Everlast PowerTig Series User manual

1
EVERLAST
POWER TIG ® SERIES
TIG (GTAW) AND MMA (SMAW)
WELDERS
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2
Thank you for purchasing an everlast product. We ap-
preciate your patronage and hope that you will enjoy
years of use from our product.
Please go directly to the Everlast website to register
your unit and receive your warranty information.
Your unit registration is important should any infor-
mation such as product updates or recalls be issued.
It is also important so that we may track your satis-
faction with Everlast products and services. If you
are unable to register by website, contact Everlast di-
rectly through the consumer department at the main
number. Your unit will be registered and warrantee
will be issued and in full effect.

3
Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________
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EVERLAST
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4
TABLE OF CONTENTS
Section……………………………………………….Page
General ...……………………………………………
Safety Precautions..……………………………….
Introduction and Specifications…………………
Know Your Machine………………………………..
2.1 Panel Face and Functions……………………
2.2 Lower Panel and functions….………………
Getting Started……………………………………..
3.1 General Guidelines……………………………
3.2 Shielding Gas Selection………………………
3.3 Regulator/Flow meter Selection……………
3.4 Regulator Connection………………………...
3.5 Regulator Adjustment………………………..
3.6 Machine Setup………………………………….
3.7 Tungsten Selection……………………………
3.8 TIG Torch………………………………………..
3.9 TIG Welding Principles and Guide…………
3.13 MMA (Stick Welding)…………………………
Trouble Shooting……………………………………
Addendum……………………………………………
5
6
12
13
13
16
17
17
17
17
17
17
18
19
20
21
23
24
25

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

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

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

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

9
Product Feature Comparison
INTRODUCTION AND SPECIFICATIONS
SECTION 1
(OCV 60-80V)
* *
GTAW-P
@35% Duty Cycle

10
INTRODUCTION AND SPECIFICATIONS
SECTION 1
PowerTig DX, LX and EX Models, I-Tig Models
PowerTig DX Series PowerTig LX Series
PowerTig EX Series Power I-Tig Series

11
INTRODUCTION AND SPECIFICATIONSSECTION 1
PowerTig 315
Industrial
PowerTig TIG (GTAW)
WP 26 Torch Assembly
PowerTig TIG (GTAW)
Foot Pedal Assembly
PowerTig Deluxe
Stick (SMAW, MMA)
Electrode Holder
And Ground Clamp
For TIG and STICK
Operation
PowerTig TIG (GTAW)
Torch Accessory Pack

12
1.1 This manual has been compiled to give
an overview of operation and is designed to
offer information centered around safe,
practical use of the machine. It is not in-
tended to teach welding technique. All
suggestions and techniques given are ap-
proximations and should be used as a gen-
eral guide only.
1.2 To ensure that your Everlast product is
in top condition, carefully inspect unit for
damage upon opening the box, looking for
damage on the surface of the unit and to
the machine itself and all its accessories.
Do this immediately upon receipt of prod-
uct. Any damage issues must be resolved
right away. It is further recommended that
the product be tested at the same time for
proper operation, even if it is to be stored
for a while. Check to make sure all pas-
sages, connections and fittings are clear of
any packing material or other obstruction.
Record the serial number on the page pro-
vided in this manual. Include purchase date
for warranty reference. Serial numbers are
located on the rear of the machine.
1.3 The PowerTig (includes I–Tig) units
are used daily in the industry performing
day to day fabrication and repair activities.
The exceptional arc characteristics are
provided by the inverter based technology
that employs the use of reliable IGBT tran-
sistors technology from Germany. Light-
weight inverters allow a machine to be
finely tuned for precise arc characteristics,
while consuming less power than the lar-
ger transformer based machines. Power-
Tig units allow non-contact starts, eliminat-
ing the problem of tungsten contamination.
Depending upon the unit, precise control
of the welding arc is allowed through the
adjustments available on the panel face.
The independent controls allow for a virtu-
ally limitless number of configurations to
suit every type metal and weld condition
encountered. The use of High Frequency
arc starting in AC and DC modes, greatly
simplifies the TIG(GTAW) process.
1.4 Be careful to observe duty cy-
cles of the machine posted in this
manual and on the machine itself.
A duty cycle is a rating of percentage of
time out of 10 minutes the machine can be
used at the rated power setting . Over-
heating may occur if the duty cycle is ex-
ceeded. On multi-voltage, multi-phased
machines, note that the rated duty cycle
will change. Duty cycle for Maximum rated
GTAW amps is @ 35% DX series and 60% I-
Tig, LX, and EX series. For SMAW operation
duty cycle is rated @ 35% for all units.
1.5 The unit should be stored in a dry
place for long term storage. Humid/wet
conditions can contribute to the eventual
decay of the circuitry in the machine. For
safety reasons, do not use this machine
directly in the rain or with soaked clothing
or protective gear.
1.6 Use only the provided handles to lift the
unit. Do not suspend by cables or chains
or use fork trucks to lift the units. If neces-
sary, use two people to carry the unit.
1.7 Make sure that the units cooling fan
and exhaust vents are kept free of obstruc-
tion. Before every operation, inspect the
unit for unexpected obstructions such as
insect and rat nests. From time to time, a
cleaning of the machine with low pressure
air and a small plastic bristle brush is nec-
essary to ensure long life. On these occa-
sions only, unplug unit and remove cover
to access interior. Concentrate efforts on
aluminum heat sinks and panel vents to
remove dust and dirt.
1.8 Refer to the following pages to locate
your particular unit and its specifications.
Note that product specifications are sub-
ject to change without notice due to prod-
uct improvements. If any additional infor-
mation is needed contact Everlast. Sche-
matics are not offered due to the proprie-
tary information that they contain. How-
ever, simple wiring diagrams may be ob-
tained for basic diagnosis and may be ob-
tained from technical support.
INTRODUCTION AND SPECIFICATIONS
SECTION 1

