Everlast PoweTig 185 Micro User manual

1
Rev. 1 0 00131-11
EVERLAST
POWERTIG 185 MICRO
Operator’s Manual for the PowerTig 185 Micro
Safety, Setup and General Use Guide
AC/DC TIG (GTAW) WELDER

2
Table of contents
Section……………………………………………….Page
Letter to the Customer ………………...…………
Everlast Contact Information…………………….
Safety Precautions…………………………………
Introduction and Specifications…………………
Quick Setup Guide…………….……………………
Specifications……………………….………………
Know Your Machine………………………………..
2.1 Upper Panel ……………………………………
2.2 Lower Panel…………….………………………
2.3 Rear Panel………………………….……………
Getting Started…………...………………………...
3.1 TIG Torch………………….……..……………..
3.2 TIG Operation and Welding Principles…….
3.3 Shielding Gas Selection…….………………..
3.4 Regulator/ Flow Meter ………….…………….
3.6 Machine Setup (Wiring)…………….…………
3.7 Tungsten Electrodes ………….…………….
3.10 Filler Rod……………………………………….
4.0 General Advice…………………………………
Foot Pedal……………………………………………
Point Gap Adjustment……………………………..
Trouble Shooting……………………………………
3
4
5
9
10
11
13
14
15
16
17
17
20
21
21
22
22
24
25
25
25
27

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 infor-
maon. Your unit registraon is important should any informaon such as product updates or re-
calls be issued. It is also important so that we may track your sasfacon with Everlast products
and services. If you are unable to register by website, contact Everlast directly through the sales
department through the main customer service number in your country. Your unit will be regis-
tered 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 before your welder can be a candi-
date for warranty service and returned.
Please review the current online warranty statement and informaon found on the web-
site of the Everlast division located in or nearest to your country. Print it for your records
and become familiar of its terms and condions.
Everlast oers full technical support, in several dierent forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interacon.
Technical advisors are acve on the forum daily. We also divide our support into two divisions:
technical and welding performance. Should you have an issue or queson concerning your unit,
please contact performance/technical support available through the main company headquarters
available in your country. For best service call the appropriate support line and follow up with an
email, parcularly if o hours, or you cannot reach a live person. In the event you do not reach a
live person, parcularly during heavy call volume mes, holidays, and o hours, leave a message
and your call will normally be returned within 24 hours. Also for quick answers to your basic ques-
ons, join the company owned forum available through the website. You’ll nd knowledgeable,
helpful people and sta available to answer your quesons, and perhaps nd a topic that already
addresses your queson at hp://www.everlastgenerators.com/forums/.
Should you need to call or write, always know your model name, purchase date and welder manu-
facturing inspecon date. This will assure the quick and accurate customer service. REMEMBER:
Be as specic and informed as possible. Technical and performance advisors rely upon you to
carefully describe the condions and circumstances of your problem or queson. Take notes of
any issues as best you can. You may be asked many quesons by the advisors to clarify prob-
lems or issues that may seem very basic. However, diagnosis procedures MUST be followed to
begin the warranty process. Advisors can’t assume anything, even with experienced users, and
must cover all aspects to properly diagnose the problem. Depending upon your issue, it is advisa-
ble to have basic tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive
test meter with volt/ohm funcons before you call.
Let us know how we may be of service to you should you have any quesons.
Sincerely,
Everlast Customer Service

4
Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________
EVERLAST
Contact Information
Everlast US:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Support Forum: http://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 satisfaction email: [e-mail]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Austrailia:
Sydney: 5A Karloo Parade Newport NSW 2106
( 0 2 ) 9999 2949
Port Macquarie: 2B Pandorea Place Port Macquarie
( 0 2 ) 6584 2037
After hours support: 0410 661 334
Everlast Technical Support: [e-mail]

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, oper-
ation 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 disturb-
ance 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.
Safety Precautions

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
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 gas-
es which contains 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 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. Prop-
er maintenance is your responsibility. Make sure all equipment is properly maintained
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
Introduction and SpecificationsSection 1
PowerTig 185 MICRO
PowerTig WP 17 Torch Assembly
PowerTig
Optional Foot Pedal Assembly
PowerTig
Consumable Kit
PowerTig
Work Clamp

