Everlast PowerPro 256 User manual

1
EVERLAST
POWER ® SERIES
MULTIPROCESS TIG//SMAW/PLASMA CUTTER UNITS
Operator ’ s Manual
Includes AC/DC PowerPro and DC PowerUltra Units
Safety, Setup and General Use Guide
Rev. 4 0516-12
Pro256

2
IMPORTANT NOTICE:
This document has been prepared by Everlast Power Equipment INC. as general information
and does not contain and is not to be taken as containing any specific recommendation. The
document has been prepared in good faith and is professional opinion only. Information in this
document has been derived from third parties, and though Everlast believes it to be reliable as at
the time of printing. Everlast makes no representation or warranty as to the accuracy, reliability or
completeness of information in this document and does not assume any responsibility for updat-
ing any information or correcting any error or omission which may become apparent after the
document has been issued, Neither Everlast nor any of its agents has independently verified the
accuracy of the information contained in this document. The information is commercial in confi-
dence and not to be reproduced.
The recipient acknowledges and agrees that it must make its own independent investigation and
should consider seeking appropriate professional recommendation in reviewing and evaluating
the information. This document does not take into account the particular circumstances of the re-
cipient and the recipient should not rely on this document in making any decisions, including but
not limited to business, safety or other operations decisions. Except insofar as liability under any
statute cannot be excluded. Everlast and its affiliates, directors, employees, contractors and con-
sultants do no accept any liability ( whether arising in contract, tort or otherwise ) for any error or
omission in this document or for any resulting loss or damage ( whether direct, indirect, conse-
quential or otherwise) suffered by the recipient of this document or any other person relying on
the information contained herein. The recipient agrees that it shall not seek to sue or hold Ever-
last or their respective agents liable in any such respect for the provision or this document or any
other information.

3
Serial number: __________________________
Model number: ____________________________
Date of Purchase: ___________________________
EVERLAST
Contact Information
Everlast US:
Everlast consumer satisfaction email: sa[email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
Everlast Canada:
Everlast consumer satisfaction email: sa[email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: s[email protected]
Telephone: [phone]am-4:00pm EST M-F
10am-2pm EST Sat.
FAX: [phone]
Everlast Austrailia:
Sydney: 5A Karloo Parade Newport NSW 2106 (02) 9999 2949
Port Macquarie: 4/18 Acacia Avenue Port Macquarie [phone]
After hours support: 0413 447 492 Everlast Technical Support: [email protected]

4

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informaon.Yourunitreg-
istraonisimportantshouldanyinformaonsuchasproductupdatesorrecalls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registeredandwarrantywillbeissuedandinfulleffect.Keepallinformaonregardingyourpur-
chase.Intheeventofaproblemyoumustcontacttechnicalsupportbeforeyourweldercanbeacandidatefor
warrantyserviceandreturned.

Please review the current online warranty statement and informaƟon found on the website of the Everlast
division located in or nearest to your country. Print it for your records and become familiar of its terms and
condiƟons.

Everlastoffersfulltechnicalsupport,inseveraldifferentforms.Wehaveonlinesupportavailablethroughemail,
andaweldingsupportforumdesignedforcustomersandnoncustomer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off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offhours,leaveamessageandyourcallwillnor-
mally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findknowledgeable,helpfulpeopleandstaffavailabletoansweryourques-
ons,andperhapsfind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manufacturinginspec-
ondate.Thiswillassurethequickandaccuratecustomerservice.REMEMBER:Beasspecificandinformedas
possible.Technicalandperformanceadvisorsrelyuponyoutocarefullydescribethecondionsandcircumstanc-
es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problemsorissuesthatmayseemverybasic.However,diagnosisproceduresMUSTbefol-
lowedtobeginthewarrantyprocess.Advisorscan’tassumeanything,evenwithexperiencedusers,andmust
coverallaspectstoproperlydiagnosetheproblem.
.
Letusknowhowwemaybeofservicetoyoushouldyouhaveanyquesons.

