Everlast POWERTIG 315LX User manual

EVERLAST
POWERTIG 315LX
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1-3
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…………………………
3
4
5
9
10
11
11
12
13
14
16
19
22
29
30
31
32
33
34
35
36
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

11
General overview: The PowerTIG 315LX is an in-
dustrial class 315 Amp AC/DC TIG and DC Stick
welder. This unit features excellent duty cycle and
excellent arc performance due to its new Digital IGBT
inverter design.
A. Digital design takes advantage of reduced com-
ponents, and surface mounting of components
to improve service life and repairability.
B. Plug and Play design of many internal circuits
reduce unit down time in the event of failure and
improves diagnosis.
C. Employment of copper components in areas
where some manufacturers choose to use alu-
minum improves arc quality and stability.
D. HF point gap maintenance has been reduced
with the introduction of a new HF point design.
E. The digitally controlled square wave design cre-
ates a stable arc in AC, with a fast melting pud-
dle and good wet-in arc characteristics.
F. 240 single phase operation is rated for under 50
amps input.
General Use and Care: With proper care, the Power-
TIG 315LX’s digitally controlled inverter components
are designed to withstand years of use in many dif-
ferent welding environments. However, remember
to keep the unit out of direct contact with water
spray and corrosive areas. The unit has an ingress
rating of IP21S, for light dripping water
(condensation). It is a good idea to remove the
welder from the vicinity of any water or moisture
source to reduce the possibility of electrocution or
shock. Never operate in standing water or where
water spray is an issue. Every 1-2 months, depend-
ing upon use, the welder should be unplugged,
opened up and carefully cleaned with compressed
air. Regular maintenance will extend the life of the
unit. Metallic dust build up may lead to premature
board and component failure.
CAUTION: Before opening the unit for any reason,
make sure the unit has been unplugged for at least
10 minutes to allow time for the capacitors to fully
discharge. Severe shock and/or death can occur.
Free, unobstructed air flow is critical to cooling and
duty cycle. Do not restrict air flow or movement of
air around the welder. Allow a buffer distance of 2 ft
from all sides, with a minimum distance of 18” clear-
ance. Do not operate the welder in the immediate
vicinity of the weld area or the discharge of air from
the fan will cause turbulence and will destabilize the
arc and cause weld porosity. This welder generates a
huge volume of air to maintain its industrial level
duty cycle. Mounting on the same level as where
you are working can create problems with arc and
shielding gas disturbance.
Do not mount in areas that are prone to severe shock
or vibration. Do not drop the unit. Lift and carry the
welder by the handle. Strap the welder down for
maximum stability during use. Do not direct metallic
dust or any dirt toward the machine, particularly in
grinding and welding operations. Flip down the clear
front cover after completing adjustments and while in
operation to protect the control panel.
Duty Cycle. For the 315EX, the duty cycle is rated for
60% at 315 amps. The duty cycle is based off a 10
minute duty cycle rating 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 time. A full 4 mi-
nute rest should be given to the welder for maximum
life. The temperature light will come on and the weld-
er will automatically stop welding when an overheat
condition has occurred. The fan and display will re-
main on. Do not turn the unit off, or attempt to reset
the unit for at least 15 minutes after an overheat con-
dition has occurred since heat will continue to be
generated by and transferred to the electronics after
welding has ceased. Welding in humid or hot condi-
tions greater than 40°C can negatively affect duty cy-
cle. Once the overheated condition has cleared, weld-
ing can resume. Do not operate the welder with the
covers removed.
HF Start. The welder uses High Frequency to start
the arc. The heavy duty design of the point gap
mechanism features a new, improved design that re-
duces point gap adjustment issues and the related
maintenance needs. A bright blue light as may be
seen emanating from the front panel during starts.
This not a cause for concern. For best starts, con-
nect the work clamp directly to the work (part to be
welded). Unstable or inconsistent starts and low
power are often a result of poor work clamp connec-
tion. See the last page of this manual for point gap
adjustment information.
IMPORTANT:
This manual has been compiled to give an overview
of operation and is centered around safe, practical
operation of the welder. Any type of welding has in-
herent dangers. Do not operate this machine until you
have thoroughly read the manual, including the safety
section. If you do not have the skill or knowledge to
safely operate this welder, do not use this welder until
formal training or tutelage is received.
Section 1 Introduction and Specications

