Everlast POWERTIG 185 DV User manual

1
EVERLAST
POWERTIG 185 DV
AC/DC Pulse TIG/STICK WELDER
Operator’s Manual for the PowerTIG 185 DV
Safety, Setup and General Use Guide
Specicaons and Accessories subject to change without noce.
Rev. 2 0 01005-18ETL
everlastwelders.com
329 Littlefield Ave. South San Francisco, CA
1-877-755-9353
CC
GTAW-P
SMAW
IGBT
1
~PHASE
AC/DC
120V
240V

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 Welding Informaon…………..………………..
Overview of Product Features and Care...………….
Expanded Descripon of Features/Purposes...……
Quick Setup Guide, TIG Torch Connecon…………..
Quick Setup Guide, Sck Torch Connecon………...
Front Panel View and Descripons…………….……….
Rear Panel View and Descripons……………………….
Point Gap Adjustment Procedure……………………….
Tungsten Preparaon………………………………………...
TIG High Frequency and Li Starng Procedure...
Sck Starng Methods………………………………………
Expanded View of TIG torch……….…….……….………
7 Pin Connector Pinout………………….…….……………
Troubleshoong………………………………………………..
3
4
5
9
10
11
12
13
17
18
19
22
25
26
27
28
29
30
31
NOTE: Product specicaons, accessories 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 manual is intended to be a general guide
and not intended to be exhausve in its content regarding safety, welding, or the operaon/
maintenance of this unit. Everlast Power Equipment INC. does not guarantee the accuracy, complete-
ness, authority or authencity of the informaon contained within this manual. The owner of this prod-
uct 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 performance/accuracy or for
suitability of applicaon. Furthermore, Everlast Power Equipment INC. does not accept liability for injury
or damages, consequenal or incidental, resulng from the use of this product or resulng from the con-
tent found in this document or accept claims by a third party of such liability. This manual has been com-
piled in an aempt to give a basic overview of operaon and oers praccal informaon centered
around safe use of the welder for some one with a basic level of welding knowledge. Since welding is
inherently dangerous, this manual is no substute for common sense and formal safety training. Ul-
mately, only the operator of this welder can ensure that safe operang pracces are being followed in
and around the work area. Take me to read this manual thoroughly. Pay aenon to safety notaons
and other important notaons made throughout this manual. If you do not possess the skill and training
needed to safely and competently operate this welder, do not use this welder unl professional consul-
taon and instrucon is received.

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__________________________
Everlast US:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353)
Tech Support Extension: 207
Welding Support Extension: 204
FAX: [phone]
Sales Hours: 9am—5pm PST M-F
Tech Support Hours: 9am-5pm EST M-F
Everlast Canada:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
Telephone: [phone] FAX: [phone]
Operating Hours: 9am-4:30pm EST M-F
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
After hours support: 0413 447 492
Everlast Technical Support: [e-mail]

5
Everlast is dedicated to providing you with the best possible equipment and service to meet
the demanding jobs that you have. We want to go beyond merely delivering a sasfactory
product to you. That is the reason we oer free technical support to assist you with your
needs should an occasion occur. In the event that you need a repair, or have an issue, please
call tech support to iniate a warranty claim and an Return Authorizaon number if needed.
With proper use and care your product should deliver years of trouble free service.
Safe operaon and proper maintenance is your responsibility.
We have compiled this operator’s manual to instruct you in basic safety, operaon and
maintenance of your Everlast product to so you may enjoy the best possible operang experi-
ence. Most welding and cung is based upon experience and common sense. As thorough as
this welding manual may be, it is no substute. 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
accidents 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 wrien for the safe use of the machine, but also to assist in obtaining the best perfor-
mance out of your unit. Do not operate this 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 safety device of your unit. 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 further 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) energy. These energy
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 a disturbance is noted. Somemes, improper wire roung
or poor grounding of the surrounding equipment 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 welding and cung can be extremely noisy. Ear protec-
on is necessary to prevent hearing loss. Even prolonged low levels of noise has been known to cre-
ate long term hearing damage. Hearing protecon also further protects against hot sparks and debris
from entering the ear canal and doing harm.
Always wear personal protecve clothing. Flame proof clothing is required at all mes. Sparks and
hot metal can lodge in pockets, hems and cus. Make sure loose clothing is tucked in neatly. Leather
aprons and jackets are recommended. Suitable welding jackets and coats may be purchased made
from re proof material from welding supply stores. Discard any burned or frayed clothing. Keep
clothing away from oil, grease and ammable liquids.
Leather boots or steel toed leather boots with rubber booms are required for adequate foot pro-
tecon. Canvas, polyester and other man made materials oen found in shoes will either burn or
melt. Rubber or other non conducve soles are necessary to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cung or handling met-
al. Simple work gloves for the garden or chore work are not sucient. Gauntlet type welding gloves
are available from your local welding supply companies. Never aempt to weld with out gloves.
Welding with out gloves can result in serious burns and electrical shock. If your hand or body parts
comes into contact with the arc of a plasma cuer or welder, instant and serious burns will occur.
Proper hand protecon is required at all mes when working with welding or cung machines!

