Everlast superultra series User manual

MultiProcess Pulse Tig/Smaw/Plasma Cutter Units
Operator’s Manual For
DC Output SuperUltra Series Units
Safety, Setup and General Use Guide
Rev. 1 0 00714-14
CC
GTAW-P
SMAW
1
~
PHASE
DC
everlastwelders.com
1-877-755-9353 Specicaons and Accessories subject to change without noce.
329 Lileeld Ave. South San Francisco, CA 94080 USA
PAC
EVERLAST
SUPERULTRA SERIES

2
Table of contents
Secon……………………………………………………………..Page
Leer to the Customer ………………...………………….
Everlast Contact Informaon…………………………….
Safety Precauons…………………………………………....
Introducon and Specicaons…………………….…..
Unit Specicaons……………………….……………………
General Overview…………….…..…………………………..
General Use and Care………...……………………………..
Quick Setup Guide, TIG Torch/Cooler Connecon
Quick Setup Guide, Plasma Connecon.…..………..
Quick Setup Guide, Sck Polarity and Connecon
Quick Setup Guide, Rear Connecon for Plasma…
Quick Setup Guide, Rear Connecon for TIG..…….
Front Panel Features and Controls……………………..
Rear Panel Features and Controls……………………...
Tungsten Preparaon………………………………………...
High Frequency Start TIG Operaon……………………
Sck Arc Starng Procedure………………………………..
Plasma Funcon and Operaon………………………....
Recommendaons for Polarity/Amps/Tungsten..
Expanded View of TIG torch……….…….……….………
Expanded View of AG60 Plasma Torch………………..
7 Pin Connector Pin-out…………..…….…….…………….
Troubleshoong………………………………………………....
3
4
5
9
10
11
11
12
13
14
15
16
17
19
21
22
23
24
28
29
30
31
32
NOTE: Product Specicaons and features are subject to change without noce. While every aempt has
been made to provide the most accurate and current informaon possible at the me of publicaon, this manu-
al is intended to be a general guide and not intended to be exhausve in its content regarding safety, welding,
or the operaon/maintenance of this unit. Everlast Power Equipment INC. does not guarantee the accuracy,
completeness, authority or authencity of the informaon contained within this manual. The owner of this
product assumes all liability for its use and maintenance. Everlast Power Equipment INC. does not warrant this
product or this document for tness for any parcular purpose, for performance/accuracy or for suitability of
applicaon. Furthermore, Everlast Power Equipment INC. does not accept liability for injury or damages, conse-
quenal or incidental, resulng from the use of this product or resulng from the content found in this docu-
ment or accept claims by a third party of such liability.

3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast. We appreciate you
as a customer and hope that you will enjoy years of use from your welder.
Please go directly to the Everlast website to register your unit and receive your warranty 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 during o hours, or in the event 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 sasfacon email: sale[email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [email protected]
Everlast Support Forum: hp://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
Everlast Canada:
Everlast consumer sasfacon email: sal[email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Austrailia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
Aer hours support: 0413 447 492
Everlast Technical Support: [email protected]m

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 a licensed electrician if dis-
turbance 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
26 series TIG torch Sck Electrode Holder
Consumable Starter Kit
AG60 Plasma Torch
Work Clamp
Foot Pedal
Argon and Air Regulator
NOTE: Accessory and consumable style and quanes are subject to change without noce. Consumable starter kits provide only enough
consumables to get started. Extra consumables can be purchased through Everlast or almost any local welding supply store.