10
Introduction and SpecificationsSection 1
QUICK SETUP GUIDE
(US/Canada)
220/240V NEMA 6-50 PLUG SHOWN
(Customer Supplied)
USA/CANADA STANDARD
GREEN (Ground)
L1,BLACK 120V
L2,WHITE 120V
(OPT. NEUTRAL FOR 120 /240V UNITS)
-
+
Ar, Ar/He
CO2
WORK TORCH
SWITCH ON/OFF
EVERLAST
30/50 AMP
FOOT PEDAL (OPTIONAL)
CLAMP
GAS IN 220V, (120/240V OPT)
GAS OUT
TORCH OR FOOT PEDAL
CONTROL
HF!
REGULATOR
NOTE: LITERS/MINUTE (lpm)
EVERLAST
EVERLAST
EVERLAST
EVERLAST
RECEPTACLE SIDE

11
Introduction and SpecificationsSection 1
PowerTig 185 Micro Technical Parameters*
U0 = Open Circuit Voltage
U1 = Input Voltage
U2 = Output Voltage
I1max = Inrush Current ( Maximum Amp Demand)
I1 ef f = Operang Current ( Amperage use aer start)
I2 = Output Amps
X= Duty Cycle
*Early 2011 Models 35% duty cycle @ 160 Amps Max amps at 185 @20% duty cycle

12
Introduction and Specifications
Section 1
1.1 General Description, Purpose and Fea-
tures. The PowerTig 185 Micro, is a simple
AC/DC TIG (GTAW) machine with basic func-
tions designed for home, fabrication, and
general industrial use. With low amp DC start
and 185 amp capability, it compares favora-
bly with any competitor’s equivalent welder.
Basic features include:
1. HF Start. High Frequency starting makes
starting a touch-free process and is impera-
tive to keeping the tungsten contamination
free. It is required to weld Aluminum. To
start the arc, the torch should be as close to
the metal as practical without actually touch-
ing, no more than 3/16”.
2. 5-185 Amps DC. Low amp start capability
allows welding on the thinnest of metals with-
out burn through and blow outs.
3. 20-185 Amps AC. A 20 amp start allows
for light gauge Aluminum welding. Due to
the rapid heat dissipation of Aluminum, 20
amps is sufficient for all but the very thinnest
gauges of Aluminum alloy.
4. Automatic Pre and Post Flow. For conven-
ience and worry free operation, the Power-
Tig 185 Micro has adopted an automatic pre
and post flow that is preset to give optimal
results with a wide range of amperages and
flow rates, without wasting gas. Should
more pre or post flow be needed, a simple,
quick tap of the torch switch or foot pedal
will provide more time.
5. 35% Duty Cycle @ 185 Amps. (40° C) The
duty cycle refers to the amount of time out of
10 minutes a unit should be able to operate
before overheating. 35% of 10 minutes is 3.5
minutes of operation. This is rated at maxi-
mum amps. Using less amps will increase
duty cycle. 3.5 minutes of welding is longer
than it may seem when actually welding and
provides sufficient time at maximum amps to
make quality welds with minimal interruption.
Actual uninterrupted welding time may vary
somewhat with ambient temperature, humid-
ity, fan blockage, and poor power sources.
Running extended lengths of time with short
rest cycles will also be an contributing factor
for thermal buildup and limiting duty cycles.
Running extreme frequency or balance set-
tings while welding in AC mode will reduce
duty cycle as well.
6. Torch Switch or Pedal Operation. Hav-
ing the option of welding without a foot pe-
dal, greatly increases the versatility of the
PowerTig 185 Micro. The torch switch ena-
bles greater flexibility, especially when weld-
ing in tight areas where a foot pedal is not
practical, such as in a roll cage or welding
overhead. While using the torch switch amps
are accurately set and controlled by the pan-
el amp knob. To start the arc the user has to
light press and hold the torch switch. Contin-
uing light pressure will keep the arc ener-
gized until the switch is released, terminat-
ing the arc. Of course many prefer to con-
trol the amps with the foot pedal, which of-
fers on-demand change in amps. It is useful
for making slight changes in amps to accom-
modate varying issues with fit up, heat build
up and changes in torch position without
stopping to make adjustments. To start the
arc, simply press on the pedal with the foot
and hold the pedal down, slowly varying the
pressure and position of the foot pedal to
control the intensity of the heat. The foot
pedal overrides the panel amp control. Cor-
rect use of the foot pedal is accomplished
through experience and practice. While
learning, it is suggested to master torch
switch control before moving on to the foot
pedal, because it develops techniques of
manipulation and control without relying up-
on the pedal as a crutch to cover mistakes in
amp selection and manipulation techniques.

