Everlast Powertig 255 EXT User manual

EVERLAST
POWERTIG 255 EXT
Operator’s Manual for the PowerTig 255 EXT
Safety, Setup and General Use Guide
Rev.2 0 021212-14
Digital AC/DC TIG/STICK WELDER
GTAW/SMAW
CC
GTAW-P
SMAW
IGBT
AC/DC
everlastwelders.com
1-877-755-9353
329 Lileeld Ave. South San Francisco, CA 94080 USA
Specicaons and Accessories subject to change without noce.
DV
120/240V

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 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 Pinout………………….…….……………
Troubleshoong………………………………………………..
Trouble Codes…………………………………………………….
3
4
5
9
10
11
11
12
13
14
15
21
23
29
30
31
32
33
34
35
36
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 LLC 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 to download your current war-
ranty informaon. Your unit registraon is important should any informaon such as product up-
dates or recalls be issued. It is also important so that we may track your sasfacon with Everlast
products and services. If you are unable to register by website, contact Everlast directly through
the sales department through the main customer service number in your country. Your unit will be
registered and warranty will be issued and in full eect. Keep all informaon regarding your pur-
chase. In the event of a problem you must contact technical support before your welder can be a
candidate for warranty service and returned.
Please review the current online warranty statement and informaon found on the web-
site of the Everlast division located in or nearest to your country. Print it for your records
and become familiar of its terms and condions.
Everlast oers full technical support, in several dierent forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interacon.
Technical advisors are acve on the forum daily. We also divide our support into two divisions:
technical and welding performance. Should you have an issue or queson concerning your unit,
please contact performance/technical support available through the main company headquarters
available in your country. For best service call the appropriate support line and follow up with an
email, parcularly if o hours, or you cannot reach a live person. In the event you do not reach a
live person, parcularly during heavy call volume mes, holidays, and o hours, leave a message
and your call will normally be returned within 24 hours. Also for quick answers to your basic ques-
ons, join the company owned forum available through the website. You’ll nd knowledgeable,
helpful people and sta available to answer your quesons, and perhaps nd a topic that already
addresses your queson at hp://www.everlastgenerators.com/forums/.
Should you need to call or write, always know your model name, purchase date and welder manu-
facturing inspecon date. This will assure the quick and accurate customer service. REMEMBER:
Be as specic and informed as possible. Technical and performance advisors rely upon you to
carefully describe the condions and circumstances of your problem or queson. Take notes of
any issues as best you can. You may be asked many quesons by the advisors to clarify prob-
lems or issues that may seem very basic. However, diagnosis procedures MUST be followed to
begin the warranty process. Advisors 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: sale[email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Support Forum: hp://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
Everlast Canada:
Everlast consumer sasfacon email: sal[email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: sa[email protected]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
Aer hours support: 0413 447 492
Everlast Technical Support: [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 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
PowerTIG 255EXT Accessories
NOTE: Accessory and consumable appearance, style, length and quanty subject to change without noce.
Qty Accessory
120 Series TIG torch and cable
19 Series TIG torch and cable
1Everlast 47k Ω Pedal
1Heavy duty work clamp
1Heavy duty electrode holder
1Regulator and hose assy.
1240 to 120V Pigtail adapter