Sincerely,
EverlastCustomerService

5
TABLE OF CONTENTS
Section……………………………………………….Page
General ...……………………………………………
Safety Precautions..……………………………….
Introduction and Specifications…………………
Know Your Machine………………………………..
2.1 Panel Face and Functions……………………
2.2 Lower Panel and Functions….……………...
2.3 Rear Panel ……………………………………..
Getting Started……………………………………..
3.1 General Guidelines……………………………
3.2 Shielding Gas Selection………………………
3.3 Regulator/Flow meter Selection……………
3.4 Regulator Connection………………………...
3.5 Regulator Adjustment………………………..
3.6 Machine Setup………………………………….
3.7 Tungsten Selection……………………………
3.8 TIG Torch………………………………………..
3.9 TIG Welding Principles and Guide…………
3.13 MMA (Stick Welding)…………………………
3.16 Plasma Torch …………………………………
3.17 Plasma Cutting Principles………………….
4.0 Trouble Shooting……………………………….
6
7
10
14
14
16
17
18
18
18
18
18
19
19
20
21
21
23
25
25
28

6
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.
GENERAL

7
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!

8
SAFETY PRECAUTIONS
continued
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.

9
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.

10
INTRODUCTION AND SPECIFICATIONS
SECTION 1
PowerPro 164, 205, 236, (AU only), 256 and PowerUltra Models
PowerPro 256, 236 (AU)
PowerUltra 205P
PowerPro 205
PowerPro 164

11
INTRODUCTION AND SPECIFICATIONS
SECTION 1
Power Series TIG (GTAW)
WP 17/18/26 Torch Assembly
Power Series TIG (GTAW)
Foot Pedal Assembly
Power Series Deluxe Stick (SMAW, MMA)
Electrode Holder And Work Clamp Power Series TIG (GTAW)
Torch Accessory Pack
Power Series Plasma Torches
S45 - P80—A81

12
1.1 This manual has been compiled to give
an overview of operation and is designed to
offer information centered around safe,
practical use of the machine. It is not in-
tended to teach welding technique. All
suggestions and techniques given are ap-
proximations and should be used as a gen-
eral guide only.
1.2 To ensure that your Everlast product is
in top condition, carefully inspect unit for
damage upon opening the box, looking for
damage on the surface of the unit and to
the machine itself and all its accessories.
Do this immediately upon receipt of prod-
uct. Any damage issues must be resolved
right away. It is further recommended that
the product be tested at the same time for
proper operation, even if it is to be stored
for a while. Check to make sure all passag-
es, connections and fittings are clear of
any packing material or other obstruction.
Record the serial number on the page pro-
vided in this manual. Include purchase date
for warranty reference. Serial numbers are
located on either the rear or side of the ma-
chine.
1.3 The Power® Series multi-process units
are used in industrial settings performing
day to day fabrication and repair activities.
The exceptional arc characteristics are
provided by the inverter based technology
that employs the use of reliable IGBT tran-
sistor technology from Germany. Light-
weight inverters allow a machine to be fine-
ly tuned for precise arc characteristics,
while consuming less power than the larg-
er transformer based machines. Although
it varies upon the model, precise control of
the welding arc cycle is managed through
the adjustments available on the panel
face. The independent controls allow for a
virtually limitless number of configurations
to suit every type metal and weld condition
encountered. The use of High Frequency
arc starting in the TIG mode, greatly simpli-
fies the TIG(GTAW) process. The incorpo-
ration of the advanced Pilot Arc in the Plas-
ma Mode eliminates the need for touch
starts and greatly improves consumable
life.
1.4 Be careful to observe duty
cycles of the machine posted in
this manual and on the machine
itself. A duty cycle is a rating of
percentage of time out of 10 minutes the
machine can be used at the rated power
setting . Overheating may occur if the duty
cycle is exceeded. On multi-voltage, multi-
phased machines, note that the rated duty
cycle will change. For example, the duty
cycle of the PowerPro 256 is 35% at 250
amps which continuous operation is al-
lowed for 6 out of 10 minutes before a cool-
ing period of 4 minutes is needed. SMAW
operation on all units is restricted to 35% at
maximum amperage.
1.5 The unit should be stored in a dry
place for long term storage. 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 protective gear.
1.6 Use only the provided handles to lift the
unit. Do not suspend by cables or chains
or use fork trucks to lift the units. If neces-
sary, use two people to carry the unit.
1.7 Make sure that the units cooling fan
and exhaust vents are kept free of obstruc-
tion. Before every operation, inspect the
unit for unexpected obstructions such as
insect and rat nests. From time to time, a
cleaning of the machine with low pressure
air and a small plastic bristle brush is nec-
essary to ensure long life. On these occa-
sions only, unplug unit and remove cover
to access interior. Concentrate efforts on
aluminum heat sinks and panel vents to
remove dust and dirt.
1.8 Refer to the following pages to locate
your particular unit and its specifications.
Note that product specifications are sub-
ject to change without notice due to prod-
uct improvements. If any additional infor-
mation is needed contact Everlast. Simple
wiring diagrams may be obtained for basic
diagnosis and may be obtained from tech-
nical support.
INTRODUCTION AND SPECIFICATIONSSECTION 1

