Everlast ULTRA-ARC 205 User manual

EVERLAST
ULTRA-ARC 205
Operator’s Manual for the Ultra-Arc 205
Safety, Setup and General Use Guide
CC
IGBT
Rev. 1 0 000226-20
1-877-755-9353 Specications and Accessories subject to change without notice.
329 Littleeld Ave. South San Francisco, CA 94080 USA
everlastwelders.com
50 Amp Digital IGBT TIG/Stick/Plasma Cutter
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PHASE
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120/240V
GTAW-P
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2
TABLE OF CONTENTS
Section………………………………..…………..Page
Letter to the Customer ………………...……………...
Everlast Contact Information……………………...……
Safety Precautions……………………………………
Introduction and Specications………………….…….
Unit Specications……………………….…………...
General Overview…………….…..…………………...
General Maintenance…...………...………………...…
Quick Setup Guide, TIG Torch Connections..……………
Stick Electrode Holder Connections...…………………..
Plasma Torch Connections……………………………
Rear TIG and Power Connections……………………...
Compressor and Air Dryer Connections..……..………...
Quick Operating Tips and Warning…….……………….
Denitions and Explanation of Features and Terms……...
Front Panel Controls…………...……………………..
Rear Panel………….……………………………….
Operation…………..………………………………...
S-45 Plasma Torch and Parts Breakdown………………
TIG Torch and Parts Breakdown.……………………….
Troubleshooting……………….……………………...
Point Gap Adjustment……...…………………………
Error Codes………………………………………….
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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 information 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. Everlast Power Equipment INC.
does not guarantee the accuracy, completeness, authority or authenticity of the information 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 prod-
uct or this document for tness for any particular purpose, for performance/accuracy or for suitability of application. Furthermore,
Everlast Power Equipment INC. does not accept liability for injury or damages, consequential or incidental, resulting from the use
of this product or resulting from the content found in this document or accept claims by a third party of such liability.

3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast Product. 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 information.
Your unit registration is important should any information such as product updates or recalls be issued.
It is also important so that we may track your satisfaction with Everlast products and services. If you are
unable to register by website, contact Everlast directly through the sales department via the main cus-
tomer service number in your country/region. Your unit will be registered and warranty will be issued
and in full effect. Keep all information regarding your purchase. In the event of a problem you must
contact technical support before your welder can be a candidate for warranty service and returned.
Please review and download the ofcial warranty statement, located on our website
www.everlastwelders.com. If you are not in the United States, visit the distributor’s website warranty
information nearest to your region or country. Print it for your records and become familiar the terms
and conditions outlined in the warranty. Warranty terms vary from country to country and region to re-
gion. For this reason, the warranty is honored through the original national/regional branch of Everlast
that originally sold the unit only. If a product is purchased in one country or region, another country or
region is not responsible for the enforcement or backing the terms of the warranty and sale.
Everlast offers full technical support in several different forms. We offer domestic based phone support
and online support. Online support is available through email and through our website contact forms.
We also provide a welding support forum designed for customers and noncustomer interaction. Tech-
nical advisors are active on the forum on a regular basis. We also divide our support into two divi-
sions: technical and welding performance. Should you have an issue or question concerning your unit,
please contact performance/technical support available through the main company headquarters availa-
ble in your country. For best service, call the appropriate support line and follow up with an email. In
the event you do not reach a live person, particularly during heavy call volume times, holidays, or off
hours, leave a message and your call will normally be returned within 24 hours. For quick answers to
basic operating or service questions, join the company owned forum linked through the US website.
You should be able to nd knowledgeable, helpful people and staff available to answer your questions,
and perhaps nd a topic that already addresses your question at http:// www.everlastgenerators.com/
forums/.
Should you need to call or write, always know your model name, purchase date and welder manufac-
turing inspection 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 de-
scribe the conditions and circumstances of your problem or question. Take notes of any issues as best
you can. You may be asked a series of questions by the advisors meant to clarify problems or issues.
Some of these questions may seem basic or fundamental, but even with experienced users technical
advisors can’t assume that correct operating procedures are being followed for proper operation. They
must cover all aspects to properly diagnose the problem. Depending upon your issue, it is advisable to
have basic tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive test meter with
volt/ohm functions before you call.
Please note: To establish a warranty claim and return a unit for repair or replacement, you must call tech-
nical support rst and go through basic diagnosis before an Return Authorization will be issued.

4
Serial number: ____________________________
Model number: ____________________________
Date of Purchase___________________________
Everlast USA:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [email protected]
Everlast Welding Support: [email protected] Everlast Support
Forum: http://www.everlastgenerators.com/forums/ index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
FAX: [phone]
Everlast Canada:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [email protected]
Telephone: [phone]am-4:30pm EST M-F
Everlast Australia:
Port Macquarie 4/18
Acacia Ave.
Port Macquarie NSW 2444
(02) 6581 23888
After Hours Support
0431 016 416
Sales: [email protected]
Support: [email protected].au

5
Safety Precautions
Everlast is dedicated to providing you with the best possible equipment and service to meet the de-
manding job requirements that you may have. We want to go beyond delivering a satisfactory prod-
uct to you. That is the reason we offer free technical and basic welding support to assist you with
your needs, should an occasion occur where it is needed. 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, operation and maintenance
of your Everlast product to give you the best possible operator/owner experience. Welding and re-
lated cutting operations require basic experience and common sense. 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. Stay alert!
Please carefully read this manual before you operate your Everlast unit. This manual, if read in full,
can assist the user in obtaining helpful information concerning the safe operation of this unit. Do not
operate the unit until you have read this manual and you are thoroughly familiar ith the safe operation
of the unit. If you feel you need more information please contact Everlast Support. The content of
this manual is not meant to be an exhaustive primer on welding. It is written to an audience that, if
not professional, will have at least some basic knowledge of welding terms and practices.
The 5 year warranty does not cover improper use, maintenance, accessories or consumables. Acces-
sories are covered by a separate warranty (length varies), which is also listed on our website along
with the full terms of the welder warranty. Consumables have no warranty.
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 malfunctioning parts or accessories have been repaired or replaced by qualied personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves. These waves may dis-
turb 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 elec-
trician if disturbance is noted. Sometimes, improper wire routing or poor shielding may be the
cause.
WARNING! HF can interfere with pacemakers. See EMF warnings in following safety section for fur-
ther information. Always consult your physician before entering an area known to have welding or
cutting equipment if you have a pacemaker.

