Everlast POWERTIG 350 EXT User manual

EVERLAST
POWERTIG 350 EXT
Operator’s Manual for the PowerTIG 350 EXT
Safety, Setup and General Use Guide
Digitally Controlled AC/DC Pulse TIG/Stick Welder
CC
GTAW-P
SMAW
IGBT
AC/DC
Specicaons and Accessories subject to change without noce.
Rev.3 0 030103-17
everlastwelders.com
1-877-755-9353
329 Lileeld Ave. South San Francisco, CA 94080 USA

2
Table of Contents
Secon……………………………………………………………..Page
Leer to the Customer ………………...………………….
Everlast Contact Informaon…………………………….
Safety Precauons…………………………………………....
Introducon and Specicaons…………………….…..
Unit Specicaons……………………….……………………
General Overview…………….…..…………………………..
General Use and Care………...……………………………..
Quick Setup Guide, TIG Torch/Cooler Connecon
Quick Setup Guide, Sck Polarity……………………….
Rear Panel Gas Connecon and Wiring.…………….
Front Panel Features and Controls……………………..
Rear Panel Features and Controls……………………...
Welder Funcon Summary and Explanaons…….
Tungsten Preparaon………………………………………...
Li Start and High Frequency Start……………………
Sck Starng Methods………………………………………
Recommendaons for Polarity/Amps/Tungsten..
Expanded View of TIG torch……….…….……….………
7 Pin Connector 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 US:
Everlast consumer sasfacon email: [email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [email protected]
Everlast Support Forum: hp://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
Everlast Canada:
Everlast consumer sasfacon email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [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: [email protected]

5
Everlast is dedicated to providing you with the best possible equipment and service to meet
the demanding jobs that you have. We want to go beyond delivering a sasfactory product to
you. That is the reason we oer technical support to assist you with your needs should an oc-
casion occur. With proper use and care your product should deliver years of trouble free ser-
vice.
Safe operaon and proper maintenance is your responsibility.
We have compiled this operator’s manual, to instruct you in basic safety, operaon and
maintenance of your Everlast product to give you the best possible service and welding experi-
ence. Much of welding and cung is based upon experience and common sense. As thor-
ough as this welding manual may be, it is no substute for either. Exercise extreme cauon
and care in all acvies related to welding or cung. Your safety, health and even life de-
pends upon it. While accidents are never planned, prevenng an accident requires careful
planning and aenon to detail.
Please carefully read this manual before you operate your Everlast unit. This manual is not
only for the use of the machine, but is intended to assist you in obtaining the best perfor-
mance out of your unit. Do not operate the unit unl you have read this manual and you are
thoroughly familiar with the safe operaon of the unit.
If you feel you need more informaon please contact Everlast Support at 877-755-9353 ext.
207 or email at suppo[email protected]
The warranty does not cover improper use, maintenance or consumables. Do not aempt to
alter or defeat any piece or part of your unit, parcularly any safety device. Keep all shields
and covers in place during unit operaon should an unlikely failure of internal components re-
sult in the possible presence of sparks and explosions. If a failure occurs, disconnue further
use unl malfunconing parts or accessories have been repaired or replaced by qualied per-
sonnel.
Note on High Frequency electromagnec disturbances:
Certain welding and cung processes generate High Frequency (HF) waves. These waves may
disturb sensive electronic equipment such as televisions, radios, computers, cell phones, and
related equipment. High Frequency may also interfere with uorescent lights. Consult with a
licensed electrician if disturbance is noted. Somemes, improper wire roung or poor shield-
ing may be the cause.
HF can interfere with pacemakers. See EMF warnings in following safety secon for further
informaon. Always consult your physician before entering an area known to have welding or
cung equipment if you have a pacemaker.
Safety Precautions

