EVERLAST

POWERTIG 250EX
A Digitally controlled pulse tig/stick inverter welder

CC
GTAW-P

SMAW

IGBT

1-3
~
PHASE

AC/DC

Operator’s Manual for the PowerTig 250EX

Safety, Setup and General Use Guide
Rev. 6 0 01001-15

everlastwelders.com
Specifications and Accessories subject to change without notice.
1-877-755-9353
329 Littlefield Ave. South San Francisco, CA 94080 USA
 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……………………... 19
Welder Function Summary and Explanations……. 21
Tungsten Preparation………………………………………... 25
Lift Start and High Frequency Start…………………… 26
Stick Starting Methods……………………………………… 27
Recommendations for Polarity/Amps/Tungsten.. 28
Expanded View of TIG torch……….…….……….……… 29
7 Pin Connector Pin-out…………..…….…….…………… 30
Troubleshooting……………………………………………….. 31
Optional Accessories…………………………………………..32

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 manu-
al 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 INC. does not accept liability for injury or damages, con-
sequential or incidental, resulting from the use of this product or resulting from the content found in this docu-
ment or accept claims by a third party of such liability.

2
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 is-
sued. 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 war-
ranty service and returned.

Please review and download the official 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 of its terms and conditions.

Everlast offers full technical support in several different forms. We offer domestic based phone sup-
port 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 interac-
tion. Technical advisors are active on the forum on a regular basis. 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 head-
quarters available 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 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 manu-
facturing 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 a series of questions by the advisors
meant to clarify problems or issues. Some of these questions may seem basic or fundamen-
tal, but even with experienced users technical advisors can’t assume that correct operating
procedures are being followed for proper operation, 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.

Please note: To establish a warranty claim and return a unit for repair or replacement, you
must call technical support first and go through basic diagnosis before an Return Authoriza-
tion will be issued.

Let us know how we may be of service to you should you have any questions.

Sincerely,

Everlast Customer Service

3
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) 9am—5pm 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 Australia:
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]

4
 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 deliv-
ering a satisfactory product to you. That is the reason we offer technical sup-
port to assist you with your needs should an occasion occur. With proper use
and care your product should deliver years of trouble free service.

Safe operation and proper maintenance is your responsibility.

We have compiled this operator’s manual, to instruct you in basic safety, oper-
ation and maintenance of your Everlast product to give you the best possible
experience. Much of welding and cutting is based upon experience and com-
mon sense. As thorough as this welding manual may be, it is no substitute for
either. Exercise extreme caution and care in all activities related to welding or
cutting. Your safety, health and even life depends upon it. While accidents are
never planned, preventing an accident requires careful planning.
Please carefully read this manual before you operate your Everlast unit. This
manual is not only for the use of the machine, but to assist in obtaining the
best performance out of your unit. Do not operate the unit until you have read
this manual and you are thoroughly familiar with the safe operation of the unit.
If you feel you need more information please contact Everlast Support.

The warranty does not cover improper use, maintenance or consumables. Do

not attempt to alter or defeat any piece or part of your unit, particularly any
safety device. Keep all shields and covers in place during unit operation should
an unlikely failure of internal components result in the possible presence of
sparks and explosions. If a failure occurs, discontinue further use until mal-
functioning parts or accessories have been repaired or replaced by qualified
personnel.

Note on High Frequency electromagnetic disturbances:

Certain welding and cutting processes generate High Frequency (HF) waves.
These waves may disturb sensitive electronic equipment such as televisions,
radios, computers, cell phones, and related equipment. High Frequency may
also interfere with fluorescent lights. Consult with a licensed electrician if dis-
turbance is noted. Sometimes, improper wire routing or poor shielding may be
the cause.

HF can interfere with pacemakers. See EMF warnings in following safety sec-
tion for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.
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 ob-
serve the following to minimize potential accidents and injury:

Use appropriate safety glasses with wrap around shields while in the work area, even
under welding helmets to protect your eyes from flying sparks and debris. When chip-
ping slag or grinding, goggles and face shields may be required.

When welding or cutting, always use an approved shielding device, with the correct
shade of filter installed. Always use a welding helmet in good condition. Discard any
broken or cracked filters or helmets. Using broken or cracked filters or helmets can
cause severe eye injury and burn. Filter shades of no less than shade 5 for cutting
and no less than shade 9 for welding are highly recommended. Shades greater than 9
may be required for high amperage welds. Keep filter lenses clean and clear for maxi-
mum visibility. It is also advisable to consult with your eye doctor should you wear
contacts for corrective vision before you wear them while welding.

Do not allow personnel to watch or observe the welding or cutting operation unless
fully protected by a filter screen, protective curtains or equivalent protective equip-
ment. If no protection is available, exclude them from the work area. Even brief expo-
sure to the rays from the welding arc can damage unprotected eyes.

Always wear hearing protection because welding and cutting can be extremely noisy.
Ear protection is necessary to prevent hearing loss. Even prolonged low levels of
noise has been known to create long term hearing damage. Hearing protection also
further protects against hot sparks and debris from entering the ear canal and doing
harm.

Always wear personal protective clothing. Flame proof clothing is required at all
times. Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose
clothing is tucked in neatly. Leather aprons and jackets are recommended. Suitable
welding jackets and coats may be purchased made from fire proof material from
welding supply stores. Discard any burned or frayed clothing. Keep clothing away
from oil, grease and flammable liquids.

Leather boots or steel toed leather boots with rubber bottoms are required for ade-
quate foot protection. Canvas, polyester and other man made materials often found
in shoes will either burn or melt. Rubber or other non conductive soles are necessary
to help protect from electrical shock.

Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient.
Gauntlet type welding gloves are available from your local welding supply companies.
Never attempt to weld with out gloves. Welding with out gloves can result in serious
burns and electrical shock. If your hand or body parts comes into contact with the
arc of a plasma cutter or welder, instant and serious burns will occur. Proper hand
protection is required at all times when working with welding or cutting machines!

6
 SAFETY PRECAUTIONS

WARNING! Persons with pacemakers should not weld, cut or be in the welding area
until they consult with their physician. Some pacemakers are sensitive to EMF radiation
and could severely malfunction while welding or while being in the vicinity of someone
welding. Serious injury or death may occur!

Welding and plasma cutting processes generate electro-magnetic fields and radiation.
While the effects of EMF radiation are not known, it is suspected that there may be
some harm from long term exposure to electromagnetic fields. Therefore, certain pre-
cautions should be taken to minimize exposure:
 Lay welding leads and lines neatly away from the body.
 Never coil cables around the body.
 Secure cables with tape if necessary to keep from the body.
 Keep all cables and leads on the same side the body.
 Never stand between cables or leads.
 Keep as far away from the power source (welder) as possible while welding.
 Never stand between the ground clamp and the torch.
 Keep the ground clamp grounded as close to the weld or cut as possible.

Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible
need for respiratory equipment while welding or cutting. Always weld with adequate
ventilation. Never weld in closed rooms or confined spaces. Fumes and gases re-
leased while welding or cutting may be poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
 Stop immediately and relocate work if necessary until adequate ventilation is ob-
tained.
 Stop work completely and seek medical help if irritation and discomfort persists.

WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, cop-
per, cadmium, lead or zinc without proper respiratory equipment and or ventilation.

WARNING! This product when used for welding or cutting produces fumes and gas-
es which contains chemicals known to the State of California to cause birth defects
and in some cases cancer. (California Safety and Health Code §25249.5 et seq.)

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

Release of Phosgene gas can be deadly. Consider all chemicals to have potential
deadly results if welded on or near metal containing residual amounts of chemicals.

Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain
regulations regarding high pressure cylinders can be obtained from OSHA or local
regulatory agency. Consult also with your welding supply company in your area for
further recommendations. The regulatory changes are frequent so keep informed.

All cylinders have a potential explosion hazard. When not in use, keep capped and
closed. Store chained so that overturn is not likely. Transporting cylinders incorrectly
can lead to an explosion. Do not attempt to adapt regulators to fit cylinders. Do not
use faulty regulators. Do not allow cylinders to come into contact with work piece or
work. Do not weld or strike arcs on cylinders. Keep cylinders away from direct heat,
flame and sparks.
7
 SAFETY PRECAUTIONS
continued
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly
grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not
stand, lean or rest on ground clamp. Do not stand in water or damp areas while weld-
ing or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain
or in extremely humid conditions. Use dry rubber soled shoes and dry gloves when
welding or cutting to insulate against electrical shock. Turn machine on or off only
with gloved hand. Keep all parts of the body insulated from work, and work tables.
Keep away from direct contact with skin against work. If tight or close quarters ne-
cessitates standing or resting on work piece, insulate with dry boards and rubber
mats designed to insulate the body from direct contact.

All work cables, leads, and hoses pose trip hazards. Be aware of their location and
make sure all personnel in area are advised of their location. Taping or securing ca-
bles with appropriate restraints can help reduce trips and falls.

WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodi-
cally check work area for smoldering embers or smoke. It is a good idea to have
someone help watch for possible fires while you are welding. Sparks and hot metal
may travel a long distance. They may go into cracks in walls and floors and start a fire
that would not be immediately visible. Here are some things you can do to reduce the
possibility of fire or explosion:
 Keep all combustible materials including rags and spare clothing away from area.
 Keep all flammable fuels and liquids stored separately from work area.
 Visually inspect work area when job is completed for the slightest traces of smoke
or embers.
 If welding or cutting outside, make sure you are in a cleared off area, free from
dry tender and debris that might start a forest or grass fire.
 Do not weld on tanks, drums or barrels that are closed, pressurized or anything
that held flammable liquid or material.

Metal is hot after welding or cutting! Always use gloves and or tongs when handling
hot pieces of metal. Remember to place hot metal on fire-proof surfaces after han-
dling. Serious burns and injury can result if material is improperly handled.

WARNING! Faulty or poorly maintained equipment can cause injury or death. Prop-
er maintenance is your responsibility. Make sure all equipment is properly maintained
and serviced by qualified personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding
parts. Touching uncovered parts inside machine can cause discharge of high
amounts of electricity. Do not allow employees to operate poorly serviced equipment.
Always check condition of equipment thoroughly before start up. Disconnect unit
from power source before any service attempt is made and for long term storage or
electrical storms.

Further information can be obtained from The American Welding Society (AWS) that
relates directly to safe welding and plasma cutting. Additionally, your local welding
supply company may have additional pamphlets available concerning their products.
Do not operate machinery until your are comfortable with proper operation and are
able to assume inherent risks of cutting or welding.

8
Section 1 Introduction and Specifications

PowerTIG 250EX

Argon Regulator

Consumable Kit
(Does not include Tungsten)

22K Ω
Foot Pedal Assembly

Water-Cooled Work Clamp Stick Electrode Holder

18 Series Torch Assembly

NOTE: Appearance and quantity of accessories are 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 DIGITAL IGBT Construction
Minimum/Maximum Rated Output TIG AC/DC: 5A/10.2V - 250 A/20V (± 3A)
Minimum/Maximum Rated Output Stick 5A/20.2V - 200A/28V (±3A)

Start Type Solid State HF and Lift Start

HF Point Gap Solid state/ non adjustable
TIG Duty Cycle @ Rated Amps/Volts 60% @ 250A/20 .0V
100% @ 200A/18 .0V
Stick Duty Cycle @ Rated Amps/Volts 35% @ 200A/28.0V
60% @ 160A/26.4V
100% @ 130A/25.2V
OCV (U0) 80V
Voltage Input (U1) Standard 220/240V; 50/60Hz 1 and 3 Phase
Maximum Inrush Amps (I1MAX) 40A @ 220V 1 Phase/21A @ 220V 3 Phase
Maximum Operating Amps (Rated Effective) (I1EFF) 32 A @ 220V 1 Phase/16A @ 220V 2 Phase
Gas Pre-Flow /Post Flow Time 0-10 Seconds/ 0-25 Seconds
Start Amps/End Amps 5-250A/5-250A (±3A)
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%
Minimum Water Ingress Protection Standard IP21S
Efficiency >85%
Cooling Method One Single Speed Full-Time High Velocity Fan
Dimensions (approximate) 18” H X 10” W X 25” L
Weight (Bare Unit) 65 lbs

