Everlast POWERPRO 256SI User manual

EVERLAST
POWERPRO 256Si
CC
GTAW-P
SMAW
IGBT
AC/DC
Operator’s Manual for the PowerPro 256Si
Safety, Setup and General Use Guide
Specicaons and Accessories subject to change without noce.
Rev. 1 0 01207-15ETL
everlastwelders.com
1-877-755-9353
329 Lileeld Ave. South San Francisco, CA 94080 USA
A Digitally controlled pulse tig/stick/Plasma Multi-Process welder/Cutter
PAC

2
Table of contents
Secon……………………………………………………………..Page
Leer to the Customer ………………...………………….
Everlast Contact Informaon…………………………….
Safety Precauons…………………………………………....
Introducon and Specicaons…………………….…..
Unit Specicaons……………………….……………………
General Overview…………….…..…………………………..
General Use and Care………...……………………………..
Quick Setup Guide, TIG Torch/Cooler Connecon.
Quick Setup Guide, Plasma Connecon……………...
Quick Setup Guide, Sck Polarity……………………….
Rear Panel Gas Connecon and Wiring.…………….
Front Panel Features and Controls……………………..
Rear Panel Features and Controls……………………...
Welder Funcon Summary and Explanaons…….
Tungsten Preparaon………………………………………...
Li Start and High Frequency Start……………………
Sck Starng Methods………………………………………
Recommendaons for Polarity/Amps/Tungsten..
Plasma Cung Techniques………………………………….
Expanded View of TIG torch……….…….……….………
Expanded View and Parts List of TIG Torch………...
7 Pin Connector Pin-out…………..…….…….……………
Troubleshoong………………………………………………..
Oponal Accessories…………………………………………..
3
4
5
9
10
11
11
13
14
15
16
18
22
23
28
29
30
31
32
36
37
38
39
41
NOTE: Product Specicaons and features are subject to change without noce. While every aempt has
been made to provide the most accurate and current informaon possible at the me of publicaon, this manu-
al 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 accuracy of performance or for parcular
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 resul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 information.
Your unit registration is important should any information such as product updates or recalls be is-
sued. It is also important so that we may track your satisfaction with Everlast products and services.
If you are unable to register by website, contact Everlast directly through the sales department via
the main customer service number in your country. Your unit will be registered and warranty will be
issued and in full effect. Keep all information regarding your purchase. In the event of a problem
you must contact technical support before your welder can be a candidate for warranty ser-
vice and returned.
Please review and download the official warranty statement, located on our website
www.everlastwelders.com. If you are not in the United States, visit the distributor’s website
warranty information nearest to your region or country. Print it for your records and become
familiar of its terms and conditions.
Everlast offers full technical support in several different forms. We offer domestic based phone sup-
port and online support. Online support is available through email and through our website contact
forms. We also provide a welding support forum designed for customers and noncustomer interac-
tion. Technical advisors are active on the forum on a regular basis. We also divide our support into
two divisions: technical and welding performance. Should you have an issue or question concerning
your unit, please contact performance/technical support available through the main company head-
quarters available in your country. For best service, call the appropriate support line and follow up
with an email. In the event you do not reach a live person, particularly during heavy call volume
times, holidays, or off hours, leave a message and your call will normally be returned within 24
hours. For quick answers to basic operating or service questions, join the company owned forum
linked through the US website. You should be able to find knowledgeable, helpful people and staff
available to answer your questions, and perhaps find a topic that already addresses your question at
http://www.everlastgenerators.com/forums/.
Should you need to call or write, always know your model name, purchase date and welder manu-
facturing inspection 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 conditions and circumstances of your problem or question. Take
notes of any issues as best you can. You may be asked a series of questions by the advisors
meant to clarify problems or issues. Some of these questions may seem basic or fundamen-
tal, but even with experienced users technical advisors can’t assume that correct operating
procedures are being followed for proper operation, and must cover all aspects to properly
diagnose the problem. Depending upon your issue, it is advisable to have basic tools handy
such as screwdrivers, wrenches, pliers, and even an inexpensive test meter with volt/ohm
functions before you call.
Please note: To establish a warranty claim and return a unit for repair or replacement, you
must call technical support first and go through a basic diagnosis process before an Return
Authorization will be issued.
Let us know how we may be of service to you should you have any questions.
Sincerely,
Everlast Customer Service

4
Serial number: ____________________________
Model number: ____________________________
Date of Purchase:__________________________
Contact Informaon
Everlast US:
Everlast consumer sasfacon email: sale[email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Support Forum: hp://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 sasfacon email: sal[email protected]
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]
Aer hours support: 0413 447 492
Everlast Technical Support: suppo[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 delivering a sasfactory product to
you. That is the reason we oer technical support to assist you with your needs should an oc-
casion occur. With proper use and care your product should deliver years of trouble free ser-
vice.
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 product to give you the best possible experience. Much of
welding and cung is based upon experience and common sense. As thorough as this welding
manual may be, it is no substute for either. Exercise extreme cauon and care in all acvies
related to welding or cung. Your safety, health and even life depends upon it. While acci-
dents are never planned, prevenng 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 op-
erate the unit unl you have read this manual and you are thoroughly familiar with the safe
operaon of the unit. If you feel you need more informaon 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 a
licensed electrician if disturbance is noted. Somemes, improper wire roung or poor shield-
ing 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
SAFETY PRECAUTIONS
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 observe the following to minimize potenal acci-
dents 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 the welding and cung environment can be extremely
noisy. Ear protecon is necessary to prevent hearing loss. Even prolonged low levels of noise is
known to create 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 oc-
cur. Proper hand protecon is required at all mes when working with welding or cung machines!

