Everlast Typhoon 330 User manual

Operator’s Manual
Publish Date: June 2023
EVPTYP330 Rev. 1
USA/North America
©Everlast Power Equipment
AC/DC
330A
AC/DC
275A
240V
1 and 3 Phase
Optional 480V 3 phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide
FUNCTION: AC/DC TIG with Pulse Function/ DC Stick
PURCHASE DATE:
WELDER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:

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, OPERATING VOLTAGE AND OTHER GENERAL INFORMATION 10
DUTY CYCLE EXPLANATION STATEMENT 11
SPECIFICATIONS: DUTY CYCLE, PERFORMANCE SPECIFICATIONS AND INPUT AMPERAGE INFORMATION 12
SETUP GUIDE: GETTING STARTED, UNPACKING YOUR UNIT, ASSEMBLY AND INSPECTION 13
SETUP GUIDE: CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION 15
SETUP GUIDE: SHIELDING GAS INFORMATION AND CONNECTION OF REGULATOR 16
SETUP GUIDE: TUNGSTEN SELECTION AND GRINDING 17
SETUP GUIDE: GETTING STARTED WITH TIG AND STICK BASIC STARTING POINT GENERAL INFORMATION 20
SETUP GUIDE: CONNECTING YOUR UNIT AND READYING TO WELD (POLARITY AND PANEL CONNECTIONS) 21
FRONT PANEL VIEW AND COMPONENT ID 23
REAR PANEL VIEW AND COMPONENT ID 24
CONTROL PANEL LAYOUT 25
STARTING UP THE WELDER 26
CONTROL PANEL OPERATION AND NAVIGATION 27
WELD CYCLE AND GRAPH LINE DETAILS 37
AC TIG SCREEN SETUP, FUNCTIONS AND PARAMETERS 40
DC TIG SCREEN SETUP, FUNCTIONS AND PARAMETERS 44
AC AND DC STICK SCREEN SETUP, FUNCTIONS AND PARAMETERS 47
BACKGROUND MENU SCREEN SETUP AND PARMETERS OF OPERATION 49
TIG ARC STARTING, REMOTE FUNCTIONS AND OPERATION 50
EXPLANATION OF TIG PARAMETERS, FUNCTIONS AND WELDING TERMS 52
EXPLANATION OF STICK PARAMETERS, FUNCTIONS AND WELDING TERMS 59
TORCH PARTS AND ASSEMBLY 61
7 PIN CONNECTOR PINOUT AND INFORMATION FOR REMOTE 63
TROUBLE SHOOTING: COMMON WELDING ISSUES 64
TROUBLE SHOOTING: ERROR CODES 65
MAINTENANCE 66
IMPORTANT!
Before operating the welder, read this manual from beginning to end. A thorough read-through of this manual is important to
help guide you in the safe and competent operation of the welder. This welder is a complex machine with many features that
new owners or users may not understand or be familiar with. The manual is written in a way that builds knowledge upon pre-
vious information presented in the manual. If sections are randomly read through, details of important information will be
missed. In certain sections, where details of operation may overlap, some information may be repeated from previous sec-
tions to highlight continuity between different functions and settings. Though some general welding information is given to
illustrate the parameters and functions of the welder, the manual is not meant to train or instruct in welding. The manual’s
scope and intent is to guide the professional user in safe use of the basic parameters and functions of the welder. Any ex-
plicit setting or detail offered in this manual is intended as a general guide, or a starting point, and should not be construed to
be a nal setting to be applied in any or all circumstances.

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 it-
self, Everlast Power Equipment INC. does not guarantee the accuracy, complete-
ness, 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 perfor-
mance/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
NOTICE:
The Typhoon Series of welders are designed for use by professional welders in commercial settings. Commercial
settings are equipped with industrial wiring and power supply. This welder requires a dedicated circuit and special
welder outlets that are not typically found in home garages. The higher Amperage outlets and breakers required by
this welder may not allow connection to a standard home panel box with out signicant modication to meet nation-
al electric codes and the input requirements of the welder. (See specications page of inrush and rated current.)
Additionally, use in home settings may cause interference with electronics. Besides a required dedicated circuit,
this welder may also require additional grounding of all metal items and the welder by a commercial electrician to
prevent undesirable operation if interference is observed.

4
THANK YOU! We appreciate you as a valued customer and hope that you will enjoy years of use from your welder. 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 infor-
mation 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 is restricted to per-
sons who have read, understand and follow the warnings and instructions in this manual. If
you or the operator needs further instruction, contact Everlast welding support 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. Some pacemakers have limited shielding. Alert any users or customers
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 poses shock and electrocution risks. Keep this welding equipment 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 weld-
ing. Keep all parts of the body insulated from the part being welded when possible. Do
not touch both terminals or connections at the same time. Consider all welder parts to be
“live” at all times even if no welding is being performed. Do not use frayed welding cables.
CAUTION! Fires are possible but also preventable while welding. Always remove flamma-
ble 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, espe-
cially if pressurized 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/HV starting of TIG 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. 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).
WARNING! The intense flashing and strobing effects that are common with welding pro-
cesses, particularly when using the Pulse function may cause seizures in people with a
history of photo-sensitive Epilepsy. Be mindful of others in the welding area who may
have such sensitivities. Keep them clear of the area.

9
Safety Warnings, Dangers, Cautions and Instructions
CAUTION! Trip Hazards exist around welders. Cords, cables, welding leads and hoses pose
a trip hazard. Be aware of their location and inform others of their location. Tape and se-
cure 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 welder 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.
**NOTICE:
If any electrical disturbance is noticed as a result of the High Frequency operation of this unit during arc starting, the HF ser-
vice bolt located on the rear of this unit should be connected directly to a 12 gauge wire that is bonded directly to an outside
copper ground rod driven into moist soil. (see location on rear panel page) 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 sur-
rounds, etc. that may act as “antenna” to radiate/absorb HF energy. Additionally, all cords and welding leads should be twist-
ed together and run directly to the work without coils or excess cabling.

