before, during and after the weld. Before start-
ing the arc, the knob should be opened briefly for a second or
two. This is the Pre-flow period. The Post-Flow period, like-
wise, provides shielding after the arc is terminated and the weld
cools. If proper flow of shielding gas is not used or established
before, during, and after the weld, porosity of the weld or rapid
consumption of the tungsten will be experienced. Always make
sure the torch gas valve is fully closed after terminating the
weld. To turn the torch gas flow off, twist the valve clockwise
until it closes and the valve is snug (be careful not to overtight-
en). Check the gas flow on the regulator to conrm gas is not
flowing (if using a ball type regulator). With a torch rig like this,
the arc is terminated by quickly snapping the torch up and away
from the weld with a flick of the wrist, so the torch ends up
roughly parallel to the weld surface. Be sure to turn the torch
back down to the work for a few seconds for the Post-Flow to
work correctly. Be sure to remember to close the valve! A sud-
den rush of gas may be heard when the gas valve is rst turned
on, especially if the valve is opened quickly. The sound should
dissipate within the pre-flow cycle or shortly after the arc starts.
The “surge” of gas is normal, and you will not normally hear the
gas flowing while welding. If the sound of continuous gas flow
is easily distinguishable from background noises, this may be
wasting too much gas and creating turbulence while destabiliz-
ing the arc. If you are worried that you are not getting gas flow
while welding, have someone look at the flow meter to verify
that the regulator ball is continuing to float while welding. You
may also be able to do this if you have an auto-darkening hel-
met. If you take a glance, keep your welding helmet (hood) in
the down position. As a good rule of thumb, set the welder Post
-flow time for 1 second for every 10-20 Amps of power. See
the page later in the manual for proper TIG arc starting tech-
nique.
To get started in TIG mode, stand to the side of the Argon cyl-
inder (never in front of the discharge side!) and purge the gas
by quickly twisting the valve open and then back closed to dis-
lodge any particles of dirt or metal shavings from the connec-
tion and valve seat. Then, connect the regulator to the unit by
hand and complete the tightening process with a wrench. Nev-
er use pliers to tighten. Make sure all gas connections are
tight, including the torch connections. Apply soapy water to the
connections to determine if there is any leakage. Leaking gas
can create contamination issues. So, this step should not be
overlooked. Use cylinders that are considered pure Argon or
100% compressed Argon only. Medical grade Argon is not
required. Many issues with TIG welding result from wrong gas
selection or cross contaminated cylinders that were not purged
properly before use. Never use a mixed shielding gas for MIG
welding, especially any with CO2 in the mix. Shielding gases
that include Argon and Helium or pure helium are permissible.
However Helium can destabilize the arc and make are starting
more difcult in larger amounts. It is also much more expensive
and just isn’t necessary. The torch valve can also be used to
ne tune gas flow, but it will not be as accurate or repeatable. In
most cases, the torch valve should be opened to the point for
maximum flow and so as not to restrict gas flow when in use.
(Do not open too far as the valve can unscrew completely and
fall apart.)
To set the machine up to TIG weld, press the green button on
the upper right side of the panel to select the icon which re-
sembles a TIG torch. (When selected the LED associated with
the process will be lit.) No remote or foot pedal control of this
unit is possible. Amps will only be set and controlled at the
panel. With TIG, always ensure that the torch cable is fully en-
gaged in the negative terminal of the welder and the work
clamp cable is located in the positive terminal. (Twist the con-
nector about 1/4 turn clockwise to lock it in place). Make sure
the gas cylinder is open and the regulator is adjusted to 10-20
CFH (5-10 lpm). To start, place the cup on the metal, then
lightly roll the tip of the tungsten to the metal to start the arc
and quickly roll back and lift up to a distance of 1/8” or less to
begin welding. Stop the arc by quickly snapping the torch up
and away from the weld with a twisting motion of the wrist.