13
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 welder Only YOU, the
operator of this welder, can ensure that
safe operating practices are followed,
through the exercise of common sense and
training. Do not operate this machine until
you fully read the manual.
1.2 To ensure that your PowerTig 185 Mi-
cro is in top condition, carefully inspect
welder for damage upon opening the box,
looking for damage on the surface of the
unit and to the machine itself and all its ac-
cessories. Do this immediately upon re-
ceipt of product. Any damage issues must
be resolved right away. The product
should be tested at the same time for prop-
er operation, even if it is to be stored for a
while. Check to make sure all passages,
connections and fittings are clear of any
packing material or other obstruction. Fail-
ure to test and check the unit may result in
denial of shipping damage and warranty
claims. Record the serial number on the
page provided in this manual. Include pur-
chase date for warranty reference. Serial
numbers are located on the top or rear of
the machine. Be sure to register your unit
online as well.
1.3 The PowerTig 185 Micro is ideal for
day to day fabrication and repair activities.
Overall function and design has been
geared toward simple, trouble free opera-
tion, without sacrificing the basic necessi-
ties to make a sound weld. The IGBT invert-
er design and compact size allows you to
carry the unit almost anywhere it is need-
ed. In comparison to other Tig (GTAW)
welders on the market, the PowerTig 185
Micro is among the most compact AC/DC
TIG welders on the market. While it’s small
size is a bonus, it offers higher duty cycle
and better control over the weld than any
of its competitors. With a 5 amp DC start
and full AC frequency and AC balance con-
trol. The PowerTig 185 is an ideal portable
jobsite welder that can operate with clean
power generator/welders or limited jobsite
power availability due to its low input amp
requirement and good duty cycle.
1.4 Be careful to observe the duty cycle
of the welder. The duty cycle of the
PowerTig 185 Micro is 35%. This means
that the machine may be run for up to 3.5
minutes out of 10 minutes of operation at
maximum amperage. Overheating may oc-
cur if the duty cycle is exceeded. Overheat-
ing will cause the unit safety cutout to en-
gage, and interrupt the welding. Allow the
unit to run for 10 minutes after the safety has
triggered. Then reset the unit at the main
switch by cycling it off and back on. On
110/220V machines, the duty cycle and the
output of the machine will be reduced when
operated on 110V. High heat and humid con-
ditions will also affect the duty cycle of the
welder.
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 damp protective
gear. The service rating for this unit is
IP21S, sufficient for dripping water protec-
tion, but is not recommended for wet envi-
ronment use.
1.6 Use the carry strap provided to lift the
welder. Do not suspend the unit in the air.
1.7 Make sure that the units cooling fan and
exhaust vents are kept free of obstruction.
Before every operation, inspect unit for un-
expected obstructions such as insect and
vermin nests. From time-to-time cleaning of
the machine with low pressure air and a
small plastic bristle brush will be necessary
to ensure long life. On these occasions only,
unplug unit and remove cover to access inte-
rior. Concentrate the air pressure on the
aluminum heat sinks and plastic vents.
1.8 Refer to the following pages for specifi-
cations. Note that product specifications
are subject to change without notice due to
product improvements. If any additional in-
formation is needed contact Everlast. As
with any product, some changes in specifi-
cations do occur that do not affect overall
scope and function of the machine, and may
not be noted until a major production
change occurs.
Know your machineSection 1

14
Section 2 Know Your machine
1
2 3
4
5 6
7 8
2.1 Upper Panel Features. The Everlast
PowerTig 185 Micro has a simple panel lay-
out with basic, functional controls and fea-
tures. See section 3 for more detailed expla-
nation on welding functions and techniques.
1. On Indicator. The lamp will stay illuminat-
ed while unit is powered on. The LED may
remain lit for a few seconds after powering
off while capacitors are discharging.
2. Duty Cycle/Over Current Indicator. This
lamp will illuminate when the temperature
sensor indicates that operating tempera-
tures have been exceeded or when an over-
current has taken place. Extreme ambient
temperature can skew the operation of the
Duty Cycle indicator. When the duty cycle
light is triggered, cease welding, even if the
unit does not interrupt automatically. Do not
turn the machine off. Allow 10 full minutes of
cooling before turning off the machine.
Then, cycle the machine off and back on with
the switch on the back of the unit to reset the
duty cycle lamp. Do not attempt to shorten
the cooling cycle by prematurely cycling the
switch. The machine can be “tricked” into
resetting once the temperature at the sensor
is below a given level, and before the full 10
minutes expires. However, it may not have
been able to adequately dissipate some of
the residual heat transferred to the circuits.
3. Digital Display. The display posts the ap-
proximate welding amps selected in Panel
mode. Accuracy is usually within ± 3 amps.
After the arc is started the display function
changes to read actual amp output until re-
leasing the switch. The display will relay the
final welding amperage for a few seconds
after terminating the arc before resetting to
the original selected amp setting. Using the
foot pedal alters the function of the display.
Until the pedal is pressed, it will not display
the actual amps, because the amps are de-
termined by the foot pedal position.
4. Amp Control. While welding in Panel
mode (see 6) the control adjusts welding
amps within the range of 5-185 amps DC
and 20-185 amps AC. Ignore the printed dis-
crepancy on the panel of 5 amps while in AC
mode. Minimum welding amperage availa-
ble in AC mode, is 20 (±3) amps for arc sta-
bility during starts. The control knob is by-