10
Important Information: Operating this unit with a generator or other off-grid service.
This welder 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 distortion (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 welder off of “dirty” power or
modied sine waves may not be readily apparent and is usually cumulative in nature. However, damage may present itself immediately. The damage
caused by running this welder on “dirty” power usually leaves internal tell-tale signs and damages specic parts.
When operating on 240V 1 phase generator power, you will need a minimum size of 15,000 Surge Watts. Ideally, it is recommended for use with
16,000 Surge Watt generators or larger. 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
provides clean power. Price paid does not guarantee a clean power output either. There are multiple brands at various price points capable of produc-
ing clean power. Investigate this before purchasing a generator. The manufacturer will usually state that a unit is clean power in the advertising infor-
mation and will state actual THD. If the manufacturer does not state it, contact the manufacturer directly for actual THD.
NOTICE! Operation of this unit with a generator not stated to provide clean power (5% or less THD) by the manufacturer of the generator is prohibited
and will 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. Do not use with any off-grid power delivery system that produces more than 5% Total Harmonic Distortion (THD).
WARNING! Do not start or stop the generator with the welder 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 on the welder 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 completely shut down with the welder plugged in.
For best practice: do not start or stop the generator with this welder plugged in, even if it is turned off. Unplug the welder 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 mod-
els do not. Some newer models use “divided” power between welding and generating and cannot supply the full power to the welder 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, just 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 grounded, according to local code and manufacturer’s instructions.
Ground the machine per the generator manufacturers instructions to meet code. Improperly grounded generators may damage the machine and more
importantly may cause severe injury or death. Damage resulting from improperly grounded generators is not covered under warranty.
Single and Three Phase Operation:
The standard Typhoon unit may be operated on either single phase or three phase 220/240V supply power. It can also be operated on 208V 1 phase or
3 phase power as long as the power supply does not drop below 200V during peak demand times. Operating on 208V will increase Amperage draw.
If 208 or 240V 3 phase is present, the wiring must be congured to use only the black and white conductors (power legs) of power that produce ap-
proximately 110-120V to ground and measure nominally between 208 and 240V between any two conductors. The green wire should be wired for
ground. The red wire should be used only for three phase as L3. Use the red wire for high voltage power leg if it is a Delta system. The power conduc-
tors are also tagged for single phase or three phase operation as a reminder. Installation on single phase or three phase power should present no is-
sues if codes are followed and proper sized conductors are used. The optional 480V Typhoon model may only be operated on 3 phase power. The
voltage can range between 460V to 485V 3 phase for this optional 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 consulta-
tion 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.
Optional 480V 3 phase units are not suitable for small shops or home operation unless provisions have been made for 3 phase supply. Do not with use
a rotary-type/mechanical phase converter or damage may result.
WARNING! Do not modify the 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.

11
WARNING!
This unit is not designed for Air Carbon Arc Gouging or Cutting. Do not this unit for this application. It is not designed to
sustain the high volt and long arc characteristics needed for Carbon-Arc use.
WARNING: Any Carbon-Arc use will instantly void the warranty! Do not be tempted to use Carbon-Arc Gouging or Cutting
under any circumstances, regardless of the electrode diameter that is intended for use.
Specifications
Duty Cycle
Duty Cycle is dened per North American Specications as the amount of time out of a 10 minute period in which the unit
can operate when tested at 40° C (104° F). For example, this unit has a duty cycle of 40% at maximum output. That means
that the unit can be operated for 4 minutes out of 10 minutes at 330A (TIG). For this unit, the 40% rating is at the maximum
output of the machine whether in TIG or Stick Mode. This rating means it be continuously, or intermittently operated during
the 10 minute period of time up to the duty cycle limit.
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 welder. 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 welder 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. Be sure to set the fan to run continuously instead of on-demand. 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 sec-
onds before turning the machine back on. If the unit does not reset, contact technical support for further advice and assis-
tance. 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 without 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
welder and can lead to early failure.
NOTICE:
This manual has been written to guide in safe operation of the Typhoon welder. It is important to note that due to our contin-
ual effort to improve and advance the design of the series, units currently in production may have updated designs and pro-
gramming improvements not found in earlier production models. Older models many not be updateable without returning the
units for major service at customer’s expense. Realistically, updating previous generations of units, to current model speci-
cations and conguration may not be possible or practical. Additionally, if an update is deemed possible, this is not consid-
ered to be a part of warranty work and is not eligible for return/exchange. Some updates and modications are not possible
due to complete revisions of parts and internal design changes that are incompatible with the older designs. Major changes
and differences in operation and specications are noted where possible in this manual. However, some functions and speci-
cations, not affecting overall function or operation, may change from time to time without further notice or update from Ever-
last. Everlast accepts and bears no responsibility, nor provides any guaranty or promise, to update programming, features,
functions or ratings for older units already in service, free of charge or otherwise unless specically stated in writing.