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 observe 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 chipping 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
lter installed. Always use a welding helmet in good condition. Discard any broken or cracked
lters or helmets. Using broken or cracked lters or helmets can cause severe eye injury and
burn. Filter shades of no less than shade 5 for cutting and no less than shade 9 for welding are
highly recommended. Shades greater than 9 may be required for high amperage welds. Keep
lter lenses clean and clear for maximum visibility. It is also advisable to consult with your eye
doctor should you wear 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 lter screen, protective curtains or equivalent protective equipment. If no
protection is available, exclude them from the work area. Even brief exposure to the rays
from the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy. Ear pro-
tection 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 re 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 adequate 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 electri-
cal shock.
Flame proof and insulated gauntlet or cuffed type gloves are required whether welding or cut-
ting or handling metal. Simple work gloves for the garden or chore work are not sufcient.
Gauntlet type welding gloves are available from your

7
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 elds 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 elds. Therefore, certain precautions should be taken to mini-
mize exposure:
•Lay welding leads and lines neatly away from the body.
•Never coil cables around the body or limbs.
•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 conned spaces. Fumes and gases released 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 obtained.
Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, copper, cadmium,
lead or zinc without proper respiratory equipment and or ventilation.
WARNING! The use of this product can expose you to chemicals such as lead, which is known to
the State of California to cause birth defects, reproductive harm and cancer. Proposition 65 Warn-
ing. For more information visit: www.P65Warnings.ca.gov
DANGER! Do not weld or cut around Chlorinated solvents or degreasing areas. Release of Phos-
gene 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 re-
garding high pressure cylinders can be obtained from OSHA or local regulatory agency. Consult
also with your welding supply company in your area for further 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 t cylinders. Do not use faulty regulators. Do not allow cylin-
ders 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.
Safety Precautions

8
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do not use frayed,
cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground clamp. Do not stand in water or
damp areas while welding or 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 necessitates 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 cables with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep re extinguishers close by and
additionally a water hose or bucket of sand. Periodically check work area for smoldering embers or smoke. It is a
good idea to have someone help watch for possible res while you are welding. Sparks and hot metal may travel a
long distance. They may go into cracks in walls and floors and start a re that would not be immediately visible.
Here are some things you can do to reduce the possibility of re or explosion:
• Keep all 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 re.
• 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 re-proof surfaces after handling. Serious burns and injury can result if material is improperly
handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper maintenance is your respon-
sibility. Make sure all equipment is properly maintained and serviced by qualied personnel. Do not abuse or misuse
equipment. Remove any faulty cords, plugs or electrical equipment from service or access.
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.
If operating on a generator: Always switch off and disconnect the unit before shutting the unit down. Never start the
generator with the unit switched on or connected. Failure to do so may result in damage to the unit. This damage is
not covered under warranty. Make sure that any required generator grounding is performed properly and to the man-
ufacturer’s recommendations.
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 con-
cerning their products. Do not operate machinery until your are comfortable with proper operation and are able to
assume inherent risks of cutting or welding.
Safety Precautions

9
ULTRA ARC 205 PACKAGE CONTENTS
NOTICE! Accessory and consumable style and quantities are subject to change without notice. Consumable starter kits provide only enough consumables to get
started. Extra consumables can be purchased through Everlast or through other local and online iPT 60 Innotec distributors. Full original consumable kits are sold
through Everlast. Various diameter consumables for lower amp use are available. The unit comes with a spare 30 Amp glass-type (slow-blow) fuse for the pilot
arc. Set this fuse aside where you can nd it. Replacement fuses may be bought locally (use part number printed on fuse for reference) or directly from Everlast.
Consumable and Plasma Pressure Regulator Kit
Work Clamp
Section 1 Introduction and Specifications
S-45 Series Plasma Torch (12 ft.)
TIG Regulator 240V to 120V Adapter

