EVERLAST

POWERTIG 250EX

AC/DC TIG/STICK (GTAW/SMAW) WELDER

Operators Manual for the PowerTig 250EX

Safety, Setup and General Use Guide
1
Rev. 4

0 00201-13

Table of contents
Section..Page
Letter to the Customer .... 3
Everlast Contact Information. 4
Safety Precautions.... 5
Introduction and Specifications... 9
Unit Specifications. 10
General Overview..... 11
General Use and Care..... 11
Quick Setup Guide, TIG Torch/Cooler Connection 12
Quick Setup Guide, Stick Polarity. 13
Rear Panel Gas Connection and Wiring.. 14
Front Panel Features and Controls.. 15
Rear Panel Features and Controls... 18
Welder Function Summary and Explanations. 20
Tungsten Preparation... 24
Lift Start and High Frequency Start 25
Stick Starting Methods 26
Recommendations for Polarity/Amps/Tungsten.. 27
Expanded View of TIG torch... 28
7 Pin Connector Pinout.. 29
Troubleshooting.. 30

NOTE: Product Specifications 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
product or this document for fitness for any particular purpose, for performance/accuracy or for suitability of
application. Furthermore, Everlast Power Equipment LLC 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.

Dear Customer,
THANKS! You had a choice, and you bought an Everlast. We appreciate you
as a customer and hope that you will enjoy years of use from your welder.
Please go directly to the Everlast website to register your unit and receive your warranty 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 through the main customer service number in your country. 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 the current online warranty statement and information found on the website of the Everlast division located in or nearest to your country. Print it for your records
and become familiar of its terms and conditions.
Everlast offers full technical support, in several different forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interaction.
Technical advisors are active on the forum daily. We also divide our support into two divisions:
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
available in your country. For best service call the appropriate support line and follow up with an
email, particularly if off hours, or you cannot reach a live person. In the event you do not reach a
live person, particularly during heavy call volume times, holidays, and off hours, leave a message
and your call will normally be returned within 24 hours. Also for quick answers to your basic questions, join the company owned forum available through the website. Youll find knowledgeable,
helpful people and staff available to answer your questions, and perhaps find 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 manufacturing inspection date. This will assure the quick and accurate customer service. REMEMBER:
Be as specific and informed as possible. Technical and performance advisors rely upon you to
carefully describe the conditions and circumstances of your problem or question. Take notes of
any issues as best you can. You may be asked many questions by the advisors to clarify problems or issues that may seem very basic. However, diagnosis procedures MUST be followed to
begin the warranty process. Advisors cant assume anything, even with experienced users, and
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.
Let us know how we may be of service to you should you have any questions.
Sincerely,
Everlast Customer Service

Serial number: __________________________

Model number: ____________________________
Date of Purchase___________________________

EVERLAST

Contact Information

Everlast US:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [email protected]
Everlast Support Forum: http://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am5pm PST M-F
11am-4pm PST Sat.
FAX: 1-650-588-8817
Everlast Canada:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [email protected]
Telephone: 905-637-1637 9am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: 1-905-639-2817
Everlast Austrailia:
Sydney: 5A Karloo Parade Newport NSW 2106
(02) 9999 2949
Port Macquarie: 2B Pandorea Place Port Macquarie
(02) 8209 3389
After hours support: 0413 447 492
Everlast Technical Support: [email protected]

Safety Precautions
Everlast is dedicated to providing you with the best possible equipment and
service to meet the demanding jobs that you have. We want to go beyond delivering a satisfactory product to you. That is the reason we offer technical support to assist you with your needs should an occasion occur. With proper use
and care your product should deliver years of trouble free service.

Safe operation and proper maintenance is your responsibility.

We have compiled this operators manual, to instruct you in basic safety, operation and maintenance of your Everlast product to give you the best possible
experience. Much of welding and cutting is based upon experience and common sense. As thorough as this welding manual may be, it is no substitute for
either. Exercise extreme caution and care in all activities related to welding or
cutting. Your safety, health and even life depends upon it. While accidents are
never planned, preventing an accident requires careful planning.
Please carefully read this manual before you operate your Everlast unit. This
manual is not only for the use of the machine, but to assist in obtaining the
best performance out of your unit. Do not operate the unit until you have read
this manual and you are thoroughly familiar with the safe operation of the unit.
If you feel you need more information please contact Everlast Support.
The warranty does not cover improper use, maintenance or consumables. Do
not attempt to alter or defeat any piece or part of your unit, particularly any
safety device. Keep all shields and covers in place during unit operation should
an unlikely failure of internal components result in the possible presence of
sparks and explosions. If a failure occurs, discontinue further use until malfunctioning parts or accessories have been repaired or replaced by qualified
personnel.

Note on High Frequency electromagnetic disturbances:

Certain welding and cutting processes generate High Frequency (HF) waves.
These waves may disturb sensitive electronic equipment such as televisions,
radios, computers, cell phones, and related equipment. High Frequency may
also interfere with fluorescent lights. Consult with a licensed electrician if disturbance is noted. Sometimes, improper wire routing or poor shielding may be
the cause.
HF can interfere with pacemakers. See EMF warnings in following safety section for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.
5

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 filter installed. Always use a welding helmet in good condition. Discard any
broken or cracked filters or helmets. Using broken or cracked filters or helmets can
cause severe eye injury and burn. Filter shades of no less than shade 5 for cutting
and no less than shade 9 for welding are highly recommended. Shades greater than 9
may be required for high amperage welds. Keep filter lenses clean and clear for 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 filter 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 protection is necessary to prevent hearing loss. Even prolonged low levels of
noise has been known to create long term hearing damage. Hearing protection also
further protects against hot sparks and debris from entering the ear canal and doing
harm.
Always wear personal protective clothing. Flame proof clothing is required at all
times. Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose
clothing is tucked in neatly. Leather aprons and jackets are recommended. Suitable
welding jackets and coats may be purchased made from fire proof material from
welding supply stores. Discard any burned or frayed clothing. Keep clothing away
from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for 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 electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient.
Gauntlet type welding gloves are available from your local welding supply companies.
Never attempt to weld with out gloves. Welding with out gloves can result in serious
burns and electrical shock. If your hand or body parts comes into contact with the
arc of a plasma cutter or welder, instant and serious burns will occur. Proper hand
protection is required at all times when working with welding or cutting machines!

SAFETY PRECAUTIONS
WARNING!

Persons with pacemakers should not weld, cut or be in the welding area
until they consult with their physician. Some pacemakers are sensitive to EMF radiation
and could severely malfunction while welding or while being in the vicinity of someone
welding. Serious injury or death may occur!
Welding and plasma cutting processes generate electro-magnetic fields and radiation.
While the effects of EMF radiation are not known, it is suspected that there may be
some harm from long term exposure to electromagnetic fields. Therefore, certain precautions should be taken to minimize exposure:

Lay welding leads and lines neatly away from the body.

Never coil cables around the body.

Secure cables with tape if necessary to keep from the body.

Keep all cables and leads on the same side the body.

Never stand between cables or leads.

Keep as far away from the power source (welder) as possible while welding.

Never stand between the ground clamp and the torch.

Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible
need for respiratory equipment while welding or cutting. Always weld with adequate
ventilation. Never weld in closed rooms or confined spaces. Fumes and gases 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! This product when used for welding or cutting produces fumes and gases which contains chemicals known to the State of California to cause birth defects
and in some cases cancer. (California Safety and Health Code 25249.5 et seq.)

WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas.

Release of Phosgene gas can be deadly. Consider all chemicals to have potential
deadly results if welded on or near metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain
regulations regarding high pressure cylinders can be obtained from OSHA or local
regulatory agency. Consult also with your welding supply company in your area for
further recommendations. The regulatory changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and
closed. Store chained so that overturn is not likely. Transporting cylinders incorrectly
can lead to an explosion. Do not attempt to adapt regulators to fit cylinders. Do not
use faulty regulators. Do not allow cylinders to come into contact with work piece or
work. Do not weld or strike arcs on cylinders. Keep cylinders away from direct heat,
flame and sparks.

SAFETY PRECAUTIONS
continued
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly
grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not
stand, lean or rest on ground clamp. Do not stand in water or damp areas while 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
fire 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 fires while you are welding. Sparks and hot metal
may travel a long distance. They may go into cracks in walls and floors and start a fire
that would not be immediately visible. Here are some things you can do to reduce the
possibility of fire or explosion:
Keep all combustible materials including rags and spare clothing away from area.
Keep all flammable fuels and liquids stored separately from work area.
Visually inspect work area when job is completed for the slightest traces of smoke
or embers.
If welding or cutting outside, make sure you are in a cleared off area, free from
dry tender and debris that might start a forest or grass fire.
Do not weld on tanks, drums or barrels that are closed, pressurized or anything
that held flammable liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling
hot pieces of metal. Remember to place hot metal on fire-proof surfaces after 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 responsibility. Make sure all equipment is properly maintained
and serviced by qualified personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding
parts. Touching uncovered parts inside machine can cause discharge of high
amounts of electricity. Do not allow employees to operate poorly serviced equipment.
Always check condition of equipment thoroughly before start up. Disconnect unit
from power source before any service attempt is made and for long term storage or
electrical storms.
Further information can be obtained from The American Welding Society (AWS) that
relates directly to safe welding and plasma cutting. Additionally, your local welding
supply company may have additional pamphlets available concerning their products.
Do not operate machinery until your are comfortable with proper operation and are
able to assume inherent risks of cutting or welding.

Section 1

Introduction and Specifications

PowerTig 250EX

Water-Cooled, 18 Series Torch Assembly

(Style may Vary)

Argon Regulator

Work Clamp
Consumable Kit
(Does not include Tungsten)

47K
Foot Pedal Assembly

Stick Electrode Holder

NOTE: Accessory and consumable appearance, style and quantity subject to change without notice.
9

Section 1

Introduction and Specifications

PowerTIG 250 EX TIG/Stick Welder

Specification

Process

AC/DC GTAW-P/DC SMAW

Inverter Type

Analog, IGBT Module Construction

Minimum/Maximum Rated Output TIG

AC/DC: 5 A/10.2 V - 250 A/20 V

Minimum/Maximum Rated Output Stick

5 A/20.2 V - 200 A/28 V

Start Type

HF and Lift Start

HF Point Gap

.030-.045 (.035 suggested)

TIG Duty Cycle @ Rated Amps/Volts

60% @ 250 A/ 28 V
100% @ 200 A/ 18 V

Stick Duty Cycle @ Rated Amps/Volts

35% @ 200 A/ 28.0 V

60% @ 160 A/ 26.4 V
100% @ 130 A/ 25.2 V

OCV (U0)

70 V

Voltage Input (U1)

Standard 220/ 240 V; 50/60Hz 1~3 Ph

Maximum Inrush Amps (I1MAX)

45 A @ 220 V

Maximum Operating Amps (I1EFF)

36 A @ 220 V

Gas Pre-Flow /Post Flow Time

0-10 Seconds/ 0-25 Seconds

Start Amps/End Amps

5-250 A/ 5-250 A

Up/Down Slope

0-10/0-25 Seconds

AC Frequency Control

20-250 Hz

AC Balance Control

10-90% of Electrode Positive (EP)

Pulse Frequency Hz (Pulses Per Second)

.5-500 Hz

Pulse Amps (Ratio)

5-95%

Pulse Time On (Balance)

10-90%

Stick Arc Force Control

0-100%

Stick Surge Amp Control (Available late 2013)

0-100%

Minimum Water Ingress Protection Standard

IP21S

Efficiency

>85%

Cooling Method

Full Time High Velocity Fan with Tunnel design

Dimensions (approximate)

18 H X 10 W X 25 L

Weight (Bare Unit)

70 lbs

10

Introduction and Specifications

Section 1
General overview: The new, redesigned 250 EX TIG/
Stick welder from Everlast is the latest in a new generation of analog style GTAW (TIG) /SMAW (Stick)inverter
welders. With an Siemens IGBT design the inverter
cycles at a frequency of up to 120 kHz, to deliver a stable, smooth arc. Several key design elements give the
PowerTig 250 EX series a competitive edge:
A. Siemens IGBT modules improve reliability while
make servicing a unit quicker, and more cost efficient. Most parts are standard components reducing the cost of long term repair.
B. Full bridge design features soft switching technology which further extends IGBT component life and
extends its capabilities.
C. Improved HF point design offers better and more
stable arc starts, even at lower amperages.
D. Features automatic over-voltage, over current and
duty cycle protection (over-heat).
E. The square wave AC design creates a stable arc in
AC, with a fast melting puddle and good wet in.
F. Arc force control and built in hot start helps improve the SMAW process performance. Surge amp
control (available late 2013) makes starting the arc
easy .
G. New improved design offers more intuitive adjustments , and provides better panel protection.

charge. Severe shock and/or death can occur.

Do not restrict air flow or movement of air around the
welder. Allow a buffer distance of 2 ft from all sides if
possible, with a minimum distance of at least 18 clearance. Do not operate the welder immediately in the
weld areaor the force of the fan will cause welding issues such as unstable arc, or porosity.
Do not mount in areas that are prone to severe shock
or vibration. Lift and carry the welder by the handle.
Do not direct metallic dust or any dirt intentionally toward the machine, particularly in grinding and welding
operations. Make sure the panel is protected from
damage while welding and cutting operations by flipping down the clear protective cover.
Duty Cycle. The duty cycle has been determined for
the 250 EX (220/240 V 1 and 3 phase ). For the 250EX,
the duty cycle is rated for 60% at 250 amps. The duty
cycle is based off a 10 minute duty cycle rating at 40 C.
This means that the unit is capable of being operated at
the stated amps for 6 out of every 10 minutes without
a break for cooling down the unit. This does NOT mean
that the unit can work 60% of any other length of time.
A full 4 minute rest should be given to the welder for
maximum life. The welder will automatically stop welding when an overheat condition has occurred and the
temperature light will come on. If the unit does not
stop and the light is on, this does not necessarily mean
that you have not exceeded duty cycle. Heat will continue to be generated by and transferred to the electronics after welding has ceased. Welding in humid, or
hot conditions can affect duty cycle as well. Do not
shut down an overheated welder until it has safely
cooled. Once the Overheat condition has cleared,
welding can resume. Do not operate the welder with
the covers removed.