12
Specifications
Product Specications
Construction Type Digital IGBT Inverter-Based Design with 7.3” HD (720) Screen.
Input Voltage/ Hertz/ Phase 220V (± 15% ) 50/60 Hz 1 and 3 Phase (480V 3 phase Optional)
I1MAX Current Rating (Inrush Amps) 220V 1phase @ 65A 240V 3phase @ 32A (Optional 480V 3 phase @ 18A)
I1EFF Current Rating (Effective Rated Amps) 220V 1phase @ 42A 240V 3phase @ 21A (Optional 480V 3 phase @ 12A)
OCV/ OCV with Voltage Reduction Device Selected TIG: 105V, Stick: 85V / With VRD Selected <24V)
TIG Duty Cycle @ Rated Output (Rated at 40° C/104° F) * 40% @ 330A/ 60% @ 270A/ 100% @ 210A
Stick Duty Cycle @ Rated Output (Rated at 40° C/104° F )* 40% @ 275A/ 60% @ 220A/ 100% @ 170A
TIG Output Range V/A (AC/DC) AC: 10.1-23.2V/ 3-330A / DC: 10.1-23.2V/ 2-330A
Stick Output Range V/A (AC/DC) AC/DC: 20.4-31V/10-275A
Independent Amplitude The Electrode Positive Value can be set independently at 10% to 125% of the Electrode Negative Value.
TIG Start Type Solid State HF (Simulated HF, No points), Lift with Remote, Live Lift
Pre Flow / Post Flow Gas Time PREFLOW: 0-30 Seconds; POSTFLOW: 0-60 Seconds
Start Amps (Initial Current); End Amps, AC/DC (Crater Current) START AMPS: AC 3A, DC 2A END AMPS: AC 3, DC 2A (In manual setting for Tungsten Size Selection.*)
Upslope/ Downslope (Ramp up/Ramp Down Current) Time UPSLOPE: 0-30 Seconds DOWNSLOPE: 0-60 Seconds
TIG Pulse Frequency Hz (Standard DC/Standard AC Advanced AC) Std. Pulse DC .1-999.9Hz Std. Pulse AC .1-500Hz Adv. AC Pulse .1-10Hz
DC TIG Pulse Wave Forms (4) Advanced Square, Triangular, Sine, Trapezoid
TIG Pulse Time On (Duty Cycle) 5-95% Peak (Welding Amp Time vs Pulse Amp Time)
TIG Pulse Amps (Background Current) 3-100% of Peak (Welding Amp Value)
AC Wave Forms (5) Adv. Square /Soft Square /Trapezoid/Triangular/Sine (Stick allows Advanced Square Only for AC Output)
AC Split Wave Form Control Both Electrode Positive (+) and Negative (-) halves of the AC cycle can be assigned a specic wave shape.
AC Frequency 20-400 Hz (AC TIG and AC Stick)
AC Balance (Cleaning, % of Electrode Positive) 5-70% of Electrode Positive (+) (AC TIG and AC Stick)
TIG Spot Timer 0-10 Seconds (in Tenths)
Stitch Timer 0-5 Seconds (in Tenths) Set to 0 to turn off activity of the Stitch function.
DC TIG Fast Tack (Cold Weld) 10-250 Milliseconds ( .001 to .250 Seconds)
DC TIG Fast Tack Stitch Timer 0 -250 Milliseconds ( 0 to .250 Seconds) Set to 0 to turn off operation of the function.
Stick Arc Force Control 0-100% over set Amperage. Limited to the maximum available overhead current.
Stick Hot Start Amps (Intensity) 0-100% over set Amperage. Limited to the maximum available overhead current.
Stick Hot Start Time (Duration) 0-2 Seconds
Ant Stick Function (Stuck Rod) Yes, lowers Amperage when rod is stuck for easy removal.
Stick E6010 or EXX10 Capable (Cellulose Type Electrodes) Yes, with E6010 selected.
TIG Gun Type/Length/ Connector Type NOVA Rigid-Neck 9 Series Air Cooled, 12.5 ft. (4m) DINSE 35/50mm2 (1/2” nominal diameter)
NOVA Rota-Flex 20 Series Water-Cooled, 12.5 ft. (4m) DINSE 35/50mm2 (1/2” nominal diameter)
400A Work Clamp with Cable Length 9.5 ft. (2m) DINSE 35/50mm2 (1/2” nominal diameter)
300A Stick Electrode Holder Length 9.5 ft. (3m) DINSE 35/50mm2 (1/2” nominal diameter)
Power Cable Length 6.5 ft. (2m)
Power Plug Type for Single Phase Operation NEMA 6-50P (Standard 240V Welder Type, 3 Wire in North American Markets Only.)
Cooling Type Fan with full-time, thermo-controlled 60° C (140°F) activation or on-as-demanded when arc start settings.
PowerSet Mode (Synergic Assist for User Setup) For both TIG and Stick modes.
Dimensions with Handles installed (installation optional) 17.8” H X 9.6” W X 25.4” L (453mm H X 244 W X 646mm L)
Weight (Bare Unit) 68 lbs. (31 Kg)
Ingress Protection Rating IP21S
Operating Temperature Range 14-104°F/ -10-40°C (If operated higher than 104°F/40°C then duty cycle will be lowered signicantly.
Recommmended Water Cooler and Welding Cart (Optional) Water Cooler: PowerCool 375 Welding Cart: PowerCart 375 or PowerCart 330
* Early models did not have manual setting for Tungsten size selection. Minimum Start Amperage was 6A for .040” Tungsten.

