Everlast Storm 215c User manual

Operator’s Manual
Publish Date: AUG 2021
EVSTORM215c Rev. 1
USA/North America
©Everlast Power Equipment
120/240V
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide For The
Storm 215c
FUNCTION: MIG/Stick/Plasma Cutter
PURCHASE DATE:
MODEL NAME:
SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:
DC
40A
DC
160A
DC
200A

2
TABLE OF CONTENTS
SPECIAL NOTICE AND CALIFORNIA PROPOSITION 65 WARNING 3
CUSTOMER GREETING AND EXPLANATION OF PROCEDURES 4
WARRANTY AND CONTACT INFORMATION 5
SAFETY DISCLAIMER AND HF WARNING 6
SAFETY WARNINGS, DANGERS, CAUTIONS AND INSTRUCTIONS 7
GENERATOR OPERATION INFORMATION 10
SPECIFICATIONS 11
DUTY CYCLE INFORMATION 11
BREAKER AND WIRING REQUIREMENT INFORMATION 12
GETTING STARTED, UNPACKING YOUR UNIT AND INSPECTION 14
CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION 15
CONNECTION OF AIR COMPRESSOR, REGULATORS, AND TORCH INSTALLATION AND POLARITY INFORMATION 17
INSTALLING THE MIG WIRE AND SPOOL GUN CONNECTION 20
FRONT PANEL VIEW AND COMPONENT ID 22
REAR PANEL VIEW AND COMPONENT ID 23
CONTROL PANEL LAYOUT 24
GETTING READY TO WELD 25
SETTING UP THE UNIT FOR WELDING AND CUTTING MANUALLY 27
SETTING UP THE POWERSET MODE 29
EXPLANATION OF MIG FUNCTIONS AND TERMS 31
MIG TORCH COMPONENT BREAKDOWN 35
STICK WELDING INFORMATION 36
PLASMA CUTTING WARNINGS 38
EXPLANATION OF PLASMA CUTTING FUNCTIONS AND TERMS 40
PLASMA CUTTING TORCH PARTS AND ASSEMBLY (IPT 40 INNOTEC TORCH) 45
ADDITIONAL TORCH INFORMATION 47
TROUBLESHOOTING ERROR CODES 48
TROUBLESHOOTING COMMON MIG WELDING ISSUES 49
TROUBLESHOOTING COMMON PLASMA CUTTING ISSUES 50

3
NOTICE:
Product Specications and features are subject to change without notice. While
every attempt has been made to provide the most accurate and current infor-
mation possible at the time of publication, this manual is intended to be a general
guide and not intended to be exhaustive in its content regarding safety, welding,
or the operation/maintenance of this unit. Due to multiple variables that exist in
the welding eld and the changing nature of it and of the Everlast product line,
Everlast Power Equipment INC. does not guarantee the accuracy, completeness,
authority or authenticity of the information contained within this manual or of any
information offered during the course of conversation or business by any Everlast
employee or subsidiary. 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 particular purpose, for performance/accuracy
or for suitability of application. Furthermore, Everlast Power Equipment INC. does
not accept liability for injury or damages, consequential or incidental, resulting
from the use of this product or resulting from the content found in this document
or accept claims by a third party of such liability.
WARNING!
California Proposition 65 Warning:
This product, when used for welding or cutting, produces fumes or gases which
contain chemicals known to the State of California to cause birth defects and, in
some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)
Warning: Cancer and/or Reproductive Harm
www.P65warnings.ca.gov

4
THANK YOU! We appreciate you as a valued customer and hope that you will enjoy years of use from your welder/plasma cutter multi-process unit. We
work to please the customer by providing a well supported, quality product. To make sure that you receive the best quality ownership experience,
please see below for important information and time sensitive details.
What to do right now:
1. Print your receipt from your conrmation email that should have been sent to you after your purchase and put it up for safe keeping. If you do not
have one, contact us at 1-877-755-9353 (US customers) or 1-905-570-1818 (Canadian Customers). You will need this if anything should ever
happen for original owner verication (if bought as a gift, original receipt will still be needed, or explanation sent to Everlast).
2. Read this manual! A large number of tech and service calls are a result of not reading the manual from start to nish. Do not just scan or casually
peruse this manual. There are different features and functions that you may not be familiar with, or that may operate differently than you expect.
Even if you have expertise in the eld of welding, you should not assume this unit operates like other brands or models you have used.
3. Carefully unpack and inspect all items immediately. Look for missing or damaged items. Please report any issues within 48 hours (72 hours on
weekend or holidays) of receiving your product,. Take pictures if you are able and contact us at 1-877-755-9353, ext. 207 if any issue is discov-
ered between 9 am and 5 pm Eastern Time M-F (US customers) or at 1-905-570-1818 (Canadian Customers) between 9am and 4 pm weekdays
except on Fridays when hours are from 9 am to 12pm Eastern. If outside of the US or Canada, contact your in-country/or regional distributor di-
rect at their service number.
What to do within the next 2-3 days:
1. Make sure your electrical system is up to date and capable of handling the inrush and rated current of the unit. Consult and use a licensed and
knowledgeable electrician. If you have downloaded this manual in expectation of delivery, get started now.
2. Make sure this machine is plugged in, turned on, and tested with every process and major feature, checking for proper function. You have a 30
day period to test and thoroughly check out the operation of this unit under our 30 day satisfaction period. If something is wrong, this policy co-
vers shipping on the unit (30 day satisfaction policy applies to the USA only for the 48 lower states and D.C., territories and provinces are exclud-
ed) or any incidental parts that may be needed to resolve any issue. After this 30 day period, if you nd something wrong with the unit, you will not
receive the benet of free shipping back and forth to resolve this issue. Your unit is still covered under the 5 year parts/labor warranty, but ship-
ping is covered by the customer after the 30 day period is over. The rst 30 days of operation with any electronic item is the most critical and if
any issue will happen, it will often happen during this time. This is why it is very important that you put this unit to work as soon as possible. Any
issue should be reported within 48 hours (72 if on the weekend or holiday). Everlast will not be liable for any shipping after that time.
What to do within the next 30 days:
Visit our website (US customers). Go to www.everlastwelders.com. Navigate to the resources tab and to the “product registration” page to register
your product. While keeping your receipt/proof of purpose is still required for verication of ownership, registering will help us keep your details
straight and establish a chain of ownership. Don’t worry, though, your warranty is still valid if you can’t do this. Remember: Always keep your receipt
even if you register. You may want to staple a copy to your manual.
What to do if you have a warranty issue or problem with the unit:
1. Unplug the unit. (Also do this before any maintenance or cleaning is done.)
2. Do not attempt a self-repair until authorized by an Everlast representative. This does not include performing routine maintenance such as point gap
adjustments or regular internal cleaning. Any third party repairs are not covered under warranty, and can further damage your unit.
3. Within 24-48hours, (or by the next working business day) you must contact U.S. tech support at 1-877-755-9353 ext 207(U.S. hours are 9 am to
5pm Eastern for tech support and 9 am to 5 pm Pacic for the business/sales ofce). If you are in Canada contact 1-905-570-1818 (Canada hours
are 9am to 4pm M-Th, 9am to 12pm Fri). Although phone contact is preferred to establish a warranty claim, you may send an email to
[e-mail] (US) or [e-mail] (Canada) along with your contact information and brief explanation of the issue and
ask for a follow up call. If you contact us via phone, and you do not reach a live person, please leave a brief message with the nature of your prob-
lem and your contact information. You should expect a call back within 24 hours. It is also a good idea to follow up the message with an email.
4. Be prepared with as much information as possible when you talk with a tech advisor, including a details of the failure, settings, and application of
the unit. NOTE: A Proof-Of-Purchase (receipt) is required before returning the unit for warranty or before warranty parts can be sent to you.
5. Keep in mind that, you may be asked to check a few basic things. Before you call, having a screwdriver and volt/ohm meter at hand is a good idea
and will save time. Many issues can be resolved over the phone. If the issue cannot be resolved over the phone/email, you may be given an op-
tion to return the unit, or have a part shipped to you, at Everlast’s discretion. Keep in mind, you may be asked questions that seem basic, or ele-
mentary to your knowledge base. These are not meant to question your knowledge, but rather to make sure nothing is overlooked. However the
tech chooses to proceed, please cooperate with the process, even if you think you know what the cause or issue is. You may be asked to check
something or open the unit during the diagnosis. This does not void the warranty! Opening the unit is a part of routine maintenance and cleaning.
This is an important step. The willingness of the customer to work with tech support can save lots of time and accelerate the warranty process. For