13
SECTION 2 KNOW YOUR MACHINE
1
2 3 4
5 6 7
8 9 10 11
12 13 14 15
16 17 18 19 20 21 22
2.1 Panel Face. The following is a unit panel
face from an EX series unit. Depending upon
your unit, the panel face may vary with regard
to quantity and location of controls and fea-
tures. Use the appropriate referenced num-
ber to refer to equivalent features on your
unit. Names or designation of control features
may slightly vary. I-tig model layout varies
slightly.
1. On lamp. This light illuminates while the
machine is powered on.
2. Over Current/Overheat lamp. This lamp
illuminates when the duty cycle has been ex-
ceeded or the machine has overheated due to
improper ventilation. Discontinue use until
lamp goes out. Allow the fan to continue to
run. Once lamp goes out, you may resume
using the unit. If frequent or continuous over-
heating is encountered, contact Everlast.
3. Digital Display. The display posts the
welding amps within ± 3 amps . Display will
change to reflect actual welding amps while
welding and pulse cycle amps, although at a
fast pulse setting the minimum and maximum
amperages may not be accurately posted.
4. Pulse power control*. This 3 position rocker
switch allows for use of the built in pulse. You
may select: Off, Low (L), or High (H). This fea-
ture pulses (cycles) the amperage between
base and peak amps to maintain fine control of
welding on thin materials or on out-of-position
welds. Noticeable fluctuation of the arc inten-
sity occurs when the pulsing mechanism is on
at low frequency levels.
*Note: On DX , LX Models have only 2 position
rocker switches.
I-Tig models select for DC or Pulse DC only.
Model 315 DX has no dedicated switch control
for the pulse. Turn the pulse off by turning the
pulse amps control to lowest setting and use
only the base amps to select amperage.
5. Pulse Frequency. The pulse frequency con-
trols the number of pulse cycles per second
(Hz). Where applicable, when the pulse is se-
lected for Low, the inner numbers are read. (.2
-20 cycles per second). When the pulse is se-
lected for High, read the outer numbers. (5-500)