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 expo-
sure:
• 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 re-
garding 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 per-
sonnel. 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
PowerTig 185 DV and Accessories
Oponal Foot Pedal Assembly
(22K Ω)
Consumable Kit
(Tungsten not included)
10 ft. Cable with Work Clamp
17 Series Air-Cooled Torch
12 ft. (Style May Vary)
NOTE: Accessory and consumable style and quanes are subject to change without noce.
Argon Regulator (CFH)
Oponal Sck Electrode Holder
and Cable Assembly

10
PowerTIG 185 DV TIG/Stick Welder Specification
Process AC/DC Pulse TIG /Sck Welder (GTAW/SMAW)
Minimum/Maximum Rated Output TIG 120V:
DC: 5A/10.2V-125A/15V
AC: 20A/10.8V-120A/15V
240V:
DC: 5 A/10.2 V-185 A/17.4 V
AC: 20 A/10.8V-185 A/17.4 V
Minimum/Maximum Rated Output Sck 120V:
DC: 5A/20.2V-100A/24V
AC: 20A/20.8V-100A/24V
240V:
DC: 5 A/20.2 V-150 A/26 V
AC: 20 A/20.8 V-150 A/26 V
Start Type HF and Li Start
HF Point Gap .023”-.035” (.030” suggested)
TIG Duty Cycle @ Rated Amps/Volts 110V:
35% @ 125A/15V
60% @ 100A/14V
100% @ 80A/13.2V
220V:
35% @ 185A/17.4V
60% @ 145A/15.8V
100% @ 110A/14.4V
Sck Duty Cycle @ Rated Amps/Volts 110V:
35% @ 100A/24V
60% @ 80A/23.2V
100% @ 60A/22.4V
220V:
35% @ 150A/26V
60% @ 120A/24.8V
100% @ 90A/23.6V
OCV (U0) TIG/Sck 74V/74V
Voltage Input (U1)/Hz 120/240 V (± 10%) 50/60Hz
Maximum Inrush Amps (I1MAX) (For Breaker selecon) 120V: 32.6A/ 240V: 20A
Maximum Operang Amps (I1EFF) (For wire selecon) 120V: 29.6 A/ 240V: 18A
Gas Pre-Flow Time Auto @ .3-.5 Seconds
Gas Post Flow Time Adjustable @ 0-25 Seconds
Down Slope Time 0-10 Seconds
Pulse Preset choice of 1 Hz or 50 Hz
AC Frequency Control 20-250 Hz
AC Balance Control 10-90% of EP
Minimum Water Ingress Protecon IP21S
Eciency >85%
Cooling Method Full Time Fan
Dimensions 12.5” H X 7.25” W X 19” L
Weight (Bare Unit) 30 lbs
Recommended Generator Size/Type* 120V: 4500 Was connuous
240V: 8500 Was connuous
Clean power: <5% THD
* Operang the PowerTIG 185 DV with generators, generator/welders or power sources that are considered to provide “dirty” power may damage the electronic
components. Damaged caused by operaon on dirty power is not covered under warranty. Use only with generators rated by the generator manufacturer as
“clean power”. Clean power is typically dened as less than 5% Total Harmonic Distoron (THD) in the sine wave. Everlast does not keep an approved list of gener-
ators or manufacturers due to frequent changes and model updates by manufacturers. Using a name brand generator does not ensure the quality of power pro-
duced. Always check with the manufacturer to see if the model is rated for clean power. Clean powered generators are considered safe for TV’s, computers and
other electronic items.
Introduction and SpecificationsSection 1