5
warranty to be honored, you will need to make sure that you follow these guidelines. Units that are returned without an RMA (issued by the tech
support department) may not be repaired under the warranty agreement and you may be charged for the repair and can result in a delayed repair
as well.
What to do if you need setup help, guidance, weld issue diagnosis or have general product compatibility questions.
Call us at 877-755-9353 ext. 204 for welding guidance and general welding issue diagnosis. Or email [e-mail] with the basic
issue you are having, along with your specic settings, and welding application.
Hey...wait, what is my warranty?
Warranties and service policies and procedures vary from country to country and are maintained and supported by the region-
al or in country distributor of Everlast welding equipment.
USA Customers Only: For full details on the 5 year parts and labor warranty, 30 day satisfaction policy, terms of sale, and how to proceed with a war-
ranty claim, please visit: https://www.everlastgenerators.com/standard-warranty. Accessories are covered by a separate warranty and detailed infor-
mation can also be found at the link above.
Canada Customers Only: For full details on the 3 year parts and labor warranty, terms of sale, and related policies and procedures, please visit: https://
www.everlastwelders.ca/terms.php.
Who do I contact?
USA Technical Support:
Email: [e-mail]
1-877-755-9353 ext. 207
9am-5pm Eastern (Closed holidays)
Monday-Friday
USA Welding Support and General Product Information:
Email: [e-mail]
1-877-755-9353 ext 204
9am-6:30 pm Eastern (Closed holidays)
Monday-Friday
USA Sales and Main Ofce:
Email: [e-mail]
1-877-755-9353 ext 201
9am-5pm Pacic (Closed holidays)
Monday-Friday
Canada Technical Support:
Email: [e-mail]
905-570-1818
9am-4pm Eastern Monday-Thursday
9am-12pm Eastern Friday
Canada Sales and Main Ofce:
Email: [e-mail]
905-570-1818
9am-4pm Eastern Monday-Thursday
9am-12pm Eastern Friday
Other Countries and Regions:
Visit the U.S. Website @ www.everlastwelders.com and click on the flag of the country or region represented that is closest to you. If your country or
region is not found, call the U.S. ofce at 1-650-588-8588 between the hours of 9am to 5pm Pacic, Monday through Friday.

6
Safe operation and proper maintenance is your responsibility.
Everlast is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and
maintenance of your Everlast product, it is no substitute for observing safe welding practices and behavior. Safe welding and related cutting
operations require basic knowledge, experience and ultimately the exercise of common sense. Welding does signicant hazards to your health
and life! Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even life depends upon it.
WARNING! If you do not have proper knowledge or capability to safely operate this machine, do not use this machine until proper
training has been received!
While accidents are never planned, preventing an accident requires careful planning. Stay alert!
Please carefully read this manual before you operate your Everlast unit.
The warranty does not cover damage or harm created by improper use. neglect of the machine or failure to follow safe operating practices.
NOTICE:
Welding and cutting operations may generate undesirable High Frequency (HF) and EMF
energy. This can interfere with surrounding electronic equipment such as computers,
routers, CNC equipment, televisions, radios, fluorescent lighting etc. If disturbance in
surrounding electrical and electronic equipment is noted, consult a licensed electrician to
help properly ground surrounding equipment to limit the interference. This machine may
cause GCFI and ground fault outlets to malfunction. This unit is designed to be operated
on a dedicated, properly grounded circuit.

7
Safety Warnings, Dangers, Cautions and Instructions
NOTICE. This unit manual is intended for users with basic knowledge and skillset in weld-
ing. It is your responsibility to make certain that the use of this welder/plasma cutter is re-
stricted to persons who have read, understand and follow the warnings and instructions in
this manual. If you or the operator needs further instruction, contact Everlast welding sup-
port at 1-877 755-9353 ext. 204 or seek qualied professional advice and training.
WARNING! High Frequency (HF) energy can interfere with the operation of pacemakers and
can damage pacemakers. Consult with your physician and pacemaker manufacturer before
entering an area where welding and cutting equipment is in operation and before using this
welder/plasma cutter. Some pacemakers have limited shielding. Alert any users or custom-
ers of this potential problem.
WARNING! Use approved safety glasses with wrap around shields and sides while welding
and working in the weld area or serious eye damage or loss of vision may result. Use a
grinding shield in addition to the safety glasses during chipping and grinding operations.
WARNING! When welding always use an approved welding helmet or shielding device
equipped with at least an equivalent of a shade 9 or greater. Increase the shade number
rating as amperage increase over 100 amps. Inspect helmet for cracks in lenses and in the
helmet. Keep lens covers in good condition and replace as necessary.
WARNING! Welding/cutting operations carry inherent risks which include but not limited to
possible cuts burns, electrical shocks, lung damage, eye damage and even death. Take all
appropriate measures to use proper Personal Protective Equipment (PPE). Always use
leather welding gloves, closed toe (preferably reinforced or steel toe leather shoes, and long
-sleeved flame resistant clothing (i.e. denim). Do not wear Poly/Nylon blend materials.
DANGER! Welding/cutting poses shock and electrocution risks. Keep this welding equip-
ment dry. Do not weld in the rain or where moisture accumulates. Use dry, rubber soled
shoes, gloves and clothing when welding. Do not rest or contact work clamp (ground) when
welding. Keep all parts of the body insulated from the part being welded when possible. Do
not touch terminals or connections while the unit is on. Consider all parts to be “live” at all
times even if no live work is being performed. Do not use frayed welding cables.
CAUTION! Fires are possible but also preventable while welding. Always remove flammable
rags, papers, and other materials from the weld area. Keep rags stored in an approved flame
proof canister. Keep a fully charged re extinguisher at hand. Remove any fuels, oils,
paint, pressurized spray cans, and chemicals from the weld area. Make sure any smoke/re
detectors are function properly. Do not weld on tanks, drums or barrels, especially if pres-
surized or sealed. Do not weld on any container that previously held fuel or chemicals.
Make sure the weld area is clear of flammable materials such as grass or wood shavings
solvents and fuels. Do not wear frayed or loose clothing. Visually inspect and recheck the
work area after welding looking for smoldering debris or flames.
WARNING! Welding gas cylinders are under high pressure. Keep all gas cylinders upright
and chained to a cart or held safely in a safety holding pen. Never transport gas cylinders
in an enclosed car van or other vehicle. Transport gas cylinders securely. Keep all cylin-
ders capped while not in use or during transport. Replace the cap on the cylinder when it
is going to be more than 24 hours before use. Do not use or attempt to repair faulty regu-
lators. Never weld on gas cylinders. Keep gas cylinders away from direct sparks.