10
 Section 1 Introduction and Specifications
General overview: The latest generation of the Power- the welder. Allow a buffer distance of 2 ft from all sides,
TIG 250EX has performance and reliability has been with a minimum distance of 18” clearance. Do not oper-
boosted by a complete redesign that incorporates a digi- ate the welder in the immediate vicinity of the weld area
tally controlled inverter with an analog style controls for or the discharge of air from the fan will cause turbulence
an easy to operate control panel. The main features of and will destabilize the arc and cause weld porosity. Do
this welder include: not mount in areas that are prone to severe shock or vi-
bration. Do not drop the unit. Lift and carry the welder by
A. Digital control and componentized design reduces the handle. Strap the welder down for maximum stability
complex wiring and circuitry of componentsm, re- during use. Do not direct metallic dust or any dirt toward
ducing the overall number and sizeof discreet com- the machine, particularly in grinding and welding opera-
ponents. This is aimed at improving lifespan and tions. Flip down the clear front cover after completing
long term serviceabilty of the PowerTIG 250EX adjustments and while in operation to protect the control
platform. panel.
B. Digital control offers more precise setting and con-
trol over parameters, offering a more satisfactory Duty Cycle. For the 250EX, the duty cycle is rated for 60%
operating experience. at 250 amps.(220/240 V 1 and 3 phase ). The duty cycle is
C. Full-wave bridge rectifier inverter design also also based off a 10 minute duty cycle rating at 40°C. This
features soft switching technology which further means that the unit is capable of being operated at the
extends IGBT component life. stated amps for 6 out of every 10 minutes without a break
D. HF point gap adjustment issues have been eliminat- to cool down the unit. This does NOT mean that the unit
ed with the introduction of new solid state HF board. can work 60% of any greater length of time. A full 4 mi-
E. Digital components offer reduced weight and im- nute rest should be given to the welder for maximum life.
proved operating efficiency over past analog con- The temperature light will come on and the welder will
trolled generations. automatically stop welding when an overheat condition
F. The digitally controlled square wave design creates a has occurred. The fan and display will continue to be on.
stable arc in AC, with a fast melting puddle and Do not turn the unit off, or attempt to reset the unit for at
good wet-in. least 15 minutes after an overheat condition has occurred
G. Adjustable arc force control and adaptive hot start as heat will continue to be generated by and transferred
helps improve the SMAW process performance. to the electronics after welding has ceased. Welding in
humid or hot conditions greater than 40°C can negatively
General Use and Care: With proper care, the PowerTIG affect duty cycle. Once the overheated condition has
250EX’s digitally controlled inverter components are de- cleared, welding can resume. Do not operate the welder
signed to withstand years of use in many different weld- with the covers removed.
ing environments. However, remember to keep the unit
out of direct contact with water spray and corrosive are- HF Start. The welder uses High Frequency to start the
as. The unit has an ingress rating of IP21S, for light drip- arc. The new design of the 250EX features a new, solid
ping water (condensation). It is a good idea to remove state design that eliminates point gap adjustment issues
the welder from the vicinity of any water or moisture and the related maintenance needs. A bright blue light as
source to reduce the possibility of electrocution or shock. may still be seen emanating from the front panel during
Never operate in standing water or where water spray is starts though as some of the HF components are trans-
an issue. Every 1-2 months, depending upon use, the luscent and is not a cause for concern.
welder should be unplugged, opened up and carefully
cleaned with compressed air. Regular maintenance will This manual has been compiled to give an overview of
extend the life of the unit. Metallic dust build up may operation and is designed to offer information centered
lead to premature board and component failure. around safe, practical use of the welder. Welding has
inherent dangers. Ultimately, only the operator of this
CAUTION: Before opening the unit for any reason, welder can ensure that safe operating practices are fol-
make sure the unit has been unplugged for at least 10 lowed, through the exercise of common sense practices
minutes to allow time for the capacitors to fully dis- and training. Do not operate this machine until you have
charge. Severe shock and/or death can occur. thoroughly read the manual, including the safety section.
If you do not have the skill or knowledge to safely operate
Free, unobstructed air flow is critical to cooling and duty this welder, do not use this welder until formal training is
cycle. Do not restrict air flow or movement of air around received.
11
 Section 2 QUICK SETUP AND USE GUIDE

QUICK SETUP GUIDE: TIG CONNECTIONS

AIR-COOLED TORCH
WORK (+)
TORCH (-)

GAS CONTROL

35 SERIES CONNECTOR 35 SERIES CONNECTOR

9/17 SERIES TORCH

GAS (Ar)

CONTROL
GAS (Ar)
CONTROL

TWO LINE SETUP FOR GAS (Ar)

FOOT PEDAL

WATER-COOLED TORCH
HOT WATER RETURN

18/20 SERIES TORCH

INPUT
COOLANT IN (RED) NOTE: THE ARGON GAS LINE MAY BE TAGGED AS “Ar”. IF NOT,
TAKE DRY COMPRESSED AIR AND GENTLY BLOW THROUGH THE
! COOLANT OUT (BLUE)
LINES TO DISCOVER WHICH LINE EXHAUSTS THROUGH THE TORCH
OR THROUGH THE RETURN LINE. NOTE THE DIAGRAM ABOVE
OUTPUT
AND THE RETURN LINE ON SOME AFTER MARKET 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. HOWEVER, DO NOT RELY
UPON COLOR MARKINGS ON TORCHES TO DETERMINE THE FLOW
AS THEY MAY VARY FROM BRAND TO BRAND. WARNING: IF THE
TORCH IS NOT CORRECTLY CONNECTED, WATER WILL DISCHARGE
OUT OF THE TORCH HEAD WHEN THE UNIT IS CONNECTED TO THE
COOLER. THE LINE FROM THE DINSE-STYLE CONNECTOR IN A
WATER COOLER WATER-COOLED TORCH IS ALWAYS THE WATER RETURN LINE.

NEVER OPERATE A WATER COOLED TORCH WITHOUT WATER OR THE TORCH MAY BE DAMAGED!
12
Section 2 QUICK SETUP AND USE GUIDE
QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS

GAS CONTROL

WORK (-) TORCH (+)

NOTE: Most stick (SMAW) electrodes require electrode positive (also referred to
as DCEP + or reverse polarity) to weld correctly. Some welding electrodes (rods)may
be rated for use with both electrode positive and electrode negative (DCEN(-) or
straight polarity) by the electrode manufacturer. However, most electrodes are gener-
ally welded with an electrode positive connection regardless of the electrode negative
polarity capability. When the electrode (welding rod) is rated for DCEN(-) use and is
used that way, the arc may not penetrate as fully or may seem softer.
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, INCLUDING 3 PHASE.

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

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

220 V WATER COOLER RECEPTACLE

L2,WHITE; HOT (240V 1or 3 phase) L1,BLACK; HOT(240V 1 or 3 phase)

GAS 1~220 V NEMA 6-50P

INLET OR
3~220v

5/8” CGA FITTTING (US/CANADA)

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

CLAMP

NOTE: CUBIC FEET PER HOUR (CFH) FULLY TAPE RED WIRE SO THAT IS IS OUT OF THE WAY AND COVERED FOR
SINGLE PHASE USE! RED WIRE IS FOR 3 PHASE 220/240V USE ONLY!

NEMA 6-50 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 in the Ar/He gas mix.