10
Section 1 Introduction and Specifications
NOTICE:
This unit is DC output only and is not intended to be used for TIG welding Aluminum. This unit will weld with most welding electrodes (rods) in Stick mode, but it is not suitable for use
with E6010 electrodes. E6011 may be used, but performance may be brand dependent and not as good as with E7018 or any iron powder electrodes such as E7014 or E6013. The
plasma function on this unit is intended to be used in a support role for TIG and Stick welding and is not recommended to be used exclusively as a plasma cutter. Please be aware of
duty cycle limits while plasma cutting. Adjust plasma Amperage and consumable size according to the application used. This unit is not suitable for Plasma Gouging.
Use the I1MAX value to size the breaker. Use the I1EFF current to size wiring. Consult the NEC Article 630 for details concerning wiring and breaker requirements.
ULTRA-ARC 205 Specications
Inverter Type Digital IGBT (DC Output only)
Memory Settings Up to 9 possible memory slots
Minimum/Maximum Rated Output TIG 120V: 5A/10.2V-125A/15V 240V: 5A/10.2V-200A/18V
Minimum/Maximum Rated Output Stick 120V: 5A/20.2V-100A/24V 240V: 5A/20.2V-160A/26.4V
Minimum/Maximum Rated Output Plasma 120V: 20A/88V-25A/90V 240V: 20A/88V - 50A/100V
TIG/Plasma Start Type TIG: Live Lift/Lift/HF Plasma: Blow-Back Type
Torch Type and length TIG: 26 Series Air-Cooled 12.5 ft. Plasma: S-45 12 ft. Stick: 250A 10ft. Electrode Holder
TIG Duty Cycle @ Max Rated Amps/Volts (40 C) (Output A/V) 120V: 60% @ 125A/15V 240V: 60% @ 200A/18V
Stick Duty Cycle @ Max Rated Amps/Volts (40 C) (Output A/V) 120V: 35% @ 100A/24V 240V: 35% @ 160A/26.4V
Plasma Duty Cycle @ Max Rated Amps/Volts (40° C) (Output A/V) 120V: 35% @ 25A/90V 240V: 35% @ 50A/100V
TIG Start/End Amps 5-200A
TIG/Plasma Pre/Post Flow Time Pre: 0-10 Seconds Post: 0-50 Seconds (Plasma 0-50 Seconds Post Flow Only)
TIG Upslope/Down Slope Time Up: 0-10 Seconds Down: 0-10 Seconds
TIG Pulse Frequency: .1-150Hz
TIG Pulse Time On/ Pulse Amps: P-TIG 1, P-TIG 2, P-TIG 3 Fixed. Time On/Pulse Amp values set @ P-TIG 1: 50% / 50%, P-TIG 2: 65% / 65%, P-TIG 3: 75% / 35%
Spot and Fast Tack Time .1– 15S
Stick Hot Start % 0-100%
Stick Arc Force % 0-100%
E6010 Capable No
OCV (U0) TIG/Stick/Plasma TIG: 70V Stick: 70V Plasma: 250 V
Voltage Input (U1) Dual Voltage: 120V/ 240V; 50/60Hz 1 Phase (±10%)
Maximum Inrush Amps (I1MAX) 120V: 30A 240V: 28A
Maximum Rated Effective Amps (I1EFF) 120V: 19A 240V: 18A
Air Post Flow Timer Adjustable, 0-50 Seconds
Air Compressor Requirement and Recommendations for Plasma Cutting. 4.5 - 5 CFM @ 90 PSI (127-142 lpm @ 6.2 bar)
Use a compressor with a minimum output of 5.3 CFM @ 90PSI (150lpm @ 6.2 bar), with 30 gallon (114
Liter) capacity or higher recommended for best operation. Pancake type and small oil-less compressors
are not suitable.
Duty Cycle/ Over Current Protection Yes, Self-diagnosing feature. (See code references at the end of this manual.)
Minimum Operating Plasma Cutting Air Pressure Approximately 40 PSI (2.7 bar) (safety cut-out threshold)
Low Pressure indicated by Error Code E06.
Maximum Supplied Air Pressure 90 psi (This is incoming pressure from the air compressor, not operating, or (From Compressor/Tank)
cutting pressure.) The air compressor MUST have a separate pressure regulator at the tank or inline to
control maximum supply pressure.
Recommended Maximum Daily Average Cut Thickness (Steel) 3/8” (12mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Rated Maximum Quality Cut @ 10-12 IPM (@ 250-300mm / min) (Steel) 5/8” (18mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Max Severance Cut @ 3 IPM (75mm / min) (Steel) 7/8” (22mm) Decrease 35-40% for Aluminum and Stainless Steel (INOX).
Minimum Water Ingress Protection Standard IP21S
Efciency >85%
Cooling Method Full time High Velocity Fan
Dimensions (approximate) 12.5” H x 7.5” W x 14” L (320mm x190mm x 355mm)
Weight (Bare Unit) 44 lbs. (20 kg)
Generator Requirement 7,500 W Clean Power (<5% total harmonic distortion/Clean Power Output Rated)
Minimum Storage/ Minimum Operating Temperature Storage: -10°F/-23°C Operating: 14°F/-10° C
HF Point Gap (TIG) .029” to .045” (Target Point Gap: .035”)

11
Section 1 Introduction and Specifications
NOTICE:
This manual has been compiled to give an overview of operation and is designed to offer information centered around safe, practi-
cal use of the plasma cutter. Welding and cutting operations are inherently dangerous. Only the operator of this Welder/Plasma
cutter can ensure that safe operating practices are being followed, through the exercise of common sense practices and training.
Do not operate this machine until you have fully read the manual, including the safety section. If you do not have the skill or
knowledge to safely operate this Welder/Plasma Cutter do not operate this unit until formal training is received. To prevent re,
always be aware of your surroundings.
GENERAL PRODUCT INFORMATION:
The Ultra-Arc 205 utilizes the latest in digital inverter design technology. This new design is an improvement over its predecessor,
the PowerUltra 205Pi. This unit redesign has incorporated more advanced Stick and TIG welding features and even now includes
a memory function with up to 9 memory slots to preserve favorite settings.
New features have been added to improve the TIG welding capabilities of the unit. The unit offers 3 TIG Pulse settings which have
been carefully selected for best operation in a variety of conditions where pulse may be helpful. In each pulse program, pulse is
adjustable up to 150Hz for optimal ne control by the user. The unit also features a spot weld timer to be used with the TIG
mode to allow a timed arc that can produce consistently sized large spot welds or tacks welds. The new Fast Tack feature pro-
vides a intense burst of welding power. This allows tacking of very small or thin parts without over melting the component or
seam. This is used in conjunction with the TIG torch switch in 2T mode.
Also, control over stick functions have been increased with the additions of hot start intensity and arc force control. However, this
unit is not rated for E6010 use however, or similar cellulosic rods.
POWER INPUT:
This unit may be operated on either 120V or 240V single phase input. No changeover of wiring is required. Simply plug the sup-
plied adapter to the NEMA 6-50 plug on the plasma cutter and the unit will automatically sense the voltage that is being supplied.
When operating on 120V input, please note the maximum output will be limited. For Wiring and Breaker requirements, consult
the Article 630 of the National Electric Code (NEC) for special information concerning proper wiring and breaker sizing of duty-
cycle limited welding/cutting machines. Use the I1MAX and I1EFF ratings supplied on page 10 in this manual to determine correct
breaker and wire sizing. Always consult a licensed electrician before wiring this unit to new or existing service. Never attempt to
adapt this unit to work with existing dryer or range plugs. Do not use on long or undersized extension cords. Use cords rated
for a minimum of 30 amps for 120V and 40A for 240V. Use lengths no more than 25 ft in length.
GENERAL MAINTENANCE 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. It is a good idea to remove the Welder/Plasma Cutter from the vicinity of any water or moisture source to
reduce the possibility of electrocution or shock. Never operate this unit in standing water.
IMPORTANT: Before opening the unit for any reason, make sure the unit has been unplugged for at least 10 minutes to allow time
for the capacitors to fully discharge. Severe shock and/or death can occur.
Every 1-2 months, depending upon use, the unit should be unplugged, opened up and carefully cleaned with dry compressed or
canned air. To open, remove rear plastic cover and main cover. Do not remove the front plastic cover. Regular maintenance will
extend the life of the unit. Carefully descale metal particles from the fan blades to prevent vibration and fan damage (if buildup is
present).
•Do not restrict air flow or movement of air around the welder/plasma cutter. Allow a minimum clearance of at least
18” (500mm) on all sides.
•Lift and carry the unit by the handle. Do not mount in areas that are prone to severe shock or vibration.
•Do not operate the unit immediately next to the weld/cut area. Allow at least 6 feet separation.
•Do not direct metallic dust or any dirt intentionally toward the machine, particularly in grinding and cutting operations. Make
sure the control panel is protected from damage.