General Setup and OperationSection 2

12
Basic Stick Operation Information:
The stick function of this machine features stable smooth per-
formance with minimum spatter. To get started, be sure to
select the stick icon before starting to weld or arc starting will
be difcult. Arc striking can be done quite easily with practice.
See information included later in the manual for more infor-
mation on arc striking and stick welding techniques. This unit
includes two extra features to improve overall arc welding char-
acteristics. The Hot Start helps to reduce sticking during initial
arc striking. The Hot Start is adjustable for intensity only on
this model. The duration of the hot start is managed by the
machine programming. The intensity of the Hot Start can be set
from 0-100% over available hot start amperage. Old welding
electrodes (rods) or dirty, rusted or painted metal may require
greater action. For most purposes, hot starts less than 50% are
generally used. However, higher settings are not uncommon
and can be successfully used. As amperage increases, the
available Hot Start action will be diminished due to the fact
there is less overall amperage available in the upper amp range
of the machine. In short, if amperage is raised to or approach-
es the maximum output limit of the welder, the hot start action
will be less noticeable. This is most apparent when welding with
120V. To achieve better starting with 120V, smaller welding
electrodes may need to be used to achieve a better start.
Hot start works well to improve starts, but maintaining the arc in
less-than-favorable conditions where the arc length must be
held short is the job of the arc force control. The action of the
arc force control is similar to the hot start in the fact it boosts
amps to prevent arc outage. But it only does so when the arc
voltage drops below a threshold of approximately 20V. The
amp rise responds in proportion to the drop in voltage to main-
tain overall wattage. Be sure to double check (especially after
TIG welding) that the electrode holder cable is located in the
positive terminal, and the work clamp is located in the negative
terminal. In general most iron powder fluxed rods require arc
force settings of 30% or less. For best operation with E6011,
higher arc force values from 40 to 60% may be desirable. This
unit operates best with welding rods up to 1/8” in diameter (on
240V input). In some cases 5/32” may be used, but arc force
action and hot start action may be muted or limited. If neces-
sary, drop down to the next smaller electrode for best results.
See the page dealing with arc striking technique and general
rod size selection later in this manual. Briefly, the welding rod
size while operating on 120V is generally limited to 3/32” max
diameter electrode. Oversizing a rod will increase sticking and
can create undesirable cold lap (lack of fusion at the weld toes).
As with any type of welding, practice will usually improve the
results. Remember, Arc force and Hot Start are functions of
Amperage, so when welding at high Amp settings, the amount
of arc force and hot start available will be reduced to prevent
over currenting the machine and damaging the electronics. In
these cases, where more arc force and hot start is needed or
desired, drop down to a smaller rod and reduce amperage for
best welding results and consistency of function. This is espe-
cially true when operating on 120V. For best results on 120V,
consider using easy striking rods that require low arc force
settings such as E7014.
2.3 Handling and General Maintenance.
Duty Cycle and Overcurrent:
Be careful to observe the duty cycle of the welder. Do not inten-
tionally overheat the welder. Intentional or repeated overheat-
ing will eventually damage the unit. This damage is apparent
upon inspection and not covered under warranty.
Overheating may occur if the duty cycle is exceeded. Overheat-
ing will cause the unit safety cutout to engage, will subsequent-
ly interrupt output. Allow the unit to rest while remaining
switched on for at least 15 minutes if the duty cycle safety has
triggered. After that, reset the unit by cycling the main power
switch on the rear. Even though the duty cycle rating is made
at 104°F (40°C) ambient temperature, high localized heat, air
flow restrictions around the welder and humid conditions will
also affect the duty cycle of the welder. If the unit overheats or
an overcurrent condition is experienced, an error code will be
triggered and the unit will stop welding. An over current or
under current condition is usually caused by dirty power con-
ditions, over/under, voltage power supply, faulty breaker or an
internal fault. If the light is green or yellow green, this a duty
cycle issue. In either case, if the light/code does not clear and
the unit does not resume welding output, by cycling the power
switch (after the required amount of rest, if any), contact Ever-
last.