8
Safety Warnings, Dangers, Cautions and Instructions
DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these
hazards are immediate while others are cumulative in their effect. Do not weld in enclosed
spaces or in areas without adequate ventilation. Fumes and gases released in the welding
and cutting operations can be toxic. Use fans or respiration equipment to insure adequate
ventilation if you are welding in a shop or garage area. Do not weld on galvanized metal
under any circumstance. You may develop metal fume fever. Symptoms are similar to lu-
like symptoms. Seek medical advice and treatment if you are exposed to galvanized weld-
ing fumes.
If you experience any eye burning, nose or throat irritation while welding, these are signs
that you need more ventilation.
If you feel these symptoms:
• Stop work immediately and relocate work area with better ventilation.
• Wash and clean your face and hands.
• Stop work completely and seek medical help if irritation persists
DANGER! Never use brake cleaner or any chlorinated solvent to clean or degrease metal
scheduled to be welded or other related equipment in the area being welded. The heating
of this cleaner and its residue will create highly toxic phosgene gas. Small amounts of
this vapor are harmful and can lead to organ failure and death. If degreasing of a part is
necessary, use Acetone or an approved pre-weld cleaner. Use the proper personal protec-
tive equipment (PPE) when handling any cleaners/solvents.
DANGER! People with pacemakers should consult a physician and pacemaker manufactur-
er before welding. There is a potential for damage or serious malfunction resulting in
death. High Frequency energy (HF)/Electromagnetic Fields generated during welding can
interfere with pacemaker signals, even permanently damaging it. Some pacemakers offer
some shielding, but restrictions regarding amperage and HF starting of welding arcs may
be placed upon the individual. Warn all potential bystanders that they should exit the work
area if they have a pacemaker or similar medical equipment before welding. Severe electri-
cal shock leading to injury or death may occur while using the plasma cutter if the user
becomes part of the circuit path. While the Amp output of the plasma cutter is limited, the
unit may produce an OCV of 300V or greater. Consult with a Physician if a pacemaker is
expected to be implanted.
DANGER! Never defeat or modify any safety guards or shields. Keep all safety covers and
shields in place.
Never place your ngers in or near a fan shroud or insert any object into the fan(s).
DANGER! Do not supply more than 100 PSI to the air-pressure regulator supplied with
this machine. If you do, the regulator may leak or explode, causing severe injury or
death. Use a separate regulator mounted at the air-compressor to control supply air pres-
sure. Never use an air compressor without a separate compressor mounted air regulator!

9
Safety Warnings, Dangers, Cautions and Instructions
CAUTION! Trip Hazards exist around this unit. Cords, cables, welding leads and hoses
pose a trip hazard. Be aware of their location and inform others of their location. Tape and
secure them so they will stay out of high trafc areas.
CAUTION! Welded metal can stay hot long after welding is completed. Burns may occur.
Always wear gloves or use tongs/pliers when handling welded or cut metal. Remember
the heat from the metal may catch other material on re. Always have a re-proof area
ready to place welded components until they fully cool. Use soap stone or a metal marking
marker to label the metal as “HOT” to serve as a reminder to all present in the area.
CAUTION! Welding and cutting operations generate high levels of ultraviolet (UV) radiation
which can burn and damage skin and eyes. The intensity is so high that exposed skin and
eyes can burn in a few minutes of exposure. Minimize direct skin and eye exposure to this
intense form of radiation by using proper PPE and sun screen where appropriate.
CAUTION! Do not allow bystanders. Do not allow others without proper Personal Protec-
tion Equipment (PPE) suitable for welding to stand in the welding area or to observe weld-
ing and welding related activities. If protection is not readily available, use a welding
screen to separate the welding area from the rest of the area. If no protection or screen is
available, physically exclude them from the welding area by a wall or other solid divider.
Keep all pets and young children away from the welding area.
CAUTION! Electromagnetic Fields can be generated by this unit and radiate into the work
place. The effect of EMF is not fully known. Exercise caution when welding by: NOT drap-
ing welding leads (guns/cables) over your shoulders or arms, NOT coiling them around
your body, NOT inserting yourself directly between the cables, and by NOT contacting the
unit while welding. DO keep the work clamp connected as close as possible to the area of
the weld and directly to the object being welded whenever possible.
DANGER! Never touch connectors or ttings while this machine is turned on. Keep all
safety covers in place when not in use. Never remove or replace the plasma consumables
while the machine is turned On. Even though the torch is equipped with a “parts-in-place”
safety disconnect, it is possible that overheating of the torch, excessive wear or damage to
the consumables may cause this feature to malfunction. Make sure the brass safety cut out
pins on the torch head remain in good repair and that the spring loaded function remains
operational and keeps them fully extended when the torch cap is removed. The Open Cir-
cuit Voltage (OCV) while in plasma mode may exceed 300V. This is enough to cause
burns, injury severe electrical shock, injury and instant death.

10
Important Information: Operating this unit with a generator or other off-grid service.
This multi-process unit should only be operated on a generator certied by its manufacturer to produce clean power. Clean power is
equivalent to the quality of household or shop/garage type power. This means the generator must have 5% or less total harmonic distor-
tion (THD) of the Sine wave. If you are unsure of the power output type of the generator, contact the manufacturer of the generator for
verication. Do not operate on square wave or modied square wave generators or converters/inverters or damage or malfunction may
occur. Damage caused by running this unit off of “dirty” power or modied sine waves may not be readily apparent and can be cumulative
in nature. However, damage may present itself immediately. The damage caused by running this unit on “dirty” power usually leaves
internal tell-tale signs and damages specic parts.
For recommendation for generator size, consult the specication page for surge wattage recommendations. Operating the unit on under-
powered generators and/or on generators not rated with 5% or less THD can damage your unit. The generator manufacturer determines
this rating, not Everlast. Do not assume that a name brand generator, or a “new” generator automatically provides clean power. Price paid
does not guarantee a clean power output either. There are multiple brands at various price points capable of producing clean power.
Investigate this before purchasing a generator. The manufacturer will usually state that a unit is clean power in the advertising information
and will state actual THD. If the manufacturer does not state it, contact the manufacturer directly for a statement concerning actual THD.
NOTICE! Operation of this unit with generators not rated by its manufacturer as providing clean power (5% or less THD) is prohibited and
will void the warranty. Operation with modied sine wave, or square wave generators and inverters/converters/UPS that do not produce
“sine wave” output is prohibited and doing so will also void the warranty. Use only with generators/inverters/converters that produce an
equivalent type of sine wave used in shops, homes and “shore” type systems.
WARNING! Do not start or stop the generator with the unit switched on. Never use the generator in ECO mode or an auto-idle mode.
Even with a clean power rated generator, this action can damage the unit. Turn the unit on only after full generator R.P.M. has been
achieved and the engine is sufciently warmed up. Closely monitor generator fuel level so that the engine R.P.M doesn’t drop or com-
pletely shut down with the unit plugged in. For best practice: do not start or stop the generator with this plasma cutter plugged in, even if
it is turned off. Unplug the unit before shutting down the generator.
If using with a welder/generator, make sure the manufacturer has determined that the generator portion produces a clean sine wave.
Many older models do not. Some newer models use “divided” power between welding and generating and cannot supply the full power
to the unit unless the ne current control knob is turned to maximum. Do not use this unit with such welder/generators unless the Power/
ne current control is turned to 100%. Some welder generators do have a separate alternator for generating power. If this is the case, be
sure not to weld or load the machine while this unit is in use.
WARNING! Always make sure any generator or welder generator is properly wired and grounded, according to local and national code.
Ground the machine per the generator manufacturers instructions to meet code requirements. Improperly grounded generators may dam-
age the machine and more importantly may cause severe injury or death.
Dual Voltage Single Phase 120/240V Operation:
This unit can be used with either single phase 120V or 240V output. Output will be reduced automatically when operating on 120V. How-
ever, for the higher voltage (since the standard of 240V is nominal and actual voltage may vary somewhat), the unit may be used with
single phase 208V if the voltage does not drop below 205V. If using this unit on 208V, duty cycle and display accuracy may be affected.
Rated and Inrush Amperage will rise proportionately as well. If you decide to use this machine on 208V, before installing permanently,
have an licensed electrician monitor voltage fluctuations, particularly under load and during peak use times. If the voltage remains con-
stant, and steady without dropping below the 205V threshold, this unit may be used. Damage caused by using on undervoltage power
sources is not covered by the warranty. Always be aware of the voltage output and the quality of the power source being used.
REAR OUTLET WARNING!
If equipped, never use the electrical power outlet on the back of this machine for anything other than powering an Everlast brand water
cooler. This is a special outlet designed to produce 240V with limited amperage draw. No other device or brand should be used in con-
junction with this unit’s outlet. This outlet is designed to supply 240V only. Do not attempt to modify, or change this outlet for use with
anything else other than an Everlast brand water cooler designed for 240V operation. Severe damage, re or injury may occur if other
devices or other brand equipment is connected. Not for use while operating on 120V!