10
Introduction and SpecificationsSection 1
DC SUPERULTRA INPUT/OUTPUT SPECIFICATIONS
FEATURE/SPEC. SUPERULTRA 205P
INVERTER TYPE MOSFET
INPUT VOLTAGE ±10%;PHASE/FREQUENCY 110/220V; 1PH/50-60Hz
MAXIMUM INPUT AMPS (I₁MAX) 31A @110V/ 27A @ 220V
MAXIMUM INPUT RUNNING AMPS (I₁e) 19A @ 110V/ 17 A @ 220V
DUTY CYCLE % @ AMPS
TIG: [110V] 35%@120A/14.8V 60%@ 93A/13.7V 100%@72A /12.9V
[220V] 35%@200A/18V 60%@160A/16.4V 100%@130A/15.2V
Plasma: [110V] 60%@27A/90.8V 100%@21A/88.4V
[220V] 35%@50A/100V 60%@40A/96V 100%@ 30A/92V
Sck: [110V] 35%@120A/24.8V 60%@93A/23.7V 100%@72A/22.9V
[220V] 35%@160A/26.4V 60%@130A/25.2V 100%@100A/24V
OUTPUT RANGE : AMPS/VOLTS
TIG: [110V] 10-120A/10.4-14.8V [220V] 10-200A/10.4-18V
Sck: [110V] 10-160A/120A, 20.4-24.8V [220V] 10-160A/20.4-26.4V
PLASMA: [110) 10-27A/84-94V [220] 10-50A/84V-100V
OPEN CIRCUIT VOLTAGE
TIG: 70 V
STICK: 70V
PLASMA: 220 V
TIG TORCH 26 SERIES (economy)
PLASMA TORCH AG60 High Frequency Torch
CONSTANT CURRENT (CC) OUTPUT TYPE DC (±)
STICK CELLULOSE ROD CAPABLE 6010,6011 6011 ONLY (DC+)
INCLUDES
WORK CLAMP WITH CABLE (8 FT),STICK TORCH WITH CABLE (8FT), TIG
TORCH: 12 FT, PLASMA AG60 12 FT, CONSUMABLE STARTER KIT FOR
TIG AND PLASMA (NO TUNGSTEN)
DINSE CONNECTOR TYPE 50 Series
POST FLOW ADJUSTABLE 0-60Seconds
PROTECTION CLASS IP21S
INSULATION GRADE F

11
General overview: The SuperUltra 205 from Everlast is
entry level DC TIG, sck and plasma mul-purpose unit,
designed for occasional portable repair work and small
project use. It is recommended for the welding enthusi-
ast or hobbyist with occasional repair needs and/or light
duty welding requirements The SuperUltra series fea-
tures a lightweight MOFSET inverter design and can pro-
vide capable service if used within its intended limits.
These are not intended for use in producon or intensive
fabricaon dues. NOTE: This unit is not suitable for
welding aluminum.
General Use and Care: Care should be taken to keep the
unit out of direct contact with water spray. The unit is
rated IP21S, which rates it for light contact with dripping
water but should never be used in the presence of water
for safety. It is a good idea to remove the welder from
the vicinity of any water or moisture source to reduce
the possibility of electrocuon or shock. Never operate in
standing water.
Every 1-2 months, depending upon use, the welder
should be unplugged, opened up and carefully cleaned
with compressed air. Regular maintenance will extend
the life of the unit.
IMPORTANT: Before opening the unit for any reason,
make sure the unit has been unplugged for at least 10
minutes to allow me for the capacitors to fully dis-
charge. Severe shock and/or death can occur.
Do not restrict air ow or movement of air around the
welder. Allow a buer distance of 2  from all sides if
possible, with a minimum distance of at least 18” clear-
ance. Do not operate the welder immediately in the
weld area or the force of the fan will cause welding issues
such as unstable arc, or porosity.
Do not mount in areas that are prone to severe shock or
vibraon. Li and carry the welder by the handle.
Do not direct metallic dust or any dirt intenonally to-
ward the machine, parcularly in grinding and welding
operaons. Make sure the panel is protected from dam-
age during welding and cung operaons by ipping
down the clear protecve cover.
Duty Cycle. This unit is described as a light, entry level
unit. Although it has a duty cycle limit, care should be
taken not to exceed this limit for maximum life. Once the
duty cycle has been exceeded, heat may connue to build
in the electronics. The duty cycle is based o a 10 minute
duty cycle rang at 40° C. This means that the unit is ca-
pable of being operated at the max amps for the stated
percent of me out of 10 minutes without a break to
cool down the unit. For the remainder of the 10 minute
me period, the welder should rest for maximum life.
The temperature light will come on and the welder will
automacally stop welding when an overheat condion
has occurred. Stop welding immediately. Heat will con-
nue to be generated by and transferred to the elec-
tronics aer welding has ceased. Welding in humid, or
hot condions can aect duty cycle as well. Do not shut
down an overheated welder unl it has safely cooled.
Once the overheated condion has cleared, welding can
resume. Do not operate the welder with the covers re-
moved. Only cycle the power switch to reset the unit IF
the light has not gone out aer 10 minutes. The duty
cycle for each process varies according to the voltage
input. The duty cycles at maximum rated amps of each
process are as follows:
120V:
TIG @ 35%
Sck@ 35%
Plasma@ 60%
220V:
TIG@35%
Sck@35%
Plasma@35%
HF Start. The welder uses High Frequency to start the-
TIG arc and plasma cuer arc. HF is generated by a point
gap system similar to an older automove point/coil sys-
tem. A slight buzz, or hiss may be heard immediately
upon start as the HF energizes. A bright blue light may
be emied from the front or side panel as the spark en-
ergizes. This is normal and safe as long as the covers are
in place. Do not acvate the HF unless you are in posi-
on and ready to weld to minimize point gap wear. Point
gap should measure between .030-.045”. Contact Ever-
last for adjustment instrucons if HF appears to malfunc-
on while either in Plasma or TIG mode.
This manual has been compiled to give an overview of
operaon and is designed to oer informaon centered
around safe, praccal use of the welder. Welding is in-
herently dangerous. Only YOU, the operator of this weld-
er, can ensure that safe operang pracces are followed,
through the exercise of common sense pracces and
training. Do not operate this machine unl you have fully
read the manual, including the safety secon. If you
think that you do not have the skill or knowledge to safe-
ly operate this welder, do not use this welder unl for-
mal training is received.
Introduction and Specifications
Section 1

