Everlast POWERARC 300ST User manual

EVERLAST
POWERARC 300ST
Operator’s Manual for the PowerARC 300ST
Safety, Setup and General Use Guide
Rev. 3 1 001229-16
Analog DC Stick/DC TIG IGBT Inverter Welder
CC
SMAW
IGBT
1&3
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.
GTAW

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..…………………………………….………...
Rear Panel …….………………………………………….
Wiring……………………………………………………….
Stick E6010 Configuration………..……………………
Stick Configuration……….……………………………..
Lift TIG Configuration……………………………………
Stick Operation Technique/Information……………..
Lift Start Technique……………………………………..
Trouble Shooting………………………………………...
Kit Contents…..…………………………………………..
Notes………………………………………………………..
3
4
5
9
10
10
12
13
14
15
16
17
18
19
20
21
22
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___________________________
Contact Information
Everlast US:
Everlast consumer satisfaction email: [e-mail]
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: [e-mail]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
After hours support: 0410 661 334
Everlast Technical Support: [email protected]

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 300ST Sck/TIG welder
INVERTER TYPE ANALOG CONTROLLED IGBT
INPUT VOLTAGE ±10%;PHASE/FREQUENCY 220V; 1 Phase and 3 Phase /50-60Hz
MAXIMUM INPUT AMPS (I₁max) 60A 220V 1 phase/ 45A 220V 3 phase
MAXIMUM INPUT RUNNING AMPS (I₁e) 46.8A @ 220V 1 phase / 31A 220V 3 phase
DUTY CYCLE % @ AMPS 60% @ 300A/32V
100% @ 240A/ 29.2V
OUTPUT 20-300A, 20.8-32V
OPEN CIRCUIT VOLTAGE 70 V
TIG PACKAGE OPTIONAL (Gas valve torch and regulator for scratch start DC use only)
CONSTANT CURRENT (CC) OUTPUT TYPE DC (±)
CELLULOSE ROD CAPABLE 6010,6011 YES
INCLUDES WELDER, WORK CLAMP WITH CABLE (10 FT),STICK TORCH WITH CABLE (10FT)
DINSE CONNECTOR TYPE 35/70mm² (DINSE 50 STYLE)
HOT START (SURGE CURRENT) Adjustable
ARC FORCE CONTROL Adjustable
MAXIMUM SUGGESTED ROD DIAMETER 1/4” (6-7mm)
PROTECTION CLASS IP21S
INSULATION GRADE F
PERFORMANCE AND FEATURE COMPARISON
specificationsSection 1
IMPORTANT: The PowerARC 300 is DC output only and is not designed to weld aluminum or magnesium.
Need longer welding cables or an extension cord? The welding cables are held into the DINSE style
connectors by set screws located under the connector cover and can be accessed by aggressively
twisng the rubber cover back and forth while pulling at the same me. A lile eort may be required
the rst me the connector cover is removed. If necessary, very lightly clamp the end of the connector
pin in a vise or with a pair of pliers while working the cover back unl the cover pops o. The torch has
a small set screw that holds the cover in place. It acts as a wedge to hold the cover in place. It should be
loosened (not removed) and the cover slid back to access the set screw holding the cable in place.
When adding welding cable or using an extension cord make sure that the respecve voltage/current
carrying capacity is suciently rated for carrying the maximum current of the welder over the dis-
tance of the cable. Also, whether running long or short lengths, make sure the welder is strapped
down so any “whipping” movement of the cable will not overturn the welder or jerk it out of place.