15
passed in Pedal mode because the foot pe-
dal controls min/max amps as the pedal is
pressed or released with the operator’s
foot.
5. AC/DC Selector Switch. Select DC for
Steel, and Stainless Steel and most other
ferrous and non ferrous metals. Select AC
for Aluminum and Magnesium alloys. Un-
satisfactory results will occur if DC is used
for welding aluminum.
6. Pedal or Panel Control. When Pedal or
Panel control is selected, the correct 7 pin
controlling connector must be inserted into
the lower panel receptacle marked “torch
control”. The torch switch connector and
the foot pedal connector cannot be used at
the same time. There is only one control
connector receptacle. (See lower panel
heading in this section for more infor-
mation concerning connection. See next
section, 2.2.3,for more information con-
cerning operation of devices. )
7. AC Frequency Control; 20-250 Hz .
Increasing or decreasing AC frequency
changes arc performance while welding in
AC mode, affecting arc cone width, and
penetration. The PowerTig 185, though
small offers the same AC frequency control
of the larger units in the PowerTig series.
(See section 3 for more information)
8. AC Balance Control; 10-90 %. Adjusting
between AC + and AC–polarity regulates
the amount of cleaning action (cathode
etching) while welding. To increase the
amount of etching turn the control clock-
wise. To reduce the amount of etching turn
counter clockwise. The purpose of this fea-
ture is to improve weld appearance and
quality. The PowerTig 185 Micro shares the
same range of balance control of the popu-
lar Everlast PowerTig 250 EX, and offers
excellent arc characteristics. NOTE: All
Everlast welders, including the PowerTig
185 Micro, refer to the amount of cleaning
provided by referring as a PERCENT of
POSITIVE electrode. This may be different
from some other brands that refer to per-
cent negative. However, it is correct to
refer to percent of positive electrode as it
controls cleaning action. If you are accus-
tomed to running a balance setting that
refers to electrode negative, simply sub-
Section 2 Know Your machine
tract that setting from 100% and the re-
maining number is the equal setting on an
Everlast welder. (See section 3 for more
information.)
2.2 Lower Panel Connections. Simple and
secure connections are a feature of the
PowerTig 185 Micro. Standard DINSE 25
(3/8”)Type connectors and Quick gas and
power connectors make the unit ideal for
breakdown to carry to the job site.
1. Electrode Positive Terminal; DINSE 25
type connector. Since the PowerTig 185
Micro is a welder geared toward dedicated
TIG production work, ONLY use this con-
nector (positive polarity) for the work
clamp. Engaging the TIG torch in the posi-
tive connector will result in severe prob-
lems in operation.
2. Quick Connect Argon Connector; 9mm.
To connect the male fitting from the torch,
simply press the torch fitting in to the fe-
male fitting on the unit, until the collar
clicks forward. To release the fitting, slide
collar on the female fitting back to re-
lease the torch fitting. NOTE: Occasionally
the collar may not remain in the rear posi-
tion, prepped for insertion of the male con-
nector. Simply slide the collar back with
one hand and use the other hand to seat
the torch side fitting firmly into the seat and
release the collar.
3. Torch Control. Either the foot pedal or
torch switch connector may be connected
to this point. If the operator desires to
weld with fixed amperage setting con-
trolled on the panel, then select the torch
control. If varying amperage control is re-
quired during the welding process, then
the foot pedal should be connected.
4. Electrode Negative Terminal; DINSE 25
type connector. Connect the TIG torch on-
ly to the negative side. Do not swap the
polarity of the torch and work clamp or
unsatisfactory results will occur!
1 2 3 4