11
Specifications
Duty Cycle
Duty Cycle is simply the amount of time out of a 10 minute period in which the unit can operate. For example, if this unit has a duty cycle of 35% at
maximum output means that the unit can be operated for 3.5 minutes out of 10 minutes. This may be continuously, or intermittently during the 10
minute period of time. This rating standard (United States) is based on a maximum ambient temperature of 40 C. Operating above this point, or at
lower temperatures with high humidity may reduce the duty cycle rating. Of course, the duty cycle may increase somewhat as ambient temperature
drops. Regardless, this unit’s duty cycle is not controlled by a timer. Rather, this unit is equipped with a heat sensor located on a heat sink near the
critical power components of the plasma cutter. If the operating temperature of the unit is exceeded, welding output will stop and an over-temperature
warning light/error code will be displayed on the panel. If a duty cycle event is registered, do not turn the unit off! Allow the plasma cutter to continue
to run at idle for at least 10-15 minutes until the temperature has fallen enough to reset the sensor and over-temperature warning light. Even if the unit
resets, allow the unit to cool for a full 15 minutes, or the duty cycle will be more quickly triggered since the unit resets just below the heat threshold.
The fan(s) must continue to run for a full 15 minutes to cool the unit properly after the duty cycle shut down has occurred. After 15 minutes of cool-
ing, you may switch the unit off if you are nished welding. If the unit does not automatically reset after 15 minutes, turn the unit off. Wait for 15 sec-
onds before turning the machine back on. If the unit does not reset, contact technical support for further advice and assistance. As a best practice,
when you have completed welding and have been welding continuously for extended periods of time, keep your unit on for 10 additional minutes with-
out welding to allow it to cool.
The intentional and/or repeated triggering of the duty cycle protection feature on this unit will shorten the lifespan of the unit’s electronics and can
weaken internal components. The effect of overheating your unit repeatedly takes a cumulative toll on the unit.
NOTICE: These units are tested by an international and independent certifying agency for their ability to sustain the claims of duty cycle, under lab in-
duced conditions which are typically more stringent than average shop conditions.

12
Specifications
BREAKER SIZING AND WIRING REQUIREMENTS
Before installation of this unit in any facility, always consult a licensed local electrician familiar with the requirements of properly wiring a plasma cutter
into the electrical supply. Refer to the National Electric Code (NEC) and local codes. If needed, refer the electrician to Article 630 of the NEC during
consultation to determine proper application and wiring needs. Use the I1MAX and the I1EFF ratings listed above to determine the proper breaker and
conductor (wire) sizing required. Everlast plasma cutters are designed around use in industrial wiring applications and are intended to be used with
modern electrical systems. Household wiring may need to be upgraded before this plasma cutter may be installed. Additional HF protection and isola-
tion may be needed if this plasma cutter interferes with the operation of electrical/electronic equipment.
IMPORTANT: Do not modify this unit’s wiring, power plug or conductors. This unit meets the standards for conductor sizing on the power cable and
takes into account power cable length, duty cycle and rated current.
NOTICE: POSSIBLE HF INTERFERANCE FROM THE INVERTER AND WHAT TO DO IF IT OCCURS
If any electrical disturbance is noticed as a result of the high frequency interference that is possible with the operation of the inverter switching and
operation, the HF service bolt should be connected directly to a 12 gauge wire that is bonded directly to an outside copper ground rod driven into
moist soil. Additionally, all metal items including any metal frame or sheeting of the building should be connected and grounded to separate copper
ground rods driven into the ground at 10 foot intervals around the perimeter of the building. This includes items such as tables, carts, rack material,
metal surrounds, etc. that may act as “antenna” to radiate/absorb HF energy. Additionally, all cords and welding leads should be twisted together and
run directly to the work without coils or excess cabling. Normally, this will not be required, but it is supplied in the case of any interference that may be
observed. This is usually observed in older or non standard installations where grounding and ground isolation is a problem.
NOTICE: DO NOT USE WITH DUAL SHIELD OR FLUX CORED OPERATION WITH GAS (FCAW-G)
This unit is not designed or recommended for use with Dual shield type welding. This is considered a heavy industrial process that this unit does not
have typically enough output in voltage, amperage and duty cycle to sustain welding at recommended settings. Most dual shield applications use
welding machines that are 300A and over. The synergic feature of the unit does not support dual shielded operation either. The Flux-Cored mode is a
gas-less type of operation and does not include a gas shield function.
IMPORTANT!
This unit is designed to operate with most welding rods except for E6010. If 6010 operation is desired, consider using E6011. This welding rod has
similar characteristics, but has arc stabilizers in the flux that allows it to be used in similar situations with welding machines that cannot run the higher
arc voltages generated by the E6010. Always select a good quality brand for best arc stability. If arc instability is observed, switch brands or change
the rod sufx designation. This unit operates best with a short arc, so either drag the rod, or hold a very short arc length so that arc outages are not
experienced. A dragging motion, or a slight weave is recommended, but increasing the arc length may result in arc outages. Rods like E7018, and
E7014,308, 309L, 316 and hard surfacing rods are excellent choices for use with this machine.
WARNING!
This unit is not designed for Air Carbon Arc Gouging/Cutting or for Plasma Gouging or Plasma scarng operations. Do not this unit for these applica-
tions. It is not designed to sustain the high volt and long arc characteristics needed for Carbon Arc or Plasma gouging use.