13
Setup Guide
Getting Started
UNPACK THE 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 weld-
er 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.
2. NOVA Foot pedal 25 ft. (NOVA Wireless Optional).
3. 9 Series Air-Cooled Torch (NOVA Rigid/Straight Neck) 12.5 ft.
4. 20 Series Water-Cooled Torch (NOVA Rota-Flex) 12.5 ft.
5. Torch Switches(x2) for 2T/4T use (loose or attached to torch).
6. 300A Stick Electrode Holder (approx. 9.5 ft with cable).
7. 400A Bronze Work Clamp (approx. 9.5 ft with cable).
8. TIG Consumable Starter Kit (x2) Tungsten not included.
9. Pigtail adapter 240V to 120V (NEMA 6-50R to 5-15P).
10. Argon Regulator, floating ball type with hose.
When you receive your package, inspect the unit for damage. Check for
the presence of and the general condition of the accessories. Some slight
rubbing or chafng of some of the accessories may be present. This is
considered normal. If any item is damaged or missing, please inform Ever-
last within 72 hours of product receipt. See pages 4 and 5 for more de-
tails. Check all packaging, box corners and flaps for small items.
ASSEMBLE AND READY THE UNIT.
Assemble the front, middle and rear handles with the supplied screws. Do
not overtighten. Screws are usually found pre-mounted in the case. Re-
move the factory shipped plastic over the screen. Install cut-to-t screen
protector (not included, customer supplied) on the screen if desired before
use.
POWER UP AND TEST THE UNIT.
You will need to fully test the unit as soon as possible. Within 72 hours
after delivery 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gu-
ration is being used. Then, power up your machine without any accesso-
ries installed. Allow the unit to idle for 15 minutes. Check and observe
operation of knobs, controls and keys, cycling through each as required.
Make sure the fan is operating via the control panel menu setting. After
the test is completed, turn the unit off, connect the accessories, and
shielding gas (customer supplied) to conduct live testing. Test all of the
functions and features of the machine. For testing and welding, make sure
the work clamp is connected directly to the part being welded (the work).
Check for arc starting and stability. If problems are observed, contact
Everlast for further guidance. See page 5 for more information.
NOTICE: Cosmetic damage claims made after 30 days will not be accept-
ed, unless Everlast is contacted and informed of such delay and reason for
such a required delay (i.e. Overseas deployment or sudden disability).
CHECK FOR GAS LEAKS.
Be sure to check for gas leaks before attempting to weld. You can test this
by rst installing both back caps into the torch head (from both sides).
Next, remove the gas plug on the rear (save for storage use) and install
the regulator. Tighten ttings on both cylinder and unit (see section on
regulator installation). After the regulator is secured, set post flow time to
maximum. Trigger a false start with either the foot pedal or torch switch by
tapping and releasing so that post flow can flow. Observe the ball on the
regulator. It will briefly float before settling back down. If the ball continues
to flow, or if you hear or suspect leaks, use warm, soapy water (or a dedi-
cated leak testing solution available from welding suppliers) and spray on
all connections, including the torch connections at the head, and back cap.
NOTICE:
The foot pedal may arrive with the top separated from the bottom. This is not damage.
The top can easily be installed on the bottom, by aligning the pivot pins with the
corresponding holes for the pins located in the top. The pins are spring loaded and
can be squeezed so that the top slides down onto the pins. The pins will pop out into
the holes and allow the top to pivot once the pins and holes are properly aligned. You
may need to make sure the pressure return spring is flipped so that it pushes back
against the pedal as it is assembled. Similarly, the foot pedal may be disassembled
simply by pressing in on the ends of the pins on both sides to remove the top.
1
2
3
4
5
6
8
7
9
10
Assemble the Handles
Tools Needed:
M5 Hex Key and
10mm Wrench or
Phillips #2 Screw Driver
Screws may already be mounted in the machine. If not, they are in the accessory packaging.

14
Don’t forget to check the connections underneath the torch handle. 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 problem cannot be reme-
died, contact Everlast.
DISTANCE YOUR WELDER FROM YOUR WORK.
As a best practice technique, be sure to locate the welder away from the
immediate welding area. The fan found in your unit is powerful enough to
create strong air turbulence in the weld area. When the fan cycles on, it
can disrupt the smooth, even flow of shielding gas around your weld cre-
ating unstable arcs and porous welds, resulting in dull nished weld. If
possible the welder should be located at least 6 feet away from the weld
area and should be placed on a different level to prevent weld porosity and
defects being created by the welder’s fan system. Even though this unit
offers both thermal controlled as-needed or demanded fan settings, fans
operate at full revolutions when they are triggered into operation. Keep in
mind that air flow exits from both the front and the sides of the welder.
GIVE YOUR WELDER SPACE TO COOL.
The welder needs room to cool itself. Place the unit in a place that will
allow 18” from all sides to allow for proper cooling. The welder 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. If you build a cart, never attempt to close off
one side or the back completely. The Everlast Power Cart 330 and the
NOVA Cart 375 LF have ample room for cooling built into the design of
the cart. Never attempt to restrict air flow by attaching lters to the vents or
altering the vents in any way.
USING A WATER-COOLER WITH THIS UNIT.
Even though it is optional, as 330A welder a water-cooler is practically
require for use with this welder. Even though a 9 series 125A air-cooled
torch is supplied with the welder, the unit should still be coupled to a wa-
ter cooler and water-cooled torch for most welding. Even the largest air-
cooled torch, the 26 series, is limited to only 200A for extended welding.
Additionally, many people nd that a water cooled torch connected to a
water cooler signicantly improves comfort level while welding. The water-
cooler connects directly to the torch, circulating water up through the han-
dle and into the head before returning back through the power cable to the
cooler. This unit is equipped with a special 240V plug on the rear that is
designed and intended for use with Everlast-brand water coolers. The
Typhoon is designed and ready for use with the Everlast PowerCool 375. It
is designed to t and stack directly under the welder. By interlocking with
the welder, the cooler can be semi-permanently mounted under the weld-
er. Further details on connection of the welder to the cooler can be found
in the PowerCool 375 manual and can be downloaded from the website.
The Typhoon features a “cooler-on-demand” feature which can be ac-
cessed in the background menu. It can be selected to be continuously on,
to be active only when the arc is struck, or to be temperature controlled.
See information on page 31 to access this feature.
NOTICE: The PowerCool 300 and 400 coolers may be used with this unit.
However, they cannot be stacked under the welder. They will have to be
used detached from the unit.
IMPORTANT: Make sure the cooler pump is primed before initial use, after
extended storage or after torch has been disconnected and reconnected.
See PowerCool 375 manual for details about priming the pump.
Setup Guide
Getting Started
Allow Air Flow Space of at least 18”
Keep a distance of 18” from all sides to promote cooling and preserve
duty cycle. Less air space will reduce duty cycle, accelerate overheating
and possibly decrease the service life of the welder.
18”
18”
18”
18”
Stacking the Cooler
The optional water cooler package provides the necessary connection
components to stack and mount it semi-permanently to the welder.
To mount the welder to the cooler:
• Install cooler mounting hardware onto the welder.
• Line up the interlocking grooves on the welder with the grooves on
the cooler. Place the welder on the cooler.
• Slide the welder towards the rear of the cooler until the grooves are
fully seated and the edge of the cooler bezel is flush with the welder.
• Install side mounting screws if a semi-permanent connection is de-
sired.
Use with PowerCart 330 Only.