16
Section 2 Know Your machine
2.3 Rear Panel. The following depiction is a
typical rear panel view.
Image 2.3 Rear Panel
1. Serial Number. Record serial number in
the manual for quick and future reference,
along with any other manufacturing infor-
mation, including dates of manufacture/
inspection.
2. Machine Specifications. This information
supersedes any specifications offered in the
manual when specification changes occur
from time to time. This chart includes maxi-
mum input, output amps and voltage. It also
give details regarding duty cycle and other
basic information. (May be located on the
top of the main cover.)
3. Double Pole Power Switch. This heavy du-
ty switch powers the unit. Flipping the switch
turns the unit on or off. This serves as both
interrupt, reset and main power switch. How-
ever it is not to be used without a fused or
protected circuit!
4. Fan. Allow 12 inches of clearance between
the fan and any object that could restrict air
flow. This includes walls and workbenches.
Check periodically for blockages that can oc-
cur due to excessive dust build up or insect
nests such as spiders, and mud wasps.
5. High Frequency Ground. The Everlast
PowerTig 185 Micro is equipped with a sepa-
rate ground bolt intended to add a extra
ground path to guard against HF build up and
interference. Though this ground is not re-
quired for operation, it is helpful in eliminat-
ing excess HF bleed back into the main ser-
vice panel. Use a 10-12 gauge stranded wire
(automotive grade or better) grounded di-
rectly to a metal pipe or stake driven into the
moist earth outside the operating area. This
adds an extra layer of protection to the weld-
er circuits and to surrounding equipment that
is sensitive to HF interference. For more in-
formation, consult a licensed electrician con-
cering local and national codes regarding the
appropriate connection of this type ground.
6. Shielding Gas Inlet. Connect the clear,
reinforced PVC hose between this connector
and the regulator. Be sure to use the clamps
provided in the service package of accesso-
ries and consumables to secure the hose so
there are no major leaks.
7. Power Cord. See section 3 or section 2
quick start guide for proper wiring instruc-
tions. The welder is shipped without a plug. It
is up to the customer to follow local and na-
tional wiring standards to ensure the welder
is properly wired, and grounded. It is highly
recommended that a licensed electrician be
consulted that is completely familiar with sec-
tion 630 of the NEC specifically in regards to
duty cycle limited electric arc welders and
wiring requirement before connection is
made. Everlast is not responsible or liable in
any way for an improperly wired unit, its fail-
ure and/or related damage caused by the fail-
ure of the unit. The warranty does not cover
failure related to improper wiring or failure to
ensure the unit has been properly connected
to a trustworthy power source, including gen-
erators, welding generators, operation with
low or high hertz beyond the stated limits of
50/60 Hz, low/high voltage greater than 10%
of 220V or out of phase wiring. Should any
doubt remain, it is best to have a qualified
technician check the output and the wiring.
Everlast will not be responsible for failures
associated with poor or dirty power or from
running on undersized extension cords. A
small 20 amp plug may be included with the
PowerTig 185 MICRO, not intended for US/
Canadian markets. Discard it and do not use
it under any circumstance. If it is included
the plug is for export use only! Do not attempt
to change or replace the power cord for any
other size or type. To do so may void the war-
ranty. The cord supplied is the proper size
and type for the welder.
1,2 3
4
5 6 7