Figure 1. Basic Inverter design

General Use and Care: The welders are good for use
in many industrial environments such as ship yards,
fabrication shops, pipelines. However, 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 from the vicinity of any water or
moisture source to reduce the possibility of electrocution or shock. Never operate in standing water.

This manual has been compiled to give an overview of

operation and is designed to offer information centered around safe, practical use of the welder. Welding is inherently dangerous. Only YOU, the operator of
this welder, can ensure that safe operating practices
are followed, through the exercise of common sense
practices and training. Do not operate this machine
until you have fully read the manual, including points of
safety. If you think that you do not have the skill, or
knowledge to safely operate this welder, do not use
this welder until formal training is received.

Every 1-2 months, depending upon use, the welder

should be unplugged, opened up and carefully cleaned
with compressed air. Regular maintenance will extend
the life of the unit.
IMPORTANT: Before opening the unit for any reason,
make sure the unit has been unplugged for at least 10
minutes to allow time for the capacitors to fully dis-

11

Section 2

QUICK SETUP AND USE GUIDE

QUICK SETUP GUIDE: TIG CONNECTIONS

TORCH (+)

WORK (+)
GAS

CONTROL

35 SERIES CONNECTOR

35 SERIES CONNECTOR

AIR-COOLED TORCH
GAS (Ar)

9/17 SERIES TORCH

CONTROL

CONTROL

26 SERIES TORCH

FOOT PEDAL

35 SERIES CONNECTOR
GAS (Ar)

CONTROL

NOTE: Torch switch and foot pedal

control cannot be used at the same.

WATER-COOLED TORCH
18/20 SERIES TORCH

COOLANT IN (RED)
INPUT

!
WA

OUTPUT

COOLANT OUT (BLUE)

WATER COOLER
ARGON GAS LINE SHOULD BE TAGGED AS Ar. IF NOT, TAKE DRY, COMPRESSED AIR AND GENTLY BLOW THROUGH THE LINES TO DISCOVER
WHICH LINE EXHAUSTS THROUGH THE TORCH OR THROUGH THE RETURN LINE. ON SOME TORCHES, THE WATER LINES ARE COLOR CODED:
BLUE FOR COOL WATER SUPPLY AND RED FOR HOT WATER RETURN.
COOLER FITTINGS SHOULD BE COLOR CODED BLUE AND RED AS WELL.

12

Section 2

QUICK SETUP AND USE GUIDE

QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS

GAS

CONTROL

TORCH (+)

WORK (-)

13

Section 2

QUICK SETUP AND USE GUIDE

QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING

(US/Canada)
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE
WIRING YOUR WELDER OR ATTEMPTING TO MAKE ANY ELECTRICAL CONNECTION.

1 PHASE 220/240 V SHOWN. FOR 3-PHASE 220/240 VUSE, CONSULT LICENSED ELECTRICIAN.
1~220 VAC

GREEN GROUND (220/240V 1 and 3 phase)

220 V WATER COOLER RECEPTACLE

L1,BLACK; HOT(240V 1 or 3 phase)

L2,WHITE; HOT (240V 1or 3 phase)

GAS
INLET

NEMA 6-50P

1~220 V
OR
3~220v

CLAMP

L3,RED; HOT(240V 3 phase only)

NOTE: LITERS/MINUTE (lpm)

FULLY TAPE RED WIRE SO THAT IS IS OUT OF THE WAY AND COVERED FOR
SINGLE PHASE USE! RED WIRE IS FOR 3 PHASE 220/240 V USE ONLY!

PLUG NOT INCLUDED! TO BE SUPPLIED BY CUSTOMER.

CO2
HF

EVERLAST

NOTE: Use Ar or Ar/He only. Do not use more than 25% He.

Fe, Cu
NOTE: TO PREVENT STRAY HIGH FREQUENCY INTERFERENCE, THIS UNIT PROVIDES AN ADDITIONAL GROUNDING POINT AT THE REAR OF THE UNIT. IT SHOULD BE DIRECTLY GROUNDED
THROUGH A SEPARATE WIRE TO AN OUTSIDE METAL ROD DRIVEN IN THE GROUND. THIS HELPS
PREVENT BLEEDBACK OF HF INTO THE POWER GRID, AND HELPS MUTE HF INTERFERENCE. ADDITIONALLY, ALL SURROUNDING METAL OBJECTS SHOULD BE GROUNDED SIMILARLY INCLUDING
THE TABLE, PIPES, WALLS ETC. TO PREVENT ELECTRICAL INTERFERENCE WITH OTHER CIRCUITS.
DO NOT COUPLE THIS WIRE TO THE GROUND PROVIDED IN THE ELECTRICAL CIRCUIT.

14

Section 2

QUICK SETUP AND USE GUIDE

FRONT PANEL FEATURES AND CONTROLS

1. PROTECTIVE COVER
2. SPOT WELD TIME
24. AMP DISPLAY

3. SPOT WELD TIMER ON/OFF

23. AMP CONTROL

4. 2T/PEDAL/ OR 4T SWITCH

22. ON/TEMP/O.C
5. START/END AMPS TIME

21. HF/LIFT /STICK

20. ARC FORCE (DIG)

6. UP/DOWN SLOPE TIME

19. SURGE AMPS *

18. AC FREQUENCY (HZ)

7. PRE/POST FLOW TIME

17. AC BALANCE (% OF EP)

8. PULSE HIGH/LOW/OFF

16. AC/DC SELECTOR

9. PULSE FREQUENCY (Hz)

10. PULSE AMPS (RATIO)
11. PULSE TIME ON (BALANCE)

GAS OUTLET

CONTROL

12. POSITIVE (35 SERIES)

15. NEGATIVE (35 SERIES)

13. GAS QUICK CONNECT (9mm)

14. TORCH/PEDAL CONTROL

15

Section 2

QUICK SETUP AND USE GUIDE

FRONT PANEL FEATURES AND CONTROLS CONTINUED

POWERTIG 250EX FEATURES

PARAMETERS

PURPOSE

N/A

Clear hinged cover protects panel from damage. Keep closed during welding operations.

2. Spot Weld Timer Switch

On/Off

Activates Spot Weld Timer circuit. Use only in 2T with torch switch or foot pedal. It may
also be used with CNC circuits to time spot welds. (Use pins 1 and 2) Contact Everlast for
further support and use of the Spot weld timer with CNC related equipment if needed.

3. Spot Weld Timer Control

0-10 Seconds

Selects amount of time arc remains energized when torch switch is pressed to yield uniform spot welds. Once the weld timer times out, the arc will stop automatically.

4. 2T/4T Sequencer Switch

2T -Pedal/4T

Used with torch switch function. Select 2T for simple press and hold operation of the
torch switch. Release the switch to cease operation. Select 4T for advanced use of the
panel sequencer controls such as start/end amps, up/down slope. 1) Press and hold
switch to start arc. 2) Release switch to begin current upslope to normal welding current.
3) Press and hold switch once again to begin downslope. 4) Release switch to terminate
the arc. In 4T mode, if the puddle becomes too hot, it can be ccoled by lightly tapping
the switch to begin downslope and tapping again to restart upslope before end current is
reached.
IMPORTANT: For foot pedal use: Select 2T, turn start/end amps and up/down slope to
minimum settings or foot pedal will not operate correctly.