12
Section 2 Quick Setup Guide
!
WA
INPUT
OUTPUT
WATER COOLER
Note: Optional PowerCool 300 shown. The welder
can also be used with the PowerCool 400, which
will nest under the welder directly. The Power
Cool 300 is not designed to nest (stack) under the
unit directly.
QUICK SETUP GUIDE: TIG CONNECTIONS
GAS (Ar)
CONTROL
WATER-COOLED TORCH
GAS (Ar)
WORK (+)
CONTROL
35 SERIES CONNECTOR
AIR-COOLED TORCH
CONTROL
FOOT PEDAL
IMPORTANT: Follow the diagram to the le to connect the water cooled
torch. Tradionally, the return line to the cooler is the line exing the
DINSE connector. If color coded, red, blue and black, or red, blue and
another color, the red line will usually be the return line to the cooler.
The blue line will be the input side with the cool water ow coming from
the cooler to torch. The remaining color is the gas (argon) line.
BUT... always consult the torch manufacturer recommendaons before
connecng. Color codes are not absolute and there is variaon in the
industry. To ensure proper connecon of the gas, blow through the lines
gently with compressed air and check for air exing the torch head to
determine which line is the gas line. If water exits the torch head, the
torch is incorrectly connected. Always make sure the cooler is primed
and producing water before aempng to weld or torch damage may
occur. To do so, temporarily disconnect the return line to the cooler and
direct the line into a catch container. Then, turn the cooler on and allow
water to circulate unl it exits the line. Turn cooler o and reconnect the
line to the cooler. Once primed, the cooler will not usually need priming
again unless stored for extended periods of me and drained of coolant.
TORCH (-)
35 SERIES CONNECTOR
9/17 SERIES TORCH
COOLANT IN (TO RED COUPLING)
COOLANT OUT ( TO BLUE COUPLING)
18/20 SERIES TORCH
35 SERIES CONNECTOR
NOTE: Torch switch and foot pedal
control cannot be used at the same time.
GAS (Ar)
NOTE: The TIG torch will always be
negative polarity whether DC or AC!
WORK CLAMP

13
QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS
TORCH (+)
WORK (-)
NOTE: In stick mode, the polarity will almost always be positive, except for special rods or circumstanc-
es. Consult the electrode manufacturer packaging material or website for proper polarity with specialty
rods and for conditions where electrode negative would be appropriate. When changing over to TIG
weld, do not forget to check and change the polarity. This is a common error which prompts
many technical support inquiries.
Section 2 Quick Setup Guide

14
Section 2 Quick Setup Guide
QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING
(US/Canada)
NOTE: Use Ar or Ar/He only. Do not use
more than 25% He in the Ar/He gas mix.
CO2
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL
CODES BEFORE RE-WIRING YOUR WELDER OR ATTEMPTING TO MAKE ANY
ELECTRICAL CONNECTION. REFER YOUR ELECTRICIAN TO ARTICLE 630 OF
THE NEC (NATIONAL ELECTRIC CODE) FOR MORE INFORMATION.
EVERLAST
HF
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.
ADDITIONALLY, ALL SURROUNDING METAL OBJECTS SHOULD BE GROUNDED INCLUDING THE
TABLE, PIPES, WALLS ETC. TO PREVENT ELECTRICAL INTERFERENCE WITH OTHER CIRCUITS.
DO NOT COUPLE THIS WIRE TO THE GROUND PROVIDED IN THE ELECTRICAL CIRCUIT. CONSULT
LOCAL CODES AND ELECTRICIAN FOR PROPER INSTALLATION.
Fe or Cu
NEMA 6-50P
L2,WHITE L1,BLACK; HOT
GREEN GROUND
SUPPLIED PLUG IS A NEMA 6-50P, THE STANDARD PLUG FOR
MOST 1 PHASE 240 V WELDERS IN THE US AND CANADA.
IMPORTANT: TIGHTEN ALL REGULATOR FITTINGS AND CLAMPS ON THE REGULATOR BEFORE
USE. THEN USE SOAPY WATER TO CHECK FOR LEAKS WHILE HE REGULATOR IS PRESSURIZED.
220V/240V COOLER OUTLET. USE WITH EVERLAST
POWERCOOL WC 300 or 400 ONLY. WARNING: DO NOT USE
THIS OUTLET FOR ANY OTHER APPLICATION OR SERVICE!