17
Section 3 Getting started
3.1 TIG Torch. Becoming familiar with a TIG
torch is a necessary step to
becoming proficient at TIG
welding. Due to constant is-
sues with sharpening and
changing tungsten, frequent
adjustment and breakdown of
the torch components is nec-
essary. Refer to the following
image for a typical TIG torch
breakdown. The torch provid-
ed with the PowerTig 185 is a
WP 26 or WP 17. Little or no
effort is involved in changing
the torch to other brands, siz-
es and styles. Consult Everlast for more help.
Image 3.8b Typical Torch Parts
1. Back Cap. Tightening the back cap will
wedge the collet against the tungsten, secur-
ing it from slipping. Allow the tungsten to
stick out at least 1/8” or more before tighten-
ing the back cap.
2. Tungsten electrode. (Not Included.) Al-
ways select the proper size and type of tung-
sten for the job. NOTE: Never use green
(pure) tungsten with an Everlast inverter.
3. Collet. Make sure the collet is matched to
the same size tungsten or slippage and poor
arc starting will result.
4. Torch body. The collet body and back cap
are secured to the torch body via threaded
connections. Make sure back cap and collet
body are evenly screwed into the torch body
so that the o-ring on the back cap is seated
into the torch body, preventing any gas leaks.
5. Gas Insulator. Prevents loss of shielding
gas around cup, and prevents heat transfer
back to the torch body.
6. Collet body. Slide collet into collet body
from the back side of the torch body.
7. Cup. The ceramic cup, focuses and directs
shielding gas around weld area. Changing
cup size will affect gas coverage and flow
rate requirements. Small diameter tungsten
and welding in deep corners or grooves may
require a smaller cup to gain access.
3.2 TIG Operation and Principles.
Before any welding takes place, it is neces-
sary to put on protective gear and familiarize
yourself with all safety precautions.
TIG welding is an elite form of welding. Only
practice and skill can provide the results seen
on fabrication shows and videos online. Ever-
last provides this basic information as a gen-
eral guideline to assist the new welder in get-
ting started. Notice the basic components of
the TIG process in the image below:
The shielding gas flows from the head to cool
and protect the molten puddle as the arc con-
tinues to melt the base metal. As the metal
melts and a circular puddle is formed, the
torch is slowly moved forward. While the met-
al 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 be-
gins to form a “keyhole” shaped puddle and
penetration of the metal is achieved, gently
add filler rod to the molten puddle. Then re-
moved the filler as a molten drop of metal is
added to the base material. Start with lower
amps than you think necessary in the begin-
ning. TIG welding is not fast, and usually
rushing things will result in problems. Trying
to weld at a pace similar to that of other weld-
ing processes will result in poor welds and
high levels of frustration.
2. To begin, grip the torch in a manner that is
comfortable to you. (Many skilled welders use
an underhanded grip to steady themselves on
Image 3.1a
PowerTig Torch
Assembly
1 2
4
5
6 7
3
Image 3.9a

18
the metal.) To start the arc, simply press the
trigger on the torch (select panel setting) or
step lightly on the foot pedal (select pedal
setting) while holding the torch 1/8” or less
from the weld at about 15 degree angle from
vertical, with the tungsten pointed to the di-
rection of the weld travel. A small High Fre-
quency spark will be issued at the tip of the
tungsten. If no HF buzzing sound is heard or
spark seen check connections immediately,
especially the work clamp connection to the
metal. The work clamp should be placed as
close to the piece to be welded as possible
on CLEAN metal, right next to the weld if pos-
sible. Once the HF starts, the arc should es-
tablish and the buzzing sound should cease.
On inverter style welders, the internal
switching speeds that generate the AC and
DC are are so quick, that no noticeable arc
fluctuation is observed. This is important
especially for AC welding. A fast switching
inverter means that the arc virtually never
extinguishes when polarity is switched from
negative to positive and back again and a
true square wave can be formed. Trans-
former welders, even ones with square wave
output must provide a constant overlay of HF
to keep the arc from extinguishing as it
switches polarity. With an inverter, HF is only
used to start the arc. This prevents harmful
electrical interference with other sensitive
electronic equipment that limits transformer
TIG applications.
2. After the arc starts, use a “knitting” tech-
nique to bring the edges of the puddle to-
gether by working the torch from side to side
slowly across the weld seam to heat the met-
al to the melting point. At first it may not
seem like the two sides will flow together due
to the surface tension of the metal. However,
this technique will gently coax the weld met-
al to flow together. Adding a drop of filler
will sometimes help get the puddle started if
the gap is wide between the two parts or the
sides do not want to begin to flow together.
Steady hands and practice are required for
optimal arc length. The best arc length is
one that resides just above the puddle with a
distance of about .035” or less to reduce
contamination and porosity. The force of the
arc will usually move the weld puddle togeth-
er at this distance with gentle torch manipu-
lation. Of course greater arc lengths can be
managed but generally only higher amperag-
Section 3 Getting Started
es and thicker welds. Using this low amp ap-
proach will keep heat distortion to a minimum
on thin materials. As the puddle flows togeth-
er move the torch forward slightly, and
pause while adding a drop of filler metal,
making a slight convex shape to the weld. Al-
ways look for the slight key-hole shape to ap-
pear at the front of the weld, particularly in
the first pass to judge penetration. If a con-
caved, dish shape of the weld occurs, add
more filler, speed up, or reduce heat. A con-
cave weld particularly during the first pass
may be a result of over penetration. A quick
look at the bottom of the weld will tell. The
bottom of the weld should roughly resemble
the top of the weld on the first pass. Attempt-
ing to make thick single pass welds is not ad-
visable. A single pass weld thickness should
not exceed the diameter of the filler rod for
best weld quality and strength.
3. Starting with mild steel is the best way to
perfect TIG welding skills. The properties of
steel allows more time to develop the puddle
allowing the user to recognize what is hap-
pening and develop technique. Even if weld-
ing aluminum is the ultimate goal, time and
effort spent practicing with mild steel will
help gain the necessary skills and avoid wast-
ing more expensive and difficult to weld met-
als. Trying to weld aluminum before master-
ing steel, is similar to the old adage “Trying to
run before you learn to crawl.” While welding
steel, you will notice the metal go from a dull
red, to a bright orange, to yellow and finally to
a bright yellow white where the puddle begins
to look “wet” with a shiny appearance. This is
the time to begin working the torch slowly
back and forth across the seam to get the
metal to flow together. A quick dab of filler as
the puddle flows together will fuse the two
metals firmly together. The filler should flow
into the weld seamlessly if done correctly.
Lumpy, partially melted filler, or molten filler
metal that sits on top of the weld without
drawing into the weld pool (wetting in) is too
cool or travel is too fast. If large, gaping key-
holes open up or the underside of the weld
has “icicles” hanging from it then the forward
travel speed is too slow or amps are too high.
Adding a slight pause in forward torch travel
between the dips will form the “stack of
dimes” that are often coveted while welding
and will give more time for complete wet in. A
slight 1/8” or less step backwards with the

