Everlast POWERTIG 315LX User manual

EVERLAST
POWERTIG 315LX
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AC/DC
Operator’s Manual for the PowerTig 315LX
Safety, Setup and General Use Guide.
Specicaons and Accessories subject to change without noce.
Rev. 2 0 01014-19ETL
everlastwelders.com
1-877-755-9353
329 Littleeld Ave. South San Francisco, CA 94080
Digitally Controlled AC/DC TIG and DC Stick Welder

2
Table of contents
Section…………………………………………Page
Letter to the Customer ………………...…………
Everlast Contact Information……………………...
Safety Precautions…………………………………
Introduction and Specications………...…….…..
Unit Specications……………………….………
General Overview…………….…..………………
General Use and Care………...…………………
Quick Setup Guide, TIG Torch/Cooler Connection..
Quick Setup Guide, Stick Polarity…………………
Rear Panel Gas Connection and Wiring.…...…….
Front Panel Features and Controls………………..
Rear Panel Features and Controls………………...
Welder Function Summary and Explanations…….
Tungsten Preparation……………………………
Lift Start and High Frequency Start………………
Stick Starting Methods……………………………
Recommendations for Polarity/Amps/Tungsten….
Expanded View of TIG torch……….…….……….
7 Pin Connector Pin-out…………..…….…….……
Troubleshooting…………………………………..
Optional Accessories………………………………
HF Point Gap Adjustment…………………………
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4
5
9
10
11
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13
14
16
19
22
29
30
31
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35
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37
NOTE: Product Specications and features are subject to change without notice. While every attempt has been
made to provide the most accurate and current information possible at the time of publication, this manual is in-
tended to be a general guide and not intended to be exhaustive in its content regarding safety, welding, or the
operation/maintenance of this unit. Everlast Power Equipment INC. does not guarantee the accuracy, complete-
ness, authority or authenticity of the information contained within this manual. The owner of this product as-
sumes all liability for its use and maintenance. Everlast Power Equipment INC. does not warrant this product or
this document for tness for any particular purpose, for performance/accuracy or for suitability of application.
Furthermore, Everlast Power Equipment INC. does not accept liability for injury or damages, consequential or
incidental, resulting from the use of this product or resulting from the content found in this document or accept
claims by a third party of such liability.

3
Dear Everlast Customer,
THANKS! You had a choice, and you bought an Everlast. We appreciate your loyalty 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. Please be sure to download your warranty infor-
mation for this unit while you are there. Your unit registration is important should any information such as
product updates or recalls be issued. It is also important so that we may track your satisfaction with Everlast
products and services. If you are unable to register by website, or download a copy of your warranty, contact
Everlast directly through the sales department via the main customer service telephone number in your coun-
try. Your unit will be registered and warranty will be issued and in full effect. Keep all information regarding
your purchase. In the event of a problem you must contact technical support before your welder can be a
candidate for warranty service and returned.
Please review and download the ofcial 5 year warranty statement and terms of sale, located at-
www.everlastwelders.com. If you are not in the United States, visit the distributor’s website warranty infor-
mation nearest to your region or country. Print it for your records and become familiar with the terms and
conditions of sale and warranty that relates to this unit.
Everlast offers full technical support in several different forms. We offer domestic based phone support and
online support. Online support is available through email and through our website contact forms. We also pro-
vide a welding support forum designed for customers and noncustomer interaction. Technical advisors are
active on the forum on a regular basis. We also divide our support into two divisions: technical and welding
performance. Should you have an issue or question concerning your unit, please contact performance/technical
support available through the main company headquarters available in your country. For best service, call the
appropriate support line and follow up with an email. In the event you do not reach a live person, particularly
during heavy call volume times, holidays, or off hours, leave a message and your call will normally be returned
within 24 hours. For quick answers to basic operating or service questions, join the free company owned fo-
rum linked through the US website. You should be able to nd knowledgeable, helpful people and staff availa-
ble to answer your questions, and perhaps nd a topic that already addresses your question at http://
www.everlastgenerators.com/forums/.
Should you need to call or write, always have your model name, purchase date and welder manufacturing in-
spection 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-
tions and circumstances of your problem or question. Take notes of any issues as best you can. You may
be asked a series of questions by the advisors meant to clarify problems or issues. Some of these questions
may seem basic or fundamental, but even with experienced users technical advisors can’t assume that cor-
rect operating procedures are being followed for proper operation, and must cover all aspects to properly
diagnose the problem. Depending upon your issue, it is advisable to have basic tools handy such as screw-
drivers, wrenches, pliers, and even an inexpensive test meter with volt/ohm functions before you call.
To begin the warranty process, and before you return a unit for repair or replacement, you must call tech-
nical support rst and go through basic diagnosis process before an Return Authorization for warranty will
be issued. This is a fairly simple process, but an important one. Please do not try to skip this step, or you
may be responsible for the cost of the repair to your unit.
Please let us know how we may be of service to you should you have any questions.
Sincerely,
Everlast Customer Service