14
6. Pulse Amps. This gives proportional
control of the Pulse Amps. Example: If the
Amperage is set for 100 amps, and the
Pulse Amps control knob is set for 95% (.9),
then the low (base) amperage cycle of the
pulse will be approximately 95 (90) amps.
Regardless of nomenclature, the basic
function of the control is the same. DX
model ratio are adjusted independently by
using the main amp and pulse amp con-
trols. Adjust the pulse (peak)amps above
the main (base) amps for proper control of
the pulse cycle.
7. Pulse Time On: Some models: Pulse
Width. This controls the ratio of
the relative amount of time that the pulse
spends on during a defined cycle . For ex-
ample: A setting of 50% will result in a bal-
anced and equally shared amount of time
between the Pulse current and the base
current. A setting of 95% will result in the
favoring of the Pulse stage of the cycle with
only 5% of the time spent in the base stage
of the Pulse cycle.
Note: This does not control the overall
length of the pulse. The pulse frequency
setting sets the cycle length, thereby de-
termining the overall length of each leg of
the cycle. Within each cycle length, there
is a certain amount (ratio) of time that the
pulse spends in the base (low) amperage
stage of the cycle and in the peak (high)
amperage stage of the cycle. As the cycle
frequency (Hz) increases, overall cycle
length is shortened, thereby compressing
the exact amount of time that the cycle
spends in each stage. However, the pulse
ratio continues to function within the com-
pressed cycle proportionately.
8. Main Amperage Control. Some models:
Welding Amps . Locations may vary. This
control knob allows for precise control
over the welding current. This control
knob also is used in conjunction with the
pulser to select the pulse time on amps.
9. Arc Force. This controls the dig of the
arc. The dig is a term used to describe the
intensity of the arc. It determines how hard
the arc penetrates the metal when the arc
is held short by boosting amps in a short
SECTION 2 KNOW YOUR MACHINE
FRQWLQXHGarc situation. This is an exceptionally help-
ful feature in SMAW/Stick operation. It
helps hold the molten metal in place in out-
of-position welds by providing a crisp,
forceful arc. Or, it can provide a soft, but-
tery arc that easily washes the metal into
the toes of the weld. This is a matter of op-
erator preference. Rotating the knob
clockwise increases dig. There are no
recommended settings regarding this fea-
ture. Skill, operating styles and electrode
selection are controlling variables that help
determine the optimum setting of the arc
force. With a little experimentation, the
proper setting can be found for each task.
10. AC Frequency Control. This control
narrows the welding arc and helps to con-
trol penetration and weld shape.
Image 2.1.10–Frequency effects on weld puddle.
200
AC Hz 20 AC Hz
11. AC Balance. This control determines
the amount of time the AC cycle spends in
DCEN (-) or DCEP (+). More DCEP is pre-
ferred for cleaning oxidation, particularly
in aluminum. More DCEN is preferred for
better penetration. A 30% setting is cus-
tomarily preferred. Try this setting first as
a starting point for adjustment.
12. AC/DC Rocker Switch. This switch se-
lects the use of either AC or DC current.
AC current is used primarily when TIG
welding aluminum. Certain stick electrodes
can be welded in this mode to prevent arc
blow and increase penetration.
13. 4T/2T Rocker Switch. This switch se-
lects for control of the TIG weld cycle via
the TIG torch trigger. In the 2T mode, sim-
ply touch and hold the trigger to start the
arc and continue holding while welding.
The machine will cycle automatically ac-
cording to the settings selected on the ma-
chine. Release trigger the to finish.

15
SECTION 2 KNOW YOUR MACHINE
FRQWLQXHG
4T operation allows full control of the welding
cycle. By touching and releasing the trigger
once, the pre-flow, start current and up slope
are initiated. By touching and releasing
again, the down slope, end current, and post
flow are initiated. Only a momentary pause
between touching and releasing is necessary
to activate the up or down cycle.
*Note: The use of the foot pedal overrides
some of these functions. Place the setting in
the 2T position to use the foot pedal. The foot
pedal is used to manually control the cycle.
14. Spot Timer. This allows automation of the
TIG welding cycle by providing current and
gas flow long enough to make a uniform spot
weld. Activate the spot timer by pressing and
holding the torch trigger until the spot timer
cycle is completed (2T or pedal only).
15. TIG/Stick rocker switch. This switch al-
lows you to select the use of either High Fre-
quency TIG, Lift Start TIG or the conventional
SMAW (stick) welding features. For sensitive
areas requiring a non high frequency start,
select lift start. Simply touch tungsten to work
and energize the torch. Watch the tungsten
for a slight glow and raise the torch to start
the arc. Do not use this for Aluminum.
16. Pre Gas Flow. This timer allows the
appropriate amount of shielding gas to
flow to purge the gas lines and to provide
adequate shielding gas coverage over the
weld before the weld arc initiates. The
gas flow rate is affected by the torch cup
size and welding conditions.
17. Post Flow. This timer controls the
flow of shielding gas after the weld arc is
terminated. Too little post flow time can
cause weld contamination or torch over-
heating. I-tig models have a switch that
selects a preset time for post flow.
18. Up Slope. This controls the time that
the machine takes to ramp up the current
from the start current to the normal weld-
ing current. This provides for excellent
control over the welding puddle after it is
developed and allows the operator to ad-
just manipulation techniques as the pud-
dle warms up.
19. Down Slope. This controls end cycle
of the weld by slowly ramping down the
welding current. As the end of the weld is
reached, the down slope helps prevent
weld cracking and hole formation in the
crater by allowing controlled cooling of
the puddle.
20. Start Current. This selects the initial
current for puddle development before
upslope occurs. Also it may be set higher
than main current for “hot” starts for thin
materials..
21. End Current. This selects the destina-
tion current of the down slope. This is the
residual current required for the operator
to properly fill the weld crater to prevent
cracking and holes at the end of the weld.
22. Spot Time. Controls weld time for
spot welding. Touch torch switch in 2t
mode to activate timer or use foot pedal
for controlled spot weld size.
Image 2.13a Graphic of 2T Operation
Image 2.13a Graphic of 4T Operation