10
PowerTIG 255EXT/325 EXT TIG/Sck Welder Specicaon
Process AC/DC GTAW-P/DC SMAW
Inverter Type Digital Microprocessor Controlled, IGBT Module
Minimum/Maximum Rated Output TIG 120V: DC 3 A/10.1V-150A/16V AC: 5A/10.2-150A/16V
240V: DC 3 A/10.1V- 250 A/20V AC 5 A/10.2V- 250 A/20V
Minimum/Maximum Rated Output Sck 120V: 20A-120A/20.8V-24.8V
240V: 20 A/20.8V - 225 A/29V
Start Type Solid State HF and Li Start
HF Point Gap Non-Adjustable Gapless Solid-State Design
TIG Duty Cycle @ Rated Amps/Volts 120V: 60% @ 150A/16V 100% @ 120 A/14.8V
240V: 60% @ 250A/20V 100% @ 200 A/18V
Sck Duty Cycle @ Rated Amps/Volts 120V: 60% @ 120A/ 24.8V 100% @ 90A/23.6V
240V: 60% @ 225A/ 29.0V 100% @ 175A/27V
OCV (U0)70 V
Voltage Input (U1)120/240 V; 50/60Hz 1 phase
Maximum Inrush Amps (I1MAX)35.7A @ 120V 33.6A @ 240V
Maximum Operang Amps (I1EFF)29A @ 120V 27 @ 240V
Gas Pre-Flow /Post Flow Time 0-25 Seconds/ 0-50 Seconds
Start Amps/End Amps Start: 5-250A (AC andDC)
End: 3-250A DC; 5-250A AC
Up/Down Slope 0-25/0-25 Seconds
AC Wave Forms Advanced Square, So Square, Sine, and Triangular
AC Frequency Control 20-250 Hz
AC Balance Control 5-90% of Electrode Posive (EP +)
Pulse Frequency Hz (Pulses Per Second) .1-500 Hz DC .1-250 Hz AC
Advanced Square Wave (AC) .1-10 Hz
Pulse Amps (Rao) 5-95%
Pulse Time On (Balance) 5-100%
Spot Timer Control YES
Sck Arc Force Control 0-100%
Sck Surge Amp Control (Hot Start Intensity) 0-100%
Sck Surge Amp Duraon (Hot Start Time) 0-2.0 Seconds
Minimum Water Ingress Protecon Standard IP21S
Power Factor Correcon: 99%
Cooling Method Lower decibel 4 fan design with full me running
Dimensions (approximate) 17.5” H X 9.25” W X 22” L
Weight (Bare Unit) 62 lbs
AC Easy Start Parameters (Default) AC Frequency : 120Hz AC Balance: 25% Preow: .5 Post Flow: 4 Seconds Amps: 120 A
(with pedal) Start amps: 50A End amps 50 A Upslope: 1 second, Downslope: 3 seconds,
(2T with torch switch)
DC Easy Start Parameters (Default) DC: Preow .5 Poslow: 3 Seconds Amps: 90 A (with pedal) Start amps: 50 A End amps:
50A, Upslope: 1 second Downslope 3 seconds (2T with torch switch)
Minimum Generator Requirement* 8500 Connuous Was
Introduction and SpecificationsSection 1
* Generator must be cered as a clean power unit by its manufacturer with less than 10% total harmonic distoron.

11
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”. 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 to-
ward the machine, parcularly during grinding and
welding operaons. Make sure the panel is protected
from damage while welding and cung operaons by
ipping down the clear protecve cover.
Duty Cycle. For the 255 EXT, the duty cycle is rated for
60% at 250 Amps (TIG) and 60% at 225 Amps for Sck
(240V). 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 for cooling down the unit.
This does NOT mean that the 255EXT can work 60% of
any longer length of me. A full 4 minute rest should be
given to the welder for maximum life. The welder can
also provide a 60% duty cycle while being used on 120V
at a reduced amp output of 150A for TIG, and 120A for
Sck. Overheat, over current, over voltage and under
voltage faults are indicated by a warning light accompa-
nied with an error code. Do not operate the unit unl
the cause of the problem has been determined and
corrected. Do not shut down an overheated welder
unl it has safely cooled. Once the overheat condion
has had me to clear, welding can resume when the
power switch is cycled on and back o. Do not operate
this welder with the protecve covers removed. In
case of other troubles follow the trouble diagnosis sec-
on and/or call Everlast Technical support.
This manual has been compiled to give an overview of
operaon and is designed to oer informaon cen-
tered around safe, praccal use of the welder. Weld-
ing is inherently dangerous. Only YOU, the operator of
this welder, can ensure that safe operang pracces
are followed, through the exercise of common sense
pracces and safety training. Do not operate this ma-
chine unl you have fully read the manual, including
points of safety. If you do not have the skill, and/or
knowledge to safely operate this welder, do not use
this welder unl formal training regarding safe opera-
on of this welder has been received.
General overview. The 255EXT TIG/Sck welder is one
the most advanced models in a new generaon of
digitally controlled, inverter welders from Everlast.
With a microprocessor and IGBT module design, the
welder oers stable arc performance as well as con-
venient setup and use. Key features include:
A. IGBT modules, microprocessor controller and an
overall plug and play design improve reliability and
reduces down me for service and repair.
B. Full bridge design features so switching technolo-
gy which further extends IGBT component life and
extends its capabilies.
C. Solid state High Frequency design for arc starng
has improved arc iniaon at low amperages.
D. Features automac over-voltage, over current and
duty cycle protecon (over-heat) with self diagnos-
ing trouble code feature.
E. Programmable memory stores favorite sengs
and remembers up to 9 stored programs.
F. Arc force control, Hot Start me and Hot Start in-
tensity controls expand sck welding ability.
G. Four standard wave forms in AC oer increased
aluminum capability.
H. Advanced AC Pulse and Standard AC/DC pulse
increase weld capability on thin or heat sensive
materials.
I. Easy start-up feature oers simplied operaon.
General Use and Care: The welders are good for use
in many industrial environments such as ship yards,
fabricaon shops, 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 re-
move the welder from the vicinity of any water or
moisture source to reduce the possibility of electrocu-
on or shock. Never operate or weld 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
help 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.
Introduction and Specifications
Section 1
Figure 1. Basic Inverter design

