Everlast PowerTig 200 DX User manual

Rev. 4 0 00201-13
EVERLAST
POWERTIG 200DX
Operator’s Manual for the PowerTig 200DX
Safety, Setup and General Use Guide
CC
GTAW-P
SMAW
IGBT
1
~
PHASE
AC/DC
EVERLAST
everlastwelders.com
1-877-755-9353
Specicaons and Accessories subject to change without noce.
329 Lileeld Ave. South San Francisco, CA 94080 USA

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, 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..
Expanded View of TIG torch……….…….……….………
7 Pin Connector Pin-out…………..…….…….……………
Troubleshoong………………………………………………..
3
4
5
9
10
11
11
12
13
14
15
18
20
24
25
26
27
28
29
30
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 performance/accuracy or for suitability of
applicaon. Furthermore, Everlast Power Equipment INC. does not accept liability for injury or damages, conse-
quenal or incidental, resulng from the use of this product or resulng from the content found in this docu-
ment or accept claims by a third party of such liability.

3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast. We appreciate you
as a customer and hope that you will enjoy years of use from your welder.
Please go directly to the Everlast website to register your unit and receive your warranty infor-
maon. Your unit registraon is important should any informaon such as product updates or re-
calls be issued. It is also important so that we may track your sasfacon with Everlast products
and services. If you are unable to register by website, contact Everlast directly through the sales
department through the main customer service number in your country. Your unit will be regis-
tered and warranty will be issued and in full eect. Keep all informaon regarding your purchase.
In the event of a problem you must contact technical support before your welder can be a candi-
date for warranty service and returned.
Please review the current online warranty statement and informaon found on the web-
site of the Everlast division located in or nearest to your country. Print it for your records
and become familiar of its terms and condions.
Everlast oers full technical support, in several dierent forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interacon.
Technical advisors are acve on the forum daily. We also divide our support into two divisions:
technical and welding performance. Should you have an issue or queson concerning your unit,
please contact performance/technical support available through the main company headquarters
available in your country. For best service call the appropriate support line and follow up with an
email, parcularly during o hours, or in the event you cannot reach a live person. In the event
you do not reach a live person, parcularly during heavy call volume mes, holidays, and o hours,
leave a message and your call will normally be returned within 24 hours. Also,for quick answers to
your basic quesons, join the company owned forum available through the website. You’ll nd
knowledgeable, helpful people and sta available to answer your quesons, and perhaps nd a
topic that already addresses your queson at hp://www.everlastgenerators.com/forums/.
Should you need to call or write, always know your model name, purchase date and welder manu-
facturing inspecon date. This will assure the quick and accurate customer service. REMEMBER:
Be as specic and informed as possible. Technical and performance advisors rely upon you to
carefully describe the condions and circumstances of your problem or queson. Take notes of
any issues as best you can. You may be asked many quesons by the advisors to clarify prob-
lems or issues that may seem very basic. However, diagnosis procedures MUST be followed to
begin the warranty process. Advisors can’t assume anything, even with experienced users, and
must cover all aspects to properly diagnose the problem. Depending upon your issue, it is advisa-
ble to have basic tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive
test meter with volt/ohm funcons before you call.
Let us know how we may be of service to you should you have any quesons.
Sincerely,
Everlast Customer Service

4
Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________
EVERLAST
Contact Information
Everlast US:
Everlast consumer sasfacon email: [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: [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 Austrailia:
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: [email protected]

5
Everlast is dedicated to providing you with the best possible equipment and
service to meet the demanding jobs that you have. We want to go beyond deliv-
ering a satisfactory product to you. That is the reason we offer technical sup-
port to assist you with your needs should an occasion occur. With proper use
and care your product should deliver years of trouble free service.
Safe operation and proper maintenance is your responsibility.
We have compiled this operator’s manual, to instruct you in basic safety, oper-
ation and maintenance of your Everlast product to give you the best possible
experience. Much of welding and cutting is based upon experience and com-
mon sense. As thorough as this welding manual may be, it is no substitute for
either. Exercise extreme caution and care in all activities related to welding or
cutting. Your safety, health and even life depends upon it. While accidents are
never planned, preventing an accident requires careful planning.
Please carefully read this manual before you operate your Everlast unit. This
manual is not only for the use of the machine, but to assist in obtaining the
best performance out of your unit. Do not operate the unit until you have read
this manual and you are thoroughly familiar with the safe operation of the unit.
If you feel you need more information please contact Everlast Support.
The warranty does not cover improper use, maintenance or consumables. Do
not attempt to alter or defeat any piece or part of your unit, particularly any
safety device. Keep all shields and covers in place during unit operation should
an unlikely failure of internal components result in the possible presence of
sparks and explosions. If a failure occurs, discontinue further use until mal-
functioning parts or accessories have been repaired or replaced by qualified
personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves.
These waves may disturb sensitive electronic equipment such as televisions,
radios, computers, cell phones, and related equipment. High Frequency may
also interfere with fluorescent lights. Consult with a licensed electrician if dis-
turbance is noted. Sometimes, improper wire routing or poor shielding may be
the cause.
HF can interfere with pacemakers. See EMF warnings in following safety sec-
tion for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.
Safety Precautions