16
SECTION 2 KNOW YOUR MACHINE
FRQWLQXHG2.2 Lower Panel. The lower front panel is de-
picted below. Each terminal or lug should be
kept free of dirt or obstructions.
1. Positive Lug. For TIG, most situa-
tions require the work clamp to be in the
positive lug. Mate the ground clamp cable lug
into the hole by aligning the raised tab. Give a
slight clockwise twist to lock the cable onto
the machine. Also, when using MMA/Stick,
either terminal may be used for the ground.
However, most stick electrodes require the
use of Direct Current Electrode Positive
( DCEP, or commonly known as reverse polar-
ity). In the case of the electrode positive re-
quirement, connect the electrode holder ca-
ble to this side of the panel.
2. Quick Connect Gas Outlet. To secure the
TIG torch to the outlet, simply slide the collar
rear ward to ward the machine . Hold the col-
lar and plug the gas line from the torch into
the fitting. To release, simply slide the collar
reward again and pull the torch fitting from
the coupling. Once the coupling has been
released, the collar should remain retracted
so that the subsequent connection only needs
to be pushed in and the collar will snap in
place automatically. The operation is similar
to commercial air line quick connect fit-
tings.Check for leaks.
3. Torch Control. Plug either the foot pedal
or the torch trigger lead directly into this
plug. Tighten the collar to secure the plug
onto the machine. The use of the foot pedal
prevents the use of the torch trigger.
4. Negative Lug. For TIG operation, connect
the TIG torch to this side. Connecting the
TIGTorch to the Positive side will result in
overmelting of the tungsten electrode.
*Note: For proper use of DCEN and DCEP
while stick welding, consult enclosed infor-
mation usually supplied with stick electrodes.
2.3 Rear Panel. The following depiction is a
typical rear panel view. Yours may vary.
1. Serial Number. Use for reference.
Image 2.3 Rear Panel
2. Machine Specifications. This information
supersedes any specifications offered in the
manual as specification changes do occur.
3. Double Pole Power Switch. This heavy
duty switch powers the unit. Flipping the
switch turns the unit on or off.
4. Fan. Allow 12 inches of clearance between
the fan and any object that could restrict air
flow. This includes walls and workbenches.
5. Shielding Gas Inlet. Connect to regulator.
7. HF Ground connection. See section 3.6.1
6. Power Cord. See section 3.6.1
1 2 3 4
1 2 3
4
5 7
Image 2.2
6