12
!
WA
INPUT
OUTPUT
WATER COOLER
(Oponal)
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: TIG CONNECTIONS
GAS (Ar)
CONTROL
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 time.
IMPORTANT! 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 RETURN LINE. ON SOME BRANDS OF TORCHES, THE WATER LINES ARE
COLOR CODED: BLUE FOR COOL WATER SUPPLY AND RED FOR HOT
WATER RETURN. OTHER BRANDS MAY VARY. COOLER FITTINGS HOWEV-
ER ARE COLOR CODED BLUE AND RED. BLUE COOLER FITTING IS FOR
WATER SUPPLY OUT TO THE TORCH. RED COOLER FITTINGS IS FOR
RETURN WATER FROM THE TORCH, EXITING THE DINSE CONNECTOR.
PLEASE BE CAREFUL NOT TO INSTALL THE TORCH INCORRECTLY OR
WATER WILL FLOW FROM THE TORCH HEAD. ALWAYS DOUBLE CHECK TO
BE SURE AND MARK THEM WITH EITHER COLORED TAPE OR TAG WATER
AND GAS LINES WITH ADHESIVE LABELS FOR EASY IDENTIFICATION.
TORCH (-)
35 SERIES CONNECTOR
9/17 SERIES TORCH
26 SERIES TORCH
COOLANT IN (TO RED COUPLING)
COOLANT OUT ( TO BLUE COUPLING)
18/20 SERIES TORCH
35 SERIES CONNECTOR

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

14
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING 255EXT
(US/Canada)
EVERLAST
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.
GAS INLET 110/220 V
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BE-
FORE RE-WIRING YOUR WELDER OR ATTEMPTING TO MAKE ANY ELECTRICAL CONNEC-
CLAMP
HF
Fe or Cu
NEMA 6-50P
L2,WHITE L1,BLACK; HOT
GREEN GROUND
120V/220V COOLER OUTLET. RECOMMENDED FOR DUAL VOLT-
AGE EVERLAST POWERCOOL WC 300 ONLY. WARNING: DO NOT
USE THIS OUTLET FOR ANY OTHER APPLICATION OR SERVICE!
SUPPLIED PLUG IS A NEMA 6-50P, THE STANDARD PLUG FOR MOST 1
PHASE 240 V WELDERS IN THE US AND CANADA. 120V OPERATION RE-
QUIRE S USE OF THE STEP-DOWN ADAPTER FOR 120 V OPERATION.
CONTACT EVERLAST TO PURCHASE AN ADAPTER IF NEEDED.
5/8” CGA FITTING
IMPORTANT: USE THE 240V/120V ADAPTER FOR OPERATION WITH 120V.
DO NOT REMOVE THE FACTORY SUPPLIED PLUG. NO INTERNAL CHANGE
IS REQUIRED TO OPERATE ON 120V. THIS UNIT AUTOMATICALLY SENSES
THE CHANGE IN SUPPLY POWER WHEN THE ADAPTER IS CONNECTED.
AC 120V
AC 220V

15
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT
GAS OUTLET CONTROL
1. CLEAR PROTECTIVE PANEL COVER
2. CONTROL PANEL
4.GAS OUTLET 9MM QUICK CONNECT 5. 7-PIN CONTROL FOR PEDAL/TORCH SWITCH/AMPTROL
6. POSITIVE CONNECTOR
DINSE 35-70mm²
3. NEGATIVE CONNECTOR
DINSE 35-70mm²