13
INTRODUCTION AND SPECIFICATIONS
SECTION 1
Everlast PowerPro and PPro
164 PPro
205 PPro
256/236 PU
205P
Over current Warning Yes Yes Yes Yes
Start Type (plasma) Blowback Blowback HF Blowback
Start Type (Tig) HF HF HF HF
AC Square Wave (aluminum) Yes Yes Yes No (DC only)
AC Frequency 20-250 Hz 20-250 Hz 20-250Hz None
AC Balance 10-90% 10-90% 10-90% None
Pulse Frequency .2-250 Hz .2-250 Hz .2-500 Hz None
Pulse Amps (background) 5-95% 5-95% 5-95% None
Pulse Time ON (width) 10-90% 10-90% 10-90% None
Arc Force Control (dig) Yes Yes Yes No
2T/4T remote Yes Yes Yes Panel/Remote
only
Pre-Gas Flow Timer 0-10 S 0-10 S 0-10 S No
Post-Gas Flow Timer 0-25 S 0-25 S 0-25 S 0-60
Start Amps 5-150 5-175 0-100 None
End Amps 5-150 5-175 0-100 None
Up Slope Timer 0-10 S 0-10 S 0-10 S None
Down Slope Timer 0-10 S 0-10 S 0-10 S None
Voltage
(OCV 60-80V) 220/240V 1 phase 220/240V
1 phase 220/240V
1 phase 110/220/240 1 phase
Duty Cycle TIG @ Max Rated
amps 60% at 160 60% at 200 35% @250 60% @ 200
Duty Cycle Stick @ Max Rat-
ed Amps 35% @ 140A 35% @ 160A 35%@ 200A 35%@ 160A
Duty Cycle Plasma @ Max
Rated Amps 60% @ 40 A 60% @ 50 A 35% @ 60 A 60% @ 50 A
Water Protection Class IP21S IP21S IP21S IP21S