7
SAFETY PRECAUTIONS
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 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 ex-
posure:
 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 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 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. Certain regulaons
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 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.

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 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 con-
tact.
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nguishers
close by and addionally a water hose or bucket of sand. Periodically check work area for smoldering
embers or smoke. It is a good idea to have someone help watch for possible res while you are weld-
ing. 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.
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.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper maintenance is
your responsibility. Make sure all equipment is properly maintained and serviced by qualied person-
nel. 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.
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.

9
Introduction and SpecificationsSection 1
PowerPro 256Si
22K Ω
Foot Pedal Assembly
Consumable Starter Kit
(Does not include Tungsten)
Work Clamp
Air-Cooled
18 Series Torch Assembly
Air and Argon Regulator
NOTE: Appearance and quanty of accessories are subject to change without noce. Full TIG and Plasma consumable kits may be
purchased from Everlast. Starter consumable kits oer only enough to get started. Quanty and size of consumable kits vary.
Stick Electrode Holder
iPT 60 Plasma Torch

10
PowerPRO 256Si TIG/Sck Welder/Plasma Cuer Specicaon
Process AC/DC GTAW-P, DC SMAW and PAC
Inverter Type DIGITAL IGBT Construcon
Minimum/Maximum Rated Output TIG AC: 20A/10.8V - 250A/20V (± 3A)
DC: 5A/10.2V-250A/20V(± 3A)
Minimum/Maximum Rated Output Sck 5A/20.2V - 200A/28V (±3A)
Minimum/ Maximum Rated Output Plasma 20A/88V-60A/104V (±3A)
Start Type HF only (No li TIG start available for this model)
HF Point Gap Adjustable .030”-.045”
TIG Duty Cycle @ Rated Amps/Volts 60% @ 250A/20.0V
100% @ 200A/18 .0V
Sck Duty Cycle @ Rated Amps/Volts 35% @ 200A/28V
60% @ 160A/26.4V
100% @ 130A/25.2V
Plasma Cuer Duty Cycle @ Rated Amps/Volts 35% @ 60A/104V
60% @ 50A/100V
100% @ 40A/96V
OCV (U0) TIG/Sck: 70V Plasma: 250V
Voltage Input (U1) Standard 220/240V; 50/60Hz 1 phase
Maximum Inrush Amps (I1MAX) 40A
Maximum Operang Amps (Rated Eecve) (I1EFF) 32A
Maximum Air Supply Pressure (Plasma cuer) 90 psi from Air Compressor
Recommended Operang Pressure (Plasma cuer) 70-80 psi while air is owing.
Recommended Minimum Air Compressor Size 5.3 CFM @ 90 psi, 25 gallons
Gas Pre-Flow /Post Flow Time 0-10 Seconds/ 0-25 Seconds
Start Amps/End Amps DC: 5-250A/5-250A (±3A)
AC: 20-250A/20-250A (±3A)
Up/Down Slope Time 0-10/0-25 Seconds
AC Frequency Control 20-250 Hz
AC Balance Control 10-90% of Electrode Posive (EP)
Pulse Frequency Hz (Pulses Per Second) .5-250Hz
Pulse Amps (Rao) 5-95%
Pulse Time On (Balance) 10-90%
Sck Arc Force Control 0-100%
Minimum Water Ingress Protecon Standard IP21S
Eciency >85%
Cooling Method One Single Speed Full-Time High Velocity Fan
Dimensions (approximate) 18” H X 10” W X 25” L
Weight (Bare Unit) 65 lbs.
Minimum Storage/Minimum Operang Temperature Storage: -10°F/-23°C Operang: 14°F/-10°C
Introduction and SpecificationsSection 1