15
Section 2 Quick Setup Guide
NOTE CONCERNING GENERATOR USE:
Use no less than a clean-power rated, 12,500 Surge Watt Generator with this unit.
Never operate this welder on a generator that is not certied by its manufacturer to be producing
“clean” power. This is considered to be less than 5% Total Harmonic Distortion (THD) Operating
the unit on a square wave output or modied sine wave generator is strictly prohibited. Contact
the manufacturer of the generator for this information. Everlast does not have an “approved” list
of generators. But, if the generator is not listed as clean power by its manufacturer, then opera-
tion is prohibited. Generators that do not at least meet the operating input requirements of the
welder should not be used with the welders. In most cases clean power-output generators are
clearly advertised as such. If you do not see a clean power rating, call the manufacturer of the
generator to verify. The surge amp capability of the generator should equal or exceed the maxi-
mum inrush demand of the welder. But the surge capability should not be used as the only factor.
The regular, running output of the generator should match or exceed the running or “rated” de-
mand of the welder. Any damage done by operating the welder on a generator not specied by
its manufacturer to be “clean-power” will not be covered under warranty. This also includes sus-
pect power sources where the voltage falls below 205 V and above 247V.
Remember if it isn’t rated as clean power, you can void your warranty if you use it. Even a one
time use can damage or weaken the unit.
Do not run this unit with underrated extension cords. Always use with a welder specic extension
cord rated for 50 amps. Keep the cord length to 40 feet or less to minimize voltage drop.

16
Section 2 Quick Setup Guide
FRONT PANEL FEATURES AND CONTROLS POWERTIG 315LX
1
2
3546

17
Section 2 Quick Setup Guide
FRONT PANEL FEATURES AND CONTROLS POWERTIG 315LX
POWERTIG 315LX PARAMETERS PURPOSE
1. Protective Cover N/A Clear hinged cover protects panel from damage. Keep closed during welding opera-
tions.
2. Main Control Panel Digital The main control panel includes all controls for the welder except power switch.
3. Negative Connector DINSE 35-70mm² Location of the negative terminal connection. This is a standard 35 series connector.
For Stick: Work clamp Connection. For TIG: Torch connection.
4. Gas Outlet Quick Connect 9mm “B” Connects the gas to the TIG torch. To connect: Push the torch tting into the connector
until 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 time. If the torch has a torch
switch feature or hand amptrol feature, tie the loose connector back or leave it hanging
while using the pedal.
6. Positive Connector DINSE 35-70mm² Location of the positive terminal connection. This is a standard 35 series connector.
For Stick: Torch Connection (most electrodes). For TIG: Work Clamp Connection.
NOTES:

18
Section 2 Quick Setup Guide
1
2
3
813
1514
12
11
10
9
4765
FRONT PANEL FEATURES AND CONTROLS

19
PowerTIG 315LX Features Parameters Purpose/Function
1. On/Temperature/ Over
Current
Warning
Indicator
Or Fault
On Indicator: Conrms unit is switched on. Temperature Indicator: Lights
up and interrupts welding output until the welder has cooled within normal
limits. Allow 15 minutes before attempting to reset the welder manually by
cycling the power switch. If the light does not go out after cycling the power
switch, and the cooling period has been observed, contact Everlast. Over
Current Indicator: Lights up when an over/under voltage or current has
been detected. Eliminate the source of the surge and manually cycle the
power switch to reset the welder. If the light remains on after cycling the
power switch, this may indicate an internal unit fault was created during the
over current event. In this case, contact Everlast. Do not continue to reset
the unit after two reset attempts.
2. Up/Down Slope Control 0-15/0-30 Seconds Up-Slope ramps amps from the selected start amp value up to the welding
amp value according to the time selected while in 2T/4T mode.
Down-Slope ramps amps from the welding amp value down to the end amps
value to ll the weld crater according to the time selected while in 2T/4T
mode. Set both controls to the lowest setting while using the foot pedal or
irregular operation will occur.
3. Pre/Post Flow Control 0-10/ 0-30 Seconds Pre-Flow selects the amount of shielding gas flow time before arc starts. It is
used to purge and flood the weld area with shielding gas so the arc start is
stable and weld is porosity free. The pre-flow will delay the arc start. Set pre
-flow for .5 to 1 second for best starting. The arc will not start until the pre-
flow time cycle has nished.
The Post-Flow setting dictates the amount of shielding gas flow after arc
ends to shield the weld to prevent oxidation and cool the torch. A starting
point is to use 1 second post-flow for every 10 amps used. The torch should
dwell over the puddle during this time to prevent oxidation during cooling.
4. Pulse Off/Low/High
Selector
Off/ Low/ High Press the touch-pad button to select the desired pulse mode. Low range
offers a ner range of control over the pulse amps, ranging from .2Hz to 25
Hz. High range operates with a more coarse range of control from 25 Hz to
500 Hz. Note: The low range is highlighted in green numbers.
5. 2T/4T /Remote
Sequencer Selector
2T, Pedal/4T Press the button to select the torch switch function mode. Select 2T for
simple press-and-hold operation of the torch switch or for use with foot pe-
dal. For 2T operation with the torch switch: 1) Press and hold the switch to
start the arc and weld. Release the switch to cease welding. Select 4T for
advanced use of the sequencer controls on the panel such as start/end
amps, up/down slope. To operate in 4T mode with the torch switch/remote:
1) Press and release the switch to start arc. 2) The current will begin to
upslope to reach normal welding current. 3) Press and hold switch to begin
downslope. 4) Release switch to terminate the arc. In 4T mode, if the pud-
dle becomes too hot, it can be cooled by lightly tapping the switch to begin
downslope and tapping again to restart upslope before end current is
reached. Setting a long downslope helps improve heat control in 4T as the
torch switch is cycled between downslope and upslope before the arc is
terminated.
IMPORTANT: To use the foot pedal: Select 2T, turn up/down slope to the
minimum settings or the foot pedal will not operate correctly. Do not use the
foot pedal in 4T mode as it will result in the inability to ramp amps up or
down. 2T is to be used with torch switch or Pedal.
6. AC/DC Selector AC/DC process Select DC output for Steel, Stainless and most metals.
Select AC output for Aluminum and Magnesium alloys.
7. HF Start/Lift Start/Stick
Selector
HF/Lift/Stick This button selects the type of TIG start used. HF is touch free and activates
during start only. Lift start requires brief touch to metal to draw an arc and is
good for applications where sensitive electronics are present. This also
selects the Stick welding process.
8. Amp Control Knob DC: 10-315 Amps
AC: 20-315 Amps
Sets Maximum limit for Amps with foot pedal or torch. Sets higher amp
value for pulse. NOTE: the Minimum Amp value for AC begins at 20 amps.
DC begins at 10. If the knob is against the stop in the AC mode, the display
will register a minimum of 20 amps (±3A).
FRONT PANEL FEATURES AND CONTROLS
Section 2 Quick Setup Guide