19
Section 3 Getting started
torch will magnify the effect. Of course, a
smooth fluid forward motion that is contin-
uous and steady will get the job done.
While adding filler it is important to add the
filler always in the front edge of the puddle.
Adding filler rod directly under the tung-
sten, at the back of the weld pool or under
the arc itself may result in contamination of
the tungsten or sticking of the filler to the
tungsten. To terminate the arc, you should
fill the crater by adding a drop of metal as
the foot pedal is lifted. A concave crater at
the end of a weld may crack and cause the
weld to fail, especially in aluminum.
4. Many of the same principles of welding
steel also apply to welding aluminum.
However, Aluminum is not as forgiving.
There is a much finer line between the filler
rod wetting in and the whole weld area
turning into one big molten mass and even
blowing through. Aluminum does not
change color either when it is molten. At
best, the metal will develop a slight shiny
appearance, if it is exceptionally clean.
Heavily oxidized material may even present
a skim on the surface that is hard to detect
anything at all. In fact Aluminum must be
thoroughly cleaned with a dedicated stain-
less steel brush to remove oxidation, that
inhibits welding capability. The oxide layer
melts at a much higher temperature than
the underlying aluminum. (more about this
later) To the new welder, this may seem
like riding on a razor’s edge. And to some
extent that is correct, depending upon the
joint type, and metal thickness. Aluminum
requires strict heat management and trav-
el speeds to maintain a proper puddle with-
out incomplete fusion or other defects.
The heat conductivity of Aluminum draws
the heat away from the weld area much
quicker than in steel. This typically means
starting a weld puddle and keeping it going
requires more amps than welding steel. A
good starting point is to add about 25%
more amps than normally used with steel.
There are many “rule of thumb” sugges-
tions that have been published over the
years such as using 1 amp for every .001”.
But these were developed around trans-
former welders with little adjustability
while welding AC. Experience will eventu-
ally teach you the best settings for you.
There are a couple things that relate di-
rectly to how well a welder performs on
AC. One, is AC Balance, and the other is
AC frequency. Both are discussed in the
following paragraphs.
AC Balance. To keep it simple, Alternating
Current electricity is made of two, half-
cycles of positive and negative flow of elec-
tricity that are produced in a continuous
rapid cycle. Typical residential power
you’d get from the wall provides roughly a
50/50 split of positive and negative flow of
electricity. Older transformer welders
were not able to alter this “balance” very
much, if any. Modern day inverters take
this raw input, through the use of electron-
ic switches such as diodes and transistors,
and modifies it to do just about anything
required. With AC balance control, the
percentage of time the AC cycle spends in
Electrode Negative (-) or Electrode Positive
(+) can be skewed. Notice the - and + signs
under the control on the panel that indi-
cates the direction of polarity. Full clock-
wise rotation of the control will result in
mostly electrode positive (+). Each compo-
nent of AC, Electrode Negative and Elec-
trode Positive, serves an important func-
tion while welding Aluminum. AC positive,
provides the cleaning action necessary to
break up oxidation. Even once the oxida-
tion is removed with a stainless brush, ox-
ides begin to rapidly reform before the joint
can be welded. The cleaning effect can be
observed by lowering the amps to the mini-
mum setting and making a live pass over
the metal with the control set fully positive.
A thin top layer of metal will appear to
break up and fly off from under the arc.
This is the layer of oxidation. Underneath,
will be a lighter color of metal that is
cleaned, mostly oxide-free aluminum. While
this setting isn’t practical to weld with, it
demonstrates what role positive polarity
plays in the AC cycle while welding. Ideal-
ly, many people find that only 20-40% elec-
trode positive is needed to make a satisfac-
tory weld. A higher setting may be required
if welding heavily oxidized material. The
Everlast PowerTig 185 offers an extended
range so that almost any welding require-
ment can be met. There are problems as-
sociated with too much electrode positive
due to the flow of electrons being greater
toward the electrode rather than away