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

13
NOTES:
1) Do not aempt to use the foot pedal to control the amps.
2) Do not ip the process switch while cung or unit failure may result.
3) Aempt to cut only when air pressure is beins supplied. Always check gauge to conrm air pressure is present before cut
4) Do not exceed 85 psi air supply pressure from the compressor or failure of components may result.
5) Adjust torch operaon pressure to 55-65 psi for best results while post ow is owing. (Increase post ow me to maxi-
mum to allow enough me to set pressure.)
6) When using the lower amp range, the nozzles will need to be changed out for ones with a smaller diameter orice. Ever-
last is the OEM supplier of the torch but not the manufacturer. Low amp cuts may be unstable unless the size is matched
to the amps being used. Although the unit can be adjusted as low as 10 amps, this does not guarantee stable cung at
this amperage. Minimum suggested cung amps is 25-30 amps for the AG 60 torch with the smallest available consuma-
ble. Other torches with smaller consumables may be ed to supply beer low end cung capability.
7) Do not use the pilot arc connuously. It is designed for momentary use. Do not re the torch unless ready to cut or ad-
just the cung pressure. Excessive use creates point gap wear, and can also damage surrounding electronics. ALWAYS
CUT WITH THE WORK CLAMP ATTACHED.
8) If the pilot arc does not transfer and only a shallow cut or gouge is noced, check the work clamp to make sure it is
aached directly to clean rust free area of the work piece and that the cable is secure to both the torch and work clamp.
Make sure that the cables are located securely in the connectors.
WORK (+)
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: PLASMA CONNECTIONS
PILOT
AG-60
GAS
CONTROL
PILOT ARC
AIR
SWITCH

14
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS
GAS
CONTROL
PILOT ARC
WORK (-)
TORCH (+)