5. Start/End Amps Control

(Part of 2T/4T sequence)

5-250 Amps

Serves as the 2T/4T beginning and final amp value while using the torch switch. Allows
the arc to be started and ended at a different amp value than normal welding while using
the torch switch. Typically used to start the weld puddle more quickly/slowly and to fill
the puddle at the end of the weld at a lower amp value to prevent cracking. Must be
turned to the minimum setting (fully left) while the foot pedal is in use or arc start/
finish may flare unexpectedly. The foot pedal does not override these features.

6. Up/Down Slope Control

(Part of 2T/4T sequence)

0-10/ 0-25
Seconds

Ramps amps from start amp value to welding amp value (Up slope).
Ramps amps from welding amp value to end amps value to fill crater (Down Slope).

7. Pre/Post Flow Control

0-10/ 0-25
Seconds

Pre-Flow sets the amount of shielding gas flow time before arc starts. Used to purge the
torch and flood the weld area with shielding gas so the arc start is stable and weld is free
from porosity.
Post-Flow sets the amount of shielding gas flow time after arc ends to shield the weld to
prevent oxidation and cool the torch.

Off/ Low/ High

Turns pulse on. Low range operates with a fine control from .5-25 Hz. High range operates with a more coarse range of control from 25-500 Hz

1. Protective Cover

8. Pulse Off/High/Low Switch

9. Pulse Frequency Control

.5-500 Hz

Represented by Hertz (Hz), the pulse frequency adjusts the actual number of times per
second the pulse makes one complete cycle between welding (Peak (high) amp value)
and pulse amps (Background (low) amp value). This is also commonly referred to as
Pulses Per Second (PPS). Low pulse frequencies are ideal for timing the point where filler
metal is added. This helps improve appearance and uniformity. Higher pulse frequencies
are useful for welding seams and edges of thin material. Also it is useful for overall heat
input control for thicker metals. Higher pulse frequencies are highly useful for automated
welding processes. WARNING: WELDING AT HIGH PULSE FREQUENCIES INCREASES THE
DECIBEL /NOISE LEVEL OF THE ARC. HEARING PROTECTION IS HIGHLY RECOMMENDED!
The adjustment is not 100% linear and symmetrical in adjustment. The further clockwise
the control is turned, the more rapidly the value increases.

10. Pulse Amps (Ratio) Control

5-95%

Sets the lower( base or background current) amp value during the pulse cycle by adjusting it as a percent of welding amps. When pulse mode is selected, the main amp
welding knob determines the welding amps (upper /peak) amp value.

11. Pulse Time On (Balance) Control

10-90%

Sets the duty cycle (balance) of the pulse, by dividing or skewing the amount of time the
pulse stays in the lower or upper stage of the pulse. The pulse consists of two stages:
Welding amps (upper /Peak) and Pulse amps (lower/background current). This is represented by a % of total time the pulse spends in the pulse amp part of the cycle during one
full pulse. The control can be used to increase or decrease pulse amp time relative to the
welding amp time of the cycle to help manage heat input.

12. Positive Connector

35-70 mm

Location of the positive terminal connection. Dinse-style connector. (35 Series)

For Stick: Torch connection. For TIG: Work Clamp Connection.

16

Section 2

QUICK SETUP AND USE GUIDE

FRONT PANEL FEATURES AND CONTROLS CONTINUED

FEATURE

PARAMETERS PURPOSE

13. Quick Connect Gas Outlet

9 mm

Connects the gas to the TIG torch. To connect: Push the torch fitting into the connector
until the collar slides forward with a click. To Release: Slide the outer collar back.

14. Control Connector

7 Pin

Connect the foot pedal or torch switch to this socket to control the welder. Only the foot
pedal or torch control connector can be plugged in at one time. If the torch has a torch
switch feature, tie the loose connector back or leave it hanging while using the pedal.

15. Negative Connector

35-70 mm

Location of the negative terminal connection. Dinse-style. (35 series)

For Stick: Work Clamp Connection. For TIG: Torch Connection

16. AC/DC Selector

AC/DC process

Select DC output for Steel, Stainless and most metals.

Select AC output for Aluminum and Magnesium alloys.

17. AC Balance Control

10-90% of EP

Selects percent of Electrode Positive (EP) used during AC welding to provide cleaning.
This divides the time that the AC cycle spends in Electrode Positive or Electrode Negative
during one full AC cycle. It controls the amount of cleaning and penetration via a ratio to
achieve the best balance while welding on AC. When the control knob is rotated left,
more Electrode Negative is used and more penetration will be achieved. When the control knob is rotated right, more Electrode Positive is used and more cleaning (cathodic
etching) will be achieved. Too much cleaning action will result in tungsten balling or
splitting, making a larger tungsten necessary for the same amperage range. Too little
cleaning can result in dirty, sooty welds and even a dull weld appearance. NOTE: This is
expressed as a percent of full EP Polarity. This unit uses 100% Electrode Positive as the
reference, which is just the opposite from some other brands. Using the welder in excess
of 50% EP can vaporize the tungsten. It can also reduce the duty cycle of the welder. For
most welds, no more than 45% cleaning is needed. Ideally, start with 30% EP for a reference point, and adjust it up or down to achieve best results.

18. AC Frequency Control

20-250 Hz

Controls the number of times per second that the current alternate in AC mode. To
achieve greater arc focus (constriction) and increase puddle agitation while welding in AC
mode, increase AC frequency. This allows pinpoint use on thin materials, and helps penetration on thicker materials. Ideal adjustment range is usually 100-150 Hertz. For comparison most transformer welders in the US operate on 60 Hz. Greater results can be
achieved through the higher frequency range offered by this welder. Lower Frequencies
will widen and soften the arc but reduce the level of control. WARNING: INCREASING
THE AC FREQUENCY ALSO INCREASES THE DECIBEL/NOISE LEVEL OF THE AC WELDING
ARC. HEARING PROTECTION SHOULD BE WORN!

19. Stick Surge Amps

(Available on late 2013 models)

0-100%

Adjusts the hot start amperage during the initial contact of the electrode. It makes arc
starting easier by sending a surge of amps briefly while arc is struck to prevent sticking.

20. Arc Force Control (DIG)

0-100%

Controls the arc response when an arc is held short and voltage begins to drop. Arc force
automatically compensates by modifying the volt/amp curve to maintain the energy
needed to weld. Represented as a percent of available amperage.

21. HF Start/Lift Start/Stick Switch

HF/Lift/ Stick

Selects type of TIG start. HF is touch free and activates during start only. Lift start requires brief touch to metal to draw an arc and is good for areas where sensitive electronics are present. Also selects Stick welding process.

22. On/Temperature/ Over Current

Indicator/
Warning
Or Fault

On Indicator: Confirms unit is switched on. Temperature Indicator: Lights up and stops
welding output until the welder has cooled within normal limits. Allow 10 minutes before
attempting to reset manually by cycling the power switch. If the light does not go out
after the cool down period by cycling the switch, or if comes on again when the arc is
struck, contact Everlast. Over Current Indicator: Lights up when a voltage /amp surge has
surpassed the units capabilities. Eliminate the source of surge and manually cycle the
power switch to reset. If the light remains on after cycling the switch, this may indicate a
unit fault created from the over current. In this case, contact Everlast.