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 INCLUDING THE TABLE, PIPES, WALLS ETC. TO PREVENT ELECTRICAL INTERFERENCE WITH OTHER CIRCUITS. DO NOT

14
 Section 2 QUICK SETUP AND USE GUIDE

FRONT PANEL FEATURES AND CONTROLS

1. PROTECTIVE COVER

22. AMP DISPLAY

2. ON/TEMP/O.C
21. AMP CONTROL
3. 2T/PEDAL/ OR 4T SWITCH
20. SPOT WELD TIM-
4. START/END AMPS 19. HF/LIFT /STICK
18. ARC FORCE (DIG)
5. UP/DOWN SLOPE TIME
17. AC FREQUENCY (HZ)

6. PRE/POST FLOW TIME 16. AC BALANCE (% OF EP)

7. PULSE OFF/LOW/HIGH 15. AC/DC SELECTOR

8. PULSE FREQUENCY (Hz)

9. PULSE AMPS (RATIO)

10. PULSE TIME ON (BALANCE)

GAS OUTLET CONTROL

11. NEGATIVE (35 SERIES) 14. POSITIVE (35 SERIES)

12. GAS QUICK CONNECT (9mm)

13. TORCH/PEDAL CONTROL

15
Section 2 QUICK SETUP AND USE GUIDE
FRONT PANEL FEATURES AND CONTROLS CONTINUED
POWERTIG 250EX FEATURES PARAMETERS PURPOSE
1. Protective Cover N/A Clear hinged cover protects control panel from damage. Keep the cover closed during
welding operations and any time during storage.

2. On/Temperature/ Over Current Warning On Indicator: Confirms unit is switched on. Temperature Indicator: Lights up and
Indicator interrupts welding output until the welder has cooled within normal limits. Allow 15
Or Fault minutes before attempting to reset the welder manually by cycling the power switch.
If the light does not go out after cycling the power switch, and the cooling period has
been observed, contact Everlast. Over Current Indicator: Lights up when an over/
under voltage or current has been detected. Eliminate the source of the surge and
manually cycle the power switch to reset the welder. If the light remains on after
cycling the power switch, this may indicate an internal unit fault was created during
the over current event. In this case, contact Everlast. Do not continue to reset the
unit after two reset attempts.

3. 2T/4T /Remote Sequencer 2T, Pedal/4T Press the button to select the torch switch function mode. Select 2T for simple press-
Switch and-hold operation of the torch switch or for use with foot pedal. For 2T operation
with the torch switch: 1) Press and hold the switch to start the arc and weld. Release
the switch to cease welding. Select 4T for advanced use of the sequencer controls on
the panel such as start/end amps, up/down slope. To operate in 4T mode with the
torch switch/remote: 1) Press and release the switch to start arc. 2) The current will
begin to upslope to reach normal welding current. 3) Press and hold switch to begin
downslope. 4) Release switch to terminate the arc. In 4T mode, if the puddle be-
comes too hot, it can be cooled by lightly tapping the switch to begin downslope and
tapping again to restart upslope before end current is reached. Setting a long
downslope helps improve heat control in 4T as the torch switch is cycled between
downslope and upslope before the arc is terminated.
IMPORTANT: To use the foot pedal: Select 2T, then turn start/end amps and up/
down slope to the minimum settings or the foot pedal will not operate correctly. Do
not use the foot pedal in 4T mode as it will result in the inability to ramp amps up or
down.

4. Start/End Amps Control 5-250 Amps Serves as the 2T/4T beginning and final amp value while using the torch switch.
(Part of 2T/4T sequencer) 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. May be used as a “hot start” when using the foot pedal to improve starting.
If used this way, the amps will start hotter than the minimum amperage set by the
foot pedal. This can cause the arc to flare briefly at start. Otherwise, all sequencer
settings should be turned to the minimum setting (fully left) while the foot pedal is in
use or there may be a arc flare or delay in arc start or termination. The foot pedal will
not override these features.

5. Up/Down Slope Control 0-10/ 0-25 Up-Slope ramps amps from the selected start amp value up to the welding amp value
(Part of 2T/4T sequencer) Seconds according to the time selected while in 2T/4T mode.
Down-Slope ramps amps from the welding amp value down to the end amps value to
fill the weld crater according to the time selected while in 2T/4T mode. Set both
controls to the minimum setting while using the foot pedal or irregular operation will
occur.

6. Pre/Post Flow Control 0-10/ 0-25 Pre-Flow selects the amount of shielding gas flow time before arc starts. It is used to
Seconds purge and flood the weld area with shielding gas so the arc start is stable and weld is
porosity free. The pre-flow will delay the arc start. Set pre-flow for .5 to 1 second for
best starting. The arc will not start until the pre-flow time cycle has finished.
The Post-Flow setting dictates the amount of shielding gas flow after arc ends to
shield the weld to prevent oxidation and cool the torch. A starting point is to use 1
second post-flow for every 10 amps used. The torch should dwell over the puddle
during this time.

7. Pulse Off/Low/High Switch Off/ Low/ High Press the touch-pad button to select the desired pulse mode. Low range offers a finer
range of control over the pulse amps, ranging from .5 Hz to 25 Hz. High range oper-
ates with a more coarse range of control from 25 Hz to 500 Hz. Note: The low range
is highlighted in green numbers.

16
Section 2 QUICK SETUP AND USE GUIDE
FRONT PANEL FEATURES AND CONTROLS CONTINUED
POWERTIG 250EX FEATURES PARAMETERS PURPOSE
8. Pulse Frequency Control .5-500 Hz Represented as Hertz (Hz), the Pulse Frequency adjusts the actual number of times per
second the pulse makes one complete cycle between the welding amp value (Peak)
and the pulse amp value (Background or base amps). This is also commonly referred
to as Pulses Per Second (PPS). Low pulse frequencies can be used to time the addition
of the filler metal and improve weld appearance. High pulse frequencies are useful for
preventing excessive puddle wicking on edges and thin seams. Also, it is useful for
overall heat control while welding thicker gauges of metal, which can be used to help
control warping. Higher pulse frequencies are often used in automated TIG welding
processes. Caution: Welding at high pulse frequencies increases the decibel level of
the arc. Wear hearing protection while welding at high pulse frequencies.

9. Pulse Amps (Ratio) Control 5-95% Sets the value of the Pulse Amps (also referred to as the base or background current)
during the pulse cycle. This is expressed as a percent of Welding Amps. For example, a
welding amp value of 125 amps with a pulse amps setting of 50% will result in a pulse
amp value of 50 amps. The Pulse Amp setting chosen represents the lowest amp value
achieved during the pulse cycle. When the pulse mode is selected, the position of the
main amp knob determines the Welding Amp (Peak) value.

10. Pulse Time On (Balance) 10-90% Sets the duty cycle (balance) of the pulse. This is accomplished by dividing or skewing
Control the amount of time the pulse spends at the maximum amp value of the pulse against
the Pulse Amp (background current) stage which is the lowest part of the pulse. The
pulse consists of two stages: Welding Amps (Peak) and Pulse amps (Base/Background
current). This is represented by a % of total time during one full pulse cycle that the
pulse spends in the upper (peak) stage. Practically speaking, the Pulse Time on control
can be used to increase or decrease welding amp (Peak) time relative to the pulse amp
time of the cycle to help manage heat input.

11. Negative Connector 35-70 mm² Location of the negative terminal connection. DINSE-style connector. (35 Series)
For Stick: Work Clamp connection. For TIG: Torch Connection.