11
PROCESS TORCH POLARITY WORK POLARITY
TIG (GTAW) - +
STICK (SMAW) +-
METAL THICKNESS WELDING AMPS
(A)
TUNGSTEN DIA. Ar FLOW RATE
1-3 mm/.040”-1/8” 40-80 1-2 mm/.040”-3/32” 8-15 CFH /4-7 lpm
3-6 mm/ 1/8”-3/16” 80-185 2-3 mm/ 3/32”-1/8” 15-25 CFH/ 7-14 lpm
METAL THICKNESS ELECTRODE SIZE WELDING AMPS
< 1 mm/.040”1.5 mm/ 1/16” 20-40
2 mm/.080”2 mm/3/32”40-50
3 mm/ 1/8” 3.2 mm/1/8”90-110
4-5 mm/ 3/16” 3.2-4 mm/ 1/8” 90-130
6-10 mm/ 1/4”-3/8” 4–5 mm/ 1/8” 130-150
STICK (SMAW) OPERATION GUIDE
GENERAL POLARITY RECOMMENDATIONS*
*Follow manufacturer of sck electrode for complete polarity recommendaons
TIG (GTAW) OPERATION GUIDE*
*As a general rule, set amperage using 1 amp for every .001” of metal thickness for aluminum.
Less is required for DC.
PROCESS TUNGSTEN TYPE DESIRED POINT SHAPE
AC Red2% Thoriated,
Gold 1.5% or Blue 2% Lanthanated
Orange/Gray2% Ceriated
Do not use Green (Pure) for AC in Invert-
er welders. Arc will not be stable.
Sharpen point 2.5 x’s diameter
Lower amps: Sharp
Higher amps: Slight Truncated
Point should form slight “dome”. Do not ball
tungsten. Re-sharpen when contaminated.
DC Red2% Thoriated, Gold, 1.5% or Blue 2%
Lanthanated
Orange/Gray Ceriated 2%
Do not use Green( Pure)
Sharpen point 2.5 x’s diameter
Low Amps: Sharp
High Amps: Slight Truncaon
Point should remain sharp. Re-sharpen when
it point is dull or contaminated.
TUNGSTEN SELECTION GUIDE
Introduction and SpecificationsSection 1

12
NOTE: This manual has been compiled to give an
overview of operaon and is designed to oer in-
formaon centered around safe, praccal use of
the welder Only YOU, the operator of this welder,
can ensure that safe operang pracces are fol-
lowed, through the exercise of common sense and
training. Do not operate this welder unl you have
fully read the manual.
1.1 Brief overview and basic care:
1. To ensure that your PowerTIG 185 DV is in top
condion when you receive it, carefully inspect the
welder 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 imme-
diately upon receipt of product. Any damage issues
must be resolved right away. The product should be
tested at the same me for proper operaon, even if
it is to be stored for a while. Check to make sure all
passages, connecons and ngs are clear of any
packing material or other obstrucon. Failure to test
and check the unit may result in denial of shipping
damage and warranty claims. Record the welder’s
serial number on the page provided in this manual.
Include purchase date for warranty reference. Serial
numbers are located on the top, side or rear of the
machine, wherever the specicaon scker is locat-
ed (may vary). Be sure to register your unit online
as well. Please, locate, download and read your
current warranty statement found online at
www.everlastgenerators.com, listed under the war-
ranty link.
2. The PowerTIG 185 DV is designed for day-to-day
fabricaon and repair acvies. Overall funcon
and design has been geared toward simple, trouble
free operaon, without sacricing the basic necessi-
es that make a sound weld. As of 2016 model
years, the new digitally-controlled IGBT inverter in-
corporates several new features, which includes a
pulse that oers 2 choices for frequency, 1 and 50
Hz. The pulse amps and pulse balance features are
preset, and non-adjustable. These have been op-
mized by Everlast to work well for most welding situ-
aons where pulse is required. In comparison to
other similar AC/DC TIG welders the PowerTIG 185
oers simple, intuive controls and features. This
new digital generaon of the PowerTIG 185DV fea-
tures a downslope control along with true 2T/4T
capability for improved operaon with the torch
switch. While it is small, it doesn’t compromise per-
formance or features. Other features include a 5
amp DC start, a 20 amp AC start, a fully adjustable
AC frequency control and a fully adjustable AC bal-
ance control. This welder is designed to sasfy the
basic TIG welding demands of hobbyists or pros who
are regularly welding metals 3/16” or under. The
PowerTIG 185 DV is an ideal portable AC/DC jobsite
TIG welder and can be operated on 120V or 240V
single phase power (50-60 Hz). Due to its low input
amp requirement, it can be operated with clean pow-
ered generators or welder/generators that produce
clean power. Consult the generator manufacturer
regarding the generator’s capability of providing
clean power, which is considered to be less than 5%
Total Harmonic Distoron (THD).
3. Be careful to observe the duty cycle of this weld-
er. This welder has been equipped with a safety
interrupt and duty cycle light as a measure of protec-
on, but intenonally and repeatedly running the
unit unl the duty cycle safety is triggered can cause
premature failure of the unit. Operang the welder
too close to air ow obstrucons, in hot or humid
environments or can reduce the duty cycle. A welder
not regularly maintained and that is dirty or dusty on
the inside may also experience cooling issues. The
duty cycle established for the PowerTIG 185DV is as
follows:
TIG: 120V, 35% @ 125A; 240V, 35% @ 185A (40°C)
Sck: 120V, 35% @ 100A; 240V, 35% @ 150A (40°C)
4. The unit should be stored in a dry place for long
term storage. Humid/wet condions can contribute
to the eventual decay of the circuitry in the machine.
For safety reasons, do not use this machine directly
in the rain or with soaked clothing or damp protec-
ve gear. The service rang for this unit is IP21S,
sucient for protecon against vercal dripping wa-
ter, but is not recommended for wet environments.
5. Use the carry strap provided to li and carry the
welder. Don’t suspend the unit by the strap.
6. Make sure that the cooling fan and exhaust vents
are kept free of obstrucon. Before every operang
cycle, inspect the unit for unexpected obstrucons.
From me-to-me, cleaning of the machine with low
pressure air and a small plasc bristle brush will be
necessary to ensure long life. It’s recommended that
the unit be cleaned once a month in dusty condions
or when in daily use. If it is in light use, clean three
Introduction and SpecificationsSection 1