11
General overview: The Mul-Process PowerPro 256Si
oers an improved design with a new modular structure.
This new design includes digital control and a more ro-
bust internal design to improve reliability and perfor-
mance while simplifying circuitry and reducing weight.
The key features of the PowerPro 256Si include:
A. Digital control and componenzed unit design reduc-
es complexity of circuitry and components, reducing
the overall number of components. This is aimed at
improving lifespan and long term serviceability of
the Mul-Process TIG/Sck Plasma plaorm.
B. Digital control oers more precise control over pa-
rameters, and oers a more sasfactory operang
experience by minimizing service and operaonal
issues found in the typical TIG/Sck/Plasma mul-
process welder/cuer unit.
C. Full-wave bridge recer inverter design also fea-
tures so switching technology which further ex-
tends IGBT component life.
D. HF point gap adjustment issues have been reduced
with the introducon of new HF board design.
E. Digital components oer reduced weight and im-
proved operang eciency over past analog con-
trolled generaons.
F. The digitally controlled square wave design creates a
stable arc in AC, with a fast melng puddle and
good wet-in.
G. Adjustable arc force control and adapve hot start
helps improve the SMAW process performance.
H. Plasma operaon has been improved with a new
generaon of torches featuring the iPT 60 torch.
General Use and Care: With proper care, the PowerPro’s
digitally controlled inverter components are designed to
withstand years of use in many dierent welding envi-
ronments. However, remember to keep the unit out of
direct contact with water spray and corrosive areas. The
unit has an ingress rang of IP21S, for light dripping wa-
ter (condensaon). It is a good idea to remove the weld-
er from the vicinity of any water or moisture source to
reduce the possibility of electrocuon or shock. Never
operate in standing water or where water spray is an
issue. Every 1-2 months, depending upon use, the weld-
er should be unplugged, opened up and carefully cleaned
with compressed air. Regular maintenance will extend
the life of the unit. Metallic dust build up may lead to
premature board and component failure.
CAUTION: Before opening the unit for any reason,
make sure the unit has been unplugged for at least 10
minutes to allow me for the capacitors to fully dis-
charge. Severe shock and/or death can occur.
Free, unobstructed air ow is crical to cooling and duty
cycle. Do not restrict air ow or movement of air around
the welder. Allow a buer distance of 2  from all sides,
with a minimum distance of 18” clearance. Do not oper-
ate the welder in the immediate vicinity of the weld area
or the discharge of air from the fan will cause turbulence
and will destabilize the arc and cause weld porosity. Do
not mount in areas that are prone to severe shock or vi-
braon. Do not drop the unit. Li and carry the welder by
the handle. Strap the welder down for maximum stability
during use. Do not direct metallic dust or any dirt toward
the machine, parcularly in grinding and welding opera-
ons. Flip down the clear front cover aer compleng
adjustment to protect the control panel.
Duty Cycle. For the PowerPro 256Si, the TIG duty cycle is
rated for 60% at 250 amps. The duty cycle is based o a
10 minute duty cycle rang at 40°C and 35% for Sck/
Plasma at 200/60 Amps, respecvely. This means that the
unit is capable of being operated at the stated amps for 6
out of every 10 minutes without a break in welding to cool
down the unit. (3.5 out of 10 minutes for sck/plasma
operaon.) For TIG a full 4 minute (6.5 minute for sck/
plasma) rest should be given if operang at or near maxi-
mum capacity of the welder for maximum life. The tem-
perature light will come on and the welder will automa-
cally stop welding when an overheat condion has oc-
curred. The fan and display will connue to be operate.
Do not turn the unit o or aempt to reset the unit for at
least 15 minutes aer an overheat condion has occurred
as heat will connue to be generated by and transferred
to the electronics aer welding has ceased. Welding in
humid or hot condions greater than 40°C can negavely
aect duty cycle. Once the overheated condion has
cleared, welding can resume. Do not operate the welder
with the covers removed. The welder duty cycle interrupt
is controlled by temperature sensors and not me sen-
sors, so the duty cycle limiter funcon will dier some-
what from the actual me used based o the operang
condions in the welding environment.
IMPORTANT!
Operang the PowerPro unit in such a way that causes
the unit to repeatedly surpass the duty cycle limit will
signicantly decrease the life-span of the electronics or
cause permanent damage to the welder. However, an
occasional duty cycle interrupt event should not be an
issue if the prescribed cool-down procedures are fol-
lowed. If you nd that the unit is being repeatedly oper-
ated up to and beyond the duty cycle limit of the ma-
chine, it is likely that a larger welder/cuer is needed for
the job. Or, consider separate units with higher duty cy-
cles for dedicated service. Keep in mind many things can
Introduction and Specifications
Section 1