Note: The duty cycle is 35% at the maximum output of 200
amps while operating on 240V. Maximum Amp output will be
reduced to 90±A) Amps while operating on 120V to limit cur-
rent draw. The Duty cycle is re-adjusted to 35% at 120 Amps
while operating on 120V.
The unit should be stored in a dry place where temperatures do
not drop below 0°F (-17°C) for long term storage. Do not op-
erate below 21°F (-6C°). 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, even with VRD en-
gaged. The service rating for this unit is IP21S, and is not
designed for wet environment use. Use the carry strap or han-
dle provided to lift the welder. Do not suspend the unit in the
air by the strap.
Make sure that the unit’s cooling fan and exhaust vents are kept
free of obstruction. Before every operation, inspect unit for
unexpected obstructions such as insect and vermin nests.
Once a month, or as needed, clean the machine thoroughly
inside and out with compressed air. To do this, remove the rear
plastic cover rst (check for screws on the bottom). Then re-
move the screws on the metal cover. Pull the cover off by
slightly spreading/flexing the bottom “flaps” of the metal cover
with your ngers. Pull up and to the rear to remove the cover.
Do not attempt to remove the front cover or front panel of the
machine. The front panel is part of the structure of the unit
General Setup and OperationSection 2

13
and requires signicant effort and time to remove. Removing
the cover to clean the welder will not void the warranty. How-
ever, neglecting periodic cleaning of the welder may cause
damage to the machine’s circuit board from metallic dust or
particles settling on the traces over time. The boards are coat-
ed with protective conformal coatings to protect against these
issues, but even with the protective coating, dust and metal
particles can still affect the unit if they continue to build up.
This type of neglect may be grounds to deny warranty service
as it is considered the part of routine maintenance. However,
before removing the covers, unplug the welder for 30 minutes
allowing the internal capacitors to discharge to prevent shock,
injury or death. Never remove and circuit boards unless au-
thorized. But, while you are inside the unit for maintenance,
always check all plugs and connections for tightness before
replacing the covers. Do not pinch any wires when reinstalling
the covers. Wear safety glasses to prevent eye injury from
flying particles that may get dislodged while cleaning with com-
pressed air. Do not concentrate compressed air on the skin or
injury may occur. Using “canned-air” is acceptable as well, but
do not allow components to freeze. Keep moving the nozzle
back and forth to keep components from freezing up.
General Setup and OperationSection 2

14
EVERLAST
PowerARC 200STi
%
STICK ON
A
S
6010
!
AMPS HOT START
INTENSITY
HOT START
TIME
STICK
ARC FORCE
IMPORTANT! READ OPERATOR’S MANUAL BEFORE USE!
PowerARC 200ST i
Front Panel View
1. E6010 Stick function for welding with cellulose rods.
2. Selector toggles between parameters for adjustment.
3. Parameter control adjusts highlighted parameter val-
ues.
4. Mode selector selects between Stick or TIG welding
modes. Indicated by Stick or TIG torch.
5. Display/LEDs indicate function value (#3) and value
being adjusted. Values indicated: Seconds (S), Percent
(%), Amps (A), Error/Warning, ON Status.
6. The Positive Terminal (DINSE 35/50mm² type) is used
to connect the Stick electrode holder in Stick mode. In
TIG mode the work clamp is connected here.
7. The Negative Terminal (DINSE 35/50mm² type) is used
to connect to the TIG torch in TIG mode. In Stick
mode, the work clamp is connected here Note: This
connector is not a gas-through type DINSE connector.
See #10.
2.
4.
1.
3.
7.
General Setup and OperationSection 2
8.8.8. STICK TIG 5.
6.

