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.

11
General overview: The new digitally controlled Power
Ultra 206Pi from Everlast is a DC TIG, sck and plasma
mul-purpose unit, designed for portable repair work and
small project use. It is ideal for the welding enthusiast or
hobbyist with basic non-aluminum repair needs and gen-
eral light welding requirements. The PowerUltra 206Pi
features a lightweight IGBT inverter design and can pro-
vide capable service for small projects and repairs. The
PowerUltra 206Pi is not intended for use in producon or
for heavy fabricaon chores. NOTE: This unit is not suita-
ble for welding aluminum.
General Use and Care: 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 but should never be used in the presence of water
for safety. 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 in
standing water.
Every 1-2 months, depending upon use, the welder should
be unplugged, opened up and carefully cleaned with com-
pressed air. Regular maintenance will extend the life of
the unit.
IMPORTANT: Before opening the unit’s case for any rea-
son, 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 could occur.
Do not restrict air ow or movement of air around the
welder. Allow a buer distance of 2  from all sides if pos-
sible, with a minimum distance of at least 18” clearance.
Do not operate the welder immediately in the weld 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 toward
the machine, parcularly in grinding and welding opera-
ons. Make sure the panel is protected from damage dur-
ing welding and cung operaons.
Duty Cycle. This unit can be described as a general pur-
pose, do-it-yourself type of mul-process unit and is in-
tended for hobby use and general small repair and build
acvies. Care should be taken not to exceed the duty
cycle limit of the PowerrUltra 206i for maximum service
life. Once the duty cycle has been exceeded, heat may
connue to build in the electronics. 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
maximum amps for the stated percent of me out of 10
minutes without a cool down break. For the balance of
the 10 minute me period, the welder should rest with-
out welding or cung for maximum service life. The tem-
perature light will come on and the welder will automa-
cally stop welding or cung when an overheat condion
has occurred. If this occurs, stop and allow the unit to
cool while switched on. Heat will connue to be generat-
ed by and transferred to the electronics aer welding has
ceased. Welding in humid, or hot condions can aect
duty cycle as well. Do not turn o the overheated welder
unl it has safely cooled for at least 15 minutes. Once the
overheated condion has had me to clear, cycle the
power switch o and back on to reset the unit. Do not
operate the welder with the covers removed. The duty
cycles are rated at maximum amps and are as follows:
120V:TIG @ 60%, Sck @ 35%, Plasma @ 35%
240V:TIG @ 60%, Sck @ 35%, Plasma @35%
Over Current. Over currents can occur if there is a fault
in the power supply system or inside the unit. If this oc-
curs, and the LED lights up, turn the unit o, check for
external causes and remedy the problem. If none is
found, cycle the power switch o and then back on. If
the over current light does not clear aer cycling the
power switch, contact Everlast for trouble shoong.
Blow Back and High Frequency Start. The welder uses
High Frequency to start the TIG arc. HF is generated by a
point gap system similar to an older automove point/
coil system. A slight buzz, or hiss may be heard immedi-
ately upon start as the HF energizes. A bright blue light
may be emied from the front or side panel as the spark
energizes. This is normal and safe as long as the covers
are in place. Do not acvate the HF unless you are in
posion and ready to weld to minimize point gap wear.
Point gap should measure between .030”-.045”. The
Plasma cung torch is an improved blow-back design
which eliminates the need for High Frequency and its
funcon is not dependent upon the HF points or point
gap adjustment. Compared to older TIG/Sck Plasma
designs, this helps to reduce point gap wear issues.
This manual has been compiled to give an overview of
operaon and is designed to oer informaon centered
around safe, praccal use of the welder. Welding is in-
herently 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
training. Do not operate this machine unl you have fully
read the manual, including the safety secon.
Introduction and Specifications
Section 1

12
26 SERIES
TORCH (-)
GAS (Ar)
WORK (+)
CONTROL
FOOT PEDAL
NOTE: Torch switch and foot pedal control cannot be connected at the same time.
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: TIG CONNECTIONS
GAS CONTROL PILOT ARC
CONTROL
AIR-COOLED TORCH