15
Setup Guide
Getting Started
CONNECT YOUR UNIT TO THE OUTLET.
You will notice that the welder has been shipped without a power plug.
This is because the welder will operate on either single phase or three
phase 240V voltage and the wiring is different for single phase service
than it is for three phase service. There is no one plug for all voltages and
phases. You will also notice that this unit is equipped with 4 wires. The full
4 wire conguration is not used with single phase 240V operation. Only 3
wires are used (black, white, and green in color). The remaining fourth
wire (red color) is to either to be snipped off and taped over with electrical
tape, or it is to be bent back, and taped against the cable sheathing if it is
to be used both on single and three phase service. For single phase 240V
connection, select a NEMA 6-50 Plug and Receptacle for installation. This
is the standard plug used when wiring welders for 240V single phase op-
eration in North America. (Other regions/countries vary). A neutral is not
used or required with a single phase welder. If you inspect the NEMA 6-
50 Plug closely, you will see that the plug is stamped where each color
wire should go (most brands). If you do not see a stamp, the Black wire
serves as L1(Hot), White serves as L2 (Hot) and Green serves as G
(Ground). A common mistake is to use all four wires with a NEMA 14-50
outlet. This can damage your machine and cause improper operation.
For three phase 240V service (or for the optional 480V service), the plug
type and NEMA classication is different for various applications. It is
recommended to either install the line direct into an electrical cutoff box,
or wire a 3 phase receptacle and cutoff (disconnect) close to where the
unit will be in use. When wiring 3 phase, all wires will be used. Black is
L1. White is L2. The Red wire should be reserved for L3, especially if you
have a Delta 3 phase system. The Green wire is used for Ground.
NOTICE:
There are special rules centered around wiring an outlet for service
with a welding machine. The National Electric Code under Article
630 has developed specic regulations for wiring electrical service
for welding equipment. These are different than for other types of
service such as a stove or dryer in a household or even in a com-
mercial application. You need to consult and/or employ a locally
licensed electrician before installing this unit to make sure all nation-
al and local codes are followed. If you are not qualied to make
these connections, don’t. Everlast is in no way liable for any damag-
es caused by improper connection of your welder. Your welder
should be 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 house-
hold circuits because conductor wire colors are different for welders.
Additionally, only 3 wires are used for single phase welders. No
neutral is used in a welder circuit. The white wire is a conductor in a
single phase welder 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. This will
void your warranty.
Wire Conguration 1 Phase 240V
.
NEMA 6-50P
Wire Conguration 3 Phase 240/480V
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 cur-
rent. 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 pan-
el, his determines the conductor size needed to supply the welder, Refer
your electrician to Article 630 and the specication page of this manual
(or the specication grid printed on your unit) when selecting the correct
breaker and wire size. Use a delayed trip breaker, or slow blow fuse.
Using with 208V 1 or 3 Phase
This unit may be operated with 208V service (1 or 3 phase). However
voltage should be checked under load before allowing permanent instal-
lation. Voltage should not fall below 200V or damage may occur to the
unit. Most modern 208V service runs several volts above 208V and is
not usually a concern. Older installations where service wiring may be
degraded or not up to code may produce sub standard or low voltage not
suitable for use with this unit.
480V is a special order option.
However the wiring conguration is
the same as 240V.

16
Setup Guide
Getting Started
CONNECT YOUR UNIT TO THE SHIELDING GAS.
Always wear safety glasses when changing a cylinder. Before installing the
regulator, stand to the side of the cylinder valve, away from the discharge,
and give a quick blast of Argon gas by slightly opening and closing the
valve rapidly. This will dislodge any dirt or particles stuck in the valve or
the threads. This will help reduce the chance of dirt particles making its
way into the solenoid valve, causing future sticking and failure issues.
Connecting your cylinder will require a cylinder wrench (1 1/16”) to connect
the regulator to the cylinder (North American Cylinders with CGA 580
valve). If you do not have a cylinder wrench, a large ,adjustable-type
wrench will work. However, make sure it is properly adjusted to prevent
rounding of the shoulders of the tting. Do not use pliers, or a serrated
jaw wrench such as a pipe wrench to tighten the tting.
Connect the regulator tubing to the regulator. The regulator tubing may
have either a hose barb connection or a threaded connection (for North
American markets). 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) wrenches to
hold both the regulator and the tubing connection at the same time. Hold
counter pressure on the regulator connector while tightening the hose
tting to prevent damage to the regulator and to ensure 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 an-
other 3/4”(19mm) wrench. Other markets outside of North America may
feature a hose barb connection in the rear. IMPORTANT: This is a com-
pression tting! Do not use thread tape or pipe sealant on any cylinder,
regulator or other unit connection. The residue and debris may get into the
gas solenoid and cause operational issues.
REMEMBER: Do not tighten the rear unit connection without holding the
female tting on the unit side with another wrench. If you fail to do so,
damage is likely occur to the bezel and the female tting as the tting may
turn in the plastic housing. Overtightening will cause the tting to snap-off
in the solenoid housing or crack down the threads.
What Shielding Gas Should Be Used?
Selecting shielding gas for TIG welding is straightforward. In general,
for all metals, whether using in AC or DC, select 100% Argon. Never
use a gas mix mixed with CO2. CO2 will rapidly consume the tungsten
and introduce porosity into the weld, even at low concentrations.
With that said, if you are welding at or near the maximum capability of
the unit, you may also wish to use an Argon/Helium mix. This will
increase the overall heat going into the weld. Use no more than 25%
Helium mix with this unit, or Arc starting efciency will be reduced,
resulting in hard-to-start arcs. Arc stability will also be affected at
higher mix percentages. Helium is expensive. The cost versus benet
of adding it must be weighed carefully as a cylinder or two of high
percentage Helium may approach the cost difference of upgrading to a
larger unit! If a high Helium content mix is used, expect some trade-
offs. Arc starting may be improved slightly by readjusting the arc start-
ing parameters in the background menu of this welder.
There are a few new gas mixes (blends) on the market with promise,
but as of publication they have not been thoroughly evaluated for use
with this welder. Exercise caution when using a new mixture (often
marketed with Nitrogen or Hydrogen) as the application is very spe-
cic. Pure 100% Argon is the most economical and best choice for
nearly every application. Having multiple gases should not be a con-
cern for even the most advanced users.
NOTICE: It is increasingly common for users to get cylinders of bad or
contaminated shielding gas, creating mysterious and difcult to identify
issues. An Argon cylinder is the same type of cylinder as an Argon/
CO2 cylinder used for MIG and sometimes times can get mixed in and
relabeled as pure argon. Another increasingly common issue is that a
gas mix cylinder gets relled with Argon with residual Ar/CO2 mix with-
out using proper purging techniques. Usually this occurs in batches
and complete lots of cylinders can be affected. Sometimes swapping
with another cylinder from the same supplier will not correct the prob-
lem. Another common issue is that a customer may specify “Argon”
and receive a cylinder marked as Argon/CO2 mix from the distributor
without noticing. Check your cylinder label below the cap area for
proper labeling before you accept the gas cylinder.
Connect Regulator To Cylinder And Unit.