12
aect the stated duty cycle, including temperature, in-
ternal dirt and air ow around the welder.
HF Start. The welder uses High Frequency to start the
arc. A bright blue light as may be seen emanang from
the front panel during starts as the HF acvates and is
not a cause for concern. To prevent wear to the contacts
and possible damage to the circuitry, do not engage the
HF with the foot pedal or torch switch without the inten-
on of starng the arc. Overme or when operated in
dusty/dirty condions, the point gap will need to be
checked and readjusted.
Note: Although point gap adjustment is usually consid-
ered a part of regular maintenance, and is not an item
covered by warranty, the following adjustment process is
intended for experienced users only. If you suspect you
have a a problem with the point gap due to hard starng
of the arc, contact Everlast Tech Support before proceed-
ing with point gap adjustment for proper diagnosis and a
more detailed adjustment procedure.
To open the unit to adjust the point gap:
1) Unplug the welder. Wait 20 minutes to allow ca-
pacitors to discharge to prevent possible shock and
injury. WARNING: If possible, do not touch unre-
lated circuits and components, especially capaci-
tors, during this adjustment process to reduce the
chance of possible shock and injury.
2) Remove the Rear plasc cover by removing screws
with a small screw driver, remembering to remove
screws holding the cover that are located on the
boom. There is no need to remove the front cover.
3) Remove screws in metal cover. Gently spread the
boom of the cover with your ngers about 1” on
either side. Simultaneously slide the metal cover
toward the rear and pull up to remove the cover
from the chassis.
4) Locate the HF board located toward the front of the
unit. This board is mounted under the top metal
pan and the points should be visible from the le
side (side determined by facing the front of the
unit). The points will have two carbon contacts
hanging under the boom of the metal pan. These
will be held in place by two brass nuts that are used
to lock the contacts in place. Check the point gap
with either a feeler gauge by sliding it between the
points. Access may be ght, but try several angles to
get the feeler gauge in between the points. The gap
should be set to anywhere between .030 and .045”,
with .035” being preferred.
5) If adjustment is needed, loosen the locking nuts
slightly so that the end of the brass contact holder
can be rotated with a small at bladed screw driver.
Slowly adjust the points unl slight contact is made
with the feeler gauge. When completed hold the
contact in place with the screw driver while the lock-
nut is reghtened, making sure the contact holder
does not rotate in the process.
6) Recheck the point gap. Make any necessary re-
adjustments. Reassemble the unit.
General usage and design purpose.
Keep in mind, this unit has been designed to be a viable all
-in-one soluon to many portable welding needs, where
portability and space limitaons are chief concerns. This
unit is not intended or designed for producon welding
and fabricaon dues. Rather this unit performs well as a
go-almost-anywhere soluon for on-the-spot general
repairs, prototyping, or one-o work. The unit does have
many useful features, but the portable nature of the unit
requires that the torches and gases be changed over if
swapping between welding and cung operaons. In
environments where there is a constant need to alternate
between welding and cung, this changeover process
may become me consuming so, consider purchasing sep-
arate units for Welding and Plasma cung dues.
NOTE: This manual has been compiled to give an over-
view of operaon and is designed to oer informaon
centered around safe, praccal use of the welder. Weld-
ing has inherent dangers. Ulmately, only the operator of
this welder can ensure that safe operang pracces are
followed, through the exercise of common sense pracces
and training. Do not operate this machine unl you have
thoroughly read through the enre manual, including the
safety secon. If you do not have the skill and/or basic
welding knowledge to safely operate this mul-process
welder and plasma cuer, then do not operate this ma-
chine unl formal training and instrucon is received.
Important: Do not use this machine with any type of
CNC device intended for plasma cung. It is not de-
signed or intended for this type of extended service. Al-
ways purchase a dedicated Plasma cuer for this type of
cung. For CNC plasma cung needs, consider the Ever-
last PowerPlasma line, and for dedicated CNC cung,
consider purchasing one of our PowerPlasma “C” series.
Introduction and Specifications
Section 1
HF Point Gap Location
Locking Nut
Adjustment Screw

13
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: TIG CONNECTIONS
!
W
INPUT
OUTPUT
GAS (Ar)
CONTROL
OPTIONAL WATER COOLER
WATER-COOLED TORCH
GAS CONTROL
GAS
WORK (+)
CONTROL
35 SERIES CONNECTOR
AIR-COOLED TORCH
CONTROL
FOOT PEDAL
NOTE: Torch switch and foot pedal con-
trol cannot be connected at the same time.
TORCH (-)
35 SERIES CONNECTOR
STD. 9/17/26 SERIES TORCH
26 SERIES TORCH WITH TWO LINE DESIGN
COOLANT IN FROM TORCH (TO RED COUPLER)
COOLANT OUT FROM COOOLER (TO BLUE COUPLER)
18/20 SERIES TORCH
35 SERIES CONNECTOR
NOTE: THE ARGON GAS LINE MAY BE TAGGED AS “Ar”. IF NOT, TAKE DRY
COMPRESSED AIR AND GENTLY BLOW THROUGH THE LINES TO DISCOVER
WHICH LINE EXHAUSTS THROUGH THE TORCH OR THROUGH THE RETURN
LINE. NOTE THE DIAGRAM ABOVE AND THE RETURN LINE. ON SOME AFTER
MARKET TORCHES, THE WATER LINES ARE COLOR CODED: BLUE FOR COOL
WATER SUPPLY AND RED FOR HOT WATER RETURN. COOLER FITTINGS SHOULD
BE COLOR CODED BLUE AND RED AS WELL. HOWEVER, DO NOT RELY UPON
COLOR MARKINGS ON TORCHES TO DETERMINE THE FLOW AS THEY MAY VARY
FROM BRAND TO BRAND. WARNING: IF THE TORCH IS NOT CORRECTLY CON-
NECTED, WATER WILL DISCHARGE OUT OF THE TORCH HEAD WHEN THE UNIT
IS CONNECTED TO THE COOLER. THE LINE FROM THE DINSE-STYLE CONNECT-
OR IN A WATER-COOLED TORCH IS ALWAYS THE WATER RETURN LINE.
NEVER OPERATE A WATER COOLED TORCH WITHOUT WATER OR THE TORCH MAY BE DAMAGED!
PILOT