13
GAS CONTROL PILOT ARC
NOTES:
1) Do not aempt to use the foot pedal to control the amps in Plasma mode.
2) Do not ip the process switch while cung or unit failure may result.
3) Aempt to cut only when air pressure is present. Always check gauge to conrm air pressure is present before cut.
4) Do not exceed 85 psi air supply pressure from the compressor or failure of components may result.
5) Adjust torch operaon pressure to 55-65 psi for best results while post ow is owing. (Increase post ow me to maxi-
mum to allow enough me to set pressure.)
6) When using the unit below 40 amps, the nozzles will need to be changed out for ones with a smaller diameter orice.
Everlast is the OEM supplier of the torch but not the manufacturer. Low amp cuts may be unstable unless the size is
matched to the amps being used. Although the unit can be adjusted as low as 20 amps, this does not guarantee stable
cung at this amperage. Minimum suggested cung amps is 25-30 amps for the AG 60 torch with the smallest available
consumable. Other torches with smaller consumables may be ed to supply beer low end cung capability.
7) Do not use the pilot arc connuously. It is designed for momentary use. Do not re the torch unless you are ready to cut
or you are adjusng the cung pressure. Excessive use accelerates consumable wear, point gap wear, and can also dam-
age surrounding electronics. ALWAYS CUT WITH THE WORK CLAMP ATTACHED.
8) If the pilot arc does not transfer and only a shallow cut or gouge is noced, check the work clamp to make sure it is
aached directly to clean rust free area of the work piece and that the cable is secure to both the torch and work clamp.
Make sure that the cables are located securely in the connectors.
WORK (+)
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: PLASMA CONNECTIONS
PILOT
AG-60
AIR
SWITCH
WARNING! High Volt-
age is present. Turn off
the unit when changing
or checking the torch
and its consumables.
Also turn the unit off
while changing torches.
Severe shock, burns or
electrocution can occur
if the plasma cutting
torch is accidentally
fired or if the switch be-
came stuck while the
torch is disassembled.

14
GAS CONTROL PILOT ARC
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS
WORK (-)
TORCH (+)
NOTE: When changing from Stick to Plasma cutting or TIG, don’t for-
get to change polarity of the torch and the work clamp. If polarity is
not correct, welding and cutting problems will result. Also, change
the Plasma Torch, TIG torch and stick connections with the machine
turned off for safety and to prevent accidental firing of the torches.

15
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: REAR CONNECTIONS FOR PLASMA OPERATION
Compressor and Dryer Diagram
GAS
INLET
1~220 V
NOTE: A SEPARATE AIR DRYER BETWEEN THE AIR COMPRESSOR AND REGULATOR ASSEMBLY MUST BE INSTALLED. IT SHOULD BE INSTALLED
AS CLOSE TO THE UNIT AS PRACTICAL. THIS IS A CUSTOMER SUPPLIED ITEM. THIS WILL REDUCE CUTTING ISSUES SUCH AS SPITTING, POPPING
AND RAPID CONSUMABLE WEAR. THE REGULATOR/FILTER THAT IS INCLUDED IS NOT SUFFICIENT TO REMOVE ALL MOISTURE. IT SERVES ONLY
AS A WATER TRAP AND FINE SEDIMENT FILTER. ANY AIR COMPRESSOR SYSTEM PRODUCES MOISTURE IN ALMOST ANY ENVIRONMENT REGARD-
LESS OF HUMIDITY LEVELS IN THE ATMOSPHERE. DAILY DRAINING OF THE AIR COMPRESSOR IS RECOMMENDED AS WELL FOR BEST RESULTS.
THE AIR SUPPLIED TO THE PLASMA CUTTER SHOULD BE OF SIMILAR QUALITY USED FOR AUTOMOTIVE PAINTING. DIFFERENT STYLES OF DRYERS
ARE AVAILABLE. THE MOST INEXPENSIVE AND COMMONLY AVAILABLE IS THE REPLACEABLE DESSICANT TYPE USED FOR AUTOMOTIVE PAINT-
ING. DAMAGE DONE TO THE TORCH AND THE PLASMA CUTTER (INCLUDING BUT NOT LIMITED TO: SHORTING, CORROSION AND DETERIORA-
TION OF INTERNAL LINES AND COMPONENTS) AS A RESULT OF EXCESS MOISTURE IS NOT COVERED UNDER WARRANTY. ADDITIONALLY, A FILTER
SHOULD BE INSTALLED IN-LINE NEAR THE COMPRESSOR. THAT WILL FILTER ANY EXCESS OIL OR OIL BLOW-BY FROM THE LINE IF NECESSARY. DO
NOT USE WITH AN OILING SYSTEM DESIGNED TO AUTOMATICALLY LUBRICATE AIR TOOLS. IT IS ADVISABLE TO USE THE PLASMA CUTTER WITH A
NEW AIR HOSE/LINE THAT IS FRESH WITHOUT MOISTURE OR LUBE CONTAMINATION. IF THE AIR PRESSURE DROPS FROM THE COMPRESSOR TO
THE CUTTER MORE THAN 5-10 PSI, OR AIR FLOW IS INSUFFICENT, INCREASE TO A LARGER SIZE DRYER/FILTER OR AIR HOSE. FAILURE TO USE THE
PROPER DRYER/FILTER IS THE NUMBER ONE CAUSE OF CUTTING ISSUES.
Air Dryer/Oil Filter
(Customer Supplied)
Regulator Assembly with
built-in water trap
and dirt lter (Included)
1/4” Automove Universal style
quick connector (Included)
Compressor and Air hose w ngs
(Customer Supplied)
1
2
3
4NOTE: WHEN ASSEMBLING AIR REGULATOR NOTICE THE MARKING S THAT
ARE STAMPED ON TOP OF THE REGULATOR HOUSING FOR AIR FLOW DIREC-
TION. AIR FLOW DIRECTION WILL BE NOTED AS IN/OUT OR BE STAMPED WITH
A SMALL ARROW FOR AIR FLOW DIRECTION. THE QUICK CONNECT 1/4” MALE
AUTOMOTIVE COUPLING SHOULD BE MOUNTED ON THE SIDE OF THE REGU-
LATOR WITH “IN” OR THE ARROW POINTING TO THE MIDDLE OF THE REGULA-
TOR. ALSO THE BRASS PLUG INCLUDED WITH THE ACCESSORY PACKAGE
SHOULD BE MOUNTED IN THE CENTER HOLE.
Connect for Plasma Use Only.