16
Section 2
FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT
QUICK SETUP AND USE GUIDE
POWERTIG 255 EXT
MAIN PANEL FEATURES
PARAMETERS PURPOSE
1. Protecve Cover N/A Clear hinged cover protects panel from damage. Keep closed during welding opera-
ons.
2. Main Control Panel Digital The main control features digital adjustment. It oers features that include Easy Start
Up, Pulse, Advanced AC pulse, Sck welding feature, VRD Sck welding feature, Sck
Hot Start, Arc force control, Li start Tig, HF start TIG, 2T/4T/Pedal/Amptrol Control,
and error code diagnosis.
3. Negave Connector DINSE 35-70mm² Locaon of the negave terminal connecon. This is a standard 35 series connector.
For Sck: Work clamp Cocnnecon. For TIG: Torch connecon.
4. Gas Outlet Quick Connect 9mm Connects the gas to the TIG torch. To connect: Push the torch ng into the connect-
or unl the collar slides forward with a click. To Release: Slide the outer collar back.
5. Control Connector 7 Pin
(Panasonic type)
Connect the foot pedal , amptrol or torch switch to this socket to control the welder.
Only one control connector can be plugged in at one me. If the torch has a torch
switch feature or hand amptrol feature, e the loose connector back or leave it hang-
ing while using the pedal.
6. Posive Connector DINSE 35-70mm² Locaon of the posive terminal connecon. This is a standard 35 series connector.
For Sck: Torch Connecon (most electrodes). For TIG: Work Clamp Connecon.
NOTES:

17
POWERTIG 255EXT/325EXT PARAMETERS PURPOSE
1. Memory Funcon 1-9The unit has 9 programs which allow the operator to select parameters and hen save the
sengs to the selected program channel. To operate, use the selector buon to select the
desired program number where the program is to be assigned. The red select light will be lit,
indicang that the welder is in the programming mode. Enter the desired program parame-
ters. Aer all parameter changes have been made, press the selector buon and hold for 3
seconds and release. The green save buon will light, indicang the funcon has been saved.
Aer approximately 2 seconds, the save light will go out, and the unit will default back to the
red select light. Any addional adjustment made aer this will need to be resaved.
2. Easy Start Up Menu Normal,
AC and DC
The welder includes two Easy Start Up modes, one for AC and one for DC. The Easy Start Up
features for AC and DC have been pre-programmed with parameters that are generally usa-
ble in most situaons. Most parameter adjustments are blocked and are non adjustable in
these modes. Amperage and control funcons are adjustable. Select Normal to allow stand-
ard setup. Suited for quick welds and repairs or novice use.
3. Pre-Flow 0-25 Seconds Pre-Flow sets the gas ow me before the arc starts aer the trigger or pedal is pressed.
Used to purge the torch and ood the weld area with shielding gas so the arc start is stable
and weld is free from porosity. Use enough me so that rst blast of argon is seled (usually,
about .3-.5 seconds). Note: Preow will delay the arc start by the amount of me set.
4. Start Amps 120V:
5-120A (AC/DC)
240V:
5-250 A (AC/DC)
Serves as the 2T/4T inial amp value at the me of arc iniaon while using the foot pedal,
torch switch or amptrol. This allows the arc to be iniated at a dierent amp value than the
selected maximum or minimum welding amps. Typically, this used to start the weld puddle
more quickly. This feature is usually turned to the minimum amp seng (5 amps) while the
foot pedal is in use. However, it can be used to create a “hot” start with the pedal to remedy
starng issues at low amperages with larger tungsten and resolve heat dissipaon issues.
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT/325EXT
1
2
3
45
67
8
9
10
11 12
13
14
15a
15b
16
26
17
18
19
20
23
21
22
24
25a
27
25b

