PowerTIG-255ext

EVERLAST
POWERTIG 255 EXT

Digital AC/DC TIG/STICK (GTAW/SMAW) WELDER
CC
GTAW-P
SMAW
IGBT
~
1-3
PHASE
AC/DC
Operator’s Manual for the PowerTig 255 EXT

(With 325 EXT Supplemental Information)
Safety, Setup and General Use Guide
Rev. 1 0 00821-13
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……………………... 21
Welder Function Summary and Explanations……. 23
Tungsten Preparation………………………………………... 29
Lift Start and High Frequency Start…………………… 30
Stick Starting Methods……………………………………… 31
Recommendations for Polarity/Amps/Tungsten.. 32
Expanded View of TIG torch……….…….……….……… 33
7 Pin Connector Pinout………………….…….…………… 34
Troubleshooting……………………………………………….. 35
Trouble Codes……………………………………………………. 