4
Serial number: ____________________________
Model number: ____________________________
Date of Purchase___________________________
Everlast USA:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [email protected]
Everlast Welding Support: [email protected]
Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
FAX: [phone]
Everlast Canada:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [email protected]
Telephone: [phone]am-4:30pm EST M-F
Everlast Australia:
Port Macquarie
4/18 Acacia Ave.
Port Macquarie NSW 2444
(02) 6581 23888
After Hours Support
0431 016 416
Sales: [email protected]
Support: [email protected]

5
Everlast is dedicated to providing you with the best possible equipment and service to meet the
demanding job requirements that you may have. We want to go beyond delivering a satisfactory
product to you. That is the reason we offer free technical and basic welding support to assist
you with your needs, should an occasion occur where it is needed. 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, operation and mainte-
nance of your Everlast product to give you the best possible operator/owner experience. Weld-
ing and related cutting operations require basic experience and common sense. Exercise ex-
treme 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, if read
in full, can assist the user in obtaining helpful information concerning the safe operation of this
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 Ever-
last Support. The content of this manual is not meant to be an exhaustive primer on welding.
It is written to an audience that, if not professional, will have at least some basic knowledge of
welding terms and practices.
The 5 year warranty does not cover improper use, maintenance, accessories or consumables.
Accessories are covered by a separate warranty (length varies), which is also listed on our web-
site along with the full terms of the welder warranty. Consumables have no warranty.
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, dis-
continue further use until malfunctioning parts or accessories have been repaired or replaced by
qualied 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 disturbance is noted. Sometimes, improper wire routing or poor shielding
may be the cause.
HF can interfere with pacemakers. See EMF warnings in following safety section for further in-
formation. Always consult your physician before entering an area known to have welding or
cutting equipment if you have a pacemaker.
Safety Precautions

6
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 cau-
tions 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 observe 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 chipping 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 lter installed. Always use a welding helmet in good condition. Discard any broken or
cracked lters or helmets. Using broken or cracked lters or helmets can cause severe eye
injury and burn. Filter shades of no less than shade 5 for cutting and no less than shade 9 for
welding are highly recommended. Shades greater than 9 may be required for high amperage
welds. Keep lter lenses clean and clear for maximum visibility. It is also advisable to consult
with your eye doctor should you wear 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 lter screen, protective curtains or equivalent protective equipment. If no
protection is available, exclude them from the work area. Even brief exposure 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 re 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 adequate 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 elec-
trical shock.
Flame proof and insulated gauntlet or cuffed type gloves are required whether welding or
cutting or handling metal. Simple work gloves for the garden or chore work are not suf-
cient. 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! Arc rays are more intense than
the sun and can burn and permanently damage exposed skin.
Safety Precautions

7
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 mal-
function 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 elds and radiation. While the ef-
fects of EMF radiation are not known, it is suspected that there may be some harm from long term expo-
sure to electromagnetic elds. Therefore, certain precautions 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 conned
spaces. Fumes and gases released 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 obtained.
• Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, copper, cadmium,
lead or zinc without proper respiratory equipment and or ventilation.
WARNING! The use of this product can expose you to chemicals such as lead, which is known to
the State of California to cause birth defects, reproductive harm and cancer. Proposition 65 Warning.
For more infomation visit: www.P65Warnings.ca.gov
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas. Release of Phos-
gene gas can be deadly. Consider all chemicals to have 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 re-
garding high pressure cylinders can be obtained from OSHA or local regulatory agency. Consult also
with your welding supply company in your area for further 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 t cylinders. Do not use faulty regulators. Do not allow cylinders to come
into contact with work piece or work. Do not weld or strike arcs on cylinders. Keep cylinders away from
direct heat, flame and sparks.
Safety Precautions