6
SAFETY PRECAUTIONS
These safety precautions are for protection of safety and health. Failure to
follow these guidelines may result in serious injury or death. Be careful to
read and follow all cautions and warnings. Protect yourself and others.
Welding and cutting processes produce high levels of ultraviolet (UV) radiation that
can cause severe skin burn and damage. There are other potential hazards involved
with welding such as severe burns and respiratory related illnesses. Therefore ob-
serve the following to minimize potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even
under welding helmets to protect your eyes from flying sparks and debris. When chip-
ping slag or grinding, goggles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct
shade of filter installed. Always use a welding helmet in good condition. Discard any
broken or cracked filters or helmets. Using broken or cracked filters or helmets can
cause severe eye injury and burn. Filter shades of no less than shade 5 for cutting
and no less than shade 9 for welding are highly recommended. Shades greater than 9
may be required for high amperage welds. Keep filter lenses clean and clear for maxi-
mum visibility. It is also advisable to consult with your eye doctor should you wear
contacts for corrective vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless
fully protected by a filter screen, protective curtains or equivalent protective equip-
ment. If no protection is available, exclude them from the work area. Even brief expo-
sure to the rays from the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy.
Ear protection is necessary to prevent hearing loss. Even prolonged low levels of
noise has been known to create long term hearing damage. Hearing protection also
further protects against hot sparks and debris from entering the ear canal and doing
harm.
Always wear personal protective clothing. Flame proof clothing is required at all
times. Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose
clothing is tucked in neatly. Leather aprons and jackets are recommended. Suitable
welding jackets and coats may be purchased made from fire proof material from
welding supply stores. Discard any burned or frayed clothing. Keep clothing away
from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for ade-
quate foot protection. Canvas, polyester and other man made materials often found
in shoes will either burn or melt. Rubber or other non conductive soles are necessary
to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient.
Gauntlet type welding gloves are available from your local welding supply companies.
Never attempt to weld with out gloves. Welding with out gloves can result in serious
burns and electrical shock. If your hand or body parts comes into contact with the
arc of a plasma cutter or welder, instant and serious burns will occur. Proper hand
protection is required at all times when working with welding or cutting machines!

7
SAFETY PRECAUTIONS
WARNING! Persons with pacemakers should not weld, cut or be in the welding area
until they consult with their physician. Some pacemakers are sensitive to EMF radiation
and could severely malfunction while welding or while being in the vicinity of someone
welding. Serious injury or death may occur!
Welding and plasma cutting processes generate electro-magnetic fields and radiation.
While the effects of EMF radiation are not known, it is suspected that there may be
some harm from long term exposure to electromagnetic fields. Therefore, certain pre-
cautions should be taken to minimize exposure:
 Lay welding leads and lines neatly away from the body.
 Never coil cables around the body.
 Secure cables with tape if necessary to keep from the body.
 Keep all cables and leads on the same side the body.
 Never stand between cables or leads.
 Keep as far away from the power source (welder) as possible while welding.
 Never stand between the ground clamp and the torch.
 Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible
need for respiratory equipment while welding or cutting. Always weld with adequate
ventilation. Never weld in closed rooms or confined spaces. Fumes and gases re-
leased while welding or cutting may be poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
 Stop immediately and relocate work if necessary until adequate ventilation is ob-
tained.
 Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, cop-
per, cadmium, lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product when used for welding or cutting produces fumes and gas-
es which contains chemicals known to the State of California to cause birth defects
and in some cases cancer. (California Safety and Health Code §25249.5 et seq .)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas.
Release of Phosgene gas can be deadly. Consider all chemicals to have potential
deadly results if welded on or near metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain
regulations regarding high pressure cylinders can be obtained from OSHA or local
regulatory agency. Consult also with your welding supply company in your area for
further recommendations. The regulatory changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and
closed. Store chained so that overturn is not likely. Transporting cylinders incorrectly
can lead to an explosion. Do not attempt to adapt regulators to fit cylinders. Do not
use faulty regulators. Do not allow cylinders to come into contact with work piece or
work. Do not weld or strike arcs on cylinders. Keep cylinders away from direct heat,
flame and sparks.