13
to four mes a year otherwise. On these occasions
only, unplug the welder and remove the rear panel
and main cover to access the interior. Do not re-
move the front panel as it is an integral part of the
structure and is not necessary to access or service
most parts of the unit. Concentrate the air pressure
on the aluminum heat sinks, fan and plasc vents.
Remember, keep a minimum of 18 inches distance
from any obstrucon on the front, rear and sides of
the unit during operaon.
NOTE: This unit meets the latest naonal electrical
and safety standards for welders. Contact Everlast
directly if more product informaon is required.
1.2 Expanded Descripons, Purpose and Features.
1. Dual Voltage. This unit is capable of operang on
120V or 240V input voltage. This unit is supplied with
an adapter that will adapt the exisng 240V, NEMA 6
-50 plug down to the standard 120V NEMA 5-15P.
The unit will automacally sense the reducon in
voltage. Note: Output is reduced while operang
on 120V, but should allow up to 125A output while
welding in TIG mode and up to 100A output while
welding in Sck mode. At minimum, a 30 amp slow
trip breaker ( or slow blow fuse) and heavier wiring
will be required to operate on 120V when using the
welder at sustained maximum output. This larger
120V breaker requirement is comparable to other
brands, and is not unique to Everlast. Consult with a
licensed electrician in your area for proper infor-
maon about upgrading your wiring. Wire size re-
quirements are de-rated according to duty cycle, per
the NEC. A licensed electrician can gure this re-
quirement and determine if an upgrade of the wire is
necessary. The unit may be operated on a lesser rat-
ed breaker or fuse, but will cause repeated tripping of
the breaker if operated at maximum output.
2. HF Start/Li Start. High Frequency starng
makes iniang the arc a touch-free process and
helps keep the tungsten contaminaon free in both
DC and AC welding. It is always best to select HF
start to weld aluminum. To start the arc, the torch
should be as close to the metal as praccal without
actually touching, no more than 1/8”. Pressing the
trigger or pedal down will iniate the arc. High Fre-
quency is used only to start the weld. It turns o
aer the arc is started. On older transformer units,
while welding AC, the HF would remain on constantly
and create an “overlay current” because of the slow
switching speeds. Without it, the arc would exn-
guish itself mulple mes per second during the
transion between posive and negave polarity.
Inverters switch fast enough to prevent the arc from
going out, so the HF is not needed during the actual
welding on AC. Li start is primarily designed for DC
use, and requires a brief “touch” and “li” of the
tungsten to the work piece aer the trigger or foot
pedal is pressed to start the arc. Use of this feature
in AC will result in contaminated tungsten. If you
must use this feature in AC, start the arc on a piece
of nearby copper, then transfer the arc over to the
work to start welding.
2. TIG: 5-185 Amps DC, 240V; 5-125 Amps DC, 120V.
Low amp start capability allows welding on the thin-
nest of metals without burn through and blow outs.
Direct Current (DC) allows you to weld most any
metal except Aluminum and Magnesium.
3. TIG: 20-185 Amps AC, 240V; 20-125A AC, 120V. A
decent 20 amp start allows for most light gauge Alu-
minum welding. Due to the rapid heat dissipaon of
Aluminum, 20 amps is sucient for all but the very
thinnest gauges of Aluminum alloy. If less heat is
needed to weld thinner material, raise the Alter-
nang Current (AC) balance level to 40% or greater
to reduce heat on the metal. (Tungsten may begin to
ball.)
4. Automac Pre-Flow. The PowerTig 185 uses an
automac pre-ow that is preset to provide a short
pre-weld ow of gas that remains constant in length.
5. Adjustable Post Flow. Gives greater exibility in
post weld shielding and cooling. A quick tap on the
pedal or switch will engage the post ow and it can
act as pre-ow if longer pre-ow me is needed.
6. Adjustable Down Slope. This funcon allows the
user to gradually automacally decrease the arc
intensity (amperage) and ll the crater at the end of
the weld to help prevent cracking and other defects
caused by terminang the weld abruptly. This fea-
ture is used almost exclusively with the torch switch.
When using the unit with the oponal foot pedal,
turn this seng to “0”, or an undersirable are of
the arc at the end of the weld will be experienced.
7. 2T/4T/Foot Pedal operaon. When using the
torch switch, this feature is use to change how the
Introduction and SpecificationsSection 1