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

16
NOTE: TO PREVENT STRAY HIGH FREQUENCY INTERFERENCE, THIS UNIT PROVIDES AN ADDITIONAL GROUNDING POINT AT THE REAR OF THE UNIT. IT SHOULD BE DIRECTLY GROUNDED
THROUGH A SEPARATE WIRE TO AN OUTSIDE METAL ROD DRIVEN IN THE GROUND. THIS HELPS PREVENT BLEEDBACK OF HF INTO THE POWER GRID, AND HELPS MUTE HF INTERFER-
ENCE. ADDITIONALLY, ALL SURROUNDING METAL OBJECTS SHOULD BE GROUNDED INCLUDING THE TABLE, PIPES, WALLS ETC. TO PREVENT ELECTRICAL INTERFERENCE WITH OTHER
CIRCUITS. DO NOT COUPLE THIS WIRE TO THE GROUND PROVIDED IN THE ELECTRICAL CIRCUIT.
EVERLAST
NOTE: LITERS/MINUTE (lpm)
CO2
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BE-
FORE RE-WIRING YOUR WELDER OR ATTEMPTING TO MAKE ANY ELECTRICAL CONNEC-
HF Fe, Cu
NEMA 6-50P
L1,BLACK; HOT
Section 2
NOTE: Use Ar or Ar/He only. Do not
use more than 25% He in the Ar/He
gas mix.
L2,WHITE
NOTE : The SUPERULTRA units share the same
connecon/input point for the TIG shielding
gas and for the Plasma air input. This requires
swapping the TIG and Air input hoses at the
lower connecon point when changing pro-
cesses. Do not run argon the argon line
through the air regulator. A manifold system
may be made from either ball a T conguraon
of two ball valves or a Y valve( both customer
supplied) to switch between the plasma air
input and TIG shielding gas as needed without
disconnecng and reconnecng the gas/air
lines every me the process is changed. If no
switching valve or manifold system is used,
then you must manually change the input sup-
ply tubing every me you change processes.
GAS
INLET
SWAP TUBING!
QUICK SETUP GUIDE: REAR CONNECTIONS FOR TIG / WIRING
(US/Canada)
QUICK SETUP AND USE GUIDE
SUGGESTED PLUG IS A NEMA 6-50P, THE STANDARD PLUG FOR MOST 1 PHASE 240 V WELDERS IN THE US AND CANADA.
GREEN GROUND (220/240V 1
CLAMP

17
GAS
CONTROL
PILOT ARC
2. ON/TEMP/O.C
3. AMP CONTROL
1. AMP DISPLAY
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS
9. AIR PRESSURE
NOTE: PowerPRO 256S panel shown. PowerPRO 205S panel layout, appearance and funcon is
idencal, with the excepon of the pulse frequency range, and the amp ranges being smaller.
4. POST FLOW TIME
10. TIG/CUT/STICK SWITCH
6. NEGATIVE (25 OR 35 SERIES) 8. POSITIVE (25 OR 35 SERIES)
8. TORCH/PEDAL CONTROL
7. GAS QUICK CONNECT (9mm)
5. PILOT ARC