8
SAFETY PRECAUTIONS
continued
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly
grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not
stand, lean or rest on ground clamp. Do not stand in water or damp areas while weld-
ing or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain
or in extremely humid conditions. Use dry rubber soled shoes and dry gloves when
welding or cutting to insulate against electrical shock. Turn machine on or off only
with gloved hand. Keep all parts of the body insulated from work, and work tables.
Keep away from direct contact with skin against work. If tight or close quarters ne-
cessitates standing or resting on work piece, insulate with dry boards and rubber
mats designed to insulate the body from direct contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their location and
make sure all personnel in area are advised of their location. Taping or securing ca-
bles with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodi-
cally check work area for smoldering embers or smoke. It is a good idea to have
someone help watch for possible fires while you are welding. Sparks and hot metal
may travel a long distance. They may go into cracks in walls and floors and start a fire
that would not be immediately visible. Here are some things you can do to reduce the
possibility of fire or explosion:
 Keep all combustible materials including rags and spare clothing away from area.
 Keep all flammable fuels and liquids stored separately from work area.
 Visually inspect work area when job is completed for the slightest traces of smoke
or embers.
 If welding or cutting outside, make sure you are in a cleared off area, free from
dry tender and debris that might start a forest or grass fire.
 Do not weld on tanks, drums or barrels that are closed, pressurized or anything
that held flammable liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling
hot pieces of metal. Remember to place hot metal on fire-proof surfaces after han-
dling. Serious burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Prop-
er maintenance is your responsibility. Make sure all equipment is properly maintained
and serviced by qualified personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding
parts. Touching uncovered parts inside machine can cause discharge of high
amounts of electricity. Do not allow employees to operate poorly serviced equipment.
Always check condition of equipment thoroughly before start up. Disconnect unit
from power source before any service attempt is made and for long term storage or
electrical storms.
Further information can be obtained from The American Welding Society (AWS) that
relates directly to safe welding and plasma cutting. Additionally, your local welding
supply company may have additional pamphlets available concerning their products.
Do not operate machinery until your are comfortable with proper operation and are
able to assume inherent risks of cutting or welding.

9
Introduction and SpecificationsSection 1
Water-cooled, 26 Series Torch Assembly
12 Ft (3 m) with built in 2T/4T switch
(Style may vary)
47K Ω
Foot Pedal Assembly
Consumable Kit
(Does not include Tungsten)
Work Clamp
Argon Regulator
NOTE: Accessory and consumable style and quanes are subject to change without noce.
Stick Electrode Holder
PowerTIG 200DX

10
PowerTIG 200 DX TIG/Sck Welder
Standard 240 V /Oponal Dual 120 V /240 V
Specicaon
Process AC/DC GTAW-P/DC SMAW
Inverter Type Analog, IGBT Construcon
Minimum/Maximum Rated Output TIG 240 V: DC: 5 A/10.2 V - 200 A/18V AC: 20 A/10.8 V - 200 A/18 V
(Opt. 120 V: DC : 5A/10.2 - 125 A/15.0V AC : 20 A /10.8 - 125A/15.0V)
Minimum/Maximum Rated Output Sck 240 V: DC: 5 A/20.2 V - 160 A /26.4 V AC: 20 A/ 10.8 V-160 A/26.4 V
(Opt. 120 V: DC: 5 A /20.2 V—100 A/24 V AC: 20 A/20.8 V - 100 A/ 24 V)
Start Type HF and Li Start
HF Point Gap .030”-.045” (.035” suggested)
TIG Duty Cycle @ Rated Amps/Volts 240 V: 60% @ 200 A/ 18 V; 100% @ 160 A/ 16.4 V
(Opt. 120 V: 60% @ 125 A/15 V; 100% @ 100 A 14 V)
Sck Duty Cycle @ Rated Amps/Volts 240 V: 35% @ 160 A/ 26.4 V; 60% @ 130 A/ 25.2 V; 100% @ 100 A/ 24.0 V
120 V: 35% @ 100 A/24 V; 60% @ 80 A/23.2 V; 100% @ 60 A/22.4 V
OCV (U0)70 V
Voltage Input (U1)Standard : 220/ 240 V; 50/60 Hz 1 Phase
Oponal Dual Voltage: 120/240V 50/60 Hz 1 Phase
Maximum Inrush Amps (I1MAX)34 A @ 220 V; 32.1 A @ 230 V; 30.8 A @ 240 V
31 A @ 110 V (120 V nominal)
Maximum Operang Amps (Rated Eecve) (I1EFF)28 A @ 220 V; 27A @ 230 V; 26 A @ 240 V
25 A @ 110V (120 V nominal)
Gas Pre-Flow /Post Flow Time 0-10 Seconds/ 0-25 Seconds
Down Slope 0-10 Seconds
AC Frequency Control 20-250 Hz
AC Balance Control 30-70% of Electrode Posive (EP)
Pulse Frequency Hz (Pulses Per Second) .5-150 Hz
Pulse Amps (Rao) 5-95%
Pulse Time On (Balance) 10-90%
Sck Arc Force Control 0-100%
Sck Surge Amp Control (Available late 2013) 0-100%
Minimum Water Ingress Protecon Standard IP21S
Eciency >85%
Cooling Method Full Time High Velocity Fan with Tunnel design
Dimensions (rounded) 18” H X 10” W X 25” L
Weight (Bare Unit) 70 lbs
Introduction and SpecificationsSection 1
Dual Voltage Model Oponal. Standard model is 240 V only. Output Specicaons for both models are same while operang on 240V.