6
Safety Precautions
These safety precauons are for protecon of safety and health. Failure to follow
these guidelines may result in serious injury or death. Be careful to read and follow all
cauons and warnings. Protect yourself and others.
Welding and cung processes produce high levels of ultraviolet (UV) radiaon that can cause se-
vere skin burn and damage. There are other potenal hazards involved with welding such as severe
burns and respiratory related illnesses. Therefore observe the following to minimize potenal acci-
dents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even under weld-
ing helmets to protect your eyes from ying sparks and debris. When chipping slag or grinding, gog-
gles and face shields may be required.
When welding or cung, always use an approved shielding device, with the correct shade of lter
installed. Always use a welding helmet in good condion. Discard any broken or cracked lters or
helmets. Using broken or cracked lters or helmets can cause severe eye injury and burn. Filter
shades of no less than shade 5 for cung and no less than shade 9 for welding are highly recommend-
ed. Shades greater than 9 may be required for high amperage welds. Keep lter lenses clean and
clear for maximum visibility. It is also advisable to consult with your eye doctor should you wear con-
tacts for correcve vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cung operaon unless fully protected
by a lter screen, protecve curtains or equivalent protecve equipment. If no protecon is availa-
ble, exclude them from the work area. Even brief exposure to the rays from the welding arc can
damage unprotected eyes.
Always wear hearing protecon because welding and cung can be extremely noisy. Ear protec-
on is necessary to prevent hearing loss. Even prolonged low levels of noise has been known to cre-
ate long term hearing damage. Hearing protecon also further protects against hot sparks and debris
from entering the ear canal and doing harm.
Always wear personal protecve clothing. Flame proof clothing is required at all mes. Sparks and
hot metal can lodge in pockets, hems and cus. Make sure loose clothing is tucked in neatly. Leather
aprons and jackets are recommended. Suitable welding jackets and coats may be purchased made
from re proof material from welding supply stores. Discard any burned or frayed clothing. Keep
clothing away from oil, grease and ammable liquids.
Leather boots or steel toed leather boots with rubber booms are required for adequate foot pro-
tecon. Canvas, polyester and other man made materials oen found in shoes will either burn or
melt. Rubber or other non conducve soles are necessary to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cung or handling met-
al. Simple work gloves for the garden or chore work are not sucient. Gauntlet type welding gloves
are available from your local welding supply companies. Never aempt to weld with out gloves.
Welding with out gloves can result in serious burns and electrical shock. If your hand or body parts
comes into contact with the arc of a plasma cuer or welder, instant and serious burns will occur.
Proper hand protecon is required at all mes when working with welding or cung machines!

7
Safety Precautions
WARNING! Persons with pacemakers should not weld, cut or be in the welding area unl they
consult with their physician. Some pacemakers are sensive to EMF radiaon and could severely
malfuncon while welding or while being in the vicinity of someone welding. Serious injury or death
may occur!
Welding and plasma cung processes generate electro-magnec elds and radiaon. While the
eects of EMF radiaon are not known, it is suspected that there may be some harm from long term
exposure to electromagnec elds. Therefore, certain precauons should be taken to minimize expo-
sure:
• Lay welding leads and lines neatly away from the body.
• Never coil cables around the body.
• Secure cables with tape if necessary to keep from the body.
• Keep all cables and leads on the same side the body.
• Never stand between cables or leads.
• Keep as far away from the power source (welder) as possible while welding.
• Never stand between the ground clamp and the torch.
• Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cung processes pose certain inhalaon risks. Be sure to follow any guidelines from
your chosen consumable and electrode suppliers regarding possible need for respiratory equipment
while welding or cung. Always weld with adequate venlaon. Never weld in closed rooms or con-
ned spaces. Fumes and gases released while welding or cung may be poisonous. Take precauons
at all mes.
Any burning of the eyes, nose or throat are signs that you need to increase venlaon.
• Stop immediately and relocate work if necessary unl adequate venlaon is obtained.
• Stop work completely and seek medical help if irritaon and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, tanium, copper, cadmium,
lead or zinc without proper respiratory equipment and or venlaon.
WARNING! This product when used for welding or cung produces fumes and gases which con-
tains chemicals known to the State of California to cause birth defects and in some cases cancer.
(California Safety and Health Code §25249.5 et seq.)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas. Release of Phos-
gene gas can be deadly. Consider all chemicals to have potenal deadly results if welded on or near
metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain regulaons re-
garding high pressure cylinders can be obtained from OSHA or local regulatory agency. Consult also
with your welding supply company in your area for further recommendaons. The regulatory changes
are frequent so keep informed.
All cylinders have a potenal explosion hazard. When not in use, keep capped and closed. Store
chained so that overturn is not likely. Transporng cylinders incorrectly can lead to an explosion. Do
not aempt to adapt regulators to t cylinders. Do not use faulty regulators. Do not allow cylinders to
come into contact with work piece or work. Do not weld or strike arcs on cylinders. Keep cylinders
away from direct heat, ame and sparks.