12
Section 1 Introduction and Specifications
DUTY CYCLE:
The duty cycle of this unit has been tested and established at 60% at full rated output for TIG welding. For Plasma and Stick use the duty cycle
is 35% at full rated output. This duty cycle has been established under the standard rating temperature of 104 F (40 C). If you are not familiar
with Duty Cycle ratings, duty cycle is the percent of time out of a 10 minute time period at which a welder or plasma cutter can operate continu-
ously without overheating. Lowering output increases duty cycle. It is possible to achieve a 100% duty cycle by lowering the output Amps until
the 100% duty cycle threshold has been reached. (Additional duty cycle levels at rated lower-than-maximum outputs are listed on the data plate
on the welder. i.e. 60%, 100% ) However, 100% duty cycle is still based off a 10 minute time period and does not mean it has an “innite” duty
cycle. Theoretically, if the machine were to go 11 minutes of uninterrupted operation even at a 100% Duty Cycle level of operation, you could
incur an overheat condition. Duty cycle on this machine is not controlled by a timer, but rather by one or more temperature sensors strategically
located on the heat sink(s) of the machines internal circuitry. If an overheat is detected the cutting output will be interrupted. A code of “E01” will
be displayed. If this happens, allow the unit to continue to run and cool for at least 15 minutes. Do not turn the unit off during this time! If the
unit does not automatically reset after this time, cycle the machine off and back on to clear the code. If the code does not clear at this time,
contact Everlast for further remedy. Intentionally and repeatedly triggering the duty cycle can damage the unit over time. This type of damage
becomes apparent during repair and service and is not covered under warranty.
OVER/UNDER VOLTAGE/CURRENT:
This unit is equipped with a over/under voltage/current device which senses under or over voltage conditions caused by poor power supply or
internal faults and shuts down output. If you observe an error code “E02” immediately turn the machine off. Evaluate the input power supply for
proper voltage. Also inspect the suitability of any extension cords for service. If code does not clear, after remedying common issues stated
below, contact Everlast. Do not continue to try to clear the code if it does not appear to have been corrected.
Common Items That Can Trigger the Over/Under Voltage Current:
•Operating on too long or undersized extension cord or service wiring. Damaged wiring.
•Improperly grounded service/ power supply.
•Operating on too small of a generator or on a generator not rated as “Clean Power” (5% or less THD).
•Too long of a cutting arc.
•Excessively worn or missing consumables or damaged torch head.
•Internal machine fault. (If code cannot be cleared after correcting other issues, call Everlast.)
GENERATOR REQUIREMENTS AND OPERATION
This unit may be run on a generator capable of 7500 Surge Watts. Additionally, the generator must provide “clean power”. Clean power is de-
ned as having 5% or less Total Harmonic Distortion (THD). This is a rating given by the manufacturer of the generator, and not Everlast. This
is similar to the power normally supplied at a wall outlet. This represents a sine wave (AC) that is mostly free of voltage spikes and electronic
noise. Many general purpose (GP) generators are not rated to produce clean power and are designed for emergency or construction use with
resistive loads such as lights or heaters. These generators can damage the plasma cutter. If damage does not occur immediately, the effect can
be cumulative, depending on how “dirty” the power actually is. Damage created by running this unit off a generator, or welder/generator not
rated for clean power output by its manufacturer will not be covered under warranty. If you are in doubt about your generator or welder/
generator, contact the manufacturer. Everlast does not keep an authorized list of generator brands or models. However, if the manufacturer rates
its generator for 5% or less THD, this is sufcient to meet our standards. However, do some additional research on the brand and model of the
generator to make certain there are no issues, recalls or reported equipment (electronics in particular) damage related to malfunctioning genera-
tors from the manufacturer. The generator should be properly grounded, according to the generator manufacturer instructions.
Never leave the unit on or connected while starting the generator. Never stop the generator while the unit is on or connected. Severe damage
will occur. This includes running the generator low on or out of fuel. This damage is not covered under warranty, even if the unit is rated as
“clean powered”. Always allow the generator to warm up before plugging the unit in and using it. A cold engine may not develop or maintain
proper RPM needed to provide stable, clean power even if the unit is rated to be “clean power”. Never use economy idle (ECO mode), or auto
idle modes with this unit. Always use maximum idle when this unit is plugged in and/or turned on.
NOTICE:
During TIG arc starting and during start up you may hear a quick “buzzing” sound coming from the machine. You may also observe a blue light
coming from the front panel vents. This is normal and not an issue. It does not present a danger to the machine. This is the High Frequency
(HF) circuit activating, allowing you to make a clean, touchless start. Inside the machine, toward the front of the welder, under the main metal
pan is a small HF board, with small set of points that the HF energy jumps between, creating a “spark”. You can view the HF points through the
front vents at just the right angle. This spark can also be seen briefly during the start of the weld (if in HF start mode) at the tip of the Tungsten.
Do not attempt to start the unit unless you are ready to weld. The unit discontinues the starting HF after approximately 3 seconds of attempting
to start the arc for safety and unit protection. It also discontinues after the arc starts.
Over time the points may become dirty or out of adjustment, making the HF starting more difcult. If HF starting is difcult, rst regrind the
Tungsten, then make sure the work clamp is in direct contact with the work piece and not running through the work table or table leg. If starting
is still difcult, adjustment of the point gap may be needed. This is not a candidate for warranty. Point Gap adjustment, just as cleaning out/
blowing out the machine on a regular basis is considered a part of regular maintenance. Opening the machine for cleaning or point gap adjust-
ment does not void the warranty. Always unplug the unit for 10 minutes before entering the machine for maintenance to allow capacitor bleed
down. Remove only the rear plastic cover and the metal cover to access the unit. Never remove the front plastic cover unless directed by Ever-
last. See specication page for point gap adjustment range.