20
Section 3 Getting started
from the electrode. Too much AC positive
concentrates the heat on the electrode and
not on the work, overheating the electrode.
This can result in erratic arc characteris-
tics and several other problems. Symp-
toms of too much electrode positive (EP),
include needing a higher amp setting to
obtain a satisfactory weld, wide balling (or
fast consumption) of the electrode, wide
cleaning lines over 3/32” wide and uncon-
trollable weld puddles with poor penetra-
tion.
The negative portion of the AC cycle pro-
vides an equally important function. It pro-
vides the needed penetration for proper
fusing. Less AC positive output automati-
cally provides more AC negative output as
the balance is shifted toward negative po-
larity. AC negative in turn, reduces the
amount of heat concentrated on the tung-
sten and focuses it on the work. The elec-
trons are spending more time flowing to
the work piece rather than the electrode.
However, if too much electrode negative is
used, a whole set of unique problems can
result that result in weak welds. Symptoms
of too much DCEN include, dirty looking
welds, with black sooty residue, little or no
cleaning lines beside weld, dull weld pud-
dle, and even a blow out of molten metal on
the backside of the weld without a noticea-
ble puddle developing.
Keep in mind, a good starting point for ad-
justment is to set the unit at about 20-40%
EP. This will optimize cleaning action (also
called cathode etching) with minimal clean-
ing lines along side of the weld while offer-
ing excellent penetration. Higher DCEP is
possible and required at times with heavily
oxidized aluminum alloys or specially treat-
ed aluminum, but larger tungsten elec-
trodes and higher amp settings will be re-
quired to complete the welds.
No amount of Electrode Positive can sub-
stitute for thoroughly cleaning aluminum
with a stainless steel wire brush that is not
used for anything else but cleaning Alumi-
num. Do not use plain steel brushes.
Do not use special solvents to clean metal,
especially brake cleaner or other chlorinat-
ed solvents. Even small amounts of it if it
comes in contact with the welding arc and
hot surfaces will kill you. A small wisp of
vapor inhaled will result in a slow and pain-
ful death. Don’t even try it. The basic com-
pound created is Phosgene gas, a deadly
nerve gas. There are approved cleaners
that can be bought for aluminum. Acetone
is a frequently used cleaner that is ac-
ceptable for use, but has its own set of
health risks. Much safer aluminum clean-
ers can be bought at welding supply stores
that reduce the health risks.
AC Frequency. As stated earlier, AC pow-
er is composed of rapidly cycling positive
and negative current. Hertz is the term
used refer to electrical frequency as it
measures cycles per second or specifically
the number of times per second that the
alternating current output of the welder
fully switches polarity from positive to neg-
ative. Older transformers were dependent
upon the input frequency of 60 Hz in North
America, (50 Hz in most other countries of
the world) and could not vary the frequen-
cy. It was quite simple, input frequency
was the same as the output frequency. You
welded with it or you didn’t. Just as with
AC balance control, inverter based weld-
ers have helped revolutionize the industry
by providing a wide range of frequency
control for greater arc tuning ability. At
the old standard 60 Hz level, the arc is rela-
tively wide and unfocused compared to
what is possible with the PowerTig 185 Mi-
cro. Increasing the frequency narrows the
arc, forcing it into a tightly focused area.
This assists in several important areas. It
helps control the arc in tight corners where
it is subject to wandering and erratic be-
havior. The narrowed, high hertz arc cone
will not be as prone to instability. It also
increases the ability of the arc to penetrate
by pinpointing the heat in a narrow defined
band. This provides excellent results with
lower amp settings. The result is a narrow,
well defined weld. Conversely, a lower
Hertz may also have benefit while welding
aluminum by reducing the amount of pud-
dle agitation, preventing contamination
from mixing in the puddle.
So, what is the ideal setting? Undoubtedly,
50 or 60 hz will work and do an excellent