18
SUPERULTRA FEATURES PARAMETERS PURPOSE
1. Amp Display N/A Indicates amperage while welding. While adjusng the amperage with the torch switch
connected relays selected amperage. Remains stac while foot pedal is plugged in unl the
pedal is pressed, then displays acve amps.
2. On/Temp/ Duty Cycle On/O On indicator should always be on while the unit is plugged in and the power switch is
switched on. The Duty Cycle light is an amber color. The Overcurrent light is lit, turn the unit
o and check for possible causes including undersized cables, poor connecons and over-
heang cables. If the Duty cycle is lit, Do not turn o the unit unl it has had sucient me
to cool (10-15 minutes). Cycle the power switch to reset the machine only aer the machine
has had me to cool. The duty cycle and overcurrent warning lights should go o aer cycling
the power switch on the machine. If it does not, and will not weld, contact Everlast.
3. Amp Control N/A Controls amperage output. While using the torch switch with TIG and Plasma this amp con-
trol switch sets the amperage. While using the foot pedal, however, this control becomes
inacve and the full range of amps from the minimum up to the maximum output of the
machine is available.
4. Post Flow Control 0-25 Seconds Sets the post ow me of the shielding gas while welding in TIG mode. While in plasma (cut)
mode, it sets the post ow me of the air.Time is approximate only and can vary somewhat
from the maximum limit posted from unit to unit. The air or shielding gas may stop owing
before full maximum me is reached. Consider the maximum seng mark a reference guide
only.
5. Pilot Arc N/A Pilot Arc Wire connecon. To be used only with plasma torch. The small ringed wire con-
nects here. Unscrew the plasc thumb nut and aach the wire to the post. Reinstall the
thumb nut over the wire with nger pressure only.
6. Negave Connector (Torch
on some models)
DINSE 50 Locaon of the negave terminal connecon. Dinse-style. (35 series)
For Sck: Work Clamp Connecon. For TIG: Torch Connecon For Plasma: Torch Connecon
7. Quick Connect Gas Outlet 9 mm Connects the gas to the TIG torch. To connect: Push the torch ng into the connector unl
the collar slides forward with a click. To Release: Slide the collar back.
8. Control Connector 7 Pin Connect the foot pedal or torch switch to this socket to control the welder. Only the foot
pedal or torch control connector can be plugged in at one me. If the torch has a torch
switch feature, e the loose connector back and leave it unconnected while using the pedal.
9. Posive Connector (Work
Piece on some models)
DINSE 50 Locaon of the posive terminal connecon. Dinse-style connector.
For Sck: Torch connecon. For TIG, Plasma: Work Clamp Connecon.
9. Air Pressure Gauge. 85 psi max
supply
55-65 psi
operang
Use to measure air supply pressure for plasma only. This gauge is irrelevant while being used
for TIG, although some pressure may register while the gas is acvely owing. Supply air
pressure should not exceed 85 psi. Adjust operang pressure while air is owing with gauge
provided, or adjust to 55-65 psi and increase or decrease pressure from there to achieve
opmum cung results. To adjust air pressure with torch, briey re torch with post ow set
to maximum. Adjust air ow while the air is sll owing. Use air only for cung.
10. TIG/CUT/STICK N/A This switch selects processes. Do not switch this switch while welding or cung, or with the
improper torch connected or unit failure may result. Improper polarity can lead to unit fail-
ure as well. Make sure all connecons are installed properly before cung or welding.
Section 2
FRONT PANEL FEATURES AND CONTROLS CONTINUED
QUICK SETUP AND USE GUIDE

19
QUICK SETUP AND USE GUIDESection 2
REAR PANEL FEATURES AND CONTROLS
GAS
INLET
2. POWER CABLE 1 ~ 120/240V
5. REGULATOR ASSY. 1. POWER SWITCH
4. HF GROUND BOLT
3. GAS INLET
NEMA 6-50P
(220/240V)
L1,BLACK; HOT(240V)/HOT (120V)
GREEN GROUND (240V AND 120V )
Note: Customer supplied plug. Consult Licensed electrician for proper installation.
L2 WHITE, HOT(240V )/NEUTRAL (120V)
To wire plug for 240V or possible use with 120V, use the industry standard NEMA 6-50 plug which is designed for 240V operation
and use with welders. You may then either create an 240V to 120V pigtail adapter for 120V operation, or purchase one directly from
Everlast for use on 120V. For use with 120V input only, remember output will be reduced. Be sure to maintain polarity when wiring
for 120V use, with white as the neutral, and green as the ground. Black will always be hot in both 240V and 120V welder circuits. For
240V welder circuits, note that 3 wire 240V welder circuits use different standard colors than for 4 wire 240V.