13
Section 2 Quick Setup Guide
TIG Connections:
Front View of TIG Torch and Work Clamp
GAS CONTROLTORCH WORK PIECE
PILOT ARC
IMPORTANT:
The foot pedal and the torch switch cannot be connected at the same time.

14
Section 2 Quick Setup Guide
Stick Connections:
Front View of Electrode Holder and Work Clamp
GAS CONTROL
TORCH WORK PIECE
PILOT ARC
NOTICE:
The stick function will require you to move the torch to the work piece setting for DCEP+ (Reverse Polarity).
In this case, ignore the marking and remember the left terminal is negative and the right terminal is positive.
Some electrodes can be run DCEN, however, consult the rod manufacturer suggestions for proper polarity.
The picture above depicts the standard and most commonly used rod polarity (DCEP+).

15
Section 2 Quick Setup Guide
Plasma Connections:
Front View of Plasma Torch and Work Clamp
GAS CONTROLTORCH WORK PIECEPILOT ARC
IMPORTANT:
Avoid ring the torch unless you are ready to cut. Excessive ring without cutting will wear the consumables
at an accelerated rate. Do not attempt to control the amperage with the foot pedal connected.
NOTICE:
For correct operation, use the correct consumable for the amperage selected amperage. Cutting nozzles
(tips) have different orice sizes. If you are operating on 120V, the maximum output of the cutter will only
be 25 amps. The stock consumable will not cut properly at 25 amps. See torch pages for alternative sizes
and amp range. Always maintain proper cutting air pressure (65-75 PSI). Use the Purge button to adjust the
cutting air pressure. Do not exceed 90 PSI supply pressure from the compressor to the regulator.

16
Section 2 Quick Setup Guide
EVERLAST
Regulator reads in Cubic Feet per Hour (CFH) for US
and Canada. Other regions may read in Liters per
Minute (LPM)
CO2
NEMA 6-50P
L1,BLACK; HOT
GAS
INLET
L2,WHITE; HOT
GREEN GROUND (220/240V 1
NOTICE:
The supplied plug is a NEMA 6-50P, This is the standard plug for
welders in the USA and Canada. It is a 50 amp 3 prong plug. There is
only a ground and no neutral in a welder circuit. For 120V use, use the
supplied adapter. No switching or change of wiring is necessary for
120V use if the supplied adapter is used.
IMPORTANT!
Always consult a licensed Electrician and local codes before adding or modifying any
existing wiring. Do not modify the welder wiring! Refer to Article 630 of the NEC for
more information concerning proper wiring of welders.
NOTICE:
The unit has a common connection point for both the plasma air supply and
the TIG shielding gas. This means the gas hoses must be swapped back and
forth when changing between processes. Do not run Argon through the
plasma regulator. You make a manifold system to connect both TIG shield-
ing gas and plasma air at the same time by using an Inert gas Y-valve or
series of ball valves. The rear connection is a standard 5/8” CGA tting for
inert gas/TIG welding. These are available almost anywhere welding supplies
are sold, both locally and online.
NOTICE:
TIG shielding gas must be 100% argon or Ar/He mix. If using Ar/He, never
exceed 25% Helium. Never use CO2 or Ar/CO2 or other Ar mixes.
TIG Gas Connections and Power Connection

17
Section 2 Quick Setup Guide
IMPORTANT:
A separate air dryer between the air compressor and lter assembly must be installed, usually at the compressor or right before the regulator. This is a customer supplied item. Failure to
install a separate air dryer/lter will greatly decrease consumable life. It can also lead to contamination in the torch head which will cause failure. Moisture in a plasma system is detri-
mental to all parts, including the solenoid and torch head. The included lter/water trap is designed mainly to catch dirt and moisture created during the coupling and uncoupling pro-
cess, or minute amounts of moisture that may escape the separate dryer/lter. Multiple styles of dryers/lters are available in a wide range of prices from a few dollars to several hundred
dollars. A simple, economic desiccant type dryer used in automotive paining is enough to get started. Damage caused by operating the unit without the additional dryer/lter is not
covered under warranty! Never use this plasma cutter with an oiler system, or with a worn air compressor which uses excessive oil. For best results, if installing this unit on an older
system, install a new hose and plumbing components after the air dryer before connecting to the unit.
Drain the air compressor on a daily basis after use.
Do not supply more than 90 psi to the plasma cutter from the compressor. If the air pressure on the front gauge drops too far to maintain a good cut or falls out of spec while cutting,
increase the size of the supply hose/line to the plasma cutter in lieu of increasing supply pressure.
Fittings (Push to Connect and 5/8” CGA)
Plasma Connections:
Compressor and Dryer Diagram
To adjust air pressure: Select
purge button. Then, Pull up on
top slightly until click is heard to
adjust. Push top back down to
lock air pressure.. Deselect purge.