16
NOTE: TO PREVENT STRAY HIGH FREQUENCY INTERFERENCE, THIS UNIT PROVIDES AN ADDITIONAL 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 INTERFER-
ENCE. ADDITIONALLY, ALL SURROUNDING METAL OBJECTS SHOULD BE GROUNDED INCLUDING THE TABLE, PIPES, WALLS ETC. TO PREVENT ELECTRICAL INTERFERENCE WITH OTHER
CIRCUITS. DO NOT COUPLE THIS WIRE TO THE GROUND PROVIDED IN THE ELECTRICAL CIRCUIT.
EVERLAST
Some countries/regions use Liters per minute
(LPM), and others use Standard Cubic Feet per
Hour (SCFH) as the standard unit of measurement.
Please note which unit your ow meter uses be-
fore aempng establish your ow rate. The
marking for the ow meter is located on the clear
plasc housing. 1 unit of LPM is roughly equal to 2
units of CFH.
CO2
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL
CODES BEFORE WIRING YOUR WELDER AND OR PANEL OR BEFORE AT-
TEMPTING TO MAKE ANY NEW ELECTRICAL CONNECTION.
HF
Fe, Cu
NEMA 6-50P
L1,BLACK; HOT
Section 2
NOTE: Use Ar or Ar/He only. Do not
use more than 25% He in the Ar/He
gas mix.
NOTE : The PowerUltra 206Pi uses the same
connecon/input point for the TIG shielding
gas and for the Plasma air input. This requires
swapping the TIG and Air input hoses at the
lower connecon point when changing pro-
cesses. Do not run the argon supply line
through the air regulator. A manifold system
may be made from a T conguraon consisng
of two ball valves or a Y valve (both customer
supplied) to switch between the compressed
air input and Argon shielding gas as needed
without disconnecng and reconnecng the
gas/air lines every me the process is changed.
If no switching valve or manifold system is
used, then you must manually change the input
supply every me you change processes. Do
not run Argon through the air regulator/lter.
QUICK SETUP GUIDE: REAR CONNECTIONS FOR TIG / WIRING
(US/Canada)
QUICK SETUP AND USE GUIDE
SUPPLIED PLUG IS A NEMA 6-50P, THE STANDARD PLUG FOR MOST 1 PHASE 240 V WELDERS IN THE US AND CANADA. DO NOT MODIFY.
GREEN GROUND (220/240V 1
IMPORTANT: Do not remove the installed 240V plug to use your welder on 120V.
Use the supplied adapter. If you do not have an adapter, or have lost your adapt-
er, you may purchase a 240V to 120V standard adapter from Everlast.
240V to 120V adapter.
GAS
INLET
L2,WHITE; HOT
You must swap tubing when
changing processes!