14
torch switch funcons. In 2T mode, the torch switch
serves as a simple on/o buon, requiring you to
press and hold the buon to start and maintain an
arc. When released, the arc will enter the downslope
phase, and automacally terminate the arc. In 4T
mode, to start the arc, quickly press the trigger to
start the arc, and release. The unit will connue to
weld without the trigger being pressed. When you
are ready to terminate the arc, press the trigger again
and hold it. Then, the unit will begin the downslope
cycle to terminate the arc. If the unit has not fully
down-sloped, the torch switch may be cycled again to
return to normal welding. This acon can be used as
an addional heat control feature. Having the opon
of welding without a foot pedal, greatly increases the
versality of the PowerTIG 185 DV. The torch switch
enables greater exibility, especially when welding in
ght areas where a foot pedal is not praccal, such as
in a roll cage or welding overhead. Of course many
prefer to control the amps with the foot pedal be-
cause it oers on-demand control of the amps by
varying the posion of the foot pedal. It is useful for
making slight changes in amps to accommodate vary-
ing issues with t up, heat build up and changes in
torch posion without stopping to make adjustments.
To start the arc, simply press on the pedal with the
foot and hold the pedal down, slowly varying the
pressure and posion of the foot pedal to control the
intensity of the heat. While the foot pedal is in use,
you can limit the maximum amps at the panel and
the pedal will control the amps throughout the range.
Correct use of the foot pedal is accomplished through
experience and pracce. While learning to TIG weld,
pracce with the torch switch control before moving
on to the foot pedal, to be able to focus on basic
techniques and coordinaon. NOTE: When using this
unit with the oponal foot pedal, the 2T seng
must be selected or improper operaon of the foot
pedal will occur. The Foot Pedal is an oponal item
on the PowerTIG 185 DV and must be purchased
separately from Everlast. Several opons exist for
foot pedals (including deluxe models) so be sure to
ask about the dierent pedals available when you
contact your Everlast purchase point.
8. Pulse. Pulse is simply the unit’s ability to oscillate
between two dierent predened amp values at a
certain number of mes in one second (dened as
Hz). The PowerTIG 185 DV features a simplied ver-
sion of pulse by oering two basic pulse frequency
sengs. The rst seng is a pulse frequency of 1 Hz.
This seng allows you to me your addion of ller
metal. This improves bead appearance and also does
control the heat wicking to some extent. The second
seng provides a pulse frequency of 50 Hz. This
seng is designed primarily to control heat and con-
strict the arc cone to provide improved direconal
capability of the arc. In either mode, due to the
characterisc of the pulse to “average” the amp out-
put, you will noce a cooler puddle overall, but you
should sll be able to retain a signicant degree of
penetraon in the area directly under the arc. Other
sengs normally associated with pulse such as
“pulse amps” and “pulse balance” are preset and not
user adjustable, in order to simplify pulse setup while
sll oering a valuable feature. These other pulse
sengs are factory-opmized for most general weld-
ing work. For many situaons, however, pulse may
not be needed, and can be turned to “o”. NOTE:
Due to the way the pulse operates, the unit may
seem to display randomly generated numbers on
the meter. This is because the pulse is operang at
a dierent frequency than the amp meter samples.
As the amp meter displays a reading, it is sampling
the amperage at various points between the rise
and fall of the amps, several mes a second re-
sulng in a dierent reading each me.
9. 35% Duty Cycle. The duty cycle refers to the per-
centage of me out of 10 minutes the PowerTIG 185
DV should be able to operate before overheang.
35% of 10 minutes is 3.5 minutes of operaon. This is
rated at maximum amps. Using less amps will in-
crease duty cycle. 3.5 minutes of welding is longer
than it may seem when actually welding and pro-
vides sucient me at maximum amps to make qual-
ity welds with minimal interrupon. Actual uninter-
rupted welding me may vary somewhat with ambi-
ent temperature, humidity, fan blockage, and poor
power sources. Running extended lengths of me
with short rest cycles will also be an contribung
factor for thermal buildup and liming duty cycles.
Running extreme frequency or balance sengs
(greater than 50%) while welding in AC mode may
reduce duty cycle as well.
10. AC balance and AC Frequency and their useful-
ness in welding aluminum. An AC current
“alternates” rapidly, several mes a second, be-
tween posive (+) and negave (-) poles. This alter-
nang acon provides both Posive (Reverse) and
Negave (straight) polarity which result in a more
violent arc. When the polarity (or ow of the elec-
trons) changes to a posive polarity, during welding,
Introduction and SpecificationsSection 1