10
2.1 General Descripon, Purpose and Features.
PowerARC 300:
The PowerARC 300 is a compact commercial welder
that incorporates professional features such as adjust-
able hot start and arc force control. The arc is spaer-
free and stable due to heavy duty IGBT components
and advanced inverter design.
The welder is designed to weld with any common cat-
egory of welding rod and works well with electrodes
such as E7018, E6013, E7014, E7024, 309L, and others.
It is suitable for welding in any posion recommend-
ed by the electrode manufacturer.
Equipped with a dedicated reactor circuit and addi-
onal negave polarity port (labeled as E6010), the
PowerARC 300 oers improved performance and pen-
etraon with all cellulosic welding rods compared to
standard inverter designs. This feature makes the
PowerARC 300 a perfect choice for professional use
where E6010/E7010 is commonly used. The E6010
port is also recommended for use with E6011.
The unit is capable of funconing on 1 or 3 phase
standard 208-240V current, 50-60Hz. Measured cur-
rent below 208V at the receptacle is not recommend-
ed. This unit should not be operated on long exten-
sion cords with undersized conductors.
Note: To operate in 6010 mode, the work clamp is
moved from the negave terminal connector to the
connector labeled “6010”. Reverse polarity (DCEP ) is
maintained. There is no need to change the elec-
trode holder posion, unless straight polarity (DCEN)
is desired for special operaons with E6010 or similar
rods. If DCEN (-) is desired, then the posions of the
electrode holder and the work clamp should be
swapped. Check with the manufacturer of the elec-
trodes for polarity recommendaons for each rod.
Hot Start:
The adjustable hot start reduces rod scking and po-
rosity that is created while striking an arc by providing
a controlled surge of amps unl the arc is rmly estab-
lished. Aer the arc is established, the hot start termi-
nates and the welder resumes welding with the select-
ed amp level. The intensity of the hot start contains
more adjustability than is typically required to make
good starts. The numbered scale represents a per-
centage of total available Hot start amperage over and
above the main welding amperage. Useful sengs
for hot start usually range from 3 to 7 (30-70%) on the
knob’s scale.
NOTE: The hot start can blow through the metal if
the seng is too high for the given thickness of the
metal. On thin metals use a lightly penetrang rod
such as an E6013 and a low hot start seng.
Arc Force:
The arc force control can be adjusted to improve arc
performance and allow you to use less amperage over-
all and maintain penetraon. It is also a useful tool
when welding out of posion. The arc force control
reacts to the length of the arc. Typically when the arc
length is shortened (rod held closer to the metal), arc
voltage is lowered due to the characterisc of Con-
stant Current design. In a transformer, this would typi-
cally reduce heat but can lead to the arc snung out
or even a stuck rod. With the PowerARC 300, as the
voltage drops below approximately 20V, the amps are
automacally increased in reacon to the reduced arc
length. This prevents the arc from snung and the
rod from scking. Although the funcon of voltage is
signicant in the welding process, welding is also con-
cerned with overall waage (VxA). The arc force func-
on is also referred to as “dig” or “inductance” in the
industry. Pushing the electrode into the puddle will
increase the heat and penetraon without the arc
going out if the arc force is adjusted correctly. If con-
verng from welding with a transformer based welder
to an inverter welder this funcon will require some
pracce and may feel dierent. Some users who have
been trained on transformers may nd it counter-
intuive inially, but quickly begin to appreciate the
advantage this oers. Arc force requirements vary by
electrode and even by manufacturer. Arc force is set
by feel and experience rather than a given number
and can vary by personal preference and technique.
To maintain strict control of the heat, use the lower
end of the amp range of the recommended by the
electrode manufacturer. Then, increase the arc force
seng enough to maintain the arc while using a short
arc length. This will maintain/increase penetraon,
but conne the arc and heat to a smaller area. Too
much arc force may create random pops or spaer.
Note: Some welding techniques that are maintained
with transformer welders may not be sustainable
with the PowerARC 300ST or other inverter welders.
In order to control the maximum input amps, the
inverter is designed to terminate the arc (shut down
output) if voltage increases over a predetermined arc
voltage at any given amp level. While this prevents
GENERAL SETUP AND OPERATIONSection 2