14
SECTION 2 KNOW YOUR MACHINE
3
2.1 Panel Face. The following is a unit panel
face from the PPRO 256 and PU 205P series
unit. Depending upon your unit, the panel face
may vary with regard to quantity and location
of controls and features. Use the appropriate
referenced number to refer to equivalent fea-
tures on your unit. Some numbers are omitted
on each panel because the function does not
apply to that unit.
1. Power lamp. This light illuminates while the
unit is powered on.
2. Over Current/Overheat lamp. This lamp
illuminates when the duty cycle has been ex-
ceeded or the machine has overheated due to
improper ventilation. Discontinue use until
lamp goes out. Allow the fan to continue to run.
Once lamp goes out, you may resume using the
unit and reset the breaker switch if necessary.
If frequent or continuous overheating is en-
countered, contact Everlast.
3. Digital Display. The display posts the ap-
proximate welding amps within ±3 amps. Dis-
play will change to reflect actual welding amps.
Pulse cycle amps will be displayed while weld-
ing, although when the machine is rapidly puls-
ing the meter may not catch up to the actual hi
and low amperage when it is sampling the am-
perage.
4. Pulse Power Control. This 3 position rocker
switch allows for use of the built in pulse. You
may select: Off, Low (L), or High (H). This fea-
ture pulses (cycles) the amperage between
base and peak amps to maintain fine control of
welding on thin materials or on out-of-position
welds. Noticeable fluctuation of the arc intensi-
ty occurs when the pulsing mechanism is on
at low frequency levels. Using the Pulse Time
ON switch will control the cycle length of the
pulse should more regulation be needed.
5. Pulse Frequency. The pulse frequency con-
trols the number of pulse cycles per second
(Hz). Where applicable, when the pulse is se-
lected for Low, the inner numbers are read. (.2
-25 cycles per second). When the pulse is se-
lected for High, read the outer numbers. (25-
500 for the PowerPro 256)
(25-250 for the PowerPro 164 & 205)
6. Pulse Amps. This gives proportional control
of the Pulse Amps. Example: If the Amperage is
set for 100 amps, and the Pulse Amps control
knob is set for 95% (.9), then the low (base) am-
perage cycle of the pulse will be approximately
95 (90) amps. Regardless of nomenclature, the
basic function of the control is the same.
7. Pulse Time ON. This controls the ratio of
the relative amount of time that the pulse
spends on during a defined cycle . For example:
A setting of 50% will result in a balanced and
equally shared amount of time between the
Pulse current and the base current. A setting of
95% will result in the favoring of the Pulse stage
of the cycle with only 5% of the time spent in the
base stage (low) of the Pulse cycle.
Note: This does not control the overall length of
the pulse. The pulse frequency
setting sets the cycle length, thereby predeter-
mining the maximum possible length of each leg
of the cycle. But within each cycle length, there
is a definable length (ratio) of time that the
pulse spends in the base (low) amperage stage
of the cycle and in the peak (high) amperage
stage of the cycle.
1
2
2 3
3
17
4 5 6 7
8 9 10 11 12 13 14
14
13
21
15 16 17 18 19 20
8
8 4
3
1
2
17 13 14
21
1
1
3 4 5 6 7
2
8 9 10 11 12
13 14
15 16 17 18 19 20