18
Section 2 Quick Setup Guide
STOP!
To set the air pressure or TIG torch Gas Flow Rate, use the “PURGE” feature to initiate air flow, then adjust the pressure while air is
continually flowing. Do not re the torch to initiate air or shielding gas flow. Firing the Plasma torch without cutting signicantly
increases consumable wear. Firing the TIG torch without welding increases wear on the HF Points.
STOP!
• Turn the unit off to check and change torch consumables. Shock, burn, injury or death may result if the torch trigger were
accidentally pressed during removal.
• Turn the unit off to check and change power connections/torches.
• Do not become a ground path while using this unit. This means you need to insulate/isolate yourself from the work piece
while welding or cutting. Refrain from touching or contacting the cutting tip or electrode while in use.
• Using in wet or damp material may increase your chances for shock or electrocution. Sweat can also increase your chances
of shock/electrocution.
• Do not exceed 90 P.S.I. (6.2 bar) input supply pressure (from compressor) while plasma cutting.
• Do not attempt to repair a faulty regulator other than tightening leaking lines or repairing hoses.
GENERAL PLASMA CUTTING OPERATING TIPS
• Keep torch standoff to less than 1/8” while plasma cutting.
• Do not drag the plasma torch directly on the metal unless using drag consumables.
• Always use dry air. Install inline air dryer. Do not rely on the supplied water trap/lter. Drain compressor daily to improve
effectiveness of air dryers and to prevent them from prematurely failing.
• Don’t greatly air pressure to try to reduce kerf or cut thinner material. Always reduce nozzle orice size to match amperage.
• See the Torch information page for different consumable sizes and amp ratings. Use this as a general rule of thumb for
good hand cutting speed and quality: For the rst 1/8” of thickness, use 20 amps. After the rst 1/8” add 10 amps for every
1/8” after that. For Stainless and Aluminum, use settings that are 40% higher.
• Do not attempt to operate with work clamp removed. Always connect the work clamp directly to the part being cut.
• Excessive pilot arc operation drastically reduces consumable life. Grind the area where the work clamp is attached for best
contact. If the unit only lightly cuts or gouges the surface, the pilot arc is staying on too long and continuity to the cut is not
being detected. This can blow your pilot arc fuse and cause the torch not to strike unless touched to the metal. If this hap-
pens, change the fuse and make sure your work clamp has a good, direct connection to the work piece.
WARNING!
Never attempt to change processes with plasma torch connected or severe damage may result. Do not operate the Plasma with
the foot pedal. Do not attempt to weld with TIG in stick mode. This can damage the unit.
STOP!
Don’t forget to turn off the Argon cylinder while away. Leak down and loss of cylinder contents may occur. For best practice and
safety concerns, disconnect the plasma air supply when the unit is not in use.