8
Safety Precautions
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do
not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground
clamp. Do not stand in water or damp areas while welding or cung. Keep work surface dry. Do not
use welder or plasma cuer in the rain or in extremely humid condions. Use dry rubber soled shoes
and dry gloves when welding or cung to insulate against electrical shock. Turn machine on or o
only with gloved hand. Keep all parts of the body insulated from work, and work tables. Keep away
from direct contact with skin against work. If ght or close quarters necessitates standing or resng
on work piece, insulate with dry boards and rubber mats designed to insulate the body from direct
contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their locaon and make sure all
personnel in area are advised of their locaon. Taping or securing cables with appropriate restraints
can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cung. Always keep re exnguish-
ers close by and addionally a water hose or bucket of sand. Periodically check work area for smol-
dering embers or smoke. It is a good idea to have someone help watch for possible res while you are
welding. Sparks and hot metal may travel a long distance. They may go into cracks in walls and oors
and start a re that would not be immediately visible. Here are some things you can do to reduce the
possibility of re or explosion:
• Keep all combusble materials including rags and spare clothing away from area.
• Keep all ammable fuels and liquids stored separately from work area.
• Visually inspect work area when job is completed for the slightest traces of smoke or embers.
• If welding or cung outside, make sure you are in a cleared o area, free from dry tender and
debris that might start a forest or grass re.
• Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held amma-
ble liquid or material.
Metal is hot aer welding or cung! Always use gloves and or tongs when handling hot pieces of
metal. Remember to place hot metal on re-proof surfaces aer handling. Serious burns and injury
can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper mainte-
nance is your responsibility. Make sure all equipment is properly maintained and serviced 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 em-
ployees to operate poorly serviced equipment. Always check condion of equipment thoroughly
before start up. Disconnect unit from power source before any service aempt is made and for long
term storage or electrical storms.
Further informaon can be obtained from The American Welding Society (AWS) that relates directly
to safe welding and plasma cung. Addionally, your local welding supply company may have addi-
onal pamphlets available concerning their products. Do not operate machinery unl your are com-
fortable with proper operaon and are able to assume inherent risks of cung or welding.

9
PowerTIG 350 EXT Accessories
NOTE: Accessory and consumable appearance, style, length and quanty subject to change without noce.
Qty Accessory
126 Series TIG torch and cable
118 Series TIG torch and cable
1Everlast 22k Ω Pedal
1Heavy duty work clamp
1Heavy duty electrode holder
1Regulator and hose assy.
Introduction and SpecificationsSection 1