13
Specifications
Storm 215c Product Specifications
Construction Type Inverter (IGBT based, Digital Control)
Input Voltage 120V OR 240 V (± 10%) 50/60 Hz Auto-Adjusting
Phase 1 Phase 50/60Hz
I1MAX Current Rating (Inrush Amps) 120V: 35A 240V: 33A
I1EFF Current Rating (Rated Amps) 120V: 21A 240V: 20A
OCV 74V MIG/ Stick; 280V Plasma
MIG Duty Cycle @ Maximum Output (Rated at 40° C/104 F) * 120V: 125A 240V: 35% @ 200A
Stick Duty Cycle @ Maximum Output (Rated at 40° C/104 F )* 120V: 35% @ 100A 240V: 35% @ 160A
Plasma Duty Cycle @ Maximum Output (Rated at 40° C/104 F )* 120V: 35% @ 25A 240V: 35% @ 40A
MIG Output Range V/A (DC Output Only) 120V: 15.5-20.25V/ 30-125A 240V: 15.5-24V/ 30-200A
Stick Output Range V/A (DC Output Only) 120V: 20.4-24V/10-100A 240V: 20.4-26.4V/10-160A
Plasma Output Range V/A (DC Output Only) 120V: 88V-90V/20-25A 240V: 88-96V/20-40A
MIG Wire Feed Speed: 120V: 60-400 IPM 240V: 60-600 IPM
MIG Inductance 1-100%
MIG Burn Back Time 0-2 Seconds
MIG Spot Time .5-15 Seconds
MIG Stitch Time No Stitch Timer
MIG Wire Size Handling Capability .023”-.045” (with optional drive roll and contact tip sizes)
MIG Drive Roll Sizes Included .030” / .035” (.8mm / .9mm) V-Groove for MIG
.030” / .035” (.8mm / .9mm) Serrated Groove for Flux-Core
Pre Flow Time Auto or Off
Post Flow Time Auto or Off
Stick Hot Start Time 0-2 Seconds
Stick Hot Start Intensity 0-100% above set Amperage )
Stick Arc Force 0-100% above set Amperage
Stick 6010 Capable No. Use E6011 as substitute.
Plasma Start Type Blow-back style, with Pilot Arc. (Non High frequency)
Recommended Plasma Air Pressure 65 to 75 PSI while cutting. Max. supply pressure: 90PSI
Recommended Minimum Compressor Size 30 Gallon with 5.3 CFH or greater @ 90 PSI
MIG Gun Type/Length/ Connector Type Innotec 15AK Series 12.5 ft/ 4m with Euro Quick Connect
250A Work Clamp with Cable Length 6.5 ft (2m) DINSE 35/50 (1/2 nom. dia.)
250A Stick Electrode Holder Length 9.5 ft (3m) DINSE 35/50 (1/2” nom. dia.)
Plasma Torch Type and Length Innotec iPT 40, 15 ft.
Power Cable Length 6.5 ft (2m)
Power Plug Type for Single Phase Operation 240V NEMA 6-50P (Standard 240V Welder Type)
Cooling Type Full Time, High Volume Fan(s)
Dimensions (Approximate) 17.5” H X 9.75” W X 26” L (445mm X 248mm X 661mm)
Weight (Bare Unit with Cord and Handles Attached) 60lbs.
Ingress Protection Rating IP21S
*Duty Cycle
Duty Cycle is simply the amount of time out
of a 10 minute period in which the unit can
operate. For example, if this unit has a duty
cycle of 35% at maximum output, that
means that the unit can be operated for 3.5
minutes out of 10 minutes. This is rated for
continuous or intermittent use during the 10
minute period of time. This rating standard
(United States) is based on a maximum
ambient temperature of 40 C. Operating
above this point, or at lower temperatures
with high humidity may reduce the duty
cycle rating. Of course, the duty cycle may
increase somewhat as ambient temperature
drops. Regardless, the duty cycle is not
controlled by a timer. Rather, a heat sensor
located on a heat sink near the critical power
components of the welder signals overheat.
If the operating temperature of the unit is
exceeded, welding output will stop and an
over-temperature warning light/error code
will be displayed on the screen. If a duty
cycle event occurs, do not turn the unit off!
Allow the welder to continue to run at idle
for at least 10-15 minutes until the tempera-
ture has fallen enough to reset the sensor
and over-temperature warning light. Even if
the unit resets, allow the unit to cool for a
full 15 minutes, or the duty cycle will be
more quickly triggered since the unit resets
just below the heat threshold. The fan(s)
should be allowed to continue to cool for a
full 15 minutes without welding/cutting
activity after a duty cycle shut down has
occurred. After 15 minutes of cooling, you
may switch the unit off if you are nished
welding. If the unit does not automatically
reset after 15 minutes, turn the unit off. Wait
for 15 seconds before turning the machine
back on. If the unit does not reset, contact
technical support for further advice and
assistance. As a best practice, before shut
down, if you have been welding continuous-
ly for extended periods of time, keep your
unit on for 10 additional minutes to allow it
to cool down.The intentional and/or repeated
triggering of the duty cycle protection fea-
ture on this unit will shorten the lifespan of
the unit’s electronics and can weaken inter-
nal components. Overheating your unit
repeatedly takes a cumulative toll on the
unit.
Breaker Sizing and Wiring Requirements
Before installation of this unit in any facility, always consult a licensed local electrician familiar with the requirements of properly wiring a welder into the electrical supply. Refer to
the National Electric Code (NEC) and local codes. If needed, refer the electrician to Article 630 of the NEC during consultation to determine proper application and wiring needs.
Use the I1MAX and the I1EFF ratings listed above to determine the proper breaker and conductor (wire) sizing required. Everlast welders are designed around use in industrial
wiring applications and are intended to be used with modern electrical systems. Household wiring may need to be upgraded before this welder may be installed. Additional HF
protection and isolation may be needed if this welder interferes with the operation of electrical/electronic equipment. WARNING! Do not modify welder wiring. This unit meets the
standards for conductor sizing on the power cable and takes into account power cable length, duty cycle and rated current.

14
Setup Guide
Getting Started
UNPACK YOUR UNIT.
Upon arrival, you will need to completely unpack your unit, and check
things over. This is a time sensitive matter. Do not delay or hold the
plasma cutter unopened in the box. First, make sure the unit is opened
from the top. Be careful with using knives and sharp objects so you
won’t cut cords and cables inside the boxes. Lay all items out and
inspect them.
You should have the following in your box:
1. Welder/Plasma Cutter Unit.
2. Air-Regulator with built in water trap/particulate lter.
3. Floating Ball Regulator for MIG.
4. 15 Series MIG Gun/Torch.
5. 250A Work Clamp (approx. 9.5 ft with cable).
6. 250A Stick Electrode Holder (approx. 9.5 ft with cable).
7. Consumable Starter Kit for Plasma and Misc. Parts Bag(s).
8. iPT40 Plasma Torch.
9. 240V to 120V power cord adapter.
NOTICE:
This unit includes one additional .030” MIG contact Tip (it may also
include a .040” tip for specialty wires) and no other consumables
for MIG. These are available direct from Everlast, online from other
sources and are also available locally for the 15 series MIG gun at
many places that sell welders and welding supplies. This unit does
arrive with a basic plasma consumable starter kit, designed to get
you only through a few days of plasma cutting. You should have 5
(pipe/non-shielded) cutting tips and electrodes. You will need to
purchase a more extensive kit soon after receiving and using your
unit. These consumables are also available direct from Everlast,
from other online sources, and from many local stores that sell
welding and plasma cutting equipment. If you don’t order extra
consumables soon after you receive this unit, you may run out more
quickly than you expect. This kit contains stand-off type, non-
shielded consumables that are sized for the maximum Amp opera-
tion of the unit are designed for stand-off cutting. Lower Amp oper-
ation, gouging or drag cutting will require the purchase of additional
consumables (See torch parts page for amp ratings and sizes).
Additionally, some miscellaneous parts may be found together with
the consumable kit which may include fasteners, brackets and . If
you think you are missing a needed part, check the consumable kit
bag and box before calling Everlast for replacement. If you are
missing parts, call 1-877-755-9353 ext. 206 for help(Only in the
USA, for other areas, contact the distributor in your region).
INSPECT AND ASSEMBLE YOUR UNIT.
When you receive your package, inspect the unit for damage. Check for
the presence and general condition of the accessories. Some slight
rubbing or chafng of some of the accessories may be present, but this
is considered normal. Most notably, the MIG and Plasma torches may
appear to be used or red. This is because it has been live tested in the
factory for proper operation before putting into the box. If any item is
damaged or missing, please inform Everlast within 72 hours of product
receipt. See pages 4 and 5 for more details. Assemble the front, middle
and rear handles with the supplied screws. Use a 5mm hex key to tight-
en the socket head cap screws to the front and rear handles. (Screws
may be found in the consumable bag.) Remove the cap screws from the
center of the machine and install the center, long handle. Use a Phillips
type screw driver to tight the screws, or alternately use a 10mm socket
and 1/4” drive socket wrench to tighten the screws. IMPORTANT! Do
not overtighten the screws. If desired for proper tment or for space
saving, the unit may be used without the handles. However, install the
screws and tighten them to the panels anyway. Do not leave them out.
Be sure to reinstall the handles if the unit is to be carried or lifted. Do
not lift from any other point on the machine or damage may occur.
POWER UP AND TEST YOUR UNIT.
You will need to fully test the unit as soon as possible. Within 72 hours
after receipt of the unit, be sure to have every thing you need at hand to
test the unit. Make sure the correct input power, wiring, and plug con-
guration is being used. Make sure you have the regulator and air
compressor installed (See following section). If you do not have them
installed, when you select the plasma function you will immediately
receive an error code of “E 06” because air pressure is low/
disconnected. Then, power up your machine without any accessories
1
2
5
3
7
69
Storm 215C
4
8ASSEMBLE THE HANDLES