11
over-currents internally and limits amp draw from the
power source, it also helps to improve arc termina-
on. When converng over from a transformer a
welder with a habit of stretching the arc too far may
nd the arc will stop suddenly. Constant Current
Inverters operate on somewhat dierent principles
than Constant Current transformers so some retrain-
ing and even rethinking may be necessary by welders
who have developed an exaggerated moon using a
transformer welder. A praccal example is during
the whipping moon required when welding E6010.
If the welder is accustomed to exaggerang the whip-
ping moon required, then the arc may go out. This
usually happens when the p of the rod is ipped too
far up vercally at the end of the “whip” and raises
the p up further than necessary. This can be simply
avoided if the rod is stepped out further in front of
the puddle with less ipping up to draw out the arc.
2.2 Basic Overview and operaon.
Package:
The PowerARC 300ST includes a sck electrode holder
with cable, and a work clamp with cable. Cables are
approximately 10 . in length. Longer cables can be
added to electrode holder, work clamp and connect-
ors. This unit does not include TIG torch or regulator.
Sck:
The sck funcon is fairly simple and straight forward.
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
that the electrode holder cable is located in the posi-
ve terminal, and the work clamp is located in one of
the negave terminals. See page 17 for arc striking
technique and general rod size selecon. Using too
much hot start or arc force control can result in burn
through. Using too lile will result in poor arc perfor-
mance and rod scking.
TIG:
Although the PA 300ST is sold as a DC Sck welder, the
unit can be used as a li-start DC TIG welder for weld-
ing most all metals except aluminum and magnesium.
The unit though does not provide a HF circuit, foot
pedal or torch switch for starng the arc, so a li start
method must be used to strike the arc. Note: The
torch will always be powered. Avoid touching the
tungsten to the metal unl ready to weld. When using
for li TIG, be sure to turn the arc force and hot start
controls to the minimum seng. Contact Everlast for
an oponal TIG package if desired, or source one local-
ly at a nearby welding supply store.
2.3 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 aer resng and cycling the
power switch. An over current or under current condi-
on is usually caused by dirty power condions, over/
under voltage power supply or an internal fault. If the
overcurrent light is lit, turn the machine o and check
for wiring faults, then turn the unit back on to see if
the light has cleared. If it does not clear, contact Ever-
last technical support for further instrucon. 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 rea-
sons, 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 designed
for wet environment use.
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 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/goggles 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 serious injury may occur.
GENERAL SETUP AND OPERATIONSection 2

12
GENERAL SETUP AND OPERATIONSection 2
6010
PowerARC 300ST
Front Panel View
ON INDICATOR
AMP/CURRENT CONTROL
POSITIVE (+) CONNECTOR
DIGITAL AMP METER
OVER CURRENT INDICATOR
NEGATIVE (-) STANDARD CONNECTOR
DUTY CYCLE INDICATOR
NEGATIVE (-) 6010 CONNECTOR
HOT START CONTROL
ARC FORCE CONTROL
Note: The unit cannot strike an arc if both the electrode holder and the work clamp are engaged in the two
negative (left and middle) ports. To work, either the electrode holder connector or the work clamp connector must
be engaged in the far right positive (+) connector with the other engaged in one of the two negative ports. Most
electrodes require reverse polarity. To maintain reverse polarity (also known as positive polarity or DCEP+) the
work clamp should be engaged in one of the two negative (-) ports, and the electrode holder should always be in
the positive port. When required, negative polarity may be used, and the electrode holder should then be en-
gaged in one of the two negative ports and work clamp will be moved to the positive port. Consult electrode manu-
facturer data and/or instructions for polarity recommendations and specific amp requirements. Electrode instruc-
tions are usually found attached to electrode container or box. If not, consult the electrode manufacturer’s online
resources and specifications for more specific information.
LIFT TIG/STICK SWITCH

13
GENERAL SETUP AND OPERATIONSection 2
PowerARC 300ST
Rear Panel View
1~220 V
OR
3~220v
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 concern-
ing the any requirement of this connection and its proper use and application.
MAIN POWER SWITCH/BREAKER
POWER CORD
GROUND BOLT