17
Setup Guide
SELECT THE PROPER TUNGSTEN TYPE. Purchasing Tungsten can be difcult. Local suppliers tend to put a premi-
um price on Tungsten, and may be three times an online price direct from
a distributor. In many areas, the choice of tungsten may be limited. Howev-
er, many local welding suppliers are stepping up and offering competitive
prices and range of selection, so don’t rule them out until you have
checked. Also, there are some companies that may send you free samples
to test, so be sure to investigate their product, and give them a chance as
well.
GRIND THE TUNGSTEN CORRECTLY.
An improperly ground point on tungsten is a cause of many issues with arc
stability, arc directability, and penetration. A bench grinder and a ne-grit
stone dedicated for tungsten sharpening is all you need to sharpen Tung-
sten and is the age old standard. There are special hand held grinders that
feature diamond stones with slotted guides, designed to hold the tungsten
at the exact desired angles. A dry chemical sharpener “dip” is available and
is inexpensive. When properly swirled, it does an excellent job in seconds.
With practice, it can deliver a superior result. As a bonus feature, chemical
sharpening can be done without getting up from the bench-top without
removing the tungsten from the cup. One thing to note: the Tungsten has
to be red hot before being dipped and swirled in the chemical.
Getting Started
What Type of Tungsten Do I Use?
Selecting the correct tungsten for your welder is important. Modern
inverters no longer use pure (green band) Tungsten for welding AC.
In fact pure Tungsten used with an inverter can create problems with
arc stability, arc starting and excessive balling. While Thoriated 2%
Tungsten can be used in an inverter for DC welding, and even for
AC welding, it is falling out of favor in the industry due to the slightly
radioactive nature of it. It also presents some additional issues while
welding with nodules and splitting at the higher Amp range in AC.
For welding in AC and DC consider the following types.
• Lanthanated 2% (blue band). Overall this is one of the best
choices for TIG welding and can be used for AC and DC weld-
ing. It has great arc starting characteristics, with excellent point
holding capability.
• Ceriated 2% (gray band or orange band, depending upon brand
and country of origin). This is a good choice for welding with
both AC and DC. However, it doesn’t hold up as well and starts
to erode faster than Lanthanated at higher amperages. Arc start-
ing quality is excellent.
• Lanthanated 1.5% (gold band). Holds up nearly as well as Lan-
thanated 2% and can be used for AC or DC welding. In some
tests it has rivaled the performance of Lanthanated 2%.
• Tri-Mix/Rare Earth (purple, turquois or other color band). While
still relatively new, it is being marketed as a replacement for
Thoriated 2%. Overall, it does perform fairly well and even ex-
cels in many circumstances. But some problems have been
seen with quality control and inconsistency in performance. The
primary metal oxide used is lanthanum 1.5%. Usually it also
includes a small percent of Zirconium and Cerium to complete
the mix. Some use Yttrium. But the balance of the components
in the blend are usually stated to be around .06 to .08%, but
can be allowed to vary up or down from .04% to .9%, making
the blend prone to inconsistency in quality control.
• Thoriated 2% (red band) Still considered the best for DC, works
ok for AC, but has been banned in many markets outside the
US due to a small radiation risk posed as an alpha emitter.
Do not use the following types of Tungsten.
• Pure Tungsten (green band). This will create arc instability. The
tungsten will not stand up well to the more intense arc created
by an inverter welder.
• Zirconiated Tungsten (white band). This was created as an
alternative for pure Tungsten for transformer welders. Similar
issues welding issues are presented as with pure Tungsten.
How Do I Grind My Tungsten On a Wheel?
• Grip the Tungsten rmly. Grind with the Tungsten secured.
• Grind the Tungsten perpendicular to the wheel face. Allow tungsten
to grind slowly without much pressure.
• Rotate the Tungsten quickly as it is being ground to keep the point
even and symmetrical.
• Do not grind the Tungsten parallel to the wheel face or an unstable
arc will result.
WARNING!
Wear safety glasses and leather gloves while grinding tungsten or seri-
ous injury may occur. On occasion tungsten may split or shatter. Do not
breathe or inhale tungsten dust. Do not use a angle grinder to grind!
!