10
PowerTIG 350EXT TIG/Sck Welder Specicaons
Process AC/DC GTAW-P/DC SMAW
Inverter Type Digital Microprocessor Controlled, IGBT Module
Minimum/Maximum Rated Output TIG DC 5A/10.2V– 350 A/24V AC 10A/10.4V– 350 A/240V
Minimum/Maximum Rated Output Sck (DC Only) 20 A/20.8V - 270 A/24V
Start Type Solid State HF and Li Start
HF Point Gap Heavy Duty Carbon Contact with .029”-.039” gap
TIG Duty Cycle @ Rated Amps/Volts 35% @ 350A/24V 60% @ 280A/21.2V 100% @ 210A/18.4V
Sck Duty Cycle @ Rated Amps/Volts 35%@ 270A/30.8V 60% @ 210A/ 28.4V 100% @ 160A/26.4V
OCV (U0) TIG/Sck 80V/80V
Voltage Input (U1)240 V; 50/60Hz 1 phase
Maximum Inrush Amps (I1MAX)47A @ 240V
Maximum Operang Amps (I1EFF)29A @ 240V
Gas Pre-Flow /Post Flow Time 0-25 Seconds/ 0-50 Seconds
Start Amps/End Amps Start: 5-350A DC, 10-350 AC
End: 5-350A DC; 10-350A 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) Standard AC/DC l1-500 Hz
Advanced Square Wave (Mix) .1-10 Hz
Pulse Amps (Rao) 5-95%
Pulse Time On (Balance) 3-100%
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
Cooling Method Fan with full me running
Dimensions (approximate) 25” H X 11.5” W X 25” L
Weight (Bare Unit) 83 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* 11,500 Surge Was 9500 Connuous Rated 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
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 350 EXT, the duty cycle is rated for
35% at 350 Amps (TIG) and 35% at 270 Amps for Sck.
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 3.5 minutes out of eve-
ry 10 minutes without a break for cooling down the
unit. This does NOT mean that the 350EXT can work
35% of any longer length of me. A full rest, with the
unit running (switched on) and no welding taking place
should be given to the welder for the balance of the 10
minute period for maximum life, if operang at or near
maximum output capacity. Overheat, over current,
over voltage and under voltage faults are indicated by a
warning light accompanied 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 co-
vers 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 by a
person with at least some welding experience and/or
knowledge. This manual is not designed as a primer
on welding and is not exhausve in content. Keep in
mind that welding is inherently dangerous. Only 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
machine 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 350 EXT TIG/Sck welder is the
largest of the advanced digital models in a new genera-
on of inverter welders from Everlast. With a micro-
processor and IGBT module design, the welder oers
stable arc performance as well as convenient 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. Heavy-Duty 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: This weld is good for use in
many industrial environments such as ship yards, fabri-
ca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 remove 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.
Do not restrict air ow or movement of air around the
welder. Allow a buer distance of 2 feet from all sides
if possible, with a minimum distance of at least 18”.
Do not operate the welder immediately in the weld
Introduction and SpecificationsSection 1

12
!
WA
INPUT
OUTPUT
WATER COOLER
(Oponal)
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.
Quick Setup and Use GuideSection 2
GAS (Ar)
NOTE: The TIG torch will always be
negative polarity whether DC or AC!

13
QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS
TORCH (+)
WORK (-)
Quick Setup and Use GuideSection 2
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.

14
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
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. CONSULT LOCAL
CODES AND ELECTRICIAN FOR PROPER INSTALLATION.
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE
RE-WIRING YOUR WELDER OR ATTEMPTING TO MAKE ANY ELECTRICAL CONNECTION.
EVERLAST
HF
Fe or Cu
NEMA 6-50P
L2,WHITE L1,BLACK; HOT
GREEN GROUND
220V/240V COOLER OUTLET. USE WITH 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.
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.
Quick Setup and Use GuideSection 2

15
FRONT PANEL FEATURES AND CONTROLS POWERTIG 350 EXT
2. CONTROL PANEL
350EXT
3. NEGATIVE CONNECTOR
DINSE 35-70mm²
4.GAS OUTLET QUICK CONNECT
1. CLEAR PROTECTIVE PANEL COVER
6. POSITIVE CONNECTOR
DINSE 35-70mm²
5. 7-PIN CONTROL FOR PEDAL/TORCH SWITCH/AMPTROL
Quick Setup and Use GuideSection 2

16
FRONT PANEL FEATURES AND CONTROLS POWERTIG 350 EXT
POWERTIG 350 EXT 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:
Quick Setup and Use GuideSection 2

17
POWERTIG 350 EXT 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.
FRONT PANEL FEATURES AND CONTROLS POWERTIG 350 EXT
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
Quick Setup and Use GuideSection 2

18
POWERTIG 350EXT 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 AC: 10-350 Amps
DC: 5-350 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. This feature 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%.
FRONT PANEL FEATURES AND CONTROLS POWERTIG 350EXT
Quick Setup and Use GuideSection 2

19
POWERTIG 350 EXT 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: 10-350 Amps
DC: 5-350 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.
FRONT PANEL FEATURES AND CONTROLS POWERTIG 350EXT
Quick Setup and Use GuideSection 2

20
POWERTIG 255EXT 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.
FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT
Quick Setup and Use GuideSection 2