15
the oxides that are formed on the metal break up
into small akes or pieces. This acon is needed to be
able to weld aluminum and magnesium. Both metals
form an oxide layer that is dicult to deal with when
welding. This oxide layer isn’t always apparent, and
may even appear to “shine.” However, unless these
metals are freshly cut, milled, or brushed, oxidaon
will always exist to an extent, and it will re-form rap-
idly. The oxide layer is tough and is excellent at pre-
venng further corrosion. However, it must be re-
moved to be successful at TIG welding aluminum and
magnesium. The crust-like oxide layer formed on the
aluminum and magnesium melts at a much higher
temperature than the underlying metal. By the me
the oxide layer is ready to begin melng, the underly-
ing metal is already molten. This is one of the rea-
sons that inexperienced users will oen see a large
“blow out” of metal when welding aluminum. When
beginning to weld Aluminum, it is always helpful to
pre-clean the metal and then grind or use a stainless
steel brush to remove as much of the oxidaon as
possible. This alone will not be enough. The cleaning
poron of the AC will provide the rest of what is
needed to remove the oxidaon. With an inverter,
the AC balance can be skewed to favor more me
spent in one part of the AC cycle than the other. In
reality, you may sll obtain good cleaning with a
seng as low as 20% electrode posive or even low-
er if condions are right. However, a good starng
point is around 35%. You can then ne tune the AC
balance to provide the amount of cleaning needed.
See the diagrams below.
A seng of 30-35% usually allows plenty of
“penetraon,” with most of the heat going directly
into the metal and not into the tungsten p. When
more cleaning is used, usually over a 40% seng,
the heat will eventually ball or consume the tung-
sten, which in turn will destabilize the arc. A higher
AC balance seng will also require more amps to
weld the same material than it would with a lower
AC balance seng. In fact, to extend the range of
your welder a lile, you can thoroughly pre-clean
your aluminum and use a much lower balance
seng. Combined with a good gas lens cup setup,
you may be able to weld with a seng that is as low
as 10% posive polarity if all other condions are
perfect. If a higher balance seng is needed for
cleaning or salvaging heavily oxidized material, use a
larger tungsten to prevent consumpon of the tung-
sten. AC Frequency is simply the number of mes per
second that the polarity oscillates from negave to
posive and back to the start of the negave. 1 Hz
represents one complete cycle of the polarity. The
Power TIG 185 DV can be adjusted between 20 Hz
and 250Hz. Older transformer welders were typical-
ly xed at 60 Hz, the standard electrical input from
the power line. Basically, whatever hertz were put
into it, that’s what came out. But inverters are able
to greatly modify this operang frequency and the
result allows you to adjust the arc performance while
welding in AC mode. The greater the frequency, the
more narrow, and dened the arc becomes. Oper-
ang at low frequencies, the arc becomes more
broad, lazy, and somemes will even wander about.
The higher frequency, well dened arc can be used
to pinpoint the heat. The result, though is that more
amps will be required to weld. Using a lower fre-
quency will extend the range of the welder some-
what, as to how thick it will weld. But using a fre-
quency lower than 50-60Hz can result in arc instabil-
ity. The arc will seem rough and unrened at low
EN 35%
EP 65%
50%
EN 65%
EP 35%
50%
Extreme cleaning seng. 65% EP:
Shallow penetraon, balling tungsten, excessive cleaning area.
Good penetraon seng 35% EP:
Deeper penetraon, sharper tungsten, narrow cleaning area.
EN 50%
EP 50%
50%
Standard transformer welder balance: 50% EN/EP
Balling tungsten, light penetraon, wide cleaning area.
1 Hz (one full AC cycle)
EXAMPLE: AC EP (+) BALANCE
30% EP
Narrow bead/etching/sharp tungsten
Cleaning/Frosted Area of Aluminum
50% EP
Wider bead/etching/rounded tungsten
65% EP
Wide bead/etching/balled tungsten
Introduction and SpecificationsSection 1

