Everlast PowerUltra 206Pi Safety guide

IGBT DC Multi-Process PulseTig/Stick/Plasma Cutter*
Operator’s Manual For The
DC Output PowerUltra 206Pi
Safety, Setup and General Use Guide
Rev. 1 0 01010-16
CC
GTAW-P
SMAW
1
~
PHASE
DC
everlastwelders.com
1-877-755-9353 Specicaons and Accessories subject to change without noce.
329 Lileeld Ave. South San Francisco, CA 94080 USA
PAC
EVERLAST
POWERULTRA 206P i
DV
120/240V
*Not suitable for welding aluminum. Does not weld AC.

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, Plasma Connecon.…..………..
Quick Setup Guide, Sck Polarity and Connecon
Quick Setup Guide, Rear Connecon for Plasma…
Quick Setup Guide, Rear Connecon for TIG..…….
Front Panel Features and Controls……………………..
Rear Panel Features and Controls……………………...
Tungsten Preparaon…………………..…………………….
Polarity, Tungsten and Amp Recommendaons....
High Frequency Start TIG Operaon……………………
Sck Arc Starng Procedure………………………………..
Plasma Funcon and Operaon………………………....
Expanded View of TIG torch……….…….……….………
Expanded View of AG60 Plasma Torch………………..
7 Pin Connector Pin-out…………..…….…….…………….
Troubleshoong………………………………………………....
3
4
5
9
10
11
11
12
13
14
15
16
17
20
22
23
24
25
26
31
32
33
34
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 INC. 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 receive your warranty informaon. Your
unit registraon is important should any informaon such as product updates 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 ser-
vice 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 purchase. In the event of a problem you must contact technical support be-
fore your welder can be a candidate for warranty service and returned.
Please review the current online warranty statement and informaon found on the website 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. At the me of this manual prinng the MOSFET based SuperUltra 206i, 206Pi, have a 3 year
warranty in the United States. See the Everlast website, www.everlastgenerators.com for complete de-
tails. Accessories are covered under a separate warranty which may vary in length.
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 perfor-
mance. 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 during o hours, or in the event you
cannot reach a live person. In the event you do not reach a live person, as is likely during heavy call volume
mes, holidays, and o hours, leave a message and your call will be returned normally, within 24 hours. Al-
so, 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 manufacturing
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 problems or issues that may seem very basic. However,
diagnosis procedures MUST be followed to begin the warranty process. You must receive an Return Au-
thorizaon number before returning your unit to Everlast for Repair. Repairs made by un-authorized re-
pair centers are not reimbursable under the warranty agreement.
Please, keep in mind that our technical advisors can’t assume anything diagnosing the unit, even with ex-
perienced users, and must cover all aspects to properly diagnose the problem. The advisor must start at a
basic level diagnosis before proceeding to more complex issues. Full cooperaon during the diagnoses will
help insure you have the most accurate and helpful diagnosis possible. In many cases, it may even result in
a remedy over the phone. Depending upon your issue, it is advisable 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 if you have any quesons or problems.
Sincerely,
Everlast Customer Service

4
Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________
Contact Informaon
Everlast US:
Everlast consumer sasfacon email: [email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Support Forum: hp://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
Everlast Canada:
Everlast consumer sasfacon email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
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
occasion occur. With proper use and care your product should deliver years of trouble free
service.
REMEMBER: 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 experience. Much of
welding and cung is based upon experience and common sense. As thorough 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. This manual cannot Your safety, health and even life depends
upon it. While accidents are never planned, prevenng 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 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 Ev-
erlast Support.
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 operaon in the unlikely event that a failure of internal components
results in sparks or exploding components such as a capacitor failure. If a failure occurs, dis-
connue further use unl malfunconing parts or accessories have been repaired or replaced
by qualied personnel.
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
create 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 oc-
cur. 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
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 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n-
guishers close by and addionally 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 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
Introduction and SpecificationsSection 1
26 series TIG torch Sck Electrode Holder
Consumable Starter KitS-45 Plasma Torch
Work Clamp
Foot Pedal Assembly
Argon and Air Regulator
NOTE: Accessory and consumable style and quanes are subject to change without noce. Consumable starter kits provide only enough
consumables to get started. No tungsten is provided. Extra consumables and full consumable kits may be purchased through Everlast or
almost any local welding supply store for TIG. Plasma cung consumables may be bought direct from Everlast or other online retailers.

10
Introduction and SpecificationsSection 1
POWERULTRA 206Pi INPUT/OUTPUT SPECIFICATIONS
FEATURE/SPECIFICATION POWERULTRA 206Pi
INVERTER TYPE IGBT, Digitally controlled
INPUT VOLTAGE ±10%;PHASE/FREQUENCY 120/240V; 1PH/50-60Hz
MAXIMUM INPUT AMPS (I₁MAX), Inrush. 30A @ 120V/ 28A @ 240V
MAXIMUM INPUT RUNNING AMPS (I₁e), Rated. 19A @ 120V/ 18A @ 240V
DUTY CYCLE % @ AMPS
TIG: [120V] 60% @125A/15V 100%@ 100A/14V
[240V] 60%@200A/18V 100%@160A/16.4V
Plasma: [120V] 35%@25A/90V 60%@22A/88.8V 100%@20A/88V
[240V] 35%@50A/100V 60%@40A/96V 100%@ 30A/92V
Sck: [120V] 35%@100A/24V 60%@80A/23.2V 100%@60A/22.4V
[240V] 35%@160A/26.4V 60%@130A/25.2V 100%@100A/24V
OUTPUT RANGE : AMPS/VOLTS
TIG: [120V] 5-125A/10.2-15V [240V] 5-200A/10.2-18V
Sck: [120V] 5-100A/20.2-24V [240V] 5-160A/20.2-26.4V
Plasma: [120V] 20-25A/88-90V [240V] 20-50A/88-100V
OPEN CIRCUIT VOLTAGE
TIG: 70 V
STICK: 70V
PLASMA: 250 V
TIG TORCH 26 SERIES (standard type)
PLASMA TORCH S-45 type (Blow back, non high frequency start)
CONSTANT CURRENT (CC) OUTPUT TYPE DC (±) *
STICK CELLULOSE ELECTRODE CAPABILITY 6010,6011 6011 is permissible (DC+). No 6010 capability. The unit works well and
is designed for use most other types of electrodes.
INCLUDES
WORK CLAMP WITH CABLE (8 FT),STICK TORCH WITH CABLE (8FT), TIG
TORCH: 12 FT, PLASMA S-45 12 FT, CONSUMABLE STARTER KIT FOR
TIG AND PLASMA (NO TUNGSTEN)
DINSE CONNECTOR TYPE 25 Series for both posive and negave connectors
POST FLOW ADJUSTABLE 0-50 Seconds
PROTECTION CLASS IP21S
INSULATION GRADE F
*This unit is DC output only. Practically speaking, AC TIG is required to weld aluminum . In some circumstances,
DC TIG can be used to weld aluminum, but it is not a practical solution to TIG welding aluminum. This unit is not
designed or sold to provide a suitable choice for welding aluminum with TIG. However, the plasma cutter may be
used to cut aluminum, Keep in mind, due to the metallurgical properties of aluminum, cut capacities are diminished
when cutting aluminum by 30%. Also, in stick mode, with a special aluminum electrodes, some aluminum welding
may be accomplished, but it has practical limitations due to the expensive nature of aluminum ellectrodes and skill
required to do so. Aluminum stick electrodes donot provide an acceptable solution to aluminum production weld-
ing, especially on metal thinner than 1/8” and should only be used for emergency repairs on thicker materials, after
testing the method for suitability.