18
POWERTIG 255EXT/325EXT PARAMETERS PURPOSE
5. Upslope 0-25 Seconds Upslope ramps “up” from the start amp value to the welding amp value while starng the
weld puddle. For best operaon, the value will be automacally be set to 0 with standard
foot pedal mode. NOTE: While in pedal mode, the select buon will sll cycle through the
upslope and downslope sengs. But, any adjustment made to the slope sengs will auto-
macally be overridden and zeroed out by the welder. If control over the slope while in
pedal mode is needed, select pedal mode with 2T also highlighted. This will then allow
slope to be set and adjusted. Pedal 4T mode will also allow adjustment of slope, but is not
recommended for use with a standard foot pedal.
6. Welding Amps 120V:
AC: 5-150 Amps
DC: 3-150 Amps
240V:
AC: 5-250 Amps
DC: 3-250 Amps
Welding amps are the maximum (peak) amp value that the user selects for welding. Used
with the foot pedal and amptrol, this is the maximum amp value that can be reached with
the foot pedal. Used with the torch switch, this is the desnaon current or maximum
selected current of the sequencer. When used with pulse, Welding Amps represents the
peak amps of the pulse. In advanced AC pulse mode, welding amps is designated as the AC
poron of the pulse which is also the peak amps poron of the advanced pulse.
7. Pulse Time On (Balance) 5-95% of Welding
Amp (Peak) Time
Denes the duty cycle (balance) of the pulse, by dividing or skewing the amount of me
the pulse stays in the lower or upper stage of the pulse. The pulse consists of two stages:
Welding amps (upper /Peak) and Pulse amps (lower/background current). This is repre-
sented by a % of total me the pulse spends in the welding amp stage of the cycle during
one full pulse. The feature can be used to increase or decrease pulse amp me relave to
the welding amp me of the cycle to help manage heat input. Thisfeature funcons the
same in both Standard and Advanced AC pulse modes.
8. Pulse Amps (%) 5-100% of
Welding amps
Pulse amps governs the background current (base amps) during the pulse cycle as a per-
cent of welding amps. In Advanced AC Pulse mode this also represents the DCEN
(electrode negave) which is the background current of the pulse cycle. In other words,
the pulse amps parameter actually represents a drop in amps.
9. Pulse Frequency , Hertz
(Pulses per second )
DC: .1-500 Hz
AC Advanced Square:
.1-250Hz
AC So Square:
.1-10 Hz
AC Triangular:
.1-10 Hz
AC Sine:
.1-10 Hz
Advanced AC Pulse:
.1-10 Hz
Represented by Hertz (Hz), the pulse frequency denes the actual number of mes each
second the pulse makes one complete cycle between welding amps (peak/high amp value)
and pulse amps (background/low amp value). This is also commonly referred to as Pulses
Per Second (PPS). Low pulse frequencies are ideal for ming the point where ller metal is
added. This helps improve appearance and uniformity. Higher pulse frequencies are use-
ful for welding seams and edges of thin material. Also it is useful for overall control oeat
input for while welding thicker metals. Higher pulse frequencies are highly useful for auto-
mated welding processes. WARNING: WELDING AT HIGH PULSE FREQUENCIES INCREASES THE
DECIBEL /NOISE LEVEL OF THE ARC. HEARING PROTECTION IS HIGHLY RECOMMENDED!
In Advanced mode, the funcon of the frequency is essenally the same, and represents
the number of mes per second that the welder cycles completely between AC and DC– .
10. AC Frequency 20-250 Hz Governs the number of mes per second that the current alternates 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 between 100-150 Hertz. For
comparison most transformer welders in the US operate on 60 Hz. Greater arc control and
stability can be achieved through the higher frequency range oered by this welder. Low-
er Frequencies will widen and soen the arc and 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!
11. AC Balance 10-90% of EP Denes the percent of Electrode Posive (EP) used during AC welding to provide cleaning
acon. This divides the me that the AC cycle spends in Electrode Posive or Electrode
Nega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. Too much cleaning acon will
result in tungsten balling or spling. Too lile cleaning can result in dirty, sooty welds
and even a dull weld appearance. Simply put, as the percent increases, greater cleaning
will occur, but less penetraon will be achieved. NOTE: This is expressed as a percent of
full Electrode Posive polarity. This unit uses 100% Electrode Posive as the reference,
which is opposite (a reciprocal value) from some other brands of TIG welders with this
adjustment. Using the welder in excess of 50% EP can ball and vaporize the tungsten. For
most welds, no more than 45% cleaning is needed. Ideally, start with 30% EP for a refer-
ence point and then ne tune the cleaning by adjusng up or down in increments of 5%.
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT/325EXT