12. Quick Connect Gas Outlet 9 mm Connects the gas supply 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 collar back.

13. 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.

14. Positive Connector 35-70 mm² Location of the negative terminal connection. Dinse-style. (35 series)
For Stick: Electrode Holder Connection. For TIG: Work clamp Connection

15. AC/DC Selector AC/DC process Select DC output for Steel, Stainless and most metals.
Select AC output for Aluminum and Magnesium alloys.

16. AC Balance Control 10-90% of EP Selects the percentage of Electrode Positive (EP) used during the AC welding mode to
provide to provide the needed cleaning. Represented as a percent of EP, it actually
divides the relative amount of time that the AC cycle spends in Electrode Positive and
Electrode Negative polarity during one full AC cycle. In short, it controls the balance
between cleaning and penetration to achieve the best balance or desired effect while
welding in the AC mode. When the control knob is rotated left, more Electrode Nega-
tive is present and more penetration will be achieved. When the control knob is rotat-
ed clockwise, more Electrode Positive is present and more cleaning (cathodic etching)
action will be achieved. Too much cleaning action will result in the balling of the tung-
sten tip, nodules or splitting, requiring the use of a larger tungsten necessary for the
same amperage range to prevent tungsten issues. Too little cleaning action will result
in a dull, dirty or sooty looking weld. Remember: This is expressed as a percent of full
Electrode Positive. This unit uses 100% Electrode Positive as the point of reference,
which may be contrary to what the user may find in some other brands. Using the
welder in excess of 50% EP can quickly vaporize the tungsten and reduce welding capa-
bility when all other variables are the same. For most welds, no more than 45% clean-
ing is needed. Ideally, start with 30% EP as a reference point, then adjust it up or
down to achieve best results.

17
Section 2 QUICK SETUP AND USE GUIDE
FRONT PANEL FEATURES AND CONTROLS CONTINUED
POWERTIG 250EX FEATURES PARAMETERS PURPOSE
17. AC Frequency Control 20-250 Hz Defines the number of times per second that the current alternates polarity while
being used in the AC mode. To achieve greater arc focus (constriction) and in-
crease puddle agitation while welding in AC mode, increase AC frequency. This
will allow pinpoint use on thin materials, and improve penetration on thicker
materials. Ideal adjustment range is usually 100-150 Hertz. For comparison most
transformer welders in the US operate on 60 Hz. Impressive results can be
achieved through using the middle or upper frequency range of this welder.
Lowering AC frequency will widen as well as soften the arc but can reduce the
overall level of arc control. On the other hand, lowering the AC frequency can
help to extend the capability of the welder to weld thick metals if a lower AC
balance setting is used. Caution: Increasing the AC frequency also increases the
decibel level and can injure hearing. Wear hearing protection to prevent hearing
damage.

18. Arc Force Control (DIG) 0-100% Expressed as a percent, arc force regulates the arc response in a short arc condi-
tion as the voltage begins to drop. Used only in the stick mode, the Arc force
automatically compensates for the voltage drop by modifying the volt/amp curve
to maintain the energy needed to weld. The percentage referred to is the per-
centage over the actual welding amperage that the selected arc force setting
provides.

19. HF Start/Lift Start/Stick Switch HF/Lift/ Stick This button selects the type of TIG start used. HF is touch free and activates dur-
ing start only. Lift start requires brief touch to metal to draw an arc and is good
for applications where sensitive electronics are present. This also selects the
Stick welding process.

20. Spot Weld Timer Control/Switch On/Off Activates Spot Weld Timer circuit. To activate, press button to turn on. Then
select desired amount of arc time on. Select 2T and use with either the torch
switch or foot pedal. The arc will start and stay activated for the period defined
by the control knob. After it times out, the arc will automatically terminate. This
is feature is good for spot welding panels or tacking up during fabrication. This
will help make consistent sized spot welds and tacks. 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.

21. On/Temperature/ Over Current Warning On Indicator: Confirms unit is switched on. Temperature Indicator: Lights up
Indicator and stops welding output until the welder has cooled within normal limits. Allow
Or Fault 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. Elimi-
nate the source of the 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
during the over current event. In this case, contact Everlast.

22. Amp Control Knob 5-250 Amps Sets Maximum limit for Amps with foot pedal or torch. Sets higher amp value for
pulse.

23. Amp Display N/A Displays maximum selected amps until the weld is started. Displays actual amps
while welding. Display may cycle rapidly and randomly after pulse has been
turned on. This is normal. The meter “samples” the pulse at a fixed rate and is
not synchronized with 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 the adjustment is finished, pulse will begin to cycle after a few
seconds if no input is made.

18
 Section 2 QUICK SETUP AND USE GUIDE

REAR PANEL FEATURES AND CONTROLS

1. WATER COOLER RECEPTACLE

2. 3-POLE POWER SWITCH
220/240 V WATER COOLER ONLY!

1~220 VAC

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

1~220 V
GAS
OR
INLET
3~220v

5. HF GROUND BOLT
4. ARGON GAS INLET

19
Section 2 QUICK SETUP AND USE GUIDE
REAR PANEL FEATURES AND CONTROLS CONTINUED
POWERTIG 250EX FEATURES PARAMETERS PURPOSE
1. Water Cooler Receptacle IEC 60320-1 This connection supplies power to the Everlast PowerCool 300 water cooler. This is
“C-14” 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 connection can serve as a direct
path to an outdoor 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 the point gap becomes out of adjustment, more HF energy may
build up, or even jump across circuitry within the welder. It is recommended that a
small, separate ground wire (minimum 14 gauge) be attached at this point while in
use.

5. Gas Input Connection 5/8” CGA Fitting This is the connection point where the regulator connects to the welder. The unit is
( supplied with tubing and clamps which connect this fitting to the regulator. Welders
for the US and Canada use an industry standard 5/8” CGA fitting for compatibility
with different brands of regulators. Use two wrenches to tighten the regulator to
the welder, one to hold the welder fitting and the other to tighten the regulator
fitting. Do not overtighten. Do not use one wrench or the fitting will eventually turn
in the plastic housing and cause damage. If you suspect leaking, test the connection
switch a solution of mild soapy water. If bubbles are seen, retighten or reinstall the
tubing. Use any thread tape sparingly to prevent clogging of the system.

4. Power Cord 220/240 V The PowerTIG 250 EX can be used with either one or three phase 220/240 V power,
1 and 3 phase. including good quality 208 V power. The power cord 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 connec-
tion. NOTE: In many home circuits, red and black are the power wires. But in stand-
ard 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
single phase plug for the PowerTIG 250 EX is the NEMA 6-50, which is the standard
50 amp welder plug used on single phase welders in the US and Canada. 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 miswiring or damage caused to
the unit by miwiring 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 has 3 poles. 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 three phase power.