14
GENERAL SETUP AND OPERATIONSection 2
PowerARC 300ST
Wiring
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.
PLUG IS NOT INCLUDED! IT MUST BE SUPPLIED BY CUSTOMER.RECOMMENDED
PLUG IS A NEMA 6-50P FOR SINGLE PHASE USE. CONSULT A LICENSED ELEC-
TRICIAN AND LOCAL CODES BEFORE MODIFYING EXISTING CIRCUITS OR IN-
STALLING THE WELDER. See page 20 for further details and explanation.
GAS
INLET
1~220 V
OR
3~220v
IMPORTANT:
EVERLAST IS NOT RESPONSIBLE FOR DAMAGE OR INJURY RESULTING FROM IMPROPERLY WIRED WELDERS!
HF
Fe, Cu
NEMA 6-50P
L3,RED; HOT(240V 3 phase only)
L2,WHITE; HOT (240V 1or 3 phase) L1,BLACK; HOT(240V 1 or 3 phase)
GREEN GROUND (220/240V 1 and 3 phase)
FULLY TAPE RED WIRE SO THAT IS IS OUT OF THE WAY AND COVERED FOR
SINGLE PHASE USE! RED WIRE IS FOR 3 PHASE 220/240 V USE ONLY!
1 PHASE 220/240 V SHOWN. FOR 3-PHASE 220/240 VUSE, CONSULT LICENSED ELECTRICIAN
3 PHASE WIRE COLORS FOR POWERARC 300
GREEN: GROUND
RED:L3
WHITE: L2
BLACK: L1

15
GENERAL SETUP AND OPERATIONSection 2
6010
TORCH (+)
WORK 6010(-)
NOTE: Also, suitable for use with E6011 and other electrodes with cellulose based flux such as E7010.
PowerARC 300ST
STICK E6010 WELDING CONFIGURATION

16
GENERAL SETUP AND OPERATIONSection 2
6010
TORCH (+)
WORK (-)
NOTE: Use this configuration with most standard electrodes except ones with cellulose flux such as E6010/6011.
PowerARC 300ST
STANDARD WELDING CONFIGURATION
IMPORTANT: Most electrodes require DCEP (+). Always consult electrode manufacturer directions before using DCEN (-).

17
GENERAL SETUP AND OPERATIONSection 2
6010
TORCH (-)
WORK (+)
PowerARC 300ST
TIG WELDING CONFIGURATION
TIG torch and regulator are optional items and must be purchased separately. In this type of lift start configuration, the torch
will always be live. There is no foot pedal or torch switch to activate the TIG torch power. You must purchase a torch with a
gas valve to control the gas flow. The unit does not contain a gas solenoid valve to regulate pre-flow or post flow. A regula-
tor is still needed to regulate max flow. To connect Everlast torches, some adaptation or modification of the torch gas line
will be needed, as is the case with most gas valve torches to connect directly to the regulator. The fittings needed to couple
the torch to the regulator are stocked in most well equipped welding supply stores, and hardware stores. This can be ac-
complished inexpensively in several different ways using different types of fittings, depending upon the user requirements.
Gas Valve
NOTE: The TIG torch will always be used in the far left negative terminal. Do not use the negative E 6010 Terminal or in the positive terminal.

18
STICK OPERATION TECHNIQUE
Tapping Method Scratch/Match Method
STARTING METHODS
DC STICK (SMAW) OPERATION GUIDE
GENERAL SETUP AND OPERATIONSection 2
1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program.
Select stick on the selector switch.
2. Make sure electrode holder is connected to the positive connector and the work clamp is connect-
ed to the negative connector. If welding with E6010 or a electrode (rod) with a cellulose based flux,
connect the work clamp to the 6010 port.
3. Select the amps desired. Use the electrode diameter selection chart below to determine the ap-
proximate range of amps suitable for the rod size selected. Consult the welding electrode manufac-
turer’s recommendation for proper amperage range. Each manufacturer has specific recommenda-
tions for its electrodes regarding amp range, though a general range can be determined.
4. Strike the arc with either the tapping method or the match strike method. Beginners usually find
that the match strike method yields best results. Professionals tend to gravitate toward the tapping
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
4-5 mm/ 3/16” 3.2-4 mm/ 1/8”-3/16” 100-170
6-12 mm/ 1/4”-1/2” 4–5 mm/ 3/16” 130-250
>12mm/>1/2”>5mm/3/16”200-300