15
installed except for air compressor and air pressure. Allow the unit to
idle for 15 minutes. Check and observe operation of knobs, controls
and buttons, cycling through each as required. Make sure the fan is
running at full speed. After the test is completed, turn the unit off,
connect the torches and cables. Then, conduct live testing of all the
functions and features of the machine. For testing and cutting make
sure work clamp is connected directly to the part being welded
(work). Check for arc starting and stability. If you are testing the unit
on 120V, the cutting arc may not be stable unless you have pur-
chased the optional .6 or .8mm consumables listed on the torch page
in this manual. If any welding or cutting problems are observed and
they persist, contact Everlast. See page 5 for more contact infor-
mation. NOTICE: Cosmetic damage claims after 30 days will not be
accepted, unless Everlast is contacted and informed of such delay and
reason for such a required delay (i.e. Overseas in deployment).
GIVE YOUR UNIT SOME SPACE TO COOL.
This unit needs room to cool itself and maintain proper duty cycle.
Place the unit in a place that will allow 18” from all sides to allow for
proper cooling. This welder/cutter combination unit pulls air in from
the rear, and pushes it through the unit’s heat sinks to cool the elec-
tronics. The air is then exhausted through the front panel and side
louvers of the unit. If any of sides is blocked or restricted, the duty
cycle will be reduced, and overheating will occur, leading to possible
damage if the restriction is severe enough. Never attempt to restrict
air flow by attaching lters to the vents or by modifying your fans for
“on demand” service.
CONNECT YOUR UNIT TO POWER.
Your unit has been shipped with a NEMA 6-50P plug. This is the
standard plug used for 240V 1 Phase welders and plasma cutters in
North America. For single phase 240V connection, select a NEMA 6
-50 Receptacle for operation with this unit. (Other regions/countries
vary). A neutral is not used. In a dedicated circuit, the wire wires
supplying power (the conductors and ground) are black, white and
green. A red wire, which is traditionally used as a “hot” leg (power
conducting wire) of power is not present in a three-wire 240V wire
circuit of a plasma cutter. For plasma cutters, from the panel box, the
Black wire serves as L1(Hot), White serves as L2 (Hot) and Green
serves as G (Ground). A Red wire will not typically be used as a con-
ductor in a welder circuit. No neutral wire is needed, so white is used
as a “hot” conductor wire in this instance. It is recommended to ei-
ther install a receptacle as close to the main panel as possible or
install a subpanel cutoff as close to the outlet and welder as possible.
Always follow local codes when making these connections. If you are
using this unit in conjunction with a 240V air compressor, you must
supply a separate, dedicated circuit for both. Do not share or piggy-
back a circuit with this unit. When 120V operation is required, simply
connect the supplied 240V to 120V pig tail adapter. This adapts the
unit from the NEMA 6-50 Plug to the NEMA 5-15 Plug to allow the
unit to be used with 120V input without further modication of the
welder. No wiring or buss bar changes are required. Once the unit is
plugged in, it will automatically detect the new power and boot up in
120V mode. To verify 120V mode, the display screen will reflect the
power input mode with one of the center tree information boxes
displaying “120V”. To change back to 240V input, shut the machine
down, unplug the adapter, and reconnect to the 240V power supply.
Turn the welder back on to reboot the unit back to 240V operation.
Setup Guide
Getting Started
Standard Plug Conguration 1 Phase 240V
.
NEMA 6-50P
240V to 120V Pigtail Adapter (Supplied)
NOTICE:
There are special rules centered around wiring service for a welding
machine. The National Electric Code under Article 630 has developed
specic regulations for wiring electrical service for welding equip-
ment. These are different than for other types of service such as a
stove or dryer in a household or even in a commercial application.
You need to consult and/or employ a locally licensed electrician be-
fore installing this unit to make sure all national and local codes are
followed. Do not wire connections for this machine if you are not
qualied. Everlast is in no way liable for any damages caused by
improper connection of this unit. Your welder should be operated on
a dedicated branch circuit not far from an electrical disconnect box.
Importantly, it should not share circuits with other shop or household
items. Do not attempt to “adapt” existing circuits because conductor
(wire) colors are different for welders with 3 wire conguration than
for an appliance with 4 wire operation. (Unless adapting with an ap-
proved adapter when being powered with a “clean power” generator.)
No neutral is used in a welder circuit. The white wire is a conductor
in a single phase plasma cutter service. The red wire is not used. The
input power cable conforms to North American standards for size,
length, with consideration given to inrush amperage, rated amperage
and duty cycle. Do not modify, or attempt to rewire your unit.
Selecting A Breaker and Wire Size
Select a breaker based off of the I1MAX rating of this unit. This is the
maximum inrush current of the unit. The inrush is not a sustained
current. The I1EFF rating of the unit is the maximum “rated” current of
the machine. When combined with the length of the run from the
main panel, this determines the conductor size. Refer your licensed,
local electrician to Article 630 of the NEC and the specication page
of this manual (or the specication grid printed on your unit) to select
the correct breaker and wire size. A delayed trip breaker, or slow
blow fuse should be used with this unit.

16
What do I need to be able to plasma cut?
The unit comes with everything you need as far as a basic starter kit
for consumables, torch and regulator. However, you will need to sup-
ply a few things on your own.
1. You will need a suitable air-compressor and at least 3/8” supply
line hose. 1/2” supply may be required for long distances. The
input side on the regulator is the standard industrial 1/4” quick
connect tting. Suitable compressor sizes should follow recom-
mendations found in the product specication recommendations.
Oiless and pancake compressors are not suitable.
2. You will need to be able to regulate your pressure at the air com-
pressor. Do not use the pressure switch on the air compressor to
control the air pressure. A gate or ball valve installed on the air
compressor is not enough. You will need an adjustable regulator
which will control the air pressure at the tank. The regulator that
you install on the unit is to be used to regulate actual cutting
pressure. You need to be able to regulate the supply pressure
down to 90PSI at the air-compressor.If you supply more than
100PSI to the cutter’s regulator, you may damage the regulator.
3. You will need a separate air-dryer. Moisture is the enemy of any
plasma system and destroys consumable life and eventually
torches themselves. The regulator/lter included with the unit is
not sufcient to remove moisture from the system. It is designed
to trap particulates and slugs of water created by the coupling/
decoupling process. A refrigerated system is not necessary. We
recommend you look at the cartridge type systems that have
replaceable elements for a budget alternative. If these are not
available, consider having a replaceable paint-gun dryer mounted
inline and monitor the moisture, and replace it often.
4. You will need additional consumables with different sizes to
match the cut Amperage. The stock consumables are designed
for use at the maximum amperage of the machine. The orice in
the plasma tip is specically designed for a range of Amps. To
see that range, check the plasma torch pages of this manual, and
each tip diameter corresponds to a specied amp range. Lower-
ing air pressure to try to compensate for lower Amps results in
poor quality cuts and inconsistent arc behavior. Always match
the consumable size to the Amperage being used. NOTICE: For
direct on-the-metal drag cutting, use special shielded consuma-
bles are available for most of the Innotec® iPT series torches.
However, limited drag cutting may be done under 30A with stock
consumables, but consumable wear will be increased. Since
Everlast does directly manufacture the plasma torches, every
consumable conguration for every torch may not be stocked or
available. For these or other special applications, consult OEM
distributors of the iPT/PT/PTM series torches in the North Ameri-
can Markets.
Setup Guide
Getting Started
INSTALL THE AIR REGULATOR AND AIR COMPRESSOR.
NOTE: Connect the clear hose to the air inlet at the bottom rear and to
the regulator. Use the couplings and hose clamps found in consuma-
ble/parts bag to connect the tubing to the regulator and ttings. If
missing, contact Everlast. Make sure the air flow direction is correct
according to the markings on the regulator. Do not overtighten the
ttings. Lightly tighten the regulator securing nut to the bracket.
The male air quick coupling that is supplied with the unit is a 1/4”
industrial style connector. This connector is a common one in use in
many small shops and home garages. Others may be substituted if
this connector does not match the other connectors in use in the sys-
tem. However, Everlast makes no provision for attachment of oversized
couplings. The recommended minimum size of the air supply line is
3/8”, up to 25 foot. If a longer line is needed, consider upping the
size of the air line to prevent air pressure loss. If a larger air line is
needed, make sure you have the correct adapters to t the tting on
the unit. A smaller tting at the unit’s regulator/lter should not greatly
affect flow, as long as the length of the restriction is kept to a mini-
mum. The regulator comes in its own box in the packaging. It is fully
assembled with the exception of a brass plug that is screwed into the
middle opening onto the regulator. Usually this plug is installed, but
due to the possibility of a change in manufacturing, the plug may be
found in the consumable starter kit bag for the plasma cutter. To ad-
just the regulator: Pull up on the black cap until it clicks
(approximately 1/8”). Turn the regulator clockwise to increase the
pressure and counter clockwise to decrease the pressure. Snap the
adjustment cap back down to lock the regulator into position.
Connect Air Regulator To Compressor And Unit.
0
Air Dryer
Tank
Mounted
Regulator
12
3
4
5
#2 Phillips