16
sengs. At the lowest sengs, the arc may seem to
uer. Although it is possible to lower the frequency
to 20 Hz, doing so is not likely to provide a lot of add-
ed benet.
11. AC vs. DC Welding. AC welding is useful for Alu-
minum and Magnesium welding. Situaons requiring
the welding of predominately magnesium alloys are
fairly uncommon. Aluminum is much more common,
though there are a lot of Aluminum alloys that in-
clude a signicant amount of magnesium as an alloy-
ing element. Note that not all types of aluminum are
considered weldable, parcularly hardened types.
Cast aluminum oen presents diculty in welding
due to inclusions and impuries in the base metal
due to the casng process. For the balance of TIG
welding needs, use DC polarity. Stainless (Inox),
chrome moly, copper, tanium, mild steel and many
carbon steels can be welded with DC. But again, that
does not mean that every type of steel, stainless
steel, or other metals, such as cast iron is considered
weldable by normal means or without special equip-
ment, Always try to gure out the type of metal you
are using before you start to save yourself a lot of
frustraon. New stock is usually labeled. But in
many repair situaons, the only way to determine
this and the weldability of the metal is if you call the
manufacturer of the product you are repairing. If you
are welding or praccing on a mystery metal, take
this into consideraon if you experience diculty
welding it.
200 Hz 60 Hz
Introduction and SpecificationsSection 1

17
QUICK SETUP GUIDE
(US/Canada)
CONTROL
GAS
NOTE: FOOT PEDAL IS OPTIONAL.
FOOT PEDAL AND TORCH SWITCH CONNECT AT “CONTROL.”
PEDAL AND SWITCH CANNOT BE CONNECTED AT THE SAME TIME.
TORCH (-)
FROM SWITCH
FROM PEDAL
WORK (+)
WORK CLAMP
POLARITY:
TIG MODE: TORCH NEGATIVE (-), WORK POSITIVE(+)
FOOT PEDAL
TIG TORCH WITH SWITCH
Introduction and SpecificationsSection 1

18
Optional Stick Electrode Holder Polarity Configuration
(US/Canada)
CONTROL
GAS
POLARITY:
STICK MODE: TORCH POSITIVE (+), WORK NEGATIVE(-)
NOTE: Unit is not recommended for use with E6010. However, E 6011 may be used.
WORK CLAMP
TORCH/ELECTRODE HOLDER
WORK (-)
TORCH (+)
Introduction and SpecificationsSection 1

19
Front Panel View
CONTROL
GAS
10. GAS QUICK CONNECT (9 mm “B”)
11. POSITIVE (+) 35 SERIES CONNECTOR
12. TORCH/ FOOT PEDAL CONTROL
13. NEGATIVE (-) 35 SERIES CONNECTOR
4. POST FLOW
1. AMP DISPLAY
15. AC FREQUENCY
2. ON/ TEMP/ OVER CURRENT
14. AC BALANCE5. DOWNSLOPE
6. PULSE
3. AMP CONTROL
7. REMOTE
8. AC/DC
9. MODE
Know Your Machine Section 2