20
PowerTIG 315LX Features Parameters Purpose/Function
9. Amp Display N/A Displays maximum selected amps until the weld is started. Displays actual amps
while welding. Display may cycle rapidly and randomly after 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 after 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 after a
few seconds if no input is made. This display does not display other parame-
ters. It is only used to display Amp values. Helpful Hint: If you nd a setting or
settings you like and wish to repeat, make a tic mark with a marker or pen
on the panel where you wish the pointer knob to be set the next time you
wish to repeat the setup. This can help reduce setup time in the future.
10. AC Frequency Control 20-500 Hz Denes the number of times per second that the current alternates polarity from
DCEP(+) to DCEN(-) while being used in the AC mode. To achieve greater arc
focus (constriction) and increase puddle agitation while welding in AC mode,
increase AC frequency. This will allow pinpoint use on thin materials, and im-
prove penetration on thicker materials. In extreme settings this may actually
seem to make the heat obtained from the arc very cold. Ideal adjustment range
is usually 100-150 Hertz. For comparison most transformer welders in the US
operate at a xed 60 Hz. Impressive results can be achieved through using the
middle or upper frequency range of this welder. Lowering AC frequency will
widen the puddle as well as soften the arc but can reduce the overall level of arc
control. On the other hand, lowering the AC frequency can help to extend the
capability of the welder to weld thick metals if a lower AC balance setting is
used. Caution: Increasing the AC frequency also increases the decibel level
and can injure hearing. Wear hearing protection to prevent hearing damage.
11. AC Balance Control 10-90% of EP Selects the percentage of Electrode Positive (EP) used during the AC welding
mode to provide to provide the needed cleaning. Represented as a percent of
EP, it actually divides the relative amount of time that the AC cycle spends in
Electrode Positive and Electrode Negative polarity during one full AC cycle. In
short, it controls the balance between cleaning and penetration to achieve the
best balance or desired effect while welding in the AC mode. When the control
knob is rotated left, more Electrode Negative is present and more penetration
will be achieved. When the control knob is rotated clockwise, more Electrode
Positive is present and more cleaning (cathodic etching) action will be achieved.
Too much cleaning action will result in the balling of the tungsten tip, nodules or
splitting, requiring the use of a larger tungsten necessary for the same amper-
age range to prevent tungsten issues. Too little cleaning action will result in a
dull, dirty or sooty looking weld. Remember: This is expressed as a percent of
full Electrode Positive. This unit uses 100% Electrode Positive as the point of
reference, which may be contrary to what the user may nd in some other
brands. Using the welder in excess of 50% EP can quickly vaporize the tungsten
and reduce welding capability when all other variables are the same. For most
welds, no more than 45% cleaning is needed. Ideally, start with 30% EP as a
reference point, then adjust it up or down incrementally to achieve best results.
12. Arc Force Control (DIG) 0-100% Expressed as a percent, arc force regulates the arc response in a short arc
condition as the voltage begins to drop. Used only in the stick mode, the Arc
force automatically compensates for the voltage drop by modifying the volt/amp
curve to maintain the energy needed to weld. The percentage referred to is the
percentage over the actual welding amperage that the selected arc force setting
provides. Once the voltage drops below 20V, you will notice the arc force acti-
vate if your are monitoring the display. This prevents the rod from snufng, or
sticking in the weld. Arc force is designed to help maintain total wattage while
welding. Turning the arc force down can make using some rods difcult.
13. Pulse Time On (Balance)
Control
10-90% Sets the duty cycle (balance) of the pulse. This is accomplished by dividing or
skewing the amount of time the pulse spends at the maximum amp value of the
pulse against the Pulse Amp (background current) stage which is the lowest
part of the pulse. The pulse consists of two stages: Welding Amps (Peak) and
Pulse amps (Base/Background current). This is represented by a % of total time
during one full pulse cycle that the pulse spends in the welding amps (peak)
stage. Practically speaking, the Pulse Time on control can be used to increase
or decrease welding amp (Peak) time relative to the pulse amp time of the cycle
to help manage heat input.
Section 2 Quick Setup Guide
FRONT PANEL FEATURES AND CONTROLS