14
QUICK SETUP AND USE GUIDESection 2
GAS CONTROL
AIR
WORK (+)
35 SERIES CONNECTOR
TORCH (-)
35 SERIES CONNECTOR
QUICK SETUP GUIDE: PLASMA CONNECTIONS
iPT 60 TORCH
OPERATING NOTES:
1. For safest operaon, be sure 2T is selected. Do not aempt to use the foot pedal to control the amps.
2. Do not aempt to use the plasma torch in any other mode or test in any other mode with torch connected.
3. Aempt to operate only with sucient air pressure. If pressure is too low, the unit will cease output and the green indi-
cator light next to the pressure gauge will go out to indicate the air pressure is too low to operate safely.
4. See torch manual included in this manual for best pressure sengs and parts idencaon.
5. Do not exceed 90 psi air supply pressure from compressor or failure or leakage of internal line components may result.
6. Do not use with an oiler or with an air line that has had oil run through the line.
7. Adjust torch operaon pressure to 72 psi (5 bar) for best results while post ow is owing.
8. When using lower amperage levels, the nozzles will need to be changed out for ones with a smaller diameter orice.
Everlast is an OEM supplier of the torch but not the torch manufacturer. Smaller diameter nozzles are available through
authorized distributors of the Tecmo/Innotec PT/iPT60 torches or contact Everlast to purchase them direct.
Note: Not all parts or consumables listed may be stocked, sold or serviced individually by Everlast.
STOP: Do not fire the torch continuously without attempting to make a cut. Doing so will keep the
pilot arc engaged and will drastically shorten the life of the consumables. The Pilot arc should only be
used to initiate the arc to start a cut. Always make sure the work clamp is directly connected to a deoxi-
dized, unpainted location on the part being cut. Use a grinder to ensure proper contact is being made between the
work clamp and the metal if necessary. Turn the unit off while changing torches to prevent accidental arc strikes.
WARNING: Plasma cutting uses a high voltage, high temperature arc. Do not touch any part of the con-
sumable while cutting or with the torch energized even if the arc is not present! Always switch the unit off
while changing consumables. Do not disable the yellow safety cover over the torch switch.
CAUTION: Never attempt to use the torch while hooked up to the positive (+) connector or damage may oc-
cur to the consumables and/or the torch. Always verify correct torch polarity before each use. Do not change pro-
cesses while the Plasma torch is connected or severe damage may result to the machine and torch.
PILOT
PILOT ARC CONTROL

15
GAS CONTROL
WORK (-)
TORCH (+)
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS
NOTE:
Most stick (SMAW) electrodes require electrode positive(+) (also referred to as DCEP
or reverse polarity) to weld correctly. Some welding electrodes (rods) may be rated for
use with both electrode positive and electrode negative (-) (also referred to as DCEN
or straight polarity) by the electrode manufacturer. However, most electrodes are gen-
erally welded with an electrode positive connection regardless of the electrode nega-
tive polarity capability. When the electrode (welding rod) is rated for DCEN(-) use and
is used that way, the arc may not penetrate as fully or may seem softer.

16
EVERLAST
Calibrated in Cubic Feet Per Hour (CFH)
CO2
GAS
INLET
1~220 VAC
CLAMP
HF
Fe, Cu
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE
RE-WIRING YOUR WELDER OR ATTEMPTING TO MAKE ANY ELECTRICAL CONNECTION.
NEMA 6-50P
L1,BLACK; HOT
GREEN GROUND (220/240V ) 1 PH
220 V WATER COOLER RECEPTACLE. Do not connect any other device!
SUPPLIED PLUG IS A NEMA 6-50P, THE STANDARD PLUG FOR MOST 1 PHASE 240 V WELDERS IN THE US AND CANADA.
NOTE: Use Ar or Ar/He only. Do not use more than 25% He in the Ar/He gas mix or arc starng diculty may be experienced.
L2,WHITE; HOT
*NOTE: The connecon point for the TIG shielding gas and for the Plasma
air input is shared. This requires swapping the TIG and Air input hoses at
the lower connecon point when making the changeover between pro-
cesses. Do not route the argon line through the air regulator. In lieu of
constantly swapping the gas and air lines back and forth, a manifold sys-
tem may be made from either a T conguraon of two ball valves or a Y
valve( either must be supplied by the customer) to switch between the
plasma air input and TIG shielding gas as needed without disconnecng
and reconnecng the gas and air lines every me the process is changed.
If no switching valve or manifold system is used, then you must manually
change the input supply tubing every me you change over from TIG to
Plasma or vice versa.
SWAP TUBING!*
NOTE: TO PREVENT STRAY HIGH FREQUENCY INTERFERENCE, THIS UNIT PROVIDES AN ADDITIONAL GROUNDING POINT AT THE REAR OF THE UNIT. IT SHOULD BE
DIRECTLY GROUNDED THROUGH A SEPARATE WIRE TO AN OUTSIDE METAL ROD DRIVEN IN THE GROUND. THIS HELPS PREVENT BLEEDBACK OF HF INTO THE
POWER GRID, AND HELPS MUTE HF INTERFERENCE. ADDITIONALLY, ALL SURROUNDING METAL OBJECTS SHOULD BE GROUNDED INCLUDING THE TABLE, PIPES,
WALLS ETC. TO PREVENT ELECTRICAL INTERFERENCE WITH OTHER CIRCUITS. DO NOT COUPLE THIS WIRE TO THE GROUND PROVIDED IN THE ELECTRICAL CIRCUIT.
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING
(US/Canada)
240V