23. Amp Control Knob

5-250 Amps

Sets Maximum limit for Amps with foot pedal or torch. Sets higher amp value for pulse.

24. Amp Display

N/A

Displays selected maximum selected amps until weld is started. Displays actual amps
while welding. Display will begin to cycle rapidly and somewhat randomnly after it has
been turned on. This is normal because the meter samples the pulse reading at a fixed
rate and is not synchronized with the fluctuation of the pulse. Immediately after the
pulse is turned on, a short delay is built in that prevents the display from cycling to allow
the pulse to be adjusted. Once adjustment is finished, pulse will begin to cycle.

17

Section 2

QUICK SETUP AND USE GUIDE

REAR PANEL FEATURES AND CONTROLS

1. WATER COOLER RECEPTACLE

220/240 V WATER COOLER ONLY!

2. 3-POLE POWER SWITCH

1~220 VAC

4. POWER CABLE 1/3 ~ 220/240V

1~220 V
OR
3~220v

GAS
INLET

6. HF GROUND BOLT
5. ARGON GAS INLET

18

Section 2

QUICK SETUP AND USE GUIDE

REAR PANEL FEATURES AND CONTROLS CONTINUED

FEATURE

PARAMETERS

PURPOSE

1. Water Cooler Receptacle

IEC 60320-1 C-14

This connection supplies power to the Everlast PowerCool 300 water cooler. This is a
220 VAC outlet. Do not use this connection to power any other device. 4 amp max.

2. HF Ground Bolt

N/A

HF energy can be devastating to surrounding electronic equipment. If the operating

environment includes electronic equipment, this bolt can serve as a direct path to a
grounded metal rod that is isolated from the main electrical circuit to help bleed off
excess HF circuit. All metal parts inside the building should be grounded as well, including pipes, tables, and even metal siding. HF energy has been known to bleed back
into the power grid and disrupt electronic devices further down the grid. If point gap
becomes out of adjustment, more HF energy may build up, or even jump across circuitry within the welder. It is highly recommended that a small, separate ground wire be
attached at this point while in use.

5. Gas Input Connection

1/4-5/16

This is the point where the shielding gas from the regulator connects. The unit is supplied with tubing and clamps which connect this fitting to the regulator. The hose barb
design allows universal connection of the welder to almost any regulator or setup
found throughout the world. Make sure the tubing is fully slid over the connector and
thoroughly tighten the clamp. Use an additional clamp if necessary to prevent leaking.
If you suspect leaking, test the connection with a solution of mild soapy water. If bubbles are seen, retighten.

4. Power Cord

220/240 V
1 and 3 phase.

The PowerTIG 250 EX can use either one or three phase 220/240 V power, including
good quality 208 V power. The wiring contains 4 separate wires. Everlast uses standard
wire color codes for welders. Standard welder wire colors are L-1 black (hot), L-2
white (hot), and green (ground) for 1 phase 220/240 V. Standard wire colors for 3
phase 220/240 V are L-1 black (hot), L-2 white, L-3 red (hot) and green (ground). Do
not attempt to use a 4 wire 1 phase 220/240 connection. NOTE: In many home circuits, red and black are the power wires. But in standard welding circuitry, white and
black are hot wires. Green is always the ground in both circuits. There is NO neutral
in a standard welder circuit. The suggested plug for the PowerTIG 250 EX is the NEMA
6-50, which is the standard 50 amp welder plug used on welders. See wiring diagram
for more details on wiring this plug. Always consult a licensed electrician who is aware
of local codes before attempting any wiring of the welder or of the power circuits.
Everlast is not responsible for any mis-wiring or damage caused to the unit by miswiring the welder. If additional help is needed, contact Everlast. WARNING: DO NOT
CONNECT THE WELDER TO 460/ 480 V 1 OR 3 PHASE POWER , OR SEVERE DAMAGE
WILL RESULT TO THE WELDER!

5. 3-Pole Power Switch

On/Off

The breaker switch contains 3 poles for power. It serves as the On/Off switch for the
welder. Always turn the welder on and off by the switch first before using any disconnect. In single phase, only two poles are active. The remaining pole is inactive until it is
connected to 3 phase power.

NOTES:
1. The gas input connection should be checked for tightness periodically, especially if the machine is moved.

19

Section 3

Basic theory and function

Welder Function Summary and Explanations.

Most of the green coded features on the welder panel

are devoted to the use of the 2T/4T operation and
should not be used with foot pedal. The following
features are exclusive features that can only be used
with the 2T/4T sequencer function:
1) Start/End Amps
2) Up Slope/Down Slope

1. 2T/4T sequencer. The 2T/4T feature allows operation of the welder without a foot pedal. In
many circumstances, a foot pedal is not practical
for use. So, the 2T/4T function has been created to
allow programming of the welder to simulate the
activities of the foot pedal while providing more
accurate control. The T refers to the number of
travels of the remote switch installed on the torch
required to operate the programming. 2T is essentially a press and hold operation and all programming is cycled automatically. Releasing the switch
begins the final stage of programming. 4T operates
differently in the fact that each touch activates a
different stage of the programming, allowing for
greater control. Also, in 4T,while actually welding
at full amps, no finger contact with the switch is
required. Following the graphic lines below, you
can visually trace and learn the activity and function of each part of the welding cycle. In either 2T
or 4T operation the programming can be reset to
upslope before reaching the end amp stage by
pressing the switch once more. See the graphics
below for further explanation. The up and down
arrows indicate the switch travel direction.

Pre-Flow and Post-Flow are features that work in conjunction with both the foot pedal and the 2T/4T sequencer.
2. AC Frequency. The AC frequency only applies to the
AC mode. Standard transformer welders typically
have a fixed frequency of 60 Hz which is essentially the
line input frequency supplied by the power company.
But with inverters, the capability of AC frequency adjustment is practically limitless due to the IGBT components that create its own frequency. Frequency adjustment capability is useful to help improve directional control of the arc, and to focus the arc so that a narrower bead profile can be achieved. Also, at higher
frequencies, the puddle agitation is greater which improve the breakup of undesirable oxides. See the
graphic below.