11
General overview: The new, redesigned 200 DX Pulse-
TIG/Sck welder from Everlast is the latest in a new gen-
eraon of analog style GTAW-P /SMAW inverter welders.
With a Fairchild/Siemens IGBT design, the inverter cycles
at a frequency of up to 100 kHz, to deliver a stable,
smooth arc. Several key design elements give the
PowerTig 200 DX a compeve edge:
A. Siemens IGBT modules improve reliability while
make servicing a unit quicker, and more cost e-
cient. Most parts are standard components reduc-
ing the cost of long term repair.
B. Full bridge design features so switching technology
which further extends IGBT component life and ex-
tends its capabilies.
C. Improved HF point design oers beer and more
stable arc starts, even at lower amperages.
D. Features automac over-voltage, over current and
duty cycle protecon (over-heat).
E. The square wave design creates a stable arc in AC,
with a fast melng puddle and good wet in.
F. Arc force control and built in hot start helps improve
the SMAW process performance. Surge amp control
(available late 2013) improves arc starts.
G. New, improved design oers more intuive adjust-
ments , and provides beer panel protecon.
General Use and Care: The welder is designed for use in
many industrial environments such as ship yards, fabrica-
on shops and pipelines. However, care should be taken
to keep the unit out of direct contact with water spray.
The unit is rated IP21S, which rates it for light contact
with dripping water. It is a good idea to remove the
welder from the vicinity of any water or moisture source
to reduce the possibility of electrocuon or shock. Never
operate in standing water.
Every 1-2 months, depending upon use, the welder
should be unplugged, opened up and carefully cleaned
with compressed air. Regular maintenance will extend
the life of the unit.
IMPORTANT: 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.
Do not restrict air ow or movement of air around the
welder. Allow a buer distance of 2 . from all sides if
possible, with a minimum distance of at least 18” clear-
ance. Do not operate the welder immediately in the weld
area or the force of the fan will cause welding issues such
as unstable arc, or porosity.
Do not mount in areas that are prone to severe shock or
vibraon. Li and carry the welder by the handle.
Do not direct metallic dust or any dirt intenonally toward
the machine, parcularly in grinding and welding opera-
ons. Make sure the panel is protected from damage
during welding and cung operaons by ipping down
the clear protecve cover.
Duty Cycle. The duty cycle has been determined for the
200 DX. For the 200 DX, the duty cycle is rated for 60% at
200 amps. The duty cycle is based o a 10 minute duty
cycle rang at 40° C. This means that the unit is capable of
being operated at the stated amps for 6 out of every 10
minutes without a break to cool down the unit. This does
NOT mean that the unit can work 60% of any greater
length of me. A full 4 minute rest should be given to the
welder for maximum life. The temperature light will come
on and the welder will automacally stop welding when
an overheat condion has occurred. If the light is on but
the unit does not stop welding, this does not necessarily
mean that you have not exceeded duty cycle. Heat will
connue to be generated by and transferred to the elec-
tronics aer welding has ceased. Welding in humid, or hot
condions can aect duty cycle as well. Do not shut
down an overheated welder unl it has safely cooled.
Once the overheated condion has cleared, welding can
resume. Do not operate the welder with the covers re-
moved.
HF Start. The welder uses High Frequency to start the
arc. HF is generated by a point gap system similar to an
older automove point/coil system. A slight buzz, or hiss
may be heard immediately upon start as the HF energiz-
es. A bright blue light may be emied from the front or
side panel as the spark energizes. This is normal and safe
as long as the covers are in place.
This manual has been compiled to give an overview of
operaon and is designed to oer informaon centered
around safe, praccal use of the welder. Welding is in-
herently dangerous. Only YOU, the operator of this weld-
er, 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 fully
read the manual, including the safety secon. If you think
that you do not have the skill or knowledge to safely oper-
ate this welder, do not use this welder unl formal train-
ing is received.
Introduction and Specifications
Section 1
Basic Inverter design

12
!
WA
INPUT
OUTPUT
GAS (Ar)
CONTROL
WATER COOLER
WATER-COOLED TORCH
GAS CONTROL
GAS (Ar)
WORK (+)
CONTROL
35 SERIES CONNECTOR
AIR-COOLED TORCH
CONTROL
FOOT PEDAL
NOTE: Torch switch and foot pedal
control cannot be used at the same.
THE ARGON GAS LINE SHOULD 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 RE-
TURN LINE. ON SOME 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.
TORCH (-)
35 SERIES CONNECTOR
9/17 SERIES TORCH
26 SERIES TORCH
COOLANT IN (RED)
COOLANT OUT (BLUE)
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: TIG CONNECTIONS
18/20 SERIES TORCH
35 SERIES CONNECTOR
NOTE: Dual Voltage Model connecons are
the same in funcon but the gas connector
locaon is on the far le and the work clamp.