19
Section 2 Quick Setup Guide
TERM DEFINITION AND EXPLANATION OF WELDING FEATURES AND TERMS
2T/4T In 2T or 4T modes, the torch switch is used to start and control the weld cycle. Simply put, in 2T mode, the torch switch is simply
pressed and held down to start the arc and begin welding. The switch is then released to terminate the arc and stop welding. In 4T
mode the trigger is pressed and held to start the arc. It is then released to weld. Once welding is nished, the trigger is pressed and
held and eventually released to terminate the arc. Between starting and stopping the weld, there are other things that happened during
the weld cycle such as pre-flow, upslope, down slope, and post flow. Each of these actions are signaled and controlled by a movement
of the torch switch. See the drawing below to understand what is controlled by each movement of the torch switch in both 2T and 4T
modes.
Amps In specic regards to the control and setup of this unit: this is a measure of the maximum current output of the welder. When no welding
or cutting activity is taking place, the display is static, displaying the chosen maximum amperage. When welding or cutting, it becomes
dynamic and displays the actual output of the welder/cutter. Some variation is normal, especially when stick welding and arc force and
hot start are set to a high value. Amperage variation is normal due to several things including variation in arc length and variation in
input voltage. With the TIG foot pedal plugged in, around three seconds after adjustment on the main control knob, the welder will
actually default to the lowest Amp output because the unit begins to read the value of the foot pedal potentiometer instead of the maxi-
mum Amperage selected. This is usually around 5 to 7 amps. However, the display will revert to reading the maximum amperage select-
ed if more Amperage adjustment is subsequently made with the main adjustment knob. Then, the unit will once again revert to the
minimum output position reading of the foot pedal after the three second interval. Regardless of the reading with the foot pedal plugged
in, the Maximum amps will always be what has been selected with the main adjustment knob. With the torch switch selected, the Amper-
age will not fluctuate from what is selected.
Arc Force During Stick welding, arc length (the distance of the end of the electrode to the work piece) is constantly varying. As arc length decreas-
es, voltage begins to fall with a Constant Current (CC) machine. This means the arc looses total wattage ( W=V X A ). Wattage is
actually what keeps the weld puddle going. The combination of Volts and Amps are important and one cannot exist independently of the
other as far as welding is concerned. Often focus is strictly on the Amperage value, but both are important. So as the Voltage falls, even
if the amperage stays the same, the wattage begins to fall and the puddle begins to cool off. This means that in extreme cases, the arc
can go out and the electrode can stick fast in the weld puddle. Inverters such as this one are designed to sense the fall of Voltage and
attempt to offset the voltage loss in an effort to maintain total Wattage by increasing the amp output automatically. In this case, when
Voltage falls below the threshold of 20V due to a short arc length, the arc force becomes active and the “injection” of extra Amps begin.
This value is adjustable from 0 to 100% over the set Amperage. The crispness or softness of the arc is determined by the interplay and
ratio between volts and amp output. Smooth and “buttery” arcs with “wet puddles” are usually a product of lower arc force values.
Higher arc force values make a much more crisp, penetrating arc. For most applications with iron powder rods such as E7014 and
E7018, and for rods like E7018, Arc force values of 20 to 40% are all that are usually required. For operation with more difcult rods,
such as E6011, higher arc force values are required anywhere from 60-80% typically. It is worth noting that typical Amp selections will
be lower than for traditional transformer and brush DC machines. This is because with proper use of the arc force you can actually
control your heat and even increase it somewhat by “pushing” into the puddle with the electrode. With a transformer machine, it is
customary to lengthen the arc rather than shorten it to accomplish something similar. However, pushing into the puddle actually is
preferred because you have less chance of inclusions and discontinuities in the weld. Hint: A “0” value for arc force will not typically
render satisfactory results. NOTICE: Arc Force applies only in Stick mode. Arc force is also limited by the remaining amount amperage
available for employment. The higher the set Amperage, the less Arc Force action is available, regardless of setting. Operation on 120V
signicantly reduces available Arc Force action.
Base Amperage This is a term referred only in terms of the Pulse function. Base amperage (sometimes called “Pulse Amps” or “Background Current” is
the lowest Amperage value during the pulse cycle. On this unit, the Base Amperage is xed at a different value in each Pulse Program.
Cut This is the plasma cutting selection. Before selecting or deselecting “Cut” disengage the torch. NOTICE: Do not switch the Cut mode to
stick or TIG when the plasma torch connected or damage may occur. Polarity for Plasma mode is DCEN, and the torch should be in the
negative terminal (-) marked “torch”.
Down-Slope Down-Slope is the amount of time that it takes for the Amperage to decline from the Maximum selected Amperage to the minimum
selected Amp value during the TIG welding cycle. Down-Slope is adjustable in seconds. On this unit the Down-Slope can be adjusted
from 0-10 Seconds. NOTICE: The Down-Slope only applies to 2T or 4T TIG modes. In foot pedal mode, the user determines the Down-
Slope Time by backing down the pressure on the foot pedal, lowering the amperage.
End Amps During the TIG weld cycle, this is the nal amperage, or “crater” current that is used to complete the weld. It follows the down slope
cycle and is typically set at the minimum amperage for best tail out when using the foot pedal, or set at some desired value that keeps
the arc from suddenly snapping off at a high amp value. This lower amp value, combined with the down slope cycle helps provide time
for the arc to diminish and the weld puddle to gradually cool, helping to prevent large craters in the terminal end of the weld which
create stress risers that lead to cracking of the weld.
Fast Tack This feature allows the user to create fast, intense bursts of welding power perfect for tacking without over melting the edge. This feature
can be set to repeat using the amps and pulse settings varying the intensity by changing the pulse frequency adjustment (Hz). This is
similar to spot, but with spot, pulse cannot be employed. The employment of pulse helps to “vibrate” the puddle and bring two joint
edges together without having to add ller. This is usually reserved for thin materials, but can be used for thicker materials though if
needed, but with reduced effectiveness. For thicker materials, “Spot” is a better choice.
Hertz (Hz) This term refers to the frequency at which the pulse operates. Or it is also sometimes called Pulses per Second (PPS). In other words,
this is the number of times in one second that the pulse completes a full cycle. On this unit the Pulse frequency is adjustable .1-150Hz.
4T Torch Operation Effect on Weld Cycle.
= UP ON SWITCH
= DOWN ON SWITCH
PREFLOW POST FLOW
2T Torch Operation Effect on Weld Cycle.
WELD AMPS WELD AMPS
START AMPS END AMPS
PREFLOW
WELD AMPS
POST FLOW
START AMPS END AMPS