PE

SLO

SLO
UP

END AMPS
POST FLOW

= UP ON SWITCH
= DOWN ON SWITCH
4T Torch Operation Effect on Weld Cycle

PREFLOW

UP

START AMPS

SLO

PE

WELD AMPS

DO

W
N

60 Hz

3. AC Balance. The advanced form of AC square wave

output is formed by alternating polarity rapidly between electrode negative and electrode positive, creating a wave form that resembles a square sine
wave when viewed on an oscilloscope. Normally, with
standard transformer welders, both standard sine
wave and even square wave welders have little or no
way to change the balance of EN to EP, which results
in having to weld with a molten ball at the tip of the
tungsten and a less stable arc. Electrode negative (EN)
provides penetration in the TIG welding process. Electrode positive (EP) creates a strong reverse flow of
electricity that breaks up the weld-resistant oxidation
that covers aluminum and magnesium components. It
also places a lot of heat on the tungsten. In a
balanced wave where both EP and EN are equal in
time length (50%), penetration is reduced and overcleaning results in wide etch lines running parallel to

OP

UP

SL

PE

LO

S
WN

START AMPS
PREFLOW

200 Hz

N
W

DO

PE

WELD AMPS

DO

WELD AMPS

2T Torch Operation Effect on Weld Cycle

SL

OP

E
END AMPS
POST FLOW

20

Section 3

Basic theory and function

Cleaning/Frosted Area of Aluminum

the side of the weld. Not all welds conditions will

be alike so more cleaning is required at times than
others. Similarly, more penetration will be required at times than others. Ordinarily, about 3035% electrode positive is considered an ideal
amount (65-70% electrode negative). This means
that more heat is put into the work than on the
tungsten and a sharper point can be used. Cleaning is still sufficient at that level. Good results can
be achieved with about 30% EP or less. The cleaning action is still significant even at these levels.
Ideally, the cleaning action should be adjusted until
a small amount of frosting can be seen no more
than 1/8 distance from the edge of the weld. If a
piece of metal is particularly heavily oxidized or
dirty, more cleaning action will be required. If too
much cleaning action is used, the tungsten will
begin to ball and even may start to burn away. If
this much cleaning action is truly needed, then
switch to a larger sized tungsten that can handle
the increased heating level. Signs of too little
cleaning action while welding aluminum are sooty,
black, or dull looking welds. A dedicated stainless
brush and suitable aluminum cleaner such as acetone should still be used before starting any weld in
aluminum to help break up the heaviest oxide layer
so less EP is needed and better penetration can be
achieved.
EXAMPLE: AC EP (+) BALANCE

30% EP
Narrow bead/etching/sharp tungsten

50% EP
Wider bead/etching/rounded tungsten

65% EP
Wide bead/etching/balled tungsten

NOTES:
1.

2.

1 Hz (one full AC cycle)

3.

EP 50%
EN 50%

50%

4.

Standard transformer welder balance: 50% EN/EP

Balling tungsten, light penetration, wide cleaning area.

EP 65%
EN 35%

50%

Extreme cleaning setting. 65% EP:

Shallow penetration, balling tungsten, excessive cleaning area.

50%

EP 35%

EN 65%
Good penetration setting 35% EP:
Deeper penetration, sharper tungsten, narrow cleaning area.

21

Due to the rapid switching of the inverter, High

Frequency (HF) is not used except to start the
arc. In a transformer welder, the HF would
remain on to stabilize the AC arc, but in an
inverter, this is not necessary. So, the HF
switch refers only to the Start of the arc, and
not to AC operation. However to reduce tungsten contamination, you should only operate
the AC mode with the HF start selected.
The addition of Helium to Argon can increase
the welding capacity of the welder and alter
the amount of cleaning typically needed. Do
not exceed 25% however or arc starts will be
difficult and erratic.
If arc wandering in AC is a problem, reduce
cleaning percent, then if it continues, reduce
gas flow and then check for drafts.
AC controls only apply to AC operation, and do
not affect the settings on DC.

Section 3
4. Pulse. The pulse creates two amp values, a high
and a low value that cycle back and forth between
each other while welding. The upper amperage is
called the welding amps (sometimes called peak
current) and the lower amperage is called pulse
amps (sometimes called background or
basecurrent). This creates a situation where penetration can be achieved without overheating the metal, particularly on metals that are prone to structural
deterioration or burn through. In effect you are creating an average of amps. The PowerTIG series feature three adjustable parameters concerning the
pulse:
1. Pulse Amps. Both welding amps and pulse amps
are independently set. Adjust the welding amps with
the main control knob and the pulse amps with the
pulse amp knob. However, when you adjust the pulse
amps, you are actually setting a fixed ratio of amps
expressed as a percentage of Welding Amps. When
setting Welding Amps, the welder will display actual
amp value when the pulse is turned on. However,
after about 3-5 seconds, if you do not begin adjustment of the pulse amps, the meter will begin to fluctuate rapidly (depending upon frequency setting),
sampling the pulse setting at odd points along the
pulse cycle. To be able to read and set the pulse after
the default setup time expires, turn the pulse frequency to the minimum setting first, then adjust the pulse
amps. (If the time expires to make adjustments to the
pulse amps, you will get a fairly accurate reading of
the pulse amperage while it is pulsing slowly.) Alternatively, you can turn the pulse off and back on to
reset the default display time. The display is not synchronized with the pulse so it samples at a set rate
that is independent of pulse changes, which yields
randomly fluctuating numbers. As you increase amperage, the pulse will maintain the same ratio of amps
you have selected. To adjust the pulse amps to a desired setting using an example of 100 Welding Amps,
setting the pulse amps to 50% would yield a 50 amp
value for the pulse amps. The foot pedal will control
both Welding Amps and Pulse Amps according to the
%(Ratio) selected on the panel.

Basic theory and function

AMPS

EXAMPLE 1
Welding Amps: 100 amps,
PulseAmps: 50%
Pulse Time On: 50%
DC Pulse Frequency: 1 Hz

Pulse Time ON

Welding Amps

100

Pulse Amps

50

Pulse Hz
DC
1S

AMPS

2S

3S

EXAMPLE 2
Welding Amps: 100 amps
Pulse Amps: 50%
Pulse Time On : 50%
DC Pulse Frequency: 25Hz

100

50

DC
1S

AMPS

EXAMPLE 3
Welding Amps: 100 amps
Pulse Amps: 25%
Pulse Time On: 75%
DC Pulse Frequency: 3 Hz

100

25

DC
1S

centage (%) of time that the pulse stays in the pulse

amp stage of the cycle. Increasing the Pulse time on
can increase the duration the pulse amp stage of the
cycle to decrease heat. Pulse Balance is also known in
the industry as duty cycle. For welding purposes the
term Pulse Time On is used here.

2. Pulse Frequency. Pulse speed or frequency as it is

referred to is measured in the unit standard Hertz.
Simply, it is the number of pulses per second that occur. Pulse frequency controls the arc constriction and
also help with heat management.

Setting up the pulse is not a process with a fixed adjustment procedure. Changes to frequency, balance,
and time will skew the final result. A slow pulse with a
equal 50% pulse time on and somewhere around a