13
GAS CONTROL
WORK (-)
TORCH (+)
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS

14
EVERLAST
NOTE: LITERS/MINUTE (lpm)
NOTE: Use Ar or Ar/He only. Do not use more than 25% He in the Ar/He gas mix.
CO2
NOTE: TO PREVENT STRAY HIGH FREQUENCY INTERFERENCE, THIS UNIT PROVIDES AN ADDI-
TIONAL 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. ADDI-
TIONALLY, 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
GAS
INLET
1~220 VAC
1~220 V
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE
RE-WIRING YOUR WELDER OR ATTEMPTING TO MAKE ANY ELECTRICAL CONNECTION.
CLAMP
HF
Fe, Cu
NEMA 6-50P
L2,WHITE; HOT (240V 1or 3 phase) L1,BLACK; HOT(240V 1 or 3 phase)
GREEN GROUND (220/240V 1 and 3 phase)
QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING
(US/Canada)
220 V WATER COOLER RECEPTACLE
NOTE: DO NOT USE IN 120 V MODE
TO POWER THE WATER COOLER !
SUPPLIED PLUG IS A NEMA 6-50P, THE STANDARD PLUG FOR MOST 1
PHASE 240 V WELDERS IN THE US AND CANADA. OPTIONAL DUAL VOLT-
AGE MODELS REQUIRE USE OF A STEP-DOWN ADAPTER FOR 120 V OP-
ERATION. CONTACT EVERLAST TO PURCHASE AN ADAPTER IF NEEDED.
IMPORTANT: USE A 240 V to 120 V ADAPTER FOR THE OPTIONAL DUAL VOLT-
AGE MODELS. DO NOT REMOVE THE PLUG. NO INTERNAL CHANGE IS RE-
QUIRED TO OPERATE ON 120 V. THIS UNIT AUTOMATICALLY SENSES THE
CHANGE IN SUPPLY POWER. TO PURCHASE AN ADAPTER CONTACT EVERLAST.

15
GAS OUTLET CONTROL
1. PROTECTIVE COVER
4. PRE/POST FLOW TIME
5. PULSE HIGH/LOW/OFF
6. PULSE FREQUENCY (Hz)
7. PULSE AMPS (RATIO)
8. PULSE TIME ON (BALANCE)
9. POSITIVE (35 SERIES)
10. GAS QUICK CONNECT (9mm) 11. TORCH/PEDAL CONTROL
12. NEGATIVE (35 SERIES)
13. AC/DC SELECTOR
15. AC FREQUENCY (HZ)
14. AC BALANCE (% OF EP)
16. SURGE AMPS *
17. ARC FORCE (DIG)
18. HF/LIFT /STICK
19. ON/TEMP/O.C
20. AMP CONTROL
21. AMP DISPLAY
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS
2. 2T/PEDAL/ OR 4T SWITCH
3. DOWN SLOPE (2T/4T)
NOTE: Dual Voltage Model connecons are the same in funcon but the gas connector
locaon is on the far le side and the work clamp connector is to the right of it.

16
Section 2
FRONT PANEL FEATURES AND CONTROLS CONTINUED
QUICK SETUP AND USE GUIDE
POWERTIG 200 DX FEATURES PARAMETERS PURPOSE
1. Protecve Cover N/A Clear hinged cover protects panel from damage. Keep closed during welding operaons.
2. 2T/4T Sequencer Switch 2T -Pedal/4T Used with the torch switch funcon. Select 2T for simple press and hold operaon of the
torch switch. Release the switch to cease operaon. Select 4T for advanced use of the
down slope control. 1) Press and hold switch to start arc. 2) Release switch to weld at
maximum welding amps. 3) Press and hold switch once again to begin downslope. 4)
Release switch to terminate the arc. In 4T mode, if the puddle becomes too hot, it can be
cooled by lightly tapping the switch to begin downslope and tapping again to restart
welding at max amps before the boom of the down slope is reached. Seng a long
downslope helps improve heat control with this feature.
IMPORTANT: For foot pedal use: Select 2T, turn down slope to minimum sengs or the
foot pedal will not operate correctly.
3. Down Slope Control
(Part of 2T/4T sequence)
0-10 Seconds Down Slope will ramp amps “down” from the welding amp value to the factory preset
minimum end amp value to give me to gently ll the crater le at the end of the weld
bead. Eect is minimal at low welding amperages.
4. Pre/Post Flow Control 0-10/ 0-25
Seconds
Pre-Flow sets 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 ~1 second for best starng.
Post-Flow sets the amount of shielding gas ow me aer arc ends to shield the weld to
prevent oxidaon and cool the torch. Use 1 second post-ow or less for every 10 amps.
5. Pulse O/High/Low Switch O/ Low/ High Turns pulse on. Low range operates with a ne control from .5-25 Hz. High range operates
with a more coarse range of control from 25-150 Hz
6. Pulse Frequency Control .5-150 Hz Represented by Hertz (Hz), the pulse frequency adjusts the actual number of mes per
second the pulse makes one complete cycle between welding amps (Peak value) and pulse
amps (Background (low) amp value). This is also commonly referred to as Pulses Per Sec-
ond (PPS). Low pulse frequencies are ideal for ming when ller metal is added. This
helps improve appearance and uniformity. Higher pulse frequencies are useful for welding
seams and edges of thin material. Also it is useful for overall heat control for thicker met-
als. Higher pulse frequencies are useful for automated welding processes. WARNING:
WELDING AT HIGH PULSE FREQUENCIES INCREASES THE DECIBEL /NOISE LEVEL OF THE
ARC. HEARING PROTECTION IS RECOMMENDED! The adjustment is not 100% linear and
symmetrical in adjustment. The further clockwise the control is turned, the more rapidly
the value increases.
7. Pulse Amps (Rao) Control 5-95% Sets the lower Pulse Amp (base or background current) value during the pulse cycle by
adjusng it as a percent of Welding Amps. When pulse mode is selected, the main amp
welding knob determines the Welding Amp (upper /peak) value.
8. Pulse Time On (Balance) Control 10-90% Sets the duty cycle (balance) of the pulse, by dividing or skewing the amount of me the
pulse is in the lower or upper stage of the pulse. The pulse consists of two stages: Welding
Amps (Peak) and Pulse amps (base/background current). This is represented by a percent-
age (%) of total me (typically referred to as rao of me ) the pulse spends in the pulse
amp part of the cycle during one full pulse. The control can be used to increase or de-
crease pulse amp me relave to the Welding Amp me of the cycle to help manage heat
input.
9. Posive Connector 35-70 mm² Locaon of the posive terminal connecon. Dinse-style connector. (35 Series)
For Sck: Torch connecon. For TIG: Work Clamp Connecon.
10. Quick Connect Gas Outlet 9 mm Connects the gas to the TIG 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.
11. Control Connector 7 Pin Connect the foot pedal or torch switch to this 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.
12. Negave Connector 35-70 mm² Locaon of the negave terminal connecon. Dinse-style. (35 series)
For Sck: Work Clamp Connecon. For TIG: Torch Connecon