17
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING
(US/Canada)
GAS
INLET
1~220 VAC
1~220 V
NOTE: A SEPARATE AIR DRYER BETWEEN THE AIR COMPRESSOR AND REGULATOR ASSEMBLY MUST BE INSTALLED. IT SHOULD BE INSTALLED AS CLOSE TO THE
WELDER AS PRACTICAL. THIS IS A CUSTOMER SUPPLIED ITEM. THIS WILL REDUCE CUTTING ISSUES SUCH AS SPITTING, POPPING AND RAPID CONSUMABLE WEAR.
THE REGULATOR/FILTER THAT IS INCLUDED WITH THE WELDER IS NOT SUFFICIENT TO REMOVE ALL MOISTURE. IT SERVES ONLY AS A WATER TRAP AND FINE
SEDIMENT FILTER. ANY AIR COMPRESSOR SYSTEM WILL PRODUCE AT LEAST SOME MOISTURE REGARDLESS OF HUMIDITY LEVELS AND ENVIRONMENT. DAILY
DRAINING THE AIR COMPRESSOR SUPPLYING AIR TO THE PLASMA CUTTER IS RECOMMENDED. THE AIR SUPPLIED TO THE PLASMA CUTTER SHOULD BE OF SIMI-
LAR QUALITY USED FOR AUTOMOTIVE PAINTING. DIFFERENT STYLES OF DRYERS ARE AVAILABLE. THE MOST INEXPENSIVE AND COMMONLY AVAILABLE IS THE
REPLACEABLE DESSICANT TYPE USED FOR AUTOMOTIVE PAINTING. DAMAGE DONE TO THE TORCH AND THE PLASMA CUTTER (INCLUDING BUT NOT LIMITED TO:
SHORTING, CORROSION, AND DETERIORATION OF INTERNAL LINES AND COMPONENTS) AS A RESULT OF EXCESS MOISTURE IS NOT COVERED UNDER THE WAR-
RANTY. ADDITIONALLY, A FILTER SHOULD BE INSTALLED IN-LINE AT THE COMPRESSOR TO FILTER ANY EXCESS OIL OR OIL BLOW-BY FROM THE LINE IF NECES-
SARY. DO NOT USE WITH OILING SYSTEMS DESIGNED TO AUTOMATICALLY LUBRICATE AIR TOOLS. OIL WILL DAMAGE THE TORCH AND CONSUMABLES AS WELL.
DAMAGE DONE TO THE CUTTER OR THE TORCH BY OIL IS NOT COVERED UNDER THE WARRANTY. IT IS ADVISABLE TO USE THE PLASMA CUTTER WITH A NEW AIR
HOSE/LINE THAT IS FRESH WITHOUT MOISTURE OR LUBE CONTAMINATION AND DEDICATE IT FOR PLASMA USE ONLY. IF THERE IS AN AIR PRESSURE DROP
GREATER THAN 5-10 PSI FROM THE COMPRESSOR OR AIR FLOW IS SUSPECTED TO BE INSUFFICENT, INCREASE TO A LARGER SIZE EXTERNAL DRYER/FILTER AND AIR
LINE. FAILURE TO USE A DRYER/FILTER IS A LEADING CAUSE OF PLASMA CUTTING AND CONSUMABLE WEAR ISSUES.
Air Dryer/Oil Filter
(Customer Supplied)
Regulator Assembly with built-in water trap
and dirt lter (Included)
1/4” Automove Universal style
quick connector (Included)
Compressor and Air hose with
ngs (Customer Supplied)
CLAMP
1
2
3
4
NOTE: WHEN ASSEMBLING THE AIR REGULATOR NOTICE THE MARKING S THAT ARE
STAMPED ON TOP OF THE REGULATOR HOUSING FOR AIR FLOW DIRECTION. AIR FLOW
DIRECTION WILL BE NOTED AS IN OR OUT OR BE STAMPED WITH A SMALL ARROW FOR
AIR FLOW DIRECTION. THE QUICK CONNECT 1/4” MALE AUTOMOTIVE COUPLING SHOULD
BE MOUNTED ON THE SIDE OF THE REGULATOR WITH “IN” OR THE ARROW POINTING TO
THE MIDDLE OF THE REGULATOR. IF PRESENT, REMOVE BRASS PLUG IN CENTER AND
INSTALL THE PRESSURE GAUGE. USE A LIGHT WRAPPING OF THREAD TAPE TO PREVENT
LEAKING AROUND THE PRESSURE GAUGE THREADS IF NECESSARY. USE THREAD TAPE
SPARINGLY TO PREVENT SOLENOID LEAKS AND CLOGGING.
Use with compressors capable of a minimum of 5.3 cfm
at 90 psi and with at least 25 gallon tank or larger.
Caution: Do not exceed 90 psi supply pressure from air compressor!