15
1x1110/220V
IMPORTANT: USE THE 240V TO 120V ADAPTER TO SAFELY ADAPT THE NEMA 6-50P (INDUSTRY STANDARD 240V WELDER PLUG) TO THE
STANDARD NEMA 5-15P WHEN OPERATING ON 120V. THIS PLUG ADAPTER PRESERVES THE POLARITY REQUIREMENT FOR OPERATION ON 120V.
CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE WIRING YOUR FACILITY FOR YOUR UNIT!
EVERLAST IS NOT RESPONSIBLE FOR DAMAGE OR INJURIES RESULTING FROM IMPROPER WIRING.
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. Consult a locally licensed
electrician concerning the any requirement of this
connection and its proper use and application in
your region. This connection may be used to help
reduce and drain HF interference during arc starts.
MAIN POWER SWITCH
GAS CONNECTION
NEMA 6-50P PLUG
240V TO 120V PLUG ADAPTER
PowerARC 200ST i
Rear Panel View
General Setup and OperationSection 2

16
GAS OUTLET
PowerARC 200ST i
STICK WELDING CONFIGURATION
TORCH (+) WORK (-)
WORK CLAMP
TORCH/ELECTRODE HOLDER
General Setup and OperationSection 2
POLARITY:
STICK MODE: TORCH POSITIVE (+), WORK NEGATIVE(-)

17
CONTROL
PEDAL
GAS OUTLET
PowerARC 200ST i
Torch Configuration with Optional Torch
POLARITY:
TIG MODE: TORCH NEGATIVE(-), WORK POSITIVE(+)
WORK (+)
WORK CLAMP
General Setup and OperationSection 2
TORCH (-)
GAS VALVE TIG TORCH
NOT USED IF EQUIPPED
DIRECT TO REGULATOR
NOTE: The supplied torch may be equipped with a quick connect gas fitting. This unit does not use a gas solenoid valve. In lieu of
a gas solenoid the torch is equipped with a gas valve torch which manual controls gas flow. This requires that the torch gas line be
connected directly to a regulator (optional, must be purchased separately from Everlast or may be purchased locally.) To connect
the torch directly to the regulator, the customer must cut the clamp off the fitting, and remove the fitting. Additionally, the customer
must supply at least two additional fittings. The first is a 5/8” RH to 5/8” RH female-to-female inert gas coupling. The second is a 5/8”
RH male to 1/4” Hose barb connection type fitting. The tubing will stretch and slide over the hose barb with slight effort. It may be
necessary to warm the line slightly before attempting. Use the clamping method (ferrule or clamp) provided to secure the connec-
tion to the gas line. Then connect both the regulator and the newly installed gas fitting together via the 5/8” RH female to female
coupling. These common parts are available from most local welding supply stores or from a variety of online sources.

18
GREEN GROUND (120/240v)
L1,BLACK; HOT(240V)
BLACK; HOT (120V)
L2,WHITE; HOT (240V)
WHITE; NEUTRAL (120V)
50 AMP
RECEPTACLE SIDE
IMPORTANT: While using the PowerARC 200STi on 120V power, be sure to maintain polarity and use the white wire as the common/neutral,
with the black as the “hot” and the green serving as the ground or damage and malfuncon may occur. Do not remove the NEMA 6-50 plug to
operate on 120V. Use the 240V-120V adapter available from Everlast to adapt the plug to standard 120V power. No other wiring is required.
The unit automacally senses the voltage change and adjusts the output accordingly. The unit is provided with a NEMA 6-50P welder plug for
240V operaon. This is a standard 50 amp welder plug with a ground, but no neutral. Care should be exercised when wiring a new plug and
making any modicaons to exisng wiring. A licensed electrician that is familiar with local wiring codes should be consulted before using,
adding to or making any changes to exisng circuits. The informaon given on the graphic located on the welder supplies the necessary
informaon for breaker and wire sizing. This informaon is found in the I1max and the I1e current input rangs on the graphic. The NEC
supplies special rules on wiring of welder circuits, but local codes and special circumstances may require a heavier or independent circuit.