17
POWERTIG 200 DX FEATURES PARAMETERS PURPOSE
13. AC/DC Selector AC/DC process Select DC output for Steel, Stainless and most metals.
Select AC output for Aluminum and Magnesium alloys.
14. AC Balance Control 30-70% of EP Selects the percent of Electrode Posive (EP) used during AC welding to provide cleaning.
This divides the amount of me that the AC cycle is in Electrode Posive or Electrode Neg-
ave during one full AC cycle. It controls the amount of cleaning and penetraon via a
rao to achieve the best balance while welding on AC. 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 right, more Electrode Posive is present and more cleaning
(cathodic etching) will be achieved. Too much cleaning acon will result in tungsten ball-
ing or spling, making a larger tungsten necessary for the same amperage range. Too
lile cleaning can result in dirty, sooty welds and even a dull weld appearance. NOTE: This
is expressed as a percent of full EP Polarity. This unit uses 100% Electrode Posive as the
reference, which is just the opposite from some other brands. Using the welder in excess
of 50% EP can vaporize the tungsten. It can also reduce the duty cycle of the welder. For
most welds, no more than 45% cleaning is needed. Ideally, start with 30% EP for a refer-
ence point, and adjust it up from there to achieve best results.
15. AC Frequency Control 20-250 Hz Controls the number of mes per second that the current alternate in AC mode. To
achieve greater arc focus (constricon) and increase puddle agitaon while welding in AC
mode, increase AC frequency. This allows pinpoint use on thin materials, and helps pene-
traon on thicker materials. Ideal adjustment range is usually 100-150 Hertz. For compari-
son most transformer welders in the US operate on 60 Hz. Greater results can be achieved
through the use of the higher frequency range of this welder. Lower Frequencies will wid-
en and soen the arc but reduce the level of control. WARNING: INCREASING THE AC
FREQUENCY ALSO INCREASES THE DECIBEL / NOISE LEVEL OF THE AC WELDING ARC.
HEARING PROTECTION SHOULD BE WORN!
16. Sck Surge Amps
(Available on late 2013 models)
0-100% Adjusts the “hot” start amperage during the inial contact of the electrode. It makes arc
starng easier by sending a surge of amps briey while arc is struck to prevent scking.
17. Arc Force Control (DIG) 0-100% Controls the arc response when an arc is held short and voltage begins to drop. Arc force
automacally compensates by modifying the volt/amp curve to maintain the energy need-
ed to weld. Represented as a percent of available amperage.
18. HF Start/Li Start/Sck
Switch
HF/Li/ Sck Selects type of TIG start. HF is touch free and acvates during start only. Li start requires
brief touch to metal to draw an arc and is good for areas where sensive electronics are
present. Also selects Sck welding process.
19. On/Temperature/ Over Current Indicator/Warning
Or Fault
On Indicator: Conrms unit is switched on. Temperature Indicator: Lights up and stops
welding output unl the welder has cooled within normal limits. Allow 10 minutes before
aempng to reset manually by cycling the power switch. If the light does not go out aer
the cool down period by cycling the switch, or if comes on again when the arc is struck,
contact Everlast. Over Current Indicator: Lights up when a voltage /amp surge has sur-
passed the units capabilies. Eliminate the source of the surge and manually cycle the
power switch to reset. If the light remains on aer cycling the switch, this may indicate a
unit fault created during the over current event. In this case, contact Everlast.
20. Amp Control Knob DC: 5-200 A (TIG)
AC: 20-200 A (TIG)
DC: 5-160 A (Sck)
AC: 20-160 A (Sck)
Sets Maximum limit for Amps with foot pedal or torch. Sets higher amp value for pulse.
Minimum amps for AC is 20 amps. If working with extremely thin metals is needed and
too much penetraon is being achieved or arc start is too high at the minimum seng of
20 amps, increase cleaning percent. This will direct more heat on the tungsten, and may
cause balling, and loss of some arc stability, but will reduce the heat placed on the work
and can improve weldability on very light gauge aluminum. (<.020”) NOTE: 120 V opera-
on limits TIG to maximum output to 120 A and Sck to a maximum output of 100 A.
21. Amp Display N/A Displays maximum selected amps unl the weld is started. Displays actual amps while
welding. Display may cycle rapidly and randomly aer pulse has been turned on. This is
normal. The meter “samples” the pulse at a xed rate and is not synchronized with the
pulse. Immediately aer the pulse is turned on, a short delay is built in that prevents the
display from cycling to allow the pulse to be adjusted. Once the adjustment is nished,
pulse will begin to cycle aer a few seconds if no input is made.
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS CONTINUED