20
Section 2 Quick Setup Guide
TERM DEFINITION AND EXPLANATION OF WELDING FEATURES AND TERMS
High Frequency Start This refers to the type of start in TIG mode. High Frequency (HF) provides an intense HF impulse from the internal HF board and point
gap that jumps the gap between the Tip of the Tungsten and the Work Piece. This means no contact is made directly to the metal to
start the arc. The foot pedal or torch switch is pressed and the arc will energize automatically after a brief HF spark is emitted. NOTICE:
The High Frequency Start feature does not pertain to AC welding and does not mean a welder will weld Aluminum or has an AC mode.
Hint: If HF starting is difcult make sure work clamp is directly connected to the part being welded before checking HF point Gap.
Hot Start This is used in Stick mode to provide an extra burst of Amps during the arc striking process. This helps to improve arc starting capabili-
ties and also helps to heat up the rod tip to prevent sticking and porosity at the start of the weld. The action is similar to “Arc Force” but
is limited in duration automatically by the unit’s programming. The value ranges from 0-100% over selected welding Amperage.
NOTICE: The Hot Start is limited by the remaining available welding amperage, regardless of setting. On 120V Hot Start may be limited.
Memory This is the ability of this unit to save different programmed settings. To save the setting, you should select a program # (sometimes
referred to as a “channel”) where you wish to save your settings before you begin to make any adjustments. After a program number
has been selected, you can make any adjustments you wish to the settings of the machine. Once you are satised with the programming
parameters, press the “Save/Select” arrow button in the Memory Display box and hold it for 3 seconds. While the button is held down, a
green LED will light up to indicate that the program has been saved. Hint: Any further adjustments to the programming will not be
automatically saved. If you need to resave the program after more adjustments have been made, simply press and hold the Save/Select
until the green LED lights again. Remember, to be careful not to save over old programs by changing the program number before. A
saved over program cannot be recalled or recovered if it has been saved over.
Pedal This refers to the foot pedal operation. The foot pedal is used to start the arc and increase or decrease the Amperage. The range of
Amperage controlled is limited at the panel by setting the maximum operating Amps. Usually set the max operating amperage 20% or
so above the maximum intended operating range. NOTICE: The pedal is used with TIG only. Do not use with Stick or Plasma Functions.
Post-Flow The Post-Flow is used for both TIG process and for Plasma Cutting. After terminating the Arc while TIG welding, the Argon gas should
flow briefly after the arc is terminated to prevent porosity in the weld puddle and to cool the weld and torch. This can be adjusted using
the Post-Flow feature. A good starting point is to set 1 second of Post-Flow for every 10-20 Amps selected for the weld. For Plasma
this should be used 1 second for every 10 Amps is sufcient for light cutting. Add more for extended cutting. This helps preserve the
torch and torch consumables.
Pre-Flow The Pre-Flow is used for the TIG process only. This is used to establish a protective pocket of shielding gas around the weld area
before starting the Arc preventing weld porosity or tungsten oxidation at the start. As a basic rule, any where from .5 to 1 second gener-
ally considered sufcient. However, if a large gas lens cup is used, the weld will require more Pre-Flow time, up to 3 seconds or more
to adequately purge the cup and the weld area. NOTICE: The Arc will not start until the Pre-Flow time is over.
Pulse The Pulse can used (for any single or combined purpose) to help control heat, deformation, puddle wicking or to improve the weld
aesthetics by offering a dened “Dip” point of the ller rod. The Pulse consists of three basic parameters: Base Amp Setting, Pulse Time
On (Balance) and Frequency. Of the three parameters, only Frequency is adjustable in each of the pre-programmed pulse programs.
However, the Pulse programming for Base-Amps and Pulse Time On has been carefully chosen to offer three useful, but distinct pulse
options. To ne tune each Pulse Program, the Pulse Frequency is fully adjustable from .1-150Hz.
Pulse Time On The amount of time that the stays in the Peak Amp and the Base Amp stage of the Pulse cycle can be skewed to favor more time in the
Peak stage, or less time in the Peak stage, in turn favoring more time in the Base stage. More time in the Peak stage offers a more fluid
puddle, while more time in the Base stage offers a less fluid puddle. For this welder, each of the three pulse programs the Pulse Time
On is xed but is set to work in conjunction with the Base Amps % which is also xed to offer 3 distinct but useful pulse programs.
Purge The Purge feature is used to safely allow gas to flow freely while setting the TIG or Plasma Regulator without having to trigger the torch
switch or foot pedal. Pressing the Purge button will lock on the Purge feature and allow it to flow until the Purge button is deselected.
Remote The TIG Arc cycle and amperage must be controlled either via Torch Switch or Foot Pedal. TIG can be operated without the remote in
the “Live Lift” mode, but the remote features allow you to signal the pre and post flow cycle, start and end of the weld cycle and increase
or decrease the welding amperage while welding. The foot pedal is a seamless way to control all of this manually. However, where foot
pedals aren’t practical, the torch switch can be used in either 2T mode or 4T mode to start and end the arc, or even increase or decrease
the amperage according to the programming set on the panel. NOTICE: The Live Lift Mode does not use a triggering mechanism of any
kind and the arc is started through touching the Tungsten to the metal.
Start Amps The Start Amps is used as a place where the Amperage is set once the arc starts. This can be set high for more aggressive starts, or low
for soft, easy starts. Usually softer starts are preferred for steel and stainless. Hint: Whether using the foot pedal or the torch switch, the
size of the Tungsten will affect minimum low amp starts. Although the unit is rated for 5 Amp starting, 5 Amp starts are best achieved
with a 1/16” tungsten or smaller. It’s not impossible to start at 5 Amps with larger Tungsten, but the arc will be less easily struck and
stabilized with larger Tungsten diameters. For 3/32” or 1/8” Tungsten, try setting Start Amps to 10 to 15 Amps for best results.
Spot The Spot Weld feature is used primarily to help improve tack size consistency. This feature is used for TIG only and is not meant to be
used with traditional spot weld tongs, or similar mechanisms. The idea of the spot weld is to provide a controlled Arc-On time so that
the weld will be repeatable and uniform. This is good for setting up auto body panels, tacking exhaust tubing or lling small plug welds.
TIG Start This unit allow the user to choose from three distinct TIG Arc Starting Styles. The Lift Start is a contact type of arc starting method,
which creates an arc once the Tungsten is quickly snapped up and away from the work piece. However, a remote (a foot pedal or torch
switch) is required to turn on power output to the Tungsten. This is used in many places where HF is not allowed or could interfere with
electronic equipment. Live Lift is similar to the Lift Start, but the Live lift means the Tungsten stays live and power is always present at
the Tip of the Tungsten. Since no remote is required, the arc must be broken by quickly rotating the wrist and snapping the Tungsten
up and away from the work. The High Frequency start is only able to be used with the torch switch or the foot pedal. This type of start
is usually preferred since the Tungsten is held off the metal slightly and the pedal or torch switch is triggered to initiate the HF spark,
providing a pilot path for the arc to jump across once the HF establishes continuity with the work piece. NOTICE: If selected, the Live Lift
Start feature may cause accidental arc flashes if the Tungsten is not properly insulated from the work piece.