18
Setup Guide
Getting Started
Choosing the proper grind angle is important to achieving the weld pene-
tration, bead appearance, and arc-cone width that you desire. While there
is no true one-size-ts-all angle, there are some general rules of thumb to
observe and follow:
• Always grind in-line with the length of the tungsten. Never make a
radial grind that leaves marks on the tungsten in the direction of the
grind. Radial marks will cause arc instability. Never grind with the
tungsten held parallel to the stone edge face.
• For most applications, grind a point that is 2 –2.5 times greater in
length than the tungsten is wide. This will create an angle of about
30 to 35 .
• For AC, a more blunt angle may be used (around a 60°) for best
penetration. However, the 2 to 3 times in length rule will still work
for many circumstances.
• For higher amperages, you will want to put a slightly truncated tip on
the tungsten. This prevents the tip from dropping into the metal.
• Grip the tungsten rmly. Slowly rotate it while grinding.
Depending upon what arc properties you are looking for, you may periodi-
cally want to regrind your tungsten to maintain optimal arc characteristics.
What Type of Grind Works Best?
• Never use a radial grind pattern. This can be caused by grinding
at the wrong angle, or spinning the tungsten too fast while grind-
ing at the proper angle. The arc will be unstable.
• Grind the angle so that the length of the grind measures 2 to 2.5
times the wide of the tungsten (For general purpose use this
should form about a 30 to 35 angle.) A slightly blunted end
(truncated) may be used if the amperage is over 50A to prevent
the tungsten from breaking off into the metal while welding.
• AC welding may require a blunter point for some applications
where greater penetration is desired. It may seem counter-
intuitive, but this will create a narrower arc cone and provide
more penetration.
<50 A
2.5 – 3 X Ø (DIAMETER)
>50 A
AC
IMPORTANT! Don’t Ball The Tungsten.
If you’ve ever operated an older transformer welder, or an early inverter
type TIG welder, you were probably taught to ball the Tungsten when
welding on AC. In fact, a lot of well meaning literature still exists about
proper tungsten ball size, how to ball tungsten, etc. Even now, well-
meaning instructors and seasoned welders (who have never worked
with an inverter) may even insist this is the way to weld.
However, this is no longer true or recommended with an inverter TIG
welder. In fact, if you insist on balling tungsten while welding with an
inverter, you are going to create an unstable, uncontrollable arc. You
will then have to make unwise adjustments to the machine to create
more stability. Be warned. Don’t blame the machine. Blame the ball.
Why? The old “Green” Tungsten is considered to be pure Tungsten.
This means that it does not handle heat as well at higher temperatures
as the more modern tungsten types that are blended with rare earth
metal oxides. Green Tungsten will create a signicant ball on its own
when it is used with an inverter. In the past it was needed to hold a
certain type of arc cone and was desirable. In inverters, it will lead to
arc wandering.
Due to the nature of the AC cycle and modern advancements in control,
modern inverters with advanced wave forms really punishes pure Tung-
sten. You’ll quickly end up with a large, molten ball dangling at the end
of the tungsten. This is, in part, due to the short off-time between po-
larity change from + to - and back to + during the AC cycle. In fact,
this off-time is so short that inverters do not need High Frequency
Stabilization (HF) while welding AC, and do not have it. In fact HF is
only used for establishing the arc. After Arc establishment, the HF shuts
off automatically. The extra “time-on” of the arc means that pure tung-
sten (green) isn’t able to handle the heat and will over-ball and melt
quickly. Rare-earth blends of Tungsten are used for that reason and
will handle the heat and punishment better. If given enough heat at the
high end of the operating range of a specic sized diameter, the rare
earth types form a neat bullet-shaped dome that is slightly elongated.
However, this dome still isn’t quite yet a full, rounded ball.
If you think about it, the big ball at the end is really a large “target” for
the arc to jump to as it reverses polarity. When the electrons begin to
flow from the plate to the tungsten, that is a bigger target for the elec-
trons to hit. The arc could literally jump anywhere along that balled
surface. The bigger the balled target, the more room for the arc to os-
cillate around the ball, creating a randomly wandering arc. This is why
pointed Tungsten is recommended with inverters.

19
Setup Guide
SELECT THE PROPER TUNGSTEN SIZE AND START AMPS.
The key to obtaining good, picture-perfect arc starts is to use properly
sized and ground Tungsten. A properly sized Tungsten, combined with
correct sharpening technique will display the best arc characteristics. An
undersized tungsten will tend to ball at higher amperages, especially if the
tip is too sharp for the application. A larger Tungsten will be more difcult
to start at lower amps, regardless of grind shape. A contaminated Tung-
sten, will cause no-starts, irregular starts, and wandering arcs.
The design of this unit limits the low Amp start of the welder based off the
Tungsten diameter size selected on the screen. This Start Amperage is
independent of the normal Welding Amps and even the tail-out (End Am-
perage) settings. In fact, the Welding Amps and the End Amps are actually
able to be set lower than the Start Amp setting (when not in the “Manual”
mode). The intent of this limitation is to create an optimized “surge” start
parameter for the Tungsten selected so that it starts quickly and reliably
with average user skill and knowledge. It is not designed to provide the
lowest possible Amperage start for the selected Tungsten size. Each in-
crease in Tungsten diameter raises the minimum allowed Start Amp set-
ting. The range of diameter in Tungsten sizes that are selectable under the
Tungsten function, are .040” (1.0mm), 1/16” (1.6mm), 3/32” (2.4mm), and
1/8” (3.2mm).
In addition to the selectable Tungsten size function, the machine includes
a “Manual” setting in the Tungsten size function to override the low Amp
limits and allow a full range of Amperage. The “Manual” selection should
be used to allow the full range of Starting Amperage if customer is using a
small .020” (.5mm) diameter Tungsten. It may also be used with a larger
diameter Tungsten if the user desires complete control over the start Am-
perage. Selecting the “Manual” setting allows the unit to be set at a mini-
mum TIG start of 2 Amps on DC and 3 Amps on AC. Keep in mind this
may not provide optimal start characteristics for larger diameter Tungsten
but it does allow the user to try. Manipulating the Start/Surge settings of
the electronic HF/HV settings in the background menu may improve the
low Amp starts with larger diameter Tungsten sizes as well. However, it
may also increase the chance of blow-through on thin materials by provid-
ing too forceful of a start.
Getting Started
What Size Tungsten Do I Use?
Everlast advertises low arc start capability on this. The Start Amperage of
the arc is quite low. However, when starting an arc, all TIG welders have
a momentary surge Amperage to ignite the arc, lasting just milliseconds.
This brief surge (up to 40 or 50 Amps) of Ignition Amperage is usually
kept from displaying in most brands of TIG welders. This very quick
surge ensures good arc starting. However, if the surge it is set too high,
it can blow through thin materials before the arc is established and the
unit transitions to the Start Amp setting. Everlast has kept the Ignition
Amps surge to a range that has tested best for clean starting. However,
when welding with thicker tungsten like 1/8”, arc starts may appear
“soft” and not forceful enough to start cleanly. If the arc starting is not
smooth or quick, the surge Amperage can be raised or the intensity of
the HF electronic start can be adjusted in the background menu. This
will help to clean up and improve the arc start. NOTICE: The Surge
Amps and the Start Amps are not the same thing. Starting Amperage is
the stage after the arc transitions from the Ignition surge and stabilizes.
For best results, when low amp starts are needed for welding thin gauge
materials, use a 1/16” diameter Tungsten for most light gauge materials.
For thin materials under 20 gauge use a .040” diameter tungsten or
even a .020” diameter tungsten for maximum control. Arc starts will
then be clean and crisp on thin materials. Keep in mind though that
small diameter tungsten will rapidly consume at higher Amperages.
The tungsten type, tip angle and grind preparation will ultimately affect
amperage carrying and arc starting capability of the tungsten. The ma-
chine wave form and other AC settings can also affect it. Each type of
Tungsten blend will also vary in amperage handling capability. In gen-
eral, consider the following for selecting your tungsten diameter. The list
below is not the absolute maximum range of the Tungsten, but a reliable
recommended range. It is a good practice when you approach the max-
imum limit of the Tungsten’s capability in terms of amperage, that you
switch to the next size up for best point retention and arc characteristics.
AC operation can reduce tungsten amperage capability. The setting of
the AC balance and AC frequency has an effect on tungsten point hold-
ing capability. Too much cleaning (over 40% EP) will over heat the
tungsten and ball it. Lower frequencies tend to places more heat on the
tungsten as well. But in general, for AC and DC operation, consider
using the following sizes for the ranges following:
• 2-15A: .020” (.5mm)
• 3-30A: 40” (1mm)
• 10-70A: 1/16” (1.6mm)
• 15-200A: 3/32” (2.4mm)
• 20-300+ A 1/8” (3.2mm) 20-300+A
NOTE: Starter kit does not include .020” (.5mm) or .040” (1mm) collets
or collet bodies. These can be purchased locally or online.