19
POWERTIG 255EXT/325EXT PARAMETERS PURPOSE
12. Down Slope 0-25 Seconds Down Slope will ramp amps “down” from the welding amp value to the end amp value to
give me to ll the crater le at the end of the weld bead. For best operaon, value should
be set to 0 with foot pedal in use. If used with a hand amptrol, without a separate switch to
control slope in 2T/4T mode, then the upslope should be set to 0 as well. When using the
foot pedal or amptrol without a separate control switch, the arc may are at the end of the
weld aer the weld has been lowered to the minimum amp level if the value has not been
set to 0. Can also be used in the 4T mode to help with heat control by briey tapping the
switch to cool o the weld before tapping it again to restart the up slope sequence before
the arc reaches the end amp stage.
13. End Amps AC: 5-250 Amps
DC: 3-250 Amps
Sets the nal or minimum current before the arc is terminated. Used for lling craters at the
ends of the weld and crack prevenon. When using the foot pedal, this should be set to the
lowest amp value (3 for DC; 5 for AC) or arc may suddenly get hot at the end of the weld.
14. Post Flow 0-50 Seconds Controls the amount of me in seconds that the argon ows aer the arc has terminated.
Provides proper shielding during cooling to prevent rapid oxidaon of the weld which results
in porosity. Use 1-2 seconds post ow me for every 10 amps.
15a. HF TIG/ Li TIG/Sck/
VRD Sck Process Selector
N/A This selects TIG or sck mode. It also selects the type of TIG start. The Process selector
oers the choice of Li Tig (for DC only) which requires contact with the metal to iniate the
arc and High Frequency Start which allows non contact starng of the arc (for AC and DC).
When in HF mode, the unit relies upon a gapless solid state HF module to start the arc, which
is a more reliable and trouble free design than tradional point gap HF design. The li start
funcon on the EXT models provides a cold electrode for safety, and prevents accidental
starts. This requires that the pedal or torch switch must be used to energize the arc. HF
refers to the start type only. The inverter design of the welder eliminates the need for a
constant HF overlay in AC.
15b. HF TIG/ Li TIG/Sck/
VRD Sck Process Selector
N/A This selects the sck process or the VRD sck process. A Voltage Reducon Devices (VRD) is
required in some situaons to reduce the risk of electrocuon. The VRD reduces the Open
Circuit Voltage (OCV) below 20 volts (±3V) for safer operaon unl the arc is struck and low
resistance is sensed. The VRD can make starng more dicult in some situaons, and re-
quires a brief contact with the metal to start the weld. Rusty metals, or painted surfaces may
make starng more dicult by oering too high of a resistance value for the unit to sense an
arc strike aempt. When using the VRD Sck mode, a slight delay in arc starng may be
noced. A rm scratching acon may be necessary.
16. Parameter Selector N/A The push buon selector is used to scroll le to right through dierent panel sengs.
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 needed
to weld. Represented as a percent of available arc force amperage.
18. Hot Start Time
(Surge Amp Time)
0-2 Seconds Sets the length of me that the Hot Start is acve while starng the arc. Used to reduce
scking of the electrode during the arc strike phase.
19. Hot Start Amps % 0-100% Controls 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. The
% represents the percent of addional hot start amps available.
21. TIG Pulse Mode Selector Pulse OFF
Standard Pulse
Advanced AC Pulse
The unit features two pulse modes. The standard mode is available in AC and DC modes. The
Advanced AC mode, works only in AC. Pulse is used to control heat input on metals by puls-
ing amperage between a high (Peak) and low (Base or background) amp value. The high amp
stage is represented as Welding Amps. The low amp stage is represented as Pulse Amps. The
Advanced AC pulse pulses between AC and DC– polarity to control heat input on thin alumi-
num. In advanced mode, AC is assigned the welding amps stage of the pulse, and DC– is
assigned the pulse amps stage of the pulse. Both the standard and Advanced pulse modes
have the same features of pulse me on, pulse frequency and pulse amps. Other than chang-
ing the polarity in Advanced AC pulse mode, the two pulses are similar in adjustment.
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT/325EXT