17
GAS CONTROL PILOT ARC
2. ON/TEMP/O.C/OK-TO-CUT
1. AMP DISPLAY
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS
15. AIR PRESSURE GAUGE
6. TIG/CUT/STICK SWITCH
9. NEGATIVE CONNECTOR (-)12. POSITIVE CONNECTOR (+)
11. TORCH/PEDAL CONTROL
10. GAS QUICK CONNECT (9mm)
8. PILOT ARC-PLASMA
4. POST FLOW TIMER
5. 2T/4T PEDAL SWITCH
3. DOWN SLOPE TIMER
7. PULSE, 1/25 Hz
14. AMP CONTROL
13. GAS PURGE

18
POWERULTRA 206Pi FEATURES PARAMETERS PURPOSE
1. Amp Display N/A Indicates actual amp output while welding. While adjusng or while not welding, the func-
on of the display changes to display the selected amperage.
2. On/Temp/ Duty Cycle/
OK-TO-CUT LED GROUP
On/O
Over Temp
(Duty Cycle)
Over Current
OK TO CUT
(35-40PSI)
The On LED should always be lit while the unit is plugged in and the power switch is
switched on. If the Overcurrent LED is lit, turn the unit o and check for possible causes
including undersized cables, poor connecons and overheang cables. The Over Temp LED
indicates when the Duty cycle has been exceeded and overheated. If the Over Temp LED is
lit, do not turn o the unit unl it has had sucient me to cool (10-15 minutes). Cycle the
power switch to reset the machine only aer the machine has had me to cool. The duty
cycle and overcurrent warning lights should go o aer cycling the power switch on the
machine. If it does not, contact Everlast. The OK-TO-CUT LED will be lit when the unit has
enough pressure to operate the plasma cung torch safely. If this LED goes out, cung will
not be possible as the unit will stop output when it senses low air pressure. This is a safety
feature designed to prevent torch and consumable damage should the air pressure drop
below the safe levels or the air hose is not connected. Keep in mind this does not monitor
ideal air pressure, and is only designed to prevent operaon when the air pressure is not
connected or too low to operate. The minimum safe threshold for the OK-TO-CUT light to
come on and allow the unit to cut is approximately 35-40 psi.
3. Down Slope Timer Control 0-10 Seconds While welding with the torch switch, this feature is used to set a Amperage ramp down me
during the nal phase of the welding cycle, in either 2T or 4T mode. This has the same eect
as backing o the foot pedal to nish your weld. Use this period of me to ll your crater as
the puddle begins to cool. This will help prevent cracking in the crater. Set to 0 while the
foot pedal is connected, or a are of the arc may be observed at the end of the cycle.
4. Post-Flow Timer Control 0-50 Seconds Sets the post-ow me of the shielding gas while welding in TIG mode. While in plasma (cut)
mode, it sets the post ow me of the air. Time is an approximaon only and can vary a lile
from the seng posted on the dial. The air or shielding gas may stop owing before full
maximum me is reached. Consider the maximum seng mark a reference guide only. Post-
ow helps to deliver a beer quality TIG weld by providing ow of shielding gas to the mol-
ten weld pool as it solidies and cools aer the arc has been terminated. It also cools and
protects the Tungsten and torch during this me as well. For plasma cung it helps to cool
the torch down, extending consumable life. Use about .5 to 1 seconds worth of post ow
me for every 10 amps used to weld in TIG mode. Use a minimum of 2 seconds poslow
me for every 10 amps used in the plasma cung mode.
5. 2T/4T/Pedal Selector Switch N/A This switch determines which mode controls the unit, 2T, 4T or the pedal. Using either one
will determines how the unit behaves. When using the foot pedal, the unit must always be
in 2T to operate properly. The 2T feature, when used with the torch switch allows you to
press and hold the torch buon to start the arc and connue to weld. Release the trigger to
stop the arc and begin post-ow mode. The 4T feature allows you to press down on the
switch to start the arc. Aer starng release the trigger and the unit will connue to weld
without further acon on the trigger. To stop the arc, simply press and hold and the arc will
fully terminate when the switch is released. The post-ow will begin to ow.
6. TIG/CUT/STICK Mode Switch N/A This switch selects processes. Do not switch this switch while welding or cung, Do not
switch it with the wrong torch connected or immediate failure of the unit may result. Im-
proper polarity can contribute to torch failure as well. Make sure all connecons are in-
stalled properly before cung or welding.
7. Pulse Selector Switch O, 1Hz, 25 Hz This unit is equipped with a easy to use pulse. With this feature, the operator may simply
choose from pre-programmed sengs of O, 1Hz, or 25Hz pulse. All other parameters are
preset including pulse amps and pulse me on and are opmized for a broad range of amp
sengs. This pulse feature is intended to improve bead appearance and to help control
heat on thin metal to prevent burn through and heat wicking on edges. The 1Hz seng can
be used to help me the addion of ller metal during each pulse. It is slow enough to allow
the operator me to deposit one single “add” of ller metal in the puddle during the high
amperage stage of the pulse. With the 1Hz seng, the user should be able to use this to
create an evenly spaced, rippled bead appearance. The main goal of the 1Hz seng is to
help the operator to improve consistency while helping maintain heat control. At the 25 Hz
seng, average heat will be reduced and extra control will be achievable on thin metals that
are subject to warping and burn through, especially on edges and outside corners.
Section 2
FRONT PANEL FEATURES AND CONTROLS CONTINUED
QUICK SETUP AND USE GUIDE