17
Setup Guide
Getting Started
CONNECT YOUR UNIT TO THE CORRECT SHIELDING GAS.
Always wear safety glasses when changing a cylinder. Before installing
any cylinder, stand to the site of the valve, away from the discharge,
and quickly open the cylinder to give it a quick blast. This will dis-
lodge any dirt or particles stuck in the valve or the connection seat.
This will help reduce the chance of dirt particles making its way into
the solenoid valve, causing sticking issues later on.
Connecting your cylinder will require a cylinder wrench (1 1/16”)to
connect the regulator to the cylinder (North American Cylinders with a
580 CGA valve). If you do not have a cylinder wrench, an adjustable
type wrench will work, but make sure it is properly adjusted to prevent
rounding of the tting shoulders. Do not use pliers, or a serrated-
What Shielding Gas Should Be Used?
The Storm 215C is a synergic unit which incorporates the type of
gas and metal wire being welded with as a base to make accurate
“PowerSet” settings. It is important to pay attention to the type of gas
used while in “PowerSet” mode or the unit may not determine an
accurate setting. The following gases should be used and are the
best choices in the gas selection during initial setup after powering
the unit up:
Steel: 75%/25% Ar/CO2 (75/25 or C25)
OR 100% CO2 (C100)
Stainless (Inox): 98%/2% Ar/CO2 (98/2 )
Aluminum: 100% Ar ( Argon)
Notice that Steel has a couple of gas choices. In the North American
Market, 75/25 is the standard gas choice for short circuit MIG. It
provides less spatter than CO2 and a cleaner, less oxidized weld in
general. 100% CO2 is cheaper, but can require more cleanup and
descaling after the weld is completed. In other markets, 100% CO2 is
more commonly available, or may offer slightly different combina-
tions. If 75/25 gas mix is not available for use with the PowerSet
setting, and 80/20 is an option, then this gas may be used on the
75/25 setting, but may require slight tuning to achieve perfect per-
formance.
Stainless gas mixes can range throughout the industry. However, in
the industry. this unit is designed to be used with 98/2 Ar/CO2 blend
when welding Stainless Steel. While there are other gas choices,
such as “TriMix” this is typically the most widely available and eco-
nomic one for welding Stainless Steel (Inox).
Aluminum will always require the use of pure Argon (100% Ar)
shielding gas while welding in MIG mode. This is a widely available
and a standard gas throughout the world.
Of course, if you choose manual mode, different gas mixes other
than what is suggested may be used. If you choose to use a differ-
ent gas, be sure to select the next closest gas on the panel during
setup that matches your selection and keep “PowerSet” turned off.
This will allow proper operation.
jawed wrench such as a pipe wrench or basin wrench to tighten the
tting. The design of the tting means that no thread sealing tape or
compound needs to be used.
Connect the regulator tubing to the regulator. The regulator may be
supplied with a hose barb connection, or a threaded connection for
the tubing. If the regulator supplied has a hose barb, make sure the
hose barb tting is tight on the regulator. Tighten with a 3/4” (19mm)
wrench. If it is a threaded connection, use two 3/4” (19mm) wrench-
es to hold both the regulator and the tubing connection at the same
time. Hold counter pressure on the regulator connector while tight-
ening the hose tting to prevent damage to the regulator and to en-
sure maximum sealing. After connecting the tubing to the regulator,
connect the other end of the tubing to the 5/8” CGA tting on the
unit. Hold the tting on the unit with one 3/4” (19mm) wrench rmly
while tightening the hose tting with another 3/4”(19mm) wrench.
Important: Do not use thread tape or pipe sealant on any cylinder,
regulator or unit connection. The residue and debris may get into the
gas solenoid and cause operational issues.
Connect Regulator To Cylinder And Unit.
CAUTION!
Do not tighten the rear unit connection without holding the female
5/8 CGA tting located on the unit with a wrench, or damage may
occur to the bezel and the tting as the tting may turn in the hous-
ing while the hose tting is being turned.

18
Setup Guide
Getting Started
The on screen programming will remind you what polarity to use, but
in case you forget, refer to the illustrations below.
CHECK FOR GAS AND AIR LEAKS.
Be sure to check for gas or air leaks before attempting to weld or cut.
Connect all the lines and tighten and recheck any related clamps, plugs
and ttings. If you hear or suspect leaks, use warm, soapy water (or a
dedicated leak testing solution available from welding suppliers) and
spray on all rear external connections. If any leaks are present, bubbles
will form around the area of the leak. Tighten any clamps or ttings
found to be leaking. If the MIG gas regulator is leaking, discontinue
use and contact Everlast technical support. Do not attempt to modify or
repair this regulator. If the air regulator is leaking, make sure the pres-
sure is not more than 90 psi, and tighten the small screws on the regu-
lator with a screw driver. If too much pressure is applied, the regulator
may have blown internal and external O-rings or seals. If it is the air
regulator, check and remedy the problem if the regulator persists in
leaking. If it is the gas regulator, discontinue use and contact Everlast.
If the problem cannot be remedied, or internal leak is suspected con-
tact Everlast. NOTICE: While plasma cutting, a small drop in set air
pressure and operating pressure (while cutting) is normal. This does
not indicate a leak. This drop should never be more than 4 to 5 psi and
is usually less than 3 psi. If the pressure drops more than this, this
usually indicates the air supply hose for the plasma function is too long
or too small in diameter for the length it is running before reaching the
unit. It may also indicate another restriction. Always keep the air sup-
ply hose as short as possible.
DISTANCE YOUR WELDER FROM YOUR WORK.
As a best practice technique, be sure to locate your welder away from
the immediate work area. Sparks and debris thrown by the welding
and plasma cutting processes can enter the unit and cause damage.
This includes any grinding or milling operations that may occur in the
area.
SELECT THE CORRECT STICK AND PLASMA POLARITY. Where Do I Connect The Plasma Torch?
iPT Series Torch
iPT Series Torch
Work Clamp Work
DINSE 35/50
Adapter
DINSE 35/50
Adapter
Connect the work clamp to the positive terminal. Connect the plasma
torch to the negative terminal. Make sure the pilot arc wire is connected
to the small thumbscrew and the air line is fully seated.
Where Do I Connect The Stick Torch?
Electrode
Holder
Work Clamp Work
DINSE 35/50
Adapter
DINSE 35/50
Adapter
For most all applications, connect the electrode holder to the positive
terminal. Connect the work clamp to the negative terminal.
WARNING!
Make sure plasma torch polarity is correct or damage and malfunc-
tion of the torch and machine may result! Remove the torch before
changing to another mode. Install the other torch after the mode is
selected. Do not attempt to weld or cut while the unit is in a mode
that is not supported by the connected torch! Do not leave the plas-
ma or stick torch connected while using another process. The MIG
torch may be left connected if the torch is isolated from contact with
metal. If the MIG torch must remain in place, a piece of rubber tubing
slid down over the (cool) MIG torch nozzle will help prevent acci-
dental contact and arcing of the torch when not in use. As a best
practice, remove the MIG torch when not being used for MIG or Flux-
Cored welding. Accidental cross-arcing can cause the machine to fail.
Never touch a bare or exposed part of the connectors, cables, or
consumables while the unit is in use, especially while in the plasma
cutting mode. Turn the machine off to replace or check plasma con-
sumables. Severe injury, burn or electrocution may occur if contact
is made. Keep all cables and covers in place and in good repair. Do
not operate if damage occurs to any cable or safety device. Discon-
tinue use immediately and contact Everlast for replacement or repair
of the affected part.