20
POWERTIG 255EXT/325EXT PARAMETERS PURPOSE
21. 2T/4T/ Pedal Selector 2T, 4T, Pedal,
Pedal with 2T,
Pedal with 4T
This selects the operaon of the torch switch, pedal, or hand amptrol. To weld with the torch
switch, select 2T or 4T. For 2T operaon, simply press and hold the switch. The panel pro-
gram will cycle automacally. When the switch is released, the arc will downslope and termi-
nate with post gas ow. When in 4T mode, the switch is pressed, and held to start the pre-
ow and the start amps part of the cycle. When released, upslope begins and connues unl
the amps are raised to the preset welding amps. When pressed and held again, downslope
starts and ramps down to the end amp stage (crater current). When released, the arc termi-
nates, and post ow begins. If desired, before the downslope nishes, the switch may be
tapped again to start the up slope again. To operate with the foot pedal, select pedal mode.
The features such as start amps, upslope, down slope, and end amps will funcon with the
pedal. Be sure to lower these features to the minimum values when the foot pedal is in use,
unless a desired eect is needed. The start amp feature can be parcularly useful as a brief
“hot start” g seng which provides an inial burst of amps to be to rapidly develop a pud-
dle. To operate with a hand amptrol, select Pedal, and then press the selector addionally to
select the 2T or 4T feature light. Both the Pedal and the 2T or 4T pedal will be lit. The
starng and ending of the arc will be the same as the standard 2T or 4T mode, except the
amps can be adjusted while welding with the amptrol. However, some amptrols have only a
a switch that is built into the amptrol mechanism, and is not controllable independently of
the amperage. When this type of amptrol is used, the unit should be placed into standard
pedal mode for proper operaon.
22. AC Waveform/DC Selector DC
AC
Advanced Square
So Square
Triangular
Sine
The unit features AC/DC operaon, with 4 standard wave forms available in AC for specialized
welding needs. The advanced square wave is the default mode and is the best all around
mode with excellent wet in, and arc controllability . So Square wave and Sine wave mimic
the feel and eect of the transformer welders. The So square wave is similar to Square
wave transformers, and have a smooth, buery feel, but maintains good control over the arc.
The Sine wave is similar to much older sine wave transformer TIG welders. This oers the
soest arc, and aords less control than other modes. The Triangular wave is designed for
rapid wet in, and high speed travel on the metal. It also features rapid freeze of the puddle.
DC mode is the standard mode used for all metals except aluminum and magnesium. Alumi-
num and Magnesium should be welded in AC only.
23. Data Display Amps, Seconds
Percent, Hertz
Warning, On
The unit features a single main display. The data in the display is always accompanied by a
corresponding LED light which indicates the funcon being represented. This also includes a
self diagnosing funcon which displays an error code and a corresponding warning light.
24. Standard/6010 Selector Standard Select the “Standard” mode for all sck welding except cellulosic rods. For E6010, 6011, and
other cellulosic rods select the default “6010” mode. This will improve arc performance and
stability while using E6010 and similar rods. If arc seems harsh while welding E7018, E7024,
E6013, E7014 or other similar rods, check to make sure “6010” mode is not engaged.
25. Spot Weld Timer .5-25 Seconds This is used to set the arc-on me while making spot and tack welds or other welds of a re-
peve nature. To set the spot me, press the spot weld buon (25a) so the LED above it is
lit. Then, toggle the main select buon unl the spot weld light(25b) is lit up, and use the
main control knob to increase or decrease me. To use, select 2T and use torch remote
buon. Press and hold the buon to start the arc. The arc will automacally terminate aer
the preset length of me has expired. Upslope and Downslope can be used to taper the arc
during long arc on mes. However, if using for tacking , a 0 up slope and downslope me
may provide the best tack weld results.
26. Parameter Adjuster N/A The control knob is used increase or decrease parameter values. To increase adjustment
speed, push in on the knob while turning. It will then adjust by increments of 10.
27. Purge Gas On/O This feature is used to set gas ow and provide addional, unmed post ow cooling. To set
gas ow, press the touch panel buon so the LED above it is lit. The gas should freely ow.
Then adjust the gas ow via the regulator. Press the buon again to return to normal opera-
on of the solenoid valve. This bypasses the need to set post ow and cycling the pedal or
torch switch briey to get gas to ow. IMPORTANT: Do not forget to press buon again to
turn the gas ow o aer seng the gas ow rate or using it to provide extra cooling.
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT/325EXT