3. Pulse Time On (Balance). Pulse Balance is the per-

22

Section 3
50-75% Pulse Amp setting is typically used to help
with timing the addition of filler metal to the weld
puddle. A higher pulse frequency level with variations
in Pulse Time On and a narrow/wider ratio can be used
to prevent burn through and speed up welding on thin
materials. It can also help maintain a proper bead on a
thin edge weld or prevent burn through on extremely
thin metal. A fast pulse speed will make fine ripples in
the weld while a slow pulse speed will give a much
more coarse, but visually appealing result. There are
limitless ways to adjust the pulse. Keep in mind
though, that the basic purpose of the pulse is to average the heat input while maintaining penetration. Do
not attempt to use pulse while in stick mode.
5. Arc Force Control/Surge Amp Control. When stick
welding, arc force is used to help improve weldability
of certain metals and welding rods. The arc force
boosts current flow to match the demands of arc
length and position. As an arc is held shorter, voltage
tends to drop so extra amps are introduced to help
maintain a steady arc. Surge amps boost the starting
amperage briefly to heat up the welding electrode and
weld area so the arc starts cleanly, without sticking or
porosity. Both controls are inactive while welding in
TIG mode.
6. Foot Pedal. 47k . Select 2T on the panel. Select
maximum amp value desired on the panel. The foot
pedal will only control amps up to the range governed
on the front panel. If more amperage is needed raise
the amp level on the panel. The foot pedal also controls both Welding Amps, and Pulse Amps through the
ratio established by selecting the pulse Amp % on the
panel. Welding with pulse and the foot pedal takes
practice, as it will seem the welder is welding at less
amps than it is. Always set the panel amps to about
25% more than what should be needed. Increasing the
amps more than this margin on the panel will reduce
the accuracy of the foot pedal by lowering the resolution of the foot pedal. Be sure to turn the start/end
amps and up/down slope to the minimum setting or
the 2T programming will be active and interfere with
pedal operation. The pedal cannot override the 2T
amp and slope controls. For more accurate and responsive control, Everlast offers a US made foot pedal
available as an additional option. Do not attempt to
control stick function with the foot pedal.
8. Water-cooled torch. A water cooler is necessary for
use with the PowerTIG 250 EX torches. The units are

Basic theory and function

equipped with either a WP 18 water- cooled torch. Using a
water-cooled torch even briefly without water can seriously
and permanently damage your torch. Torches used without
water-coolers cannot be warrantied unless cleared by Everlast. Everlast carries water-coolers designed to cool the
maximum amp capacity of the welder. If you are not able
to provide a water cooler or have not purchased a water
cooler, you will need to use an air cooled (gas cooled) torch
such as a 17 or 26 series.
All consumables should be interchangeable with other
brand torches with similar designations. They should be
available for local purchase. No special consumables are
required. Although a small starter kit of consumables is
included, you will need more consumables fairly quickly.
No Tungsten is included with the starter kit. Actual starter
kit contents may vary. Contact Everlast should you desire
to purchase an air cooled torch that is ready for use out of
the box
9. DINSE style connector. Everlast uses a 35-70mm connector for both negative and positive connectors, which is a
standard connector within the welding industry. This is
commonly known as a 1/2 or 35 series DINSE-style connector. The connector allows the use of almost any brand
or style of TIG torch.
10. 7 pin remote/foot pedal connector. This 7 pin connector
is available from Everlast should it become damaged. See
Pinout reference found in the appendix of this manual.
11. Argon quick connect. This is a 9 mm size quick connect
nipple. These are commonly available from Everlast or
online sites which carry torches and fittings. Should you
need a new one for your torch or damage yours, consult
Everlast. Do not use a nipple that is scarred, bent or otherwise deformed. Damage to the female connector may result. Serious leaks may occur.
12. Low amp starts. The units have been configured to be
able to start and weld at approximately 5(2) amps. However, to obtain the most stable starts, a slightly higher amp
setting may be required, or a smaller tungsten may be necessary. After the arc is started, amps may be reduced to a
minimum level. This is accomplished with setting a higher
start amp value (2T/4T) or by going further down on the
foot pedal until the arc stabilizes, then backing the amps
down slowly until the arc stabilizes at the minimum selected amps.
13. Argon Regulator. The argon regulator is listed in liters
per minute, not cubic feet per hour. (subject to change)

23

Section 3

Basic theory and function

TUNGSTEN PREPARATION

1. Use a dedicated grinding

wheel or contamination may result. Do not breath grinding dust!
Wear eye protection and gloves.

2. Hold Tungsten firmly.

3. Grind perpendicular to grinding wheel face. Allow tungsten to
grind away slowly, creating point.
4. Rotate tungsten quickly as it is
being ground to keep point even
and symmetrical.

DO NOT GRIND TUNGSTEN

PARALLEL TO WHEEL FACE OR
AN UNSTABLE ARC WILL RESULT.

2.5 3 X (DIAMETER)

<50 A
>50 A

Use a point for low amp use to

help control arc. Create a slight
truncation on the tip for higher
amp use for best arc stability.
Grind the tip so that it is2.5- 3
times longer than the tungsten is
wide (Diameter).
DO NOT BALL TUNGSTEN WHILE
USING AC. ERRATIC ARC WILL RESULT. MAKE SURE GRINDING
MARKS RUN PARRALEL TO TIP.
CONCENTRIC MARKS WILL CAUSE
ERRATIC ARC.

NEVER USE PURE (GREEN) TUNGSTEN IN AN INVERTER WELDER TO WELD ALUMINUM.

SEE FOLLOWING RECOMMENDATIONS ABOUT TUNGSTEN SELECTION FOUND IN THIS MANUAL ON NEXT PAGE.

24

Section 3

Basic theory and function

LIFT START TIG OPERATION

Note: A Lift TIG start should be done with a nearly seamless motion. Use a light touch and a quick motion for best results.

FOR DC USE. NOT RECOMMENED FOR AC.

1
3

4
<1/8

1. Position the edge of the ceramic cup on the metal. Press and hold the torch switch or press the foot pedal.
Wait for the Pre-flow to start. (Make sure pre-flow is set for less than .5 seconds or start will be delayed.)
2. Quickly rotate cup so that the tungsten comes in brief contact (< .5 seconds) with the metal.
3. After contact with the metal, quickly rock the torch back so that the tungsten breaks contact with the metal.
4. An arc should form. As the arc grows, raise the cup up off the metal and slowly rotate the torch into welding position.
5. Leave 1/8 or less gap between the tungsten tip and the metal. Proceed with welding, leaving the torch inclined at a 15 angle.

HIGH FREQUENCY START TIG OPERATION

FOR AC OR DC USE.

1
<1/8

<1/8

1. Position the point of the sharpened tungsten about 1/8 or less above the metal.
2. Press the torch trigger or press the foot pedal to initiate the arc. The HF arc will be initiated. It may appear briefly as a blue spark.
3. An arc should form, almost immediately after the pre-flow cycle is completed. HF arc initiation will be delayed by the amount of pre-flow
time used. If arc does not start after the pre-flow interval, and the HF is creating a spark, then check the work clamp contact with the work
piece. Move the tungsten closer to the work. Repeat steps 1 and 2.
4. Leave 1/8 or less gap between the tungsten tip and the metal and proceed with welding, leaving the torch inclined at a 15 angle.

General Operation of TIG

Turn unit on, allow time for power up cycle to complete its start up process.
Select either HF or Lift Start TIG with the HF/Lift Start/Stick selector switch. Select DC mode with the AC/DC torch switch.
Plug in Torch and select 4T or 2T mode with the selector switch and select OR plug in foot pedal and select 2T.
If using the torch switch select start/end amps amperage by rotating the knob to increase or decrease amps for starting and ending the weld.
If using the torch switch, select up/ down slope time by rotating the knob to increase/decrease the ramp up or ramp down time of the amperage.
Adjust amps with amp control knob.
Start arc as depicted above.
If using 2T, continue to hold the torch switch until you are ready to stop welding. Release the switch. The Arc will then cease.
If using pedal raise foot fully off the pedal and arc will stop automatically.
9. If using 4T, release the switch, after arc initiates. Continue to weld without holding the switch down. To stop, press and release the switch again.
1.
2.
3.
4.
5.
6.
7.
8.