18
GAS
INLET 1~220 V
1~220 VAC
5. 3-POLE POWER SWITCH
2. HF GROUND BOLT
1. WATER COOLER RECEPTACLE
220/240 V WATER COOLER ONLY!
3. ARGON GAS INLET
4. POWER CABLE 1 ~ 220/240V
QUICK SETUP AND USE GUIDESection 2
REAR PANEL FEATURES AND CONTROLS

19
QUICK SETUP AND USE GUIDESection 2
REAR PANEL FEATURES AND CONTROLS CONTINUED
NOTES:
1. The gas input connecon should be checked for ghtness periodically, especially if the machine is moved.
2. Never operate welder on a generator that is not cered by its manufacturer to be “clean” power, which is less than 10% total harmonic
distoron. Less than 5% is preferred. Operang the unit on square wave output or modied sine wave generators is strictly prohibited.
Contact the manufacturer of the generator for this informaon. Everlast does not have an “approved” list of generators. But, if the
generator is not listed as clean power by its manufacturer, then operaon is prohibited. Generators that do not at least meet the oper-
ang input requirements of the welder are also forbidden to be used with the welders. Surge amp capability of the generator should
equal or exceed the maximum inrush demand of the welder. But the surge capability should not be used as the only factor. The regu-
lar, running output of the generator should match or exceed the running or “rated” demand of the welder. Any damage done by oper-
ang the welder on a generator not specied by its manufacturer to be “clean”, will not be covered under warranty. This also includes
suspect power sources where voltage is below 208 V and above 250 V.
3. To properly size the breaker, the I1MAX should be used in determining breaker size. To size the wiring, the I1EFF rang should be
used to help determine the proper wire size. The NEC in Arcle 630.11 allows a derang of the wire size based o of duty cycle. The
requirements are dierent than the requirements for most other 240V electrical products. However, consult a licenced electrician and
local codes before installing any wiring or breakers.
4. Use step down adapter when operang on 120 V single phase. Do not modify the 240 V plug. No internal changes are necessary. The
unit automacally senses the input .
5. When operang on 120V (Oponal item), at maximum output, larger than standard breaker and wiring circuits may be required.
REAR FEATURES PARAMETERS PURPOSE
1. Water Cooler Receptacle IEC 60320-1 “C-14” This connecon supplies power to the Everlast PowerCool 300 water cooler. This is
a 220 VAC outlet. Do not use this connecon to power any other device. 4 amp
max. DO NOT USE THIS CONNECTION WITH WATER COOLER IN 120 V MODE!
2. HF Ground Bolt N/A HF energy can be devastang to surrounding electronic equipment. If the operang
environment includes electronic equipment, this bolt can serve as a direct path to a
grounded metal rod that is isolated from the main electrical circuit to help bleed o
excess HF circuit. All metal parts inside the building should be grounded as well,
including pipes, tables, and even metal siding. HF energy has been known to bleed
back into the power grid and disrupt electronic devices further down the grid. If
point gap becomes out of adjustment, more HF energy may build up, or even jump
across circuitry within the welder. It is highly recommended that a small, separate
ground wire be aached at this point while in use.
3. Gas Input Connecon 1/4-5/16” This is the point where the shielding gas from the regulator connects. The unit is
supplied with tubing and clamps which connect this ng to the regulator. The
hose barb design allows universal connecon of the welder to almost any regulator
or setup found throughout the world. Make sure the tubing is fully slid over the
connector and thoroughly ghten the clamp. Use an addional clamp if necessary
to prevent leaking. If you suspect leaking, test the connecon with a soluon of
mild soapy water. If bubbles are seen, reghten.
4. Power Cord 220/240 V
1 and 3 phase.
The PowerTIG 200 DX only uses 220/240 V power, including good quality 208 V
power. The wiring contains 3 separate wires. Everlast uses standard wire color
codes for welders. Standard welder wire colors are L-1 black (hot), L-2 white (hot),
and green (ground) for 1 phase 220/240 V. Do not aempt to use a 4 wire 1 phase
220/240 connecon. NOTE: In many home circuits, red and black are the power
wires. But in standard welding circuitry, white and black are hot wires. Green is
always the ground in both circuits. There is NO neutral in a standard welder cir-
cuit. The plug used for the PowerTIG 200 DX is the NEMA 6-50, which is the stand-
ard 50 amp welder plug used on welders. See wiring diagram for more details on
wiring this plug. Always consult a licensed electrician who is aware of local codes
before aempng any wiring of the welder or of the power circuits. Everlast is not
responsible for any mis-wiring or damage caused to the unit by incorrectly wiring
the welder. If addional help is needed, contact Everlast. WARNING: DO NOT
CONNECT THE WELDER TO ANY OTHER VOLTAGE , OR SEVERE DAMAGE WILL
RESULT TO THE WELDER! USE STEP-DOWN ADAPTER FOR 120 V OPERATION!
5. 2-Pole Power Switch On/O The breaker switch contains 3 poles for power. It serves as the On/O switch for
the welder. Always turn the welder on and o by the switch rst before using any
disconnect. In single phase, only two poles are acve. The remaining pole is inac-
ve unl it is connected to 3 phase power.