19
POWERULTRA 206Pi FEATURES PARAMETERS PURPOSE
8. Pilot Arc N/A This connecon is only to be used with the plasma cung torch. The small ringed wire con-
nects here. Unscrew the plasc thumb nut and aach the wire to the post. Reinstall the
thumb nut over the wire with nger pressure only. Do not overghten
9. Negave Connector DINSE 25 Locaon of the negave terminal connecon. Dinse-style.
For Sck: Work Clamp Connecon. For TIG: Torch Connecon.
For Plasma: Torch Connecon.
10. Quick Connect Gas Outlet 9 mm
“B” Size
Connects the shielding gas to the TIG torch. To connect: Push the torch ng into the con-
nector unl the collar slides forward with a click. To Release: Slide the collar back and it will
automacally release. Do not turn or twist the connector.
11. Torch/Pedal Control 7 Pin Connect the foot pedal or torch switch to this socket to control the welder. Only the foot
pedal or torch control connector can be plugged in at one me. If the torch has a torch
switch feature, e the loose connector back and leave it disconnected while using the pedal.
12. Posive Connector (Work
Piece on some models)
DINSE 25 Locaon of the posive terminal connecon. Dinse-style connector.
For Sck: Torch connecon. For TIG, Plasma: Work Clamp Connecon.
13. Gas Purge On/O This funcon is designed to allow the user to set TIG ow rate and Plasma cung PSI without
having to iniate an arc. When selected the solenoid valve will open and allow air/shielding
gas to ow uninterrupted. This saves consumables and adds a measure of safety while
seng the unit up by prevenng accidental shock or burn while trying to make adjustments.
To use this feature, simply press the buon. Depending upon which process is selected, the
shielding gas or compressed air will begin to ow from the torches when the light is lit. This
prevents the user from having to “tap” the torch to iniate post-ow to make the adjust-
ments. Be sure to turn this feature o before welding or cung.
14. Amp Control N/A Controls amperage while welding or cung by using the knob to preset maximum amperage.
15. Air Pressure Gauge. 85 psi max
supply
55-65 psi
operang
Use the air pressure to measure air supply pressure for the plasma cung process only. The
pressure is irrelevant while being used for TIG welding, although some pressure may regis-
ter while the gas is acvely owing. Supply air pressure should not exceed 85 psi from the
air compressor or internal leaks may develop. Adjust the operang pressure while air is
owing. Adjust the air pressure to 55-65 psi and increase or decrease pressure from there
to achieve opmum cung results while air is acvely owing. To adjust air pressure with
torch, briey re torch with post ow set to maximum. Adjust air ow while the air is sll
owing. Use air only for cung. If a large dierenal in air pressure is observed (more than
10-12 psi), check for restricons, kinks or blown connecons. If all checks out ok, you may
need to use a larger diameter supply hose or compressor.
Section 2
FRONT PANEL FEATURES AND CONTROLS CONTINUED
QUICK SETUP AND USE GUIDE

20
QUICK SETUP AND USE GUIDESection 2
REAR PANEL FEATURES AND CONTROLS
GAS
INLET
5. REGULATOR ASSY. 1. POWER SWITCH
4. HF GROUND BOLT
3. GAS INLET
NEMA 6-50P
(220/240V)
L1,BLACK; HOT (240V) /HOT (120V)
GREEN GROUND (240V AND 120V )
2. POWER PLUG NEMA 6-50P
Note: Use the supplied adapter for use with 120V. Do not modify the plug.
L2 WHITE, HOT (240V) /NEUTRAL (120V)
For 240V welder circuits, note that 3-wire, 240V welder circuits use different standard colors than for 4 wire 240V. Welders do not
need a “neutral” wire. The NEMA 6-50P plug is designed for 2 hot wires, and one ground wire.