15
Figure 2.1.10 Effects of AC Frequency on welding arc properties
As the cycle frequency (Hz) increases,
overall cycle length is shortened, thereby
compressing the exact amount of time that
the cycle spends in each stage. The Pulse
Time on functions within this compressible
period of time.
8. Main Amperage Control. Some models:
Welding Amps . Locations may vary. This
control knob allows for precise control
over the welding current. This control
knob also is used in the pulse mode to se-
lect maximum amps of the Pulse Time On
cycle. In Plasma mode the outer scale is
read for plasma amp adjustment.
9. Arc Force Control. It determines how
forceful the arc penetrates when it is held
short. It does so by automatically boosting
amps in a short arc situation. This operates
in SMAW/Stick operation. The force of the
arc helps stiffen the arc to hold the molten
metal in place in out of position welds sof-
ten the arc to easily wet in the toes of the
weld. The settings are matter of operator
preference, style and skill. Rotating the
knob clockwise increases arc force There
are no recommended settings regarding
this feature. Experiment with this feature
to find optimum the setting for you.
10. AC Frequency Control. This control
focuses the welding arc and helps to con-
trol penetration, and bead contour.
200Hz (AC) 20 Hz (AC)
11. AC Balance. This control determines
the amount of time the AC cycle spends in
DCEN (-) or DCEP (+). More DCEP is pre-
ferred for cleaning oxidation, particularly
in aluminum. More DCEN is preferred for
for better penetration. A 30% DCEP setting
(+)is customarily preferred. Try this setting
first as a starting point for adjustment.
SECTION 2 KNOW YOUR MACHINE
continued
12. AC/DC Rocker Switch. This switch se-
lects the use of either AC or DC current.
AC current is used primarily when TIG weld-
ing aluminum. Certain stick electrodes
can be welded in this mode to prevent arc
blow and increase penetration.
13. 4T/2T Rocker Switch, Panel/ Remote.
This switch selects for control of the TIG
weld via torch trigger or foot pedal. For the
Power Ultra, simply press and hold torch
switch while in panel mode to operate. In
Pedal mode, connect foot pedal to operate
torch. For the PowerPro series, in the 2T
mode, simply touch and hold the trigger to
start the arc and continue holding while
welding. The machine will cycle automati-
cally according to the settings selected on
the machine. Release the trigger to finish.
2t
4t
4T operation allows full control of the weld-
ing cycle. By touching and releasing the
trigger once, the pre-flow, start current and
up slope are initiated. By touching and re-
leasing again, the down slope, end current,
and post-flow are initiated. Only a momen-
tary pause between touching and releasing
is necessary to activate the up or down cy-
cle. The use of the foot pedal does not over-
ride any pre-set functions on the panel face.
Place the switch in the 2T position to use
the foot pedal.
Figure 2.1.13 Graphic of 4t/2t operation

16
SECTION 2 KNOW YOUR MACHINE
continued
14. TIG/Stick/Plasma rocker switch. This
switch allows you to select the use of either
High Frequency TIG, Cut (Plasma) or the con-
ventional SMAW (stick) welding features.
15. Pre Gas Flow. This timer allows the appro-
priate amount of shielding gas to flow to
purge the gas lines and to provide adequate
shielding gas coverage over the weld before
the weld arc initiates. The gas flow rate is af-
fected by the torch cup size and welding con-
ditions.
16. Post Gas Flow. This timer controls the
flow of shielding gas after the weld arc is ter-
minated. Too little post flow time can cause
weld contamination or torch overheating.
17. Up Slope. This controls the time that the
machine takes to ramp up the current from
the start current to the normal welding cur-
rent. This provides for excellent control over
the welding puddle after it is developed and
allows the operator to adjust manipulation
techniques as the puddle warms up.
18. Down Slope. This controls the end cycle
of the weld by slowly ramping down the weld-
ing current. As the end of the weld is reached,
the down slope helps prevent weld cracking
and hole formation in the crater by allowing
time to fill the weld crater with extra filler be-
fore the puddle cools completely.
19. Start Amps. This selects the initial start-
ing current value used to develop a proper
weld puddle before upslope is signaled to
begin.
20. End Amps. This selects the destination
current of the down slope cycle. This is the
residual current value required for the opera-
tor to properly fill the weld crater to prevent
cracking and holes at the end of the weld.
21. Pressure Gauge. On the PowerPro series,
the gauge is screwed into the pressure regu-
lator on the rear of the machine. Optimum
pressure is 60-70 psi, this gauge is for Plasma
function only.
2.2 Lower Panel. The lower front panel is de-
picted in figure 2.2.1 Each terminal or lug
should be kept free of dirt or obstructions.
Actual layout of items may vary depending on
the unit.
Figure 2.2.1 Lower Front Panel
1. Positive(+) lug. For TIG and Plasma,
connect the work clamp (ground) to
the positive side. For Stick welding,
connect electrode holder torch to this
side for most operations depending
upon the type welding rods used. Con-
sult welding rod manufacturer’s rec-
ommendation.
2. Quick-Connect Gas Outlet. To se-
cure the TIG Argon or plasma air line
from the torch to the outlet, slide col-
lar back on female fitting, mate male
torch fitting and hold the fitting in and
release the female collar. Make sure
collar returns flush with the front edge
of the female fitting. Pull the collar
forward manually if necessary. Oper-
ation is the same for any type of com-
mon quick connect air fitting. Check
for leaks.
3. Torch Control. Plug either the foot
pedal or the torch trigger lead directly
into this plug. Finger tighten the collar
to secure the plug onto the machine.
Both the torch and the foot pedal can-
not be connected at the same time.
For Plasma , the torch switch must be
used. Do not use the foot pedal for
plasma torch operation.
4. Pilot Arc. The single plasma torch
wire with the ring is attached to this to
operate the pilot arc. Finger tighten.
5. Negative (-) lug. For TIG and Plas-
ma operation, connect the TIG torch to
the negative. For most MMA/Stick
welding situations, connect the work
clamp to the negative.
1 2
3
4
5