20
STICK BASIC STARTING POINTS.
This unit also has a synergic PowerSet mode for stick. However, this may
not suit all situations. This guide is a starting point for manual settings.
Stick is a bit different from TIG in the fact that the Amp settings center
around the diameter of the electrode rather than that of the of the plate,
although plate thickness and joint design can shade the amperage range
higher or lower. Use beveled joints and multi-pass welds for best weld
strength on plates greater than 3/16” thick.
Setup Guide
Getting Started
TIG BASIC STARTING POINTS.
This machine makes use of the Synergic PowerSet feature. However, If
you are needing basic help getting started with manual settings, without
using the PowerSet mode, here are some general settings and selections
to get you started TIG welding. This guide is intended to be only a starting
point, not a completely exhaustive source. Keep in mind that no guide is a
substitute for practice and experience. You may nd that your nal settings
may be different from the ones listed. The following guide does not repre-
sent the maximum capability, or even the recommended capability of the
unit. However, it demonstrates what is considered to be a practical capa-
bility limit of multiple variables when factored together. It is possible to
weld thicker materials with the same amp range. However, as a best prac-
tice, the industry does not recommend heavy passes, rather thinner
“stacked” passes on thicker plate. Multi-pass welds are typically stronger,
have less defects and require less amperage. On heavy gauge plate, such
as 3/8” up to 3 to 5 passes may be required. Additionally beveling of the
joint is required for complete joint penetration, even at higher amperages.
The thickness rating takes into account the “heat sink” capability of the
metal, and the power of the amperage to overcome the conductivity of heat
of the metal used using multiple passes. The position of the weld also
influences the amperage, cup size, gas flow rate and tungsten size used.
For the following recommendations, these are all in “flat” position. Modify
your settings accordingly. Vertical will require less amperage the more you
weld “up hill”.
NOTE: For perspective and comparison, the chart below includes some
information that is beyond the operating range of this welder.
Amp Range Electrode Dia. Cup Number Flow Rate (CFH)
Standard Lens
Flow Rate (CFH)
Std. Gas Lens
Metal Thickness
Aluminum (AC)
Metal Thickness Steel/
Stainless (DC)
2-15A <.020” <.025” .020” (.5mm) 45 to 7 4 to 5
3-30A .040 (1.0 mm) 4 or 5 5 to 7 4 to 5.005” to .030” .003” to .035”
5-70A 1/16 (1.6mm) 4, 5, 6 6 to 15 6.005” to .0612” .005” to .093”
10-200A 3/32” (2.4mm) 5,6, 7 or 8 10 to 20 8 to 12.010” to .250” .08” to .375”
20-250A 1/8” (3.2mm) 6,7,8 or 10 15 to 25 10 to 18.020” to .375” .015” to .500”
50A-350A 5/32 (4mm) 8-10 20-40 15-35.050 to .625” .050” to .750”
Cup Size 4567810 11 12
Inside Diameter 1/4” 5/16” 3/8” 7/16” 1/2” 5/8” 11/16” 3/4”
IMPORTANT!
This unit is designed to operate with most welding rods including E6010. This unit should operate well with E6011, E7010, and E8010 as well on the E6010 setting. It should
operate well with any other welding electrodes that have a deeper penetrating cellulose-based flux on the E6010 setting. When welding with cellulosic types, some brands may
weld differently than others. Always select a good quality brand for best arc stability. If 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 recom-
mended, 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.
Electrode Diameter
Electrode Class 3/32” 1/8” 5/32” 3/16” 7/32” 1/4”
E6010 40-80A 75-120A 110-165A 145-220A 175-250A 220-315A
E6011 40-80A 75-120A 110-165A 145-220A 175-250A 220-315A
E6013 50-85A 80-125A 110-175A 150-230A 220A-300A 250-325A
E7014 85-115A 110-160A 150-210A 195-275A 265-335A 325-400A
E7018 65-100A 90-160A 145-220A 195-275A 255-335A 325-400A
E7024 100-140A 140-185A 180-240A 240-300A 285-360A 340-430A
E308/309/316 40-70 50-95A 75-130A 95-160A Not Common Not Common