NOTE:
Never operate welder on a generator that is not certified by its manufacturer to be “clean” power, which is usual-
ly considered to be less than 10% total harmonic distortion. Less than 5% is preferred. Operating the unit on a
square wave output or modified sine wave generator is strictly prohibited. Contact the manufacturer of the gen-
erator for this information. Everlast does not have an “approved” list of generators. But, if the generator is not
listed as clean power by its manufacturer, then operation is prohibited. Generators that do not at least meet the
operating input requirements of the welder should not be used with the welders. Surge amp capability of the
generator should equal or exceed the maximum inrush demand of the welder. But the surge capability should
not be used as the only factor. The regular, running output of the generator should match or exceed the running
or “rated” demand of the welder. Any damage done by operating the welder on a generator not specified by its
manufacturer to be “clean”, will not be covered under warranty. This also includes suspect power sources where
voltage is below 208 V and above 250 V.
20
Section 3 Basic theory and function

Welder Function Summary and Explanations. Most of the green coded controls on the welder panel
are devoted to the use of the 2T/4T operation and
1. 2T/4T sequencer. The 2T/4T feature allows op- should not be used with foot pedal. The following
eration of the TIG welder without a foot pedal. In features are exclusive features that can only be used
many circumstances, a foot pedal is not practical with the 2T/4T sequencer function:
for use. So, the 2T/4T function has been created to 1) Start/End Amps
allow programming of the welder to simulate the 2) Up Slope/Down Slope
activities of the foot pedal while providing more
accurate control. The “T” refers to the number of Pre-Flow and Post-Flow are features that work in con-
“travels” of the remote switch required to operate junction with both the foot pedal and the 2T/4T se-
the programming of the sequencer. 2T is essential- quencer. The start will be delayed until the preflow
ly a “press and hold” operation and all program- cycle has finished. Set for .5-1 seconds for best re-
ming is cycled automatically. Releasing the switch sults. Add more pre/post flow time for larger welds.
begins the final stage of programming. 4T operates
differently in the fact that each touch activates a 2. AC Frequency. The AC frequency only applies to the
different stage of the programming, allowing for AC mode TIG mode. Standard transformer welders
greater control. Also, in 4T,while actually welding typically have a fixed frequency of 60 Hz which is es-
at full amps, no finger contact with the switch is sentially the line input frequency supplied by the pow-
required. Following the graphic lines below, you er company. But with inverters, the AC frequency ad-
can visually trace the activity and function of each justment is practically limitless due to the IGBT compo-
part of the welding cycle. In either 2T or 4T opera- nents that create the welding power. Frequency ad-
tion the programming can be reset to “upslope” justment is useful to help improve the directional con-
before reaching the end amp stage by pressing the trol of the arc, and to focus the arc so that a narrower
switch once more. See the graphics below for fur- bead profile can be achieved. Also, at higher frequen-
ther explanation. The up and down arrows indicate cies, the puddle agitation is greater which improve the
the switch travel direction. breakup of undesirable oxides. A setting of 100-120 Hz
is a good starting point. See the graphic below.
AC FREQUENCY EFFECTS

2T Torch Operation Effect on Weld Cycle

WELD AMPS WELD AMPS

200 Hz 60 Hz

START AMPS END AMPS

PREFLOW POST FLOW 3. AC Balance. The advanced form of AC square wave
output is formed by alternating polarity rapidly be-
tween electrode negative and electrode positive, cre-
= UP ON SWITCH ating a wave form that resembles a square “sine”
= DOWN ON SWITCH wave when viewed on an oscilloscope. Normally, with
standard transformer welders, both standard sine
4T Torch Operation Effect on Weld Cycle wave and even square wave welders have little or no
way to adjust the balance of EN to EP, which results in
having to weld with a molten ball at the tip of the
WELD AMPS tungsten and a less stable arc. Electrode negative (EN)
provides penetration in the TIG welding process. Elec-
trode positive (EP) creates a strong reverse flow of
START AMPS END AMPS
PREFLOW POST FLOW electricity that breaks up the weld-resistant oxidation
that covers aluminum and magnesium components.
EP 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 over-
cleaning results in wide etch lines running parallel to
21
Section 3 Basic theory and function

Cleaning/Frosted Area of Aluminum

the side of the weld. Not all weld conditions will be
alike, so more cleaning is required at times than 30% EP
others. Similarly, more penetration will be re- Narrow bead/etching/sharp tungsten
quired at times than others. Ordinarily, about 30-
35% electrode positive is considered an ideal
amount (65-70% electrode negative). This means 50% EP
that more heat is put into the work than is placed Wider bead/etching/rounded tungsten
on the tungsten. 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 65% EP
cleaning action is still visible even at these levels. Wide bead/etching/balled tungsten
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 NOTES:
piece of metal is particularly heavily oxidized or 1. Due to the rapid cycleing of the inverter, High
dirty, more cleaning action will be required. If too Frequency (HF) is not used except to start the
much cleaning action is used, the tungsten will arc. In a transformer welder, the HF would
begin to ball and even may start to burn away. If remain on to stabilize the AC arc, but in an
this much cleaning action is needed, then switch to inverter, this is not necessary. So, the HF
a larger size of tungsten that can handle the in- switch refers only to the Start of the arc, and
creased heating level. Signs of too little cleaning not to AC operation. However to reduce tung-
action while welding aluminum include soot, po- sten contamination, you should only operate
rosity, and dull looking (scummy) welds. A dedi- the AC mode with the HF start selected.
cated stainless steel brush and suitable aluminum 2. The addition of Helium to Argon can increase
cleaner such as acetone should be used before the welding capacity of the welder and alter
starting any aluminum weld to help break up the the amount of cleaning typically needed. Do
heaviest oxide layer so less EP is needed and better not exceed 25% or arc starts may become
penetration can be achieved. more difficult and erratic.
EXAMPLE: AC EP (+) BALANCE 3. If arc wandering in AC is a problem, reduce
cleaning percent, then if it continues, reduce
1 Hz (one full AC cycle) gas flow and then check for drafts.
4. Yellow-coded AC controls only apply during AC
EP 50% TIG operation and do not affect DC settings .
5. If cleaning lines are excessive at low settings, it
EN 50% 50%
is likely not a welder issue, but rather, a speed/
Standard transformer welder balance: 50% EN/EP heat issue. The longer the electrode remains
Balling tungsten, light penetration, wide cleaning area.
in the same place, the more the cleaning
area will widen. If you find yourself with this
issue, try increasing the amperage to travel
EP 65% faster. If overheating is feared, then use pulse
EN 35% 50% to increase forward travel speed to reduce the
Extreme cleaning setting. 65% EP:
cleaning lines. You should only suspect a weld-
Shallow penetration, balling tungsten, excessive cleaning area. er issue if adjusting the AC balance to above
40-60% does not begin to ball the tungsten.
6. If tungsten balling is experienced at settings
50% EP 35% below 40%, make sure that the torch is in the
EN 65% negative connector and that pure or Zirconiat-
ed tungsten is NOT being used.
7. Do NOT use pure tungsten or Zirconiated tung-
Good penetration setting 35% EP:
Deeper penetration, sharper tungsten, narrow cleaning area. sten in an inverter to weld in AC or DC mode.