17
SECTION 2 KNOW YOUR MACHINE
continued
2.3 Rear Panel. Reference the following im-
age for guidance on rear panel setup and
function. Some panels vary slightly.
1. Air regulator/filter/water trap. To adjust
air pressure, pull up slightly on the control
knob on the top of the regulator until a click is
heard. Twist clockwise to increase pressure
or counter clockwise to decrease pressure.
Note: Do not exceed 80 psi. When installing
observe directional arrow for air flow. A step
down regulator at the tank is highly recom-
mended as well as an additional air dryer at
the tank. A tank side air filter/dryer will in-
crease consumable life and help keep mois-
ture out of air lines. On the PowerPro series,
be sure to install air pressure gauge in the
middle plug on the regulator housing.
2. Gas Inlet. This port is a dual purpose port
to provide the unit with either Argon or com-
pressed air. As configured in the picture, it
is set up for compressed air. To use Argon,
you must remove air line (5) from port (2)
and install the line from the argon regulator.
Alternately, you may install a T-fitting with
two shut off valves at the inlet to eliminate the
need to change out the plumbing when
switching functions. Do not attempt to oper-
ate the plasma cutter with argon connected
and do not operate TIG with air pressure con-
nected unless a suitable shut-off mechanism
is in place and the lines have been sufficiently
purged. Also, quick disconnect fittings may
be used, but care must be taken not to intro-
duce moisture to the system that collects on
the couplings during change out.
3. High Frequency Ground. This unit pro-
vides a separate grounding point for the high
frequency to help control interference that
high frequency may cause. This ground must
be connected to a separate wire that is
grounded to a metal rod driven into the
ground. It is strongly recommended that you
connect this to a separate ground as pre-
scribed. This will assist in draining the HF
and help prevent interference with electronic
products. Do not ground to cart, table or
ground to the ground wire in the power sup-
ply circuit. Ground only to separate ground
rod. Do not ground back to panel box! When
operating with a generator the above ground-
ing methods must be followed to ensure safe
and correct operation of the unit.
4. Specifications and Serial number. These
specifications override any other published
specifications, as changes may occur from
time to time. Register your unit’s serial num-
ber online and record it here in the manual.
5. Switch. Flip switch up to turn the unit on.
If the switch needs to be reset, due to over
current or overheating, flip the switch fully
down then back up to resume normal opera-
tion.
6. Fan Area. Keep area from being blocked.
.Air flow must be free and unobstructed. Al-
low 12 inches of clearance behind fan area.
7. Power cord. The power cord must not be
placed in a strain or the unit pulled by the
cord at any time. To wire, use a standard
NEMA 6-50 P male plug. Most plugs have
wire color coding included in the instruction
manual or printed on the plug itself. Howev-
er, the white is typically wired to the smaller
blade and the black wire to the larger flat
blade. The green wire is for ground only
(middle post). Other types of plugs may be
used, but it is suggested to use the 6-50 se-
ries plugs as it meets most codes.
1
23
4
5
6
7