18
QUICK SETUP AND USE GUIDESection 2
GAS OUTLET CONTROL
1. PROTECTIVE COVER
3. 2T/PEDAL/ OR 4T SWITCH
4. START/END AMPS
5. UP/DOWN SLOPE TIME
6. PRE/POST FLOW TIME
7. PULSE HIGH/LOW/OFF
8. PULSE FREQUENCY (Hz)
9. PULSE AMPS (RATIO)
10. PULSE TIME ON (BALANCE)
11. POSITIVE (35 SERIES)
12. GAS QUICK CONNECT (9mm) 13. TORCH/PEDAL CONTROL
PILOT ARC (PLASMAONLY)
14. NEGATIVE (35 SERIES)
15. AC/DC SELECTOR
17. AC FREQUENCY (Hz)
16. AC BALANCE (% OF EP)
18. ARC FORCE (DIG)
19. HF/CUT/STICK
20. AMP CONTROL
21. AMP DISPLAY
FRONT PANEL FEATURES AND CONTROLS
23. OK TO CUT
22. AIR PRESSURE
PILOT
2. ON/TEMP/O.C
256Si

19
POWERTIG 256Si FEATURES PARAMETERS PURPOSE
1. Protecve Cover N/A Clear hinged cover protects control panel from damage. Keep the cover closed during
welding operaons and any me during storage.
2. On/Temperature/ Over Current Warning
Indicator
Or Fault
On Indicator: Conrms unit is switched on. Temperature Indicator: Lights up and
interrupts welding output unl the welder has cooled within normal limits. Allow 15
minutes before aempng to reset the welder manually by cycling the power switch.
If the light does not go out aer cycling the power switch, and the cooling period has
been observed, contact Everlast. Over Current Indicator: Lights up when an over/
under voltage or current has been detected. Eliminate the source of the surge and
manually cycle the power switch to reset the welder. If the light remains on aer
cycling the power switch, this may indicate an internal unit fault was created during
the over current event. In this case, contact Everlast. Do not connue to reset the
unit aer two reset aempts.
3. 2T/4T /Remote Sequencer Switch 2T, Pedal/4T Press the buon to select the torch switch funcon mode. Select 2T for simple press-
and-hold operaon of the torch switch or for use with foot pedal. For 2T operaon
with the torch switch: 1) Press and hold the switch to start the arc and weld. Release
the switch to cease welding. Select 4T for advanced use of the sequencer controls on
the panel such as start/end amps, up/down slope. To operate in 4T mode with the
torch switch/remote: 1) Press and release the switch to start arc. 2) The current will
begin to upslope to reach normal welding current. 3) Press and hold switch to begin
downslope. 4) Release switch to terminate the arc. In 4T mode, if the puddle be-
comes too hot, it can be cooled by lightly tapping the switch to begin downslope and
tapping again to restart upslope before end current is reached. Seng a long
downslope helps improve heat control in 4T as the torch switch is cycled between
downslope and upslope before the arc is terminated.
IMPORTANT: To use the foot pedal: Select 2T, then turn start/end amps and up/
down slope to the minimum sengs or the foot pedal will not operate correctly. Do
not use the foot pedal in 4T mode as it will result in the inability to ramp amps up or
down. Use only in 2T for plasma cung.
4. Start/End Amps Control
(Part of 2T/4T sequencer)
DC: 5-250A
AC: 20-250A
Serves as the 2T/4T beginning and nal amp value while using the torch switch.
Allows the arc to start and end at a dierent amp value while using the torch switch.
Typically used to start the weld puddle more quickly/slowly and to ll the puddle at
the end of the weld at a lower amp value to prevent cracking. May be used as a “hot
start” when using the foot pedal to improve starng. If used this way, the amps will
start hoer than the minimum amperage set by the foot pedal. This can cause the arc
to are briey at start. Otherwise, all sequencer sengs should be turned to the
minimum seng (fully le) while the foot pedal is in use or there may be a arc are or
a delay in the arc start or terminaon. The foot pedal is not designed to override
these features. Set these controls the minimum sengs while plasma cung. For
Sck: Start amps is used to set and control the Hot Start intensity.
5. Up/Down Slope Control
(Part of 2T/4T sequencer)
0-10/ 0-25
Seconds
Up-Slope ramps current from the selected start amp value up to the welding amp
value according to the me selected while in 2T/4T mode.
Down-Slope ramps current from the welding amp value down to the end amps value
to ll the weld crater according to the me selected while in 2T/4T mode. Set both
controls to the minimum seng while using the foot pedal or irregular operaon will
occur. Set these controls to the minimum while plasma cung.
6. Pre/Post Flow Control 0-10/ 0-25
Seconds
Pre-Flow selects the amount of shielding gas ow me before arc starts. It is used to
purge and ood the weld area with shielding gas so the arc start is stable and weld is
porosity free. The pre-ow will delay the arc start. Set pre-ow for .5 to 1 second for
best starng. The arc will not start unl the pre-ow me cycle has nished.
The Post-Flow seng dictates the amount of shielding gas ow aer arc ends to
shield the weld to prevent oxidaon and cool the torch. A starng point is to use 1
second post-ow for every 10 amps used. The torch should dwell over the puddle
during this me. For plasma cung, set preow to the minimum seng. Set
poslow to equal 3-5 seconds of post ow for every 10 amps used.
7. Pulse O/Low/High Switch O/ Low/ High Press the touch-pad buon to select the desired pulse mode. Low range oers a ner
range of control over the pulse amps, ranging from .5 Hz to 25 Hz. High range oper-
ates with a more coarse range of control from 25 Hz to 250 Hz. Note: The low range
is highlighted in green numbers.
Section 2
FRONT PANEL FEATURES AND CONTROLS CONTINUED
QUICK SETUP AND USE GUIDE