PowerARC 200ST i
Wire Connection
General Setup and OperationSection 2
GREEN
GROUND
L2,WHITE; HOT
NEMA 6-50R
(Typical Type)
L1,BLACK; HOT

19
DC STICK (SMAW) OPERATION GUIDE
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”70-150
4-10 mm/ 3/16”-3/8” 3.2-4 mm/ 1/8”-5/32” 85-160
Sck Welding. Pay parcular aenon to the Arc Force seng
as it aects the aggressiveness of the arc and the amp re-
sponse. Set the Arc force to approximately 30-50% and read-
just it from that point to nd the opmum seng. Adjust in
increments of 5% up or down from there to obtain the best
results Usually, an increase in the arc force for cellulose based
ux welding rods is helpful. Lowering the Arc force seng is
generally desirable for rods iron powder/Titania based ux.
Too much arc force will create overheang of the welding rod,
and even cause them to ame up. Too lile can lead to scking
and arc snung. Use the Hot Start features to improve arc
starng and cut down on failed arc strikes. Hot Start Amps
refers to the % over the set amps that the amps will be boost-
ed during arc striking unl the arc is established. Hot Start
Intensity controls the amount of me that the Hot Start stays
engaged aer the arc is struck. Start by seng Hot Start to
somewhere between 30% and 50% and set hot start me to .2-
.3 seconds. Adjust in increments of 5% up or down to obtain
best starng results.
Striking the Arc
1. Make sure the unit is turned on and the startup cycle has nished.
2. Select the Sck icon on the Process Selector.
3. Make sure the electrode holder is in the Posive connector and the work clamp is in the negave connector.
4. Select the Amp level desired. Use the guide on page 16 to determine approximate amps suitable for the rod size selected. You
should consult the welding electrode manufacturer’s recommendaon for proper amperage as the ulmate authority. No volt-
age adjustment is available. Select Hot Start Time and Hot Start Amps % (Intensity) to improve starng reliability.
5. Use the arc force control to select the desired arc characteriscs, creang the desired arc characterisc and amp response
needed to maintain the arc. Cellulose electrodes may not have the same arc force behavior as other welding electrodes, but
each brand and size will weld a lile dierently. Typically rods such as the E6011 will require a seng over 50% for best results.
The arc force control seng will vary from person to person as well, with dierent rod angles, posions, and arc lengths all
factoring into the arc force control performance. If you are new to using a transformer welder, there are some aspects that will
seem dierent. One of the main ones is that the arc is beer controlled in most situaons by “pushing in” when the arc seems
to get weak or unstable and the arc force will kick in as the voltage drops. Holding too long of an arc will signal the inverter to
shut down and to terminate welding output. This threshold is shorter than most transformers, and an extremely long arc can-
not be maintained. However, with a lile pracce, the arc will be easy to manage.
Tapping Method Scratch/Match Method
STARTING METHODS
STICK OPERATION
Keep in mind that when sck welding, allow the metal to ll the
puddle as the rod travels forward. Be sure to try to separate the
dierence between the slag and the molten pool of metal. The
slag will coalesce behind the puddle if travel and rod angle is cor-
rect. Do not let the slag travel in front of the puddle. Keep the top
of the rod inclined to the direcon of travel around 10-20 degrees
while welding in the at posion (Electrode holder should be in
front and inline of the puddle). To begin, simply start the arc, and
then drag the rod slowly and carefully along the metal, allowing
the rod ux to provide a stando between the metal ller and the
puddle. Be sure to keep feeding the rod steadily downward into
the puddle as the rod melts. In the case of E6010, a slight stepping
moon in front of the puddle about 1/8”-1/4” in front of the pud-
dle can be used as a key hole opens up in the weld joint, ahead of
the puddle. This is also called “whipping” the rod. Do not ip the
end of the rod too far away from the puddle in a arc moon or the
arc may terminate while using E6010 or similar cellulosic rods.