19
Setup Guide
Getting Started
SELECT THE CORRECT MIG AND FLUX-CORED POLARITY.
Even though similar in concept, MIG/MAG (GMAW) and Gas-less
Flux-Cored (FCAW) welding require a polarity change when transi-
tioning between the two. The unit will remind you with an on-screen
prompt to change polarity when you change between the processes,
but this is an often over-looked issue, even when reminded by the
machine. Failure to change polarity will result in erratic operation,
bird’s nesting of the wire, poor fusion and excess spatter. Use illus-
trations below as a guide.
How Do I Change Polarity For Flux-Cored?
How Do I Change Polarity For MIG?
Work Clamp
The MIG gun must also be correct in polarity. Drop open the cover on the
left side of the MIG to access the wire spool and feeder. Just above the
feeder, the are two terminal lugs. The upper is Positive, and the lower is
negative. If there are no positive (+) or negative (-) symbols, there may also
be a label that says “Gas MIG” and “Gasless” or something similar. Regard-
less, the top terminal is positive and the bottom terminal is negative. For
MIG, the wire feeder cable should be connected to the top, positive (+) ter-
minal with via the provided screw. See below.
MIG/MAG
Work
DINSE 35/50
Adapter
5
Euro-Quick
Connector
Torch
MIG/MAG
Position
Work Clamp
When welding most all flux-cored wires, polarity will be negative. There are a
small number of exceptions. However, if the manufacturer doesn’t state the
polarity, assume it is negative. Drop open the cover on the left side of the
MIG to access the wire spool and feeder. Just above the feeder, the are two
terminal lugs. The upper is Positive, and the lower is negative. If there are
no positive (+) or negative (-) symbols, there may also be a label that says
“Gas MIG” and “Gasless” or something similar. Connect the wire feeder
cable to the bottom terminal lug via the provided screw.
Flux-Cored
Work
DINSE 35/50
Adapter
5
Torch
Euro-Quick
Connector
Flux-Cored
Position
NOTICE:
This unit is not designed for or intended to be used in dual shield
operation (FCAW-G). The Flux-cored operation that this machine
supports is a gasless process (FCAW). The PowerSet and manual
function is programmed for this type of operation.

20
INSTALL THE WIRE AND FEED THE GUN.
Once the wire spool has been installed, flip the tensioner lever down
and raise the top drive roll to the upper position. See the illustration
below. Gently guide the wire from the spool over through the wire
feeder and into the front section of the gun at least 6 inches. Make
sure the wire lays neatly in the groove. Hold it with your nger if
necessary as you lower the top drive roll down and raise the tension-
ing lever with your other hand. When complete the wire should look
like the illustration on the previous page. Hint: The wire on the spool
is usually bent and threaded through a small hole in the side of the
spool to lock it in place and prevent de-spooling of the wire. Keep
one hand on the wire spool to prevent despoiling and cut the wire
loose with a pair of wire cutters. Trim the wire to make sure the end
of the wire is straight and able to be threaded through the wire feeder
mechanism and gun. After the tensioner is raised back to the vertical
position, conrm the wire is still in the groove and is not riding up on
the shoulders of the drive roll.
Next, turn the welder on and set to a desired MIG or Flux-Cored
mode. Remove the gas nozzle by twisting it clockwise and pull. Do
not turn the nozzle counter clockwise! Unscrew the contact tip as
shown in the illustration below. Hold the gun cable and gun straight
as possible. Press and hold the wire jog button. The wire should
slowly begin to feed through the gun cable and eventually through the
gun. As the wire exits the gun, allow 3 to 4 extra inches of wire to be
fed out past the diffusor. Release the wire job button. Re-install the
contact tip over the wire and screw it in clockwise until it is tight, but
not to the point of stripping. Install the gas nozzle.
Setup Guide
Getting Started
CHECK AND CHANGE YOUR DRIVE ROLL.
The unit comes equipped with .030” and .035” drive rolls. NOTICE:
For most purposes up to 3/16” thick material you will likely want to
use .030” wire in this unit since it covers the greatest range of metal
thicknesses and amperages within the capability of this unit. .030”
wire typically can handle up to about 160A before it transitions to
globular transfer. For upper range use and materials 3/16” and over,
.035” is advisable. Remember, if you change wire size or type, you
will need to either flip the lower drive roll over or completely change
the drive roll to the correct size and type.
The top drive roll is actually an idler roll used to hold tension and
keep the wire in the groove and is not changeable. Only the bottom
drive roll needs to be changed. The bottom drive roll has two small
grooves that are sized for .030” (.8mm) and .035” (.9mm) solid wire.
Additional sizes and types of drive rolls are available as options. The
standard installed drive roll is meant to feed hard (solid) steel wire.
The groove on this drive roll has a “V” shape designed for the solid
wire. A Flux-Cored drive roll has a serrated edge to the groove,
which grips the softer, cored wire. Viewing a flux-core drive roll from
the top, you will see a “zipper” like pattern. This should never be
used to feed hard steel, stainless or aluminum wire. This will result in
damage to the wire, metal flaking and possible plugging of the MIG
gun liner. To determine the exact size of wire and type you have, look
at the side of the drive roll. The size of the drive roll groove is
stamped on the side of the drive roll closest to the corresponding
groove. The type of the drive roll will also be stamped with a V if it is
for solid, hard wire. If it is stamped with an “U”, this is a special drive
roll for feeding aluminum wire. Aluminum wire is best fed with a
spool gun.
The drive roll is held in place by a black thumbscrew. Remove the
screw to expose and change the drive roll. The drive roll is mounted
on a bushing. The bushing should be held in place with one nger of
one hand while the other hand removes the drive roll. This will pre-
vent both bushing and drive roll from being removed from the wire
feeder drive shaft. When removing make sure that the square locating
key is not dismounted. If the key falls out of the keyway, replace it
before replacing the drive roll.
Drive Roll Size and Location Info
5
.6mm =.023”/.025”
.8mm= .030”
.9mm= .035”
1.2mm= .045”
Size/Type Stamping.
(The size is stamped on
same side as the corre-
sponding groove.)
Installing the MIG Wire
How Do I Disassemble the MIG Gun?
M6 Contact Tip
Diffusor and Retaining Spring
Gun Neck
Always remove and install the gas nozzle by twisting clockwise.
Gas Nozzle
Flux-Cored Cap
(Not included, sourced from aftermarket sources)