8
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded.
Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on
ground clamp. Do not stand in water or damp areas while welding or cutting. Keep work sur-
face 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 electri-
cal 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 necessitates 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 cables with appro-
priate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep re ex-
tinguishers close by and additionally a water hose or bucket of sand. Periodically check work
area for smoldering embers or smoke. It is a good idea to have someone help watch for possi-
ble res 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 re that would not be immediately visible. Here are
some things you can do to reduce the possibility of re 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 em-
bers.
• 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 re.
• 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 piec-
es of metal. Remember to place hot metal on re-proof surfaces after handling. Serious burns
and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper
maintenance is your responsibility. Make sure all equipment is properly maintained and ser-
viced by qualied 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 operaon and are able to assume inherent risks of cung or
welding.
Safety Precautions

9
Section 1 Introduction and Specications
NOTE: Appearance and quanty of accessories are subject to change without noce. The starter consumable kit may vary
in quanty and size of its contents. Tungsten is not included. However, special consumable kits with Tungsten may be pur-
chased from Everlast. Addionally, consumables, tungsten and other TIG accessories can be purchased inexpensively for
your unit at local welding stores which deal in TIG welders and TIG welding equipment. Addional NOVA brand TIG torch
opons may be purchased from Everlast that are pre-built for your unit. Or alternavely, most welding supply store sell-
compable TIG torches and DINSE 35/50 connectors for the PowerTIG 315LX. A water cooler is required for the TIG torch
included with this welder Gas cooled TIG torches are limited in their range, usually to 200 amps or less, so an appropriate
water cooled torch has been supplied with this unit. Operang the supplied torch without water will damage the torch.
PowerTIG 315LX

10
PowerTIG 315LXTIG/Stick Welder Specications
Process AC/DC GTAW-P/DC SMAW
Inverter Type DIGITAL IGBT Construction
Minimum/Maximum Rated Output TIG DC: 10-315A AC: 20-315A
Maximum Rated Output Stick 250A
Start Type HF and Lift Start
HF Point Gap .030”-.045”/ .035” recommended
TIG Duty Cycle @ Rated Amps/Volts @ 40º C 60% @ 315A/22.6V
100% @ 250A/20V
Stick Duty Cycle @ Rated Amps/Volts @ 40ºC35% @ 250A/30V
60% @ 200A/28V
100% @ 160A/26.4V
OCV (U0)70V
Voltage Input (U1)Standard 220/240V; 50/60Hz 1 Phase
Maximum Inrush Amps (I1MAX)58A @ 240V 1 Phase
Maximum Operating Amps (Rated Effective) (I1EFF)31A @ 240V 1 Phase
Gas Pre-Flow /Post Flow Time 0-10 Seconds/ 0-30 Seconds
Start Amps/End Amps Fixed @ Minimum Output for Process
Up/Down Slope 0-15/0-30 Seconds
AC Frequency Control 20-500 Hz
AC Balance Control 10-90% of Electrode Positive (EP)
Pulse Frequency Hz (Pulses Per Second) 0-750Hz
Pulse Amps 10-315A
Pulse Time On (Balance) 10-90%
Stick Arc Force Control 0-100%
Minimum Water Ingress Protection Standard IP21S
Efciency >85%
Cooling Method One Single Speed Full-Time High Velocity Fan
Dimensions (approximate) 25” H X 11” W X 26” L (With Handle)
Weight (approximate) 112 lbs (shipped) 82 lbs bare unit
Minimum Storage/Operation Temperatures Storage, -10° F/ -23° C Operation, 14°F/ 10°C
Note for sck welding (SMAW/MMA): This unit is not intended to be used with ER 6010 or other ER XX10 weld-
ing electrodes. If used, the arc may appear to be weak or unstable. However, most all other electrodes can be
used with the machine, yielding excellent results. ER 6011, which provides similar welding capabilies to the
ER6010 electrode, may be used in this unit as well due to more stable arc characteriscs. Weld quality with
E6011 can be brand dependent since rod chemistries vary from manufacturer to manufacturer.
Section 1 Introduction and Specications