General Setup and OperationSection 2

20
General Setup. The process to set up the welder
for the basic TIG mode is much less involved than
for basic MIG or Sck. TIG voltage is not conven-
onally adjustable and is a product of the arc
length. This is not to say voltage is not important
to TIG welding, but it is not something that can be
adjusted on the unit. In praccal terms, voltage is
not a concern to the user as it is self regulang.
Amperage however, is adjustable. Seng up Am-
perage correctly for TIG is dierent as there is no
“sound” to listen for. But for each given thickness
of metal, there is an acceptable range of adjust-
ment for TIG. Tradionally, a general rule of
thumb for TIG setup is to set approximately 1 amp
for every .001” of metal thickness. For modern
inverter technology, that may be too many amps
in all but the thickest weld material, parcularly
for a DC inverter TIG welder such as this one. In
many cases, you will only need to use 75% to 80%
of that amperage. But if you are seng up the
unit to use a foot pedal, use the rule of thumb to
begin with as you can always back o the amper-
age as you are welding by leng up some on the
foot pedal. If needed, there are several online TIG
apps and calculators that you can give you
starng points for welding almost any thickness as
well as general sengs for tungsten size, and gas
ow rates. Use the general informaon on the
following pages to help guide you through arc
starng, tungsten preparaon and .
Welding. If you are new to TIG welding, it’s im-
portant that you understand that TIG welding is
much slower than forms of welding. It requires
paence and steady pracce to become procient
at TIG welding. However, most people can
achieve some level of prociency at TIG welding if
they are paent, and are willing to analyze and
adjust the way they are welding. To start weld-
ing, set the amps desired for the metal thickness
you are about to weld. Before striking the arc,
make sure the shielding gas is on, and properly
set. Also adjust your Tungsten sck-out to about
1/8”-1/4” to begin with. If a gas lens is used, the
sck out may increase up to 1”, depending upon
gas lens size. Then follow the arc starng methods
on page 24. Once the arc is started, keep a loose
but sure grip on the TIG torch to prevent cramp-
ing. An underhand hold is good, similar to the
way a pencil is held. A foregrip may be used as
well, but oers less ne control at the beginning
and requires more propping to keep the torch
steady. Pracce running slowly without ller
metal rst. Keep the torch head inclined away
from the direcon of travel, so the Tungsten stays
just above the puddle, pointed toward the front of
the puddle. Move slowly and methodically, gaug-
ing your forward movement to make sure it is
steady and paced. Imagine a thick coin is able to
be placed between the p of the Tungsten and the
weld puddle. As your skill progresses, you will
want to add ller wire to your pracce. The angle
created between the ller rod should be about 90
degrees. You should insert your head in between
the rod and torch, so that your head is about at
the 45 degree mark so that it bisects the angle.
This will allow you clearly see the arc. Do not try
to sit back and view the arc from above as detail
may be easily seen and puddle will be obscured.
When the puddle develops, feed the ller rod into
the front edge of the puddle, being careful not to
place the ller on top of the Tungsten, or touch it
in any way. If you dip the tungsten into the ller
rod or into the puddle, you must stop and regrind
it or the ar will become unstable. Feed the ller in
regular, med dips as the puddle forms. If you
need, count as you me your dips unl you can do
it without thinking. As you proceed to dip your
rod into the edge of the puddle, keep the rod
close to the puddle, within the gas cone. If the
ller metal starts to melt before you dip, you have
it too close, or you have the rod inclined too much
so that heat is being directed too far in front of
the puddle. As you add the ller, be sure to pause
momentarily with the forward travel of the torch.
If desired, a ny back step motion may be used to
improve weld appearance. There are other ways
to add ller and to create a sound weld. You can
keep the ller wire in the puddle, with the rod lay-
ing in a aer prole and weld. As the torch
moves forward and the rod melts, the ller can be
slid, with gentle pressure, into the puddle as need-
Basic TIG Operation
General Setup and Operation
Section 2