19
GENERAL SETUP AND OPERATIONSection 2
Note: This method takes some practice to master to initiate the arc on the first try. However, an arc can usually be struck fairly easily by the beginner, though
it may take 2 or 3 times to get one to initiate properly. After it is mastered, arc striking can be done with a light, seamless motion on the first try. Be sure to
protect the cup from damage when not in use. The Alumina TIG cups are fragile and can easily crack if dropped or tapped on the surface.
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 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 releasing the switch or pedal. Re-sharpen the point if necessary, then allow the point to
stop glowing before attempting the start again. Do not scratch start in Lift TIG mode, or the tungsten may stick fast. Per-
forming a scratch start instead of a lift start can also trigger this as the tungsten “skips” along the surface.
METAL THICKNESS
(STEEL)
WELDING AMPS
(A)
TUNGSTEN DIA. Ar FLOW RATE
1-3 mm/.040”-3/32” 30-80 1.5-2 mm/ 1/16”-3/32” 8-15 CFH /4-7 lpm
3-4 mm/ 3/32”-1/8” 50-120 2-3 mm/ 3/32”-1/8” 15-25 CFH/ 7-14 lpm
>4mm/ >1/8” 120-200+ 1/8” 15-25 CFH/7-14 lpm
Note: These ranges are approximate, and not absolute. There is a range of overlapping capability with each tungsten size, metal
thickness and amp settings. Experience will eventually dictate the best range and choice of Tungsten size, filler size etc. As a
general rule, select a filler metal that is no more than 1/32” larger or smaller than the Tungsten diameter. Do not use
“pure” (green) Tungsten in an inverter. Use only Lanthanated, Thoriated, or Ceriated Tungsten.

20
TROUBLE: CAUSE/SOLUTION
Machine will not turn on Check cords and wiring in the plug. Check circuit
breaker. Contact Everlast Technical Support to
check and replace main unit fuse.
Machine runs, but will not weld and/or
Red LED is on.
Check for sound work clamp connection. Make
sure work/Torch cable is securely fastened to
DINSE connector. Check circuits for over/under
voltage. Dirty power from generator. Internal fault
or incorrect wiring. (LED does not have to be lit if it
is incorrectly wired). Check wiring in plug/
receptacle if unit switches on but produces light
spark or no spark.
Reset main power switch if overcurrent light is on
after cool down period. Contact Technical Support if
if light is still on after checking/correcting the issue.
Arc has difficulty establishing, weld-
ing rod sticking
Wet welding rods. Too low of amperage. Too high
of amperage. Use fresh rods. Adjust amps. Wrong
polarity. Hot start/Arc force too low.
Welding rod is rapidly consumed. Too small of welding rod. Too high of amperage
setting. Wrong polarity.
Porosity of the Weld. Discolored
weld color. Too much spatter.
Too much arc force control. Too long of arc length.
Too high of amps.
Weld quality is poor, Cold lapped
weld, unstable arc.
Clean paint/rust from weld. Make sure work clamp
has good contact. Too low of amps
LED illuminates yellow/green. Ma-
chine runs, but no weld power.
Duty cycle exceeded. Allow machine to cool. Re-
set main power switch after full cool down period.
Make sure fan is not blocked. Cycle power switch
after 10-15 minutes of cooling.
Slight whine or squeal to arc. Normal. Sound may vary.
Circuit breaker trips. Internal Fuse
blown.
Wiring fault. Too small of wire or circuit breaker.
Welder internal short. Contact Everlast Technical
Support before resuming use.
Trouble shootingSection 3