20
2.1 Front Panel Features. The Everlast PowerTig 185
(DV) has a simple panel layout with basic but funconal
controls and features.
1. Digital Display. The display posts the maximum
welding amps selected. Aer the arc is started with
the torch switch or the foot pedal, the display func-
on changes to read actual amp output while weld-
ing. The display will show the nal welding amper-
age for a few seconds aer the arc stops before
reverng to the stac amp display. In pulse mode,
variability in the readout will be noced. This is nor-
mal due to the sampling rate of the display. Note:
Display accuracy is ± 3%.
2. On/Temperature/Over Current LED Indicator. The
On LED should come on anyme the unit is switched
on. If not check wiring and receptacle. If this does
not resolve the problem contact Everlast technical
support. The On LED may remain lit for a few sec-
onds aer powering o while the capacitors are dis-
charging. This is normal and not a defect. The Tem-
perature LED (indicated by the thermometer sym-
bol) will illuminate when the temperature sensor
indicates that safe operang temperatures have
been exceeded. Ambient air temperature over 40°
C, air ow restricons, and dirty internal compo-
nents are all factors that may reduce the duty cycle
of the welder. Also, while operang the welder at
high AC frequency and AC balance sengs, the duty
cycle of the unit may be less than normal. If the
unit’s thermally controlled duty cycle safety feature
is engaged, do not turn the machine o. Allow the
machine to connue to run and cool for 15 minutes
before reseng the machine by cycling the power
switch o and back on. Do not aempt to shorten
the cooling cycle by prematurely cycling the switch.
The machine can be forced into reseng once the
temperature at the sensor is below the trip thresh-
old, but before the full 15 minutes expires. However,
it may not have been able to adequately dissipate
some of the residual heat transferred to the circuits
and can cause long term damage. When the Over
Current LED ( indicated by a triangular shaped sym-
bol) is triggered, welding output will cease. Check
for excessive extension length, undersized cables, or
improper wiring. Overly warm extension cords or
power input lines are a symptom of undersized wir-
ing, parcularly while operang on 120V.
Aempng to operate the welder on a generator
not cered by the generator manufacturer as
“clean power” can also trigger this condion. If no
known fault exists, contact Everlast if cycling the
welder o and on does not clear the condion.
3. AMP Control. Sets the welding Amp value. While
seng amps in AC mode, the minimum value that
the amps can be set at is 20 Amps. In DC mode,
minimum set amps will be 5 Amps. (all minimum
and maximum sengs of the unit are subject to a
leeway of ±3A)
4. Post Flow Control. Adjusts the gas ow me aer
the welding arc is stopped. Use it to provide extra
shielding while the weld cools. It is also important
for torch head cooling. Use one second for every
10-15 amps as a general rule. Note: The post ow
feature can also be used to add extra pre-ow
me. To do so, quickly tap the pedal or torch
switch without striking an arc
5. Downslope. When using 2T or 4T with the torch
switch, this controls the ramp down me of the
arc. The downslope allows the user to gradually
taper o the heat while lling the end of the weld
to prevent a crater which can lead to the weld
cracking. This is the nal stage before the weld
terminates.
6. Pulse. The pulse feature of this machine oers
two basic sengs. The pulse amps and pulse bal-
ance are preset at the factory and are not adjusta-
ble items. Only the frequency may be changed.
The welder oers a 1 Hz and 50Hz frequency
seng. The 1 Hz seng is designed to assist in
bead appearance by oering enough gap between
the high stage and low stage of the pulse to stack
your bead. To an extent, the 1 Hz seng does
oer some heat control. However, the 50 Hz
seng is designed to help constrict the arc and
improve overall heat control. The 50 Hz seng
will also help directability of the arc. Bead appear-
ance may have marginal improvement due to the
change in the bead prole. Note: The pulse will
average the heat according to the frequency used,
so overall maximum welding thickness may be
reduced while the pulse is on. While in Pulse
mode, the display may seem to generate random
numbers. This is normal and not a defect.
7. Remote 2T/Pedal/4T Switch. This switch is used
to switch the machine from 2T to 4T mode. To
use this machine with the foot pedal, make sure
the 2T/Pedal LED is lit or the machine will not op-
erate properly with the foot pedal. 2T oers a
simple press and hold operaon to weld, while the
4T oers stepped control using the torch switch to
toggle between stages of the welding cycle. Aer
the weld is started, the torch switch does not
need to be held down to weld. When ready to
Know Your Machine Section 2