25

Section 3

Basic theory and function

STICK OPERATION

STARTING METHODS

Scratch/Match Method

Tapping Method

1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program.
2.

Select the Stick mode with the HF/Lift Start/Stick selector switch.

3. Make sure electrode holder is hooked into the positive connector and the work clamp is hooked the negative connector.
4. Select the amps desired. Use the electrode diameter selection chart in this manual to determine the approximate range of amps suitable for the rod size selected. Consult the welding electrode manufacturers recommendation for proper amperage range. Each manufacturer has specific recommendations for its electrodes.
5. Use the arc force control to select the desired arc characteristics, creating the desired arc characteristic and
automatic amp response needed to maintain the arc when voltage falls below the threshold. 6011 Cellulose
electrodes will require more arc force control than other rods, but each brand and size will weld a little differently. The arc force control setting will vary from person to person as well, with different rod angles, positions, and arc lengths all factoring into the arc force control performance.
6. (Available late 2013) Adjust surge current to create a hotter start than the actual weld current to prevent
rod sticking and improve starting reliability.
6. Strike the arc with either the tapping method or the match strike method. Beginners usually find that the
match strike method yields best results. Professionals tend to gravitate toward the tapping method because
of its placement accuracy which helps prevent arc striking outside of the weld zone.

IMPORTANT: Do not weld in the TIG mode with the stick electrode holder still attached.
26

Section 3

Basic theory and function

GENERAL POLARITY RECOMMENDATIONS*
*Follow manufacturer of stick electrode for complete polarity recommendations

PROCESS

TORCH POLARITY

WORK POLARITY

TIG (GTAW)

STICK (SMAW)

TIG (GTAW) OPERATION GUIDE FOR STEEL (ALUMINUM)*

*As a general rule, set amperage using 1 amp for every .001 of metal thickness for aluminum. Less is required for DC.

METAL THICKNESS

WELDING AMPS
(A)

1-3 mm/.040-1/8

40-80 (60-125)

TUNGSTEN DIA.

Ar FLOW RATE

1-2 mm/.040-3/32 8-15 CFH /4-7 lpm

3-6 mm/ 1/8-1/4

80-200 (125-200) 2-3 mm/ 3/32-1/8 15-25 CFH/ 7-14 lpm

6-10 mm 1/4-3/8

150-200 (200-250) 3-6 mm/ 1/8-1/4

20+ CFH/10-15 lpm.

STICK (SMAW) OPERATION GUIDE

METAL THICKNESS

ELECTRODE SIZE

WELDING AMPS

< 1 mm/.040

1.5 mm/ 1/16

20-40

2 mm/.080

2 mm/3/32

40-50

3 mm/ 1/8

3.2 mm/1/8

90-110

4-5 mm/ 3/16

3.2-4 mm/ 1/8

90-130

6-10 mm/ 1/4-3/8

45 mm/ 1/8-5/32

130-200

TUNGSTEN SELECTION GUIDE FOR AN INVERTER

TYPE

PERCENT

COLOR

PROCESS

RECOMMENDATION

Pure

100% Tungsten

Green

AC

NOT RECOMMENDED!
Do not use in an inverter.

Thoriated
(slightly radioactive)

2% Thorium

Red

AC/DC

YES. Great for all purpose welding.

Most economical.

Ceriated

2% Ceria

Orange

AC/DC

YES. Good for low amp use.

Lanthanated

1.5% Lanthanum Gold

AC/DC

YES. Best alternative to 2% Thoriated.

Tough performer.

Lanthanated

2% Lanthanum

Blue

AC/DC

YES. Slight advantage over 1.5%

Lanthanated.

Zirconiated

1% Zirconia

Brown

AC

NOT RECOMMENDED!
Do not use in an inverter.

NOTE: Thoriated tungsten is slightly radioactive, but is commonly used in the US. Care should be used when grinding so
not to breath the dust. If you have concern using thoriated (red) tungsten, choose from Lanthanated or Ceriated tungsten.

27

Section 3

Basic theory and function

EXPANDED VIEW OF TIG TORCH

(Actual appearance may vary slightly from what is listed.)

1
1

3
4
5
6
7
12

8
13

5/8

9
14

NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

PARTS FOR 17 Series Torch ( STYLE MAY VARY)

Long Back Cap with O-Ring
Short Back Cap
Torch Head
Insulator
Collet 1/16 or 3/32
Collet Holder
Ceramic Cup #5,6, or 7
Tungsten (customer supplied)
Torch Cable
Torch Handle (Blue ergo handle std, not pictured)
Torch Switch (Built into ergo handle, separate on straight handle)
Torch Switch Connector
9mm (1/8) b quick connect coupling (male)
Power Connector
Protective Synthetic Rubber Cover

28

QTY.
1
Opt.
1
1
1
1
1
0
1
1
1
1
1
1
1

15

Section 3

Basic theory and function

7 PIN CONNECTOR FOR 47K FOOT PEDAL

Bridge to 7

To Pedal or Torch Switch

Bridge to 6
To Pedal or Torch Switch

29

Section 4

Trouble Shooting

TROUBLE:

CAUSE/SOLUTION

Machine will not turn on.

Check cords and wiring in the plug. Check circuit breaker.

Machine runs, but will not weld in either mode.

Check for sound work clamp and cable connections.

Make sure work cable and TIG Torch are securely fastened to the Dinse style connector. Reset main power
switch if overcurrent light is on. Contact Technical Support.

Arc will not start unless lift started.

Check HF point gap. Set to .035 See addendum or

contact Technical Support. Make sure unit is set to HF

Tungsten is rapidly consumed.

Inadequate gas flow. Too small of tungsten. Wrong

shielding gas. Use only Ar. Using green tungsten. Use
red thoriated or other color. Wrong polarity. Too much
AC cleaning.

Tungsten is contaminated, arc changes to a green color.

Tungsten is dipping into weld. Check and adjust stick

out to minimum 1/8 inch. Tungsten is melting. Reduce
amperage or increase tungsten size.

Porosity of the Weld. Discolored weld color. Tungsten is

discolored.

Low flow rate of shielding gas. High flow rate of shielding gas. Too short of post flow period. Wrong TIG cup
size.
Possible gas leaks internally or externally due to loose
fittings. Base metal is contaminated with dirt or grease.

Weld quality is poor. Weld is dirty/oxidized.

Eliminate drafts. Check if there is sufficient shielding

gas left in tank. Check gas flow. Adjust for higher flow
of gas. Listen for audible click of gas solenoid. If no click
is heard, then contact Everlast Support. Clean weld
properly, especially in Aluminum. Too short of post
flow. Check tungsten stick out.

Over current/Duty cycle LED illuminates. Machine runs,

but no output.

Duty cycle exceeded or Over current. Allow machine to

cool. Reset main power switch after full cool down period. Make sure fan is not blocked. Check wiring.

Unstable Arc.

Poorly ground or shaped tungsten. Regrind to proper

point. Too much AC positive polarity. Reduce balance
to 30% or less. Increase AC Frequency.

Other issues.

Contact Everlast support.

30

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