17
SECTION 3 GETTING STARTED
3.1 These are general guidelines for use
and maintenance for your PowerTig unit.
Take into account all safety rules and rec-
ommendations first before operation and
service. Do not let untrained personnel
operate or service equipment in any way.
3.2 Shielding gas selection.
Do not attempt to operate your unit
with out proper shielding gas!
Proper shielding gas selection is crucial to
satisfactory operation of your TIG machine.
Shielding gas is a special gas or mixture of
gases designed to cover and protect your
weld from contamination from the atmos-
phere while welding and as it cools. Oxy-
gen and other gases from the atmosphere
can infiltrate the weld and make it unserv-
iceable. Do not be fooled by the weld’s ap-
pearance, because many defects are con-
tained inside the weld without the use of
proper shielding gas. The most economi-
cal and available gas is 100% Argon. He-
lium and Argon/Helium mixes are also
available. Helium offers faster weld rates
while Argon offers a more focused cone
and better cleaning action. Do not attempt
to use common shielding gases designed
for MIG welders. These will melt the tung-
sten and contaminate the weld. If you have
never developed a working relationship
with your local welding supplier, then it is
time to make a visit to purchase or lease a
tank of shielding gas. Many sizes of tanks
are available. Choose the size that best fits
your long term needs.
3.3 Regulator/ flow meter selection. You
will need a flow meter/ regulator designed
to be fitted onto your shielding gas tank. It
controls the flow rate of shielding gas into
your PowerTig. There are two styles gen-
erally available. The first has two gauges,
one for pressure the other for flow. These
are the least accurate, but usually the most
economical. The best regulator has a pres-
sure gauge and a flow meter with a ball
that floats when gas flows. Certain flow
meters can regulate Helium, Argon or He-
lium/Argon mixes equally well. However,
others cannot. It is advisable that a flow
meter be selected that can regulate both.
Always be sure to select the correct
flow meter for the type of shielding
gas that is in use. Never substitute oxygen
or acetylene regulators!
Image 3.3a Ball type flow meter
Image 3.3b Ball type flow meter
3.4 Regulator/Flow meter connection. Af-
ter connecting regulator safely to tank,
attach hose end to shielding gas inlet .
(see 2.3.5) Firmly clamp and secure hose
end to the unit. Depending upon the flow
meter manufacturer, you may have to cut
and remove the pre-crimped hose fitting to
attach the hose to the shielding gas inlet
barb. Open the tank valve slowly and
gradually increase the regulator flow to
check for leaks.
3.5. Regulator /Flow meter adjustment.

18
SECTION 3 GETTING STARTED
FRQWLQXHGAdjust the flow meter per manufacturer’s
recommendations. Generally, the flow
should be set around 15-25 CFH indoor for
Argon. Helium settings are usually at least
twice the flow rate of Argon. You will have
to increase the flow of gas if weld porosity,
sootiness, or weld discoloration is encoun-
tered. If a draft is present or welding is
done outdoor, additional flow may be
needed. Increase flow meter output until
symptoms disappear.
3.6. Machine set up .
1. Power Plug installation. Due to the lack
of standards concerning 220V plug con-
figurations, Everlast chooses to ship
most of our units without a plug for ser-
vice. We recommend a license electrician
be consulted to connect your welder for
service to ensure all codes are followed.
The following is provided as a general
guide only. Determine the plug prong pat-
tern of the existing 220V outlets in your
shop or garage. Make sure both plug and
receptacle match perfectly. We recom-
mend the standard 50 A NEMA welder
plug. Higher amperage units require twist
lock type connections. Do not force plugs
to mate . The green wire is used as the
ground and the black and white wires are
“hot” 110 V wires. To make a 220V circuit
work, two “hot” wires must be used from
separate phase 110V wires from the panel.
Do not attempt to wire the unit from the
same phase 110 V leg of the panel. Iden-
tify your green ground wire first and prop-
erly attach the wire to the ground prong.
The remaining black and white wires are
your 110V “hot” wires. Attach the two re-
maining wires to the remaining two
prongs. Multi phase/Three phase units
have a third red wire designed to be con-
nected to the third “hot” leg/wire of a three
phase system. Typically, it is recom-
mended for use in a 240V Delta 3 phase
system. 208 Y balanced leg system may be
used, but performance will be reduced
slightly. The ground bolt on the rear of
the machine is designed to help eliminate
High Frequency interference from the ma-
chine. Ground the case bolt to a separate
wire connected to a metal ground rod out-
side of the facility that is in moist soil
. Occasionally multiple ground points are
required.
Do not ground back to electrical circuit
ground as harmful HF feedback can occur.
If you notice significant computer interrup-
tions or other electronic device issues,
consult your electrician immediately for
proper HF grounding and shielding tech-
niques.
Image 3.7a Painted Tips
3.7 Tungsten Electrode Se-
lection. Currently there
are many choices available
for tungstens. Tungstens
are generally referred to by
a colored band painted on the end of each
electrode. Each color represents a certain
alloying element that is present with the
tungsten that helps to extend tungsten life.
Sizes also vary. Each size tungsten is ca-
pable of handling a certain current range.
Not all tungstens are alike. Pure tungsten
(Green) is not recommended for use in any
Everlast PowerTig machine. Pure tungsten
is not capable of handling the heat and
stress placed upon it by an inverter based
welder. Although pure Tungsten is the
most affordable, it forms a large ball that
makes the arc erratic and difficult to con-
trol in inverter based machines. Old style
transformer welders are better suited for
pure tungsten. The most widely used tung-
sten is thoriated (Red). It withstands the
heat of inverter based welding quite well
and retains its shape without over-melting.
Red (thoriated) tungsten may pose a health
risk as it is slightly radioactive. Inhalation
of the grinding dust or microscopic parti-
cles is possible. Although it is suited for
welding use in an Everlast machine, many
people choose not to risk their health. Red
tungsten has been available for a long time
and is the standard tungsten in the industry
today. However, as concerns rise, more
companies are looking for alternatives.
The most favored alternatives have be-
come either a Ceriated (Orange) tungsten
or Lanthanated (Gold) tungsten. Both are
suitable for use in an Everlast PowerTig
unit. Costs for these electrodes are con-
siderably higher than thoriated types of
tungsten. Many welders experiment with
several types, eventually finding one that
they favor in all situations.