18
SECTION 3 GETTING STARTED
3.1 These are general guidelines for use
and maintenance for your Power Series
unit. Take into account all safety rules and
recommendations first before operation
and service. Do not let untrained person-
nel operate or service equipment in any
way.
3.2 Shielding gas selection.
Do not attempt to operate the TIG func-
tion with out the proper shielding gas!
Proper shielding gas selection is crucial to
satisfactory operation of your TIG machine.
Shielding gas is a special gas or mixture of
gases designed to cover and protect your
weld from contamination from the atmos-
phere while welding and as it cools. Oxy-
gen and other gases from the atmosphere
can infiltrate the weld and make it unser-
viceable. Do not be fooled by the weld’s
appearance, because many defects are
contained inside the weld without the use
of proper shielding gas. The most econom-
ical and available gas is 100% Argon. Heli-
um and Argon/Helium mixes are also avail-
able. Helium offers faster weld rates while
Argon offers a more focused cone and bet-
ter cleaning action. Do not attempt to use
common shielding gases designed for MIG
welders. These will melt the tungsten and
contaminate the weld.
3.3 Regulator/ flow meter selection. You
will need a flow meter/ regulator designed
to be fitted onto your shielding gas tank. It
controls the flow rate of shielding gas into
your Power Series. There are two styles
generally available. The first has two gaug-
es, one for pressure the other for flow. The
best regulator has a pressure gauge and a
flow meter with a ball that floats when gas
flows. Certain flow meters can regulate
Helium, Argon or Helium/Argon mixes
equally well. However, others cannot. It is
advisable that a flow meter be selected
that can regulate both.
Always be sure to select the correct
flow meter for the type of shielding
gas that is in use. Never substitute oxygen
or acetylene regulators!
Image 3.3 Ball type flow meter
3.4 Regulator/Flow meter connection. Af-
ter connecting regulator safely to tank,
attach hose end to shielding gas inlet .
(see 2.3.5) Firmly clamp and secure hose
end to the unit. Depending upon the flow
meter manufacturer, you may have to cut
and remove the pre-crimped hose fitting to
attach the hose to the shielding gas inlet
barb. Open the tank valve slowly and grad-
ually increase the regulator flow to check
for leaks.
3.5. Regulator /Flow meter adjustment.
Adjust the flow meter per manufacturer’s
recommendations. Generally, the flow
should be set around 7-10 lpm (Everlast
Regulators register lpm or liters per mi-
ute!!!!) or 15-25 CFH (cubic feet per hour)
indoors for Argon.