22
Section 3 Basic theory and function

4. Pulse. The pulse creates two amp values, a high

EXAMPLE 1
and a low value that cycle back and forth between
Welding Amps: 100 amps,
each other while welding. The upper amperage is
PulseAmps: 50%
called the Welding Amps (sometimes called Peak cur-
Pulse Time On: 50%
rent) and the lower amperage is called pulse amps
AMPS DC Pulse Frequency: 1 Hz
(sometimes called “background” or “base“current).
This creates a situation where penetration can be Pulse Time ON
Welding Amps
achieved without overheating the metal, particularly
100
on metals that are prone to structural deterioration or Pulse Amps
burn through. In effect, you are creating an average of
50
amps but receiving the benefits of both high and low
amperages. The PowerTIG series feature three adjust- Pulse Hz
DC
able parameters concerning the pulse: 1S 2S 3S

1. Pulse Amps. Both welding amps and pulse amps

are independently set. Adjust the welding amps with EXAMPLE 2
the main control knob and the pulse amps with the Welding Amps: 100 amps
pulse amp knob. However, when you adjust the pulse AMPS
Pulse Amps: 50%
amps, you are actually setting a fixed ratio of amps Pulse Time On : 50%
expressed as a percentage of Welding Amps. When DC Pulse Frequency: 25Hz
setting Welding Amps, the welder will display actual 100
amp value when the pulse is turned on. However,
after about 3-5 seconds, if you do not begin adjust- 50
ment of the pulse amps, the meter will begin to fluc-
tuate rapidly (depending upon frequency setting), DC
sampling the pulse setting at odd points along the 1S
pulse cycle. To be able to read and set the pulse after
the default setup time expires, turn the pulse frequen-
cy to the minimum setting first, then adjust the pulse
amps. (If the default time expires before you are able
to set the pulse amps, you may get a fairly accurate EXAMPLE 3
reading of the pulse amperage while it is pulsing slow- AMPS
Welding Amps: 100 amps
ly.) Alternatively, you can turn the pulse off and back Pulse Amps: 25%
on to reset the default display time. The display is not Pulse Time On: 75%
synchronized with the pulse so it samples at a set rate DC Pulse Frequency: 3 Hz
100
that is independent of pulse changes, which yields
randomly fluctuating numbers. As you increase weld-
ing amperage, the pulse will maintain the same ratio 25
of amps you have selected. To adjust the pulse amps DC
to a desired setting using an example of 100 Welding 1S
Amps, setting the pulse amps to 50% yield s a 50 amp centage (%) of time that the pulse spends in the peak
value for the pulse amps. The foot pedal will control (welding) amp stage of the cycle. Increasing the Pulse
both Welding Amps and Pulse Amps according to the time will increase the duration the welding amp stage
percent selected on the panel. of the cycle which in turn will increase heat and
wetting in of the puddle. Pulse Balance is also known
2. Pulse Frequency. Pulse speed is the same as fre- in the industry as duty cycle. For welding purposes
quency is measured in the standard unit “Hertz”. the term “Pulse Time On” is used here.
Simply explained, it is the number of pulses per sec-
ond that occur. Pulse frequency controls the arc con- Setting up the pulse is not a process with a fixed ad-
striction and also helps with heat management. justment procedure. Changes to frequency, balance,
and time will skew the final result. A slow pulse with a
3. Pulse Time On (Balance). Pulse Balance is the per- equal 50% pulse time and somewhere around a
23
 Section 3 Basic theory and function

30-50% Pulse Amp setting is typically used to help water-cooled torch even briefly without water can seriously
with timing the addition of filler metal to the weld and permanently damage your torch. Torches used without
puddle. A higher pulse frequency level combined with water-coolers cannot be warrantied unless cleared by Ever-
variations in Pulse Time On and a narrow/wider ratio last. Everlast carries water-coolers designed to cool the
can be used to prevent burn through and speed up maximum amp capacity of the welder. If you are not able
welding on thin materials. It can also help maintain a to provide a water cooler or have not purchased a water
proper bead on a thin edge weld or prevent burn cooler, you will need to use an air cooled (gas cooled) torch
through on extremely thin metal. A fast pulse speed such as a 17 or 26 series, purchased separately.
will make fine ripples in the weld while a slow pulse
speed will give a much more coarse, but visually ap- All consumables should be interchangeable with other
pealing result. There are limitless ways to adjust the brand torches with similar designations. They should be
pulse. Keep in mind though, that the basic purpose of available for local purchase. No special consumables are
the pulse is to average the heat input while maintain- required. Although a small starter kit of consumables is
ing penetration. Do not attempt to use pulse while in included, you will need more consumables fairly quickly.
stick mode. No Tungsten is included with the starter kit. Actual starter
kit contents may vary. Contact Everlast if you desire to
5. Arc Force Control/Surge Amp Control. When stick purchase an air cooled torch that is complete, ready to go.
welding, arc force is used to help improve the perfor-
mance of the welder with certain metals and welding 8. DINSE style connector. Everlast uses a 35-70mm² con-
rods. The arc force boosts current flow to match the nector for both negative and positive connectors, which is a
demands of arc length and position. As an arc is held standard connector within the welding industry. This is
shorter, voltage tends to drop so extra amps are intro- referred to by different manufacturers as a 1/2” or 35 series
duced to help maintain a steady arc. Surge amps DINSE-style connector. The connector allows the use of
boost the starting amperage briefly to heat up the almost any brand or style of TIG torch.
welding electrode and weld area so the arc starts
cleanly, without sticking or porosity. Both controls are 9. 7 pin remote/foot pedal connector. This 7 pin connector is
inactive while welding in TIG mode. available from Everlast should it become damaged. See the
Pin-out reference found near the end of this manual.
6. Foot Pedal. 22k Ω. Select 2T on the panel. Select
the maximum amp value desired on the panel. The 10. Argon quick connect. This is a 9 mm size quick connect
foot pedal will only control amps up to the range gov- nipple. These are commonly available from Everlast or
erned by the main amp control. If more amperage is online sites which carry torches and fittings. Should you
needed raise the amp level on the panel. The foot need a new one for your torch or damage yours, consult
pedal also controls both Welding Amps, and Pulse Everlast. Do not use a nipple that is scarred, bent or other-
Amps through the ratio established by selecting the wise deformed. Damage to the female connector may re-
pulse Amp % on the panel. Welding with pulse and the sult. Serious leaks may occur.
foot pedal takes practice, as it will seem the welder is
welding at less amps than it is. Always set the panel 12. Low amp starts. The units have been configured to be
amps to about 25% more than what is needed. In- able to start and weld at approximately 5(±3) amps. How-
creasing the amps more than this margin on the panel ever, to obtain the most stable starts, a slightly higher amp
will reduce the accuracy of the foot pedal by lowering setting may be required, or a smaller tungsten may be nec-
the resolution of the foot pedal. Be sure to turn the essary. After the arc is started, amps may be reduced to a
start/end amps and up/down slope to the minimum minimum level. This is accomplished with setting a higher
settings or the 2T programming will be active and in- start amp value (2T/4T) or by pressing down more on the
terfere with pedal operation. The pedal cannot over- foot pedal until the arc stabilizes, then backing the amps
ride the 2T amp and slope controls. For more accurate down slowly until the arc stabilizes at the minimum select-
and responsive control, Everlast offers a US made foot ed amps.
pedal available as an additional option.
13. Argon Regulator. The argon regulator is calibrated in
7. Water-cooled torch. A water cooler is necessary for cfh. (subject to change)
use with the PowerTIG 250 EX torch. The units are
equipped with a WP 18 water-cooled torch. Using a
24
Section 3 Basic theory and function