19
SECTION 3 GETTING STARTED
FRQWLQXHGThe following table supplies basic information
about Tungsten selection and suitability.
Note: Use only recommended sizes in Tig
torches unless you purchase additional col-
lets to fit the electrodes snugly. Loose fitting
electrodes quickly ruin TIG torch parts.
NR
NR
O
K
O
K
NR
Table 3.7.1
Not
Recommended

20
SECTION 3 GETTING STARTED
FRQWLQXHG3.8 TIG Torch. Becoming fa-
miliar with a TIG torch is a
necessary step to becoming
proficient at TIG welding. Due
to constant issues with sharp-
ening and replacement of the
tungsten, frequent adjust-
ment and breakdown of the
torch components is often re-
quired. Refer to the following
image for a typical TIG torch
breakdown.
Image 3.8b Typical Torch Parts
1. Cap. This is also referred to as a Spur or
Rooster Spur. Short caps are available to
provide easy access to tight places.
2. Tungsten. Be sure to select proper sized
tungsten for job. Avoid use of green tungsten
(pure) on Everlast PowerTig welders.
3. Collet. A snug fitting collet must be used to
prevent slippage and internal arcing.
4. Torch body. All parts connect inside or to
the outside of the torch body through
threaded connections.
5. Gas Insulator. Prevents loss of shielding
gas around cup.
6. Collet body. Holds collet.
7. Cup. Focuses and directs shielding gas
around weld area.
3.9 TIG Operation and Principles.
Before any welding takes place, it is
necessary to put on protective gear and
familiarize yourself with safety precautions.
TIG welding is an elite form of welding. Not
many people learn to fully master the tech-
nique due to the patience and practice this art
form requires. This manual cannot make you
a good welder. Only practice and skill can do
that. Everlast provides this basic information
as a general guideline to assist the operator in
learning basic principles and techniques.
Notice the basic components of the TIG proc-
ess in the image below.
The shielding gas flows out from the torch
head to cool and protect the molten puddle
and the tungsten as the arc continues to melt
the base metal. As the metal melts and a cir-
cular puddle is formed, the Tig torch is slowly
moved forward. While the metal gently flows
together, the filler rod is kept near the arc
and in the gas cone to keep it hot and keep it
from oxidizing. As the metal begins to form a
“keyhole” shaped puddle and penetration of
the metal is achieved, the filler rod is gently
added to the molten puddle and then removed
as a molten drop of filler material is added to
the base material.
As you familiarize yourself with the above di-
gest of basic TIG welding, there are a couple
of basic knowledge items that need to be ad-
dressed.
The tungsten must be shaped prior to initiat-
ing an arc. With inverter based TIG welders,
Image 3.8a
PowerTig Torch
Assembly
1
2
4
5
67
3
Image 3.9a