20
POWERPRO 256Si FEATURES PARAMETERS PURPOSE
8. Pulse Frequency Control .5-250 Hz Represented as Hertz (Hz), the Pulse Frequency adjusts the number of mes per sec-
ond the pulse makes one complete cycle between the welding amp value (Peak) and
the pulse amp value (Background current or base amps). This is also commonly re-
ferred to as Pulses Per Second (PPS). Low pulse frequencies can be used to me the
addion of the ller metal and improve weld appearance. High pulse frequencies are
useful for prevenng excessive puddle wicking on edges and thin seams. Also, it is
useful for overall heat control while welding thicker gauges of metal, which can be
used to help control warping. Higher pulse frequencies are oen used in automated
TIG welding processes. Cauon: Welding at high pulse frequencies increases the deci-
bel level of the arc. Wear hearing protecon while welding at high pulse frequencies.
9. Pulse Amps (Rao) Control 5-95% Sets the value of the Pulse Amps (also referred to as the base or background current)
during the pulse cycle. This is expressed as a percent of Welding Amps. For example,
a welding amp value of 125 amps with a pulse amps seng of 50% will result in a
pulse amp value of 75 amps. The Pulse Amp seng chosen represents the lowest amp
value achieved during the pulse cycle. When the pulse mode is selected, the posion
of the main amp knob determines the Welding Amp (Peak) value.
10. Pulse Time On (Balance) Control 10-90% Sets the duty cycle (balance) of the pulse. This is accomplished by dividing or skewing
the amount of me the pulse spends at the maximum amp value of the pulse against
the Pulse Amp (background current) stage which is the lowest part of the pulse. The
pulse consists of two stages: Welding Amps (Peak) and Pulse amps (Base/Background
current). This is represented by a % of total me during one full pulse cycle that the
pulse spends in the upper (peak) stage. Praccally speaking, the Pulse Time on control
can be used to increase or decrease welding amp (Peak) me relave to the pulse
amp me of the cycle to help manage heat input.
11. Posive Connector 35-70 mm² Locaon of the Posive terminal connecon. DINSE-style connector. (35 Series)
Sck: Electrode holder connecon. TIG: Work clamp connecon. Plasma: Work
clamp connecon.
12. Quick Connect Gas Outlet 9 mm Connects the gas supply to the TIG and air supply to the Plasma torch. To connect:
Push the torch ng into the connector unl the collar slides forward with a click. To
Release: Slide the collar back.
13. Control and Pilot Arc Connector 7 Pin Connect the foot pedal or torch switch to the pinned socket to control the welder.
Only the foot pedal or torch control connector can be plugged in at one me. If the
torch has a torch switch feature, e the loose connector back or leave it hanging while
using the pedal. Loosen the black thumb screw to connect the pilot arc wire to the
plasma cung torch. The thumbscrew is only used with the plasma torch.
14. Negave Connector 35-70 mm² Locaon of the Negave terminal connecon. Dinse-style. (35 series)
Sck: Work clamp connecon. TIG: Torch connecon. Plasma: Torch connecon.
15. AC/DC Selector AC/DC process Select DC output for Steel, Stainless and most metals.
Select AC output for Aluminum and Magnesium alloys.
16. AC Balance Control 10-90% of EP Selects the percentage of Electrode Posive (EP) used during the AC welding mode to
provide the needed cleaning. Represented as a percent of EP, it actually divides the
relave amount of me that the AC cycle spends in Electrode Posive and Electrode
Negave polarity during one full AC cycle. In short, it controls the balance between
cleaning and penetraon to achieve the best balance or desired eect while welding
in the AC mode. When the control knob is rotated le, more Electrode Negave is
present and more penetraon will be achieved. When the control knob is rotated
clockwise, more Electrode Posive is present and more cleaning (cathodic etching)
acon will be achieved. Too much cleaning acon will result in the balling of the tung-
sten p, nodules or spling, requiring the use of a larger tungsten necessary for the
same amperage range to prevent tungsten issues. Too lile cleaning acon will result
in a dull, dirty or sooty looking weld. Remember: This is expressed as a percent of full
Electrode Posive. This unit uses 100% Electrode Posive as the point of reference,
which may be contrary to what the user may nd in some other brands. Using the
welder in excess of 50% EP can quickly vaporize the tungsten and reduce welding
capability when all other variables are the same. For most welds, no more than 45%
cleaning is needed. Ideally, start with 30% EP as a reference point, then adjust it up
or down to achieve best results.
Section 2
FRONT PANEL FEATURES AND CONTROLS CONTINUED
QUICK SETUP AND USE GUIDE