TUNGSTEN PREPARATION

1. Use a dedicated grinding

wheel or contamination may re-
sult. Do not breath grinding dust!


Wear eye protection and gloves.

2. Hold Tungsten firmly.

3. Grind perpendicular to grind-

ing 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.

Use a point for low amp use to

<50 A help control the arc. Create a

slight truncation on the tip for
2.5 – 3 X Ø (DIAMETER)  higher amp use for best arc stabil-

>50 A ity. Grind the tip so that it is2.5- 3

times longer than the tungsten is
wide (Diameter).

In AC mode, do not ball the tung-

sten as you would with a trans-
former welder. An erratic arc will
result. Make sure that all grind-
ing marks run parallel to the tip.
Concentric grinding marks will
cause an 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.
25
 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. 5

1
3
2 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 3
2
<1/8 4 <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 TIG Arc Starting Steps

1. Turn unit on, allow time for power up cycle to complete its start up process.
2. Select either HF or Lift Start TIG with the HF/Lift Start/Stick selector switch. Select DC mode with the AC/DC torch switch.
3. Plug in Torch and select 4T or 2T mode with the selector switch OR plug in foot pedal and select 2T.
4. 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.
5. 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.
6. Adjust amps with amp control knob.
7. Start arc as depicted above.
8. 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.

26
Section 3 Basic theory and function

STICK OPERATION

STARTING METHODS

Tapping Method Scratch/Match 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 connected to the positive terminal and the work clamp is connected to the
negative connector. Make sure the connectors are twisted until light resistance is met.

4. Select the amps desired. Use the electrode diameter selection chart in this manual to determine the ap-
proximate range of amps suitable for the rod size selected. Consult the welding electrode manufacturer’s rec-
ommendation for proper amperage range. Each manufacturer has specific recommendations for its elec-
trodes. Usually these can be found on the packaging or on the respective manufacturer’s website.

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 differ-
ently. The arc force control setting will vary from person to person as well, with different rod angles, posi-
tions, and arc lengths all factoring into the arc force control performance.

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.

7. Terminate the arc by flipping the tip of the electrode up quickly with a quick flick of the wrist. Alternately
pull directly back on the rod with a brisk smooth motion.

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

27
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 TUNGSTEN DIA. Ar FLOW RATE

(A)
1-3 mm/.040”-1/8” 40-80 (60-125) 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” 4–5 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 2% Thorium Red AC/DC YES. Great for all purpose welding. Most eco-
(slightly radioactive) nomical.
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 as
not to breath the dust. If you have concerns about Thoriated (red) tungsten, choose from Lanthanated or Ceriated tungsten.

28
Section 3 Basic theory and function

EXPANDED VIEW OF TIG TORCH

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

2
1 1
9
3
4
5

7
12
8

13 5/8”

13a 5/8”

9 15
14

13
NO. PARTS FOR 18 Series Torch ( STYLE MAY VARY) QTY.
1 Long Back Cap with O-Ring 1
2 Short Back Cap Opt.
3 Torch Head 1
4 Insulator 1
5 Collet 1/16 or 3/32 1
6 Collet Holder 1
7 Ceramic Cup Assorted 1
8 Tungsten (customer supplied) 0
9 Torch Cable 1
10 Torch Handle (Blue ergo handle std, not pictured) 1
11 Torch Switch (Built into ergo handle, separate on straight handle) 1
12 Torch Switch Connector 1
13 9mm (1/8”) b quick connect coupling (male) gas/water 1
13a 1
14 Power Connector with water return cable and fitting 1
15 Protective Synthetic Rubber Cover 1

29
Section 3 Basic theory and function

7 PIN CONNECTOR FOR 22K Ω FOOT PEDAL

Note: Previous models before mid 2015 typically used a 47k pedal. 22k is
only for digital models of the PowerTIG 250EX.

To Pedal or Torch Switch

Bridge to 7

Bridge to 6
To Pedal or Torch Switch

30
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 fas-
tened to their terminal connectors. Reset main power
switch if overcurrent light is on. Contact Technical
Support.
Arc will not start unless lift started. Check for good work clamp and all connections.
Ground directly to the work. If all connections are
secure, contact Everlast.
Tungsten is rapidly consumed. Inadequate gas flow. Tungsten is too small of a diam-
eter for amps used. Wrong shielding gas. Use only Ar.
Using green tungsten. Use red thoriated or other col-
or. Wrong polarity. Too much AC cleaning.
Tungsten is contaminated, arc changes to a green color. Tungsten is dipping into weld. Check and adjust stick
Weld is discolored or a dusty brown. out to minimum 1/8 inch. Tungsten is melting. Re-
duce amperage or increase tungsten size.
Porosity of the Weld. Discolored weld color. Tungsten Low flow rate of shielding gas. High flow rate of
is discolored. 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, Duty cycle exceeded or Over current. Allow machine
but no output. 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. Bad work
clamp or work clamp cable connection.
Other issues. Contact Everlast support.

31
OPTIONAL ACCESSORIES:

EV-FP22DL Deluxe Foot Pedal PC-250M Welding Cart

EV-FP22SSC US Foot Pedal PCW300-240 Water Cooler

EV-200UW US Deluxe Regulator (CFH) Everlast Brand Deluxe Torches*

*Visit our website to view full selection of optional torches, and cable lengths and con-
sumable kits. Also, be sure to ask us about our full line of CK-Worldwide TIG welding
products and accessories.

32