20
Welder Funcon Summary and Explanaons.
1. 2T/4T sequencer. The 2T/4T feature allows op-
eraon of the TIG welder without a foot pedal. In
many circumstances, a foot pedal is not praccal
for use. So, the 2T/4T funcon has been created to
allow programming of the welder to simulate the
acvies of the foot pedal while providing more
accurate control. The “T” refers to the number of
“travels” of the remote switch required to operate
the programming of the sequencer. 2T is essenal-
ly a “press and hold” operaon and all program-
ming is cycled automacally. Releasing the switch
begins the nal stage of programming. 4T operates
dierently in the fact that each touch acvates a
dierent stage of the programming, allowing for
greater control. Also, in 4T,while actually welding
at full amps, no nger contact with the switch is
required. Following the graphic lines below, you
can visually trace the acvity and funcon of each
part of the welding cycle. In either 2T or 4T opera-
on the programming can be reset to “upslope”
before reaching the end amp stage by pressing the
switch once more. See the graphics below for fur-
ther explanaon. The up and down arrows indicate
the switch travel direcon.
NOTE: Start, End Amps and Up Slope, a usual fea-
ture of 2T/4T control are preset on the PowerTIG
200 DX. It cycles automacally in conjuncon with
the slope cycles. No adjustment of Start or End
amps can be made. Up Slope is xed at less than .3
seconds. Upslope in 2T or 4T will seem quick.
Down slope is adjustable and can be used to cool
and slowly ll the weld though and can be toggled
back and forth in the 4T mode to help manage heat
while using the torch switch.
The 2T/4T secon on the welder panel are devoted to
the use of the 2T/4T operaon and should not be used
with foot pedal. The following features are exclusive
features that can only be used with the 2T/4T sequenc-
er funcon of the 200 DX:
1) Down Slope. All other features are non-adjustable.
2. Pre-Flow and Post-Flow. These are features that
work in conjuncon with both the foot pedal and the
2T/4T sequencer. The start will be delayed unl the pre-
ow cycle has nished. Set for .5-1 seconds for best
results. Add more pre/post ow me for larger welds or
welds with larger open roots or gaps.
3. AC Frequency. The AC frequency only applies to the
AC mode. Standard transformer welders typically have
a xed frequency of 60 Hz which is essenally the line
input frequency supplied by the power company. But
with inverters, the AC frequency adjustment is praccal-
ly limitless due to the IGBT components that create the
welding power. Frequency adjustment is useful to help
improve the direconal control of the arc, and to focus
the arc so that a narrower bead prole can be achieved.
Also, at higher frequencies, the puddle agitaon is
greater which improve the breakup of undesirable ox-
ides. A seng of 100-120 Hz is a good starng point.
See the graphic below.
4. AC Balance. The advanced form of AC square wave
output is formed by alternang polarity rapidly between
electrode negave and electrode posive, creang a
wave form that resembles a square “sine” wave when
viewed on an oscilloscope. Normally, with standard
transformer welders, both standard sine wave and even
square wave welders have lile or no way to adjust the
balance of EN to EP, which results in having to weld
with a molten ball at the p of the tungsten and a less
stable arc. Electrode negave (EN) provides penetra-
on in the TIG welding process. Electrode posive (EP)
creates a strong reverse ow of electricity that breaks
up the weld-resistant oxidaon that covers aluminum
and magnesium components. EP also places a lot of
heat on the tungsten. In a “balanced” wave where both
EP and EN are equal in me length (50%), penetraon is
reduced and over-cleaning results in wide etch lines
Basic theory and function
Section 3
2T Torch Operaon Eect on Weld Cycle
4T Torch Operaon Eect on Weld Cycle
`
200 Hz 60 Hz
PREFLOW POST FLOW
= UP ON SWITCH
= DOWN ON SWITCH
UP SLOPE
UP SLOPE
WELD AMPS WELD AMPS
DOWN SLOPE
DOWN SLOPE
UP SLOPE
PREFLOW
WELD AMPS
DOWN SLOPE
POST FLOW
START AMPS
START AMPS END AMPS
END AMPS
AC FREQUENCY EFFECTS