20
SUPER ULTRA FEATURES PARAMETERS PURPOSE
1. 2-Pole Power switch On/O The breaker switch has 2 poles. It serves as the On/O switch for the welder. Always
turn the welder on and o by the switch rst before using any disconnect. The Water
cooler outlet on the rear remains live aer the switch is turned o.
3. Power Cord 120/240 V
1 phase, 50/60 Hz.
The unit is prewired with a standard NEMA 6-50 plug. This is the standard plug for
welders in the US and Canada. Other countries vary plug conguraon as well as input.
As a dual voltage unit, when used with 120V supply connect the pigtail adapter to
reduce the input. When using on 120V, make sure the breaker and wiring is sized
properly for use or damage to the machine can result. NOTE: Maximum operaon, on
120V is not recommended for long periods of me as high breaker amperage are re-
quired along with heavier than normal wiring ampacity, not normally found on most
household 120V wiring. Consult licensed electrician before operang on 120V to con-
rm wiring and breaker suitability.
4. Gas Input Connecon 1/4-5/16” This is the point where the shielding gas from the regulator connects. The unit is sup-
plied with tubing and clamps which connect this ng to the regulator. The hose barb
design allows universal connecon of the welder to almost any regulator or setup
found throughout the world. Make sure the tubing slides fully over the connector,
then thoroughly ghten the clamp. Use an addional clamp if necessary to prevent
leaking. If you suspect leaking, test the connecon with a soluon of mild soapy water.
If bubbles are seen, reghten or reinstall the tubing. While changing processes, the
tubing must be swapped. Do not run the Argon gas through the air regulator/lter. A
T-ng or Y-ng may be placed inline at the connecon to leave both argon and air
hooked up without having to swap out the lines. This is not supplied by Everlast.
5. HF Ground Bolt N/A HF energy can be devastang to surrounding electronic equipment. If the operang
environment includes electronic equipment, this connecon can serve as a direct path
to an outdoor grounded metal rod that is isolated from the main electrical circuit to
help bleed o excess HF circuit. All metal parts inside the building should be grounded
as well, including pipes, tables, and even metal siding. HF energy has been known to
bleed back into the power grid and disrupt electronic devices further down the grid. If
the point gap becomes out of adjustment, more HF energy may build up, or even jump
across circuitry within the welder. It is recommended that a small, separate ground
wire (minimum 14 gauge) be aached at this point while in use.
6. Air Regulator Assembly 85 psi maximum
Supply pressure.
55-65psi operang
pressure while
cung
The regulator serves a dual purpose. 1) It controls air pressure for plasma. 2) It lters
ne parculates and large drops of water. The regulator is not designed to regulate
Argon ow or have argon owing through it. A separate air dryer must be installed
inline to prevent rapid torch and consumable wear(Customer supplied). The regulator
assembly is not designed to remove moisture from the air, only large drops of water
that may be created in the coupling and uncoupling process. Everlast does not warran-
ty damage caused to torches or consumables by moisture. Residual moisture in the
line also can contaminate the system, causing problems while TIG welding. The num-
ber one issue experienced with Plasma cung, with many dierent symptoms is the
presence of moisture in the air line. To adjust the pressure, for cung, simply pull the
knob up unl it clicks and rotate it clockwise to increase the pressure, and rotate it
counter clockwise to decrease the pressure. To adjust the pressure correctly, adjust
the pressure while the air is owing in post ow mode. If a ow tube for the torch is
provided, adjust it so the ball oats in the window as depicted in the torch manual. Do
not re torch with the ow tube installed on the torch. Turn Post ow to maximum,
re the torch, then install the ow meter and make adjustments to the air pressure
while it is owing. If no ow tube is provide, adjust pressure to 55-65 psi.
Section 2
REAR PANEL FEATURES AND
QUICK SETUP AND USE GUIDE
NOTES
1. The gas input connecon should be checked for ghtness periodically, especially if the machine is moved or when changing process.
2. Never operate welder on a generator that is not cered by its manufacturer to be “clean” power, which is less than 10% total harmonic distoron. Less than
5% is preferred. Operang the unit on square wave output or modied sine wave generator is strictly prohibited. Contact the manufacturer of the genera-
tor for this informaon. Everlast does not have an “approved” list of generators. But, if the generator is not listed as clean power by its manufacturer,
then operaon is prohibited. Generators that do not at least meet the operang input requirements of the welder are also forbidden to be used with the
welders. Surge amp capability of the generator should equal or exceed the maximum inrush demand of the welder. But the surge capability should not
be used as the only factor. The regular, running output of the generator should match or exceed the running or “rated” demand of the welder. Any dam-
age done by operang the welder on a generator not specied by its manufacturer to be “clean”, will not be covered under warranty. This also includes
suspect power sources where voltage is below 208 V and above 250 V.