19
SECTION 3 GETTING STARTED
continued
Helium settings are usually at least twice
the flow rate of Argon. You will have to
increase the flow of gas if weld porosity,
sootiness, or weld discoloration is encoun-
tered. If a draft is present or welding is
done outdoor, additional flow may be
needed. Increase flow meter output until
symptoms disappear.
3.6. Machine set up .
1. Plug installation. Due to the lack
of standards concerning 220V plug config-
urations, Everlast chooses to ship
most of our units without a plug for service.
We recommend a license electrician
be consulted to connect your welder for
service to ensure all codes are followed.
The following is provided as a general
guide only. Determine the plug prong pat-
tern of the existing 220V outlets in your
shop or garage. Make sure both plug and
receptacle match perfectly. We recom-
mend the standard 50 amp NEMA 6-50 P
welder plug. Higher amperage units re-
quire twist lock type connections. Do not
force plugs to mate . The green wire is
used as the ground and the black and
white wires are “hot” 110 V wires. To make
a 220V circuit work, two “hot” wires must
be used from separate 110V wires from the
panel box. Do not attempt to wire the unit
from the same phase 110 V leg of the pan-
el. Identify your green ground wire first and
properly attach the wire to the ground
prong. The remaining black and white
wires are your 110V “hot” wires. Attach the
two remaining wires to the remaining two
blades. The ground bolt on the rear of
the machine is designed to help eliminate
High Frequency interference from the ma-
chine. Ground the case bolt to a separate
wire connected to a metal ground rod out-
side of the facility that is in moist soil. Oc-
casionally multiple ground points are re-
quired. Do not ground back to the electri-
cal circuit ground as harmful HF feedback
can occur. Always consult your local, li-
censed electrician for proper installation!
If you used a generator (clean power). The
ground bolt on the rear panel MUST be
grounded.
Do not attach HF ground directly to table,
cart, electrical circuit or panel box.!
Image 3.7a Painted Tips
3.7 Tungsten Electrode Se-
lection (TIG)). Currently
there are many choices
available for tungsten elec-
trodes. Tungsten is general-
ly referred to by a colored
band painted on the end of each electrode.
Each color represents a certain alloying ele-
ment that is present with the tungsten that
helps to extend tungsten life. Sizes also
vary. Each size tungsten is capable of han-
dling a certain current range. Not all tung-
sten electrodes are alike. Pure tungsten
(Green) is NOT recommended for use in any
Everlast Power Series Multi-process ma-
chine! Pure tungsten is not capable of han-
dling the heat and stress placed upon it by
an inverter based welder. Although pure
Tungsten is the most affordable, it forms a
large ball that makes the arc erratic and dif-
ficult to control in inverter based machines.
Old style transformer welders are better
suited for pure tungsten.
The most widely used tungsten is
thoriated (Red). It withstands the
heat of inverter based welding
quite well and retains its shape
without over-melting. Red
(thoriated) tungsten may pose a health risk
as it is slightly radioactive. Inhalation of the
grinding dust or microscopic particles is
possible. Although it is suited for welding
use in an Everlast machine, many people
choose not to risk their health. Red tung-
sten has been available for a long time and
is the standard tungsten in the industry to-
day. However, as concerns rise, more com-
panies are looking for alternatives.
The most favored alternatives have are ei-
ther a Ceriated (Orange) tungsten or Lan-
thanated (Gold) tungsten. Both are suitable
for use in an Everlast Power Series unit.
Costs for these electrodes are considerably
higher than pure or thoriated types of tung-
sten. Many welders experiment with several
types, eventually finding one that they favor
in all situations.

20
SECTION 3 GETTING STARTED
continued
The following table supplies basic information
about Tungsten selection and suitability.
Note: Use only recommended sizes in Tig
torches unless you purchase additional col-
lets to fit the electrodes snugly. Loose fitting
electrodes quickly ruin TIG torch parts.
Table 3.7.1
Electrode Diameter Straight Polari-
ty DCEN Reverse Polar- ity DCEP Unbalanced Wave Balanced Wave
NR .020" .050mm 5–20 Not Recom-
mended
5–15 10–20
.040" 1.0mm 15–80 10–60 20–30
OK
" 1.6mm 70–150 10–20 50–100 30–80
³/" 2.4mm 150–250 15–30 100–160 60–130
⅛"3.2mm 250–400 25–40 150–210 100–180
/" 4.0mm 400–500 40–55 200–275 160–240
NR ³/" 4.8mm 500–750 55–80 250–300 190–300
¼" 6.4mm 750–1100 80–125 325–450 325–450
ALTERNATING CURRENT, A
DIRECT CURRENT, A
Material USA & Australia Europe Japan
4% Thoriated (*) Orange (*)
2% Thoriated Red Red Red
OK
2% Lanthanated Blue (+) (*) Yellow–Green
1.5% Lanthanated Gold (+) (*) (*)
1% Lanthanated Black Black Black
2% Ceriated Orange Grey Grey
1% Zirconiated Brown White (*)
NR Pure Tungsten Green Green Green
(*) not standardized; (+) Pending 1997 revision to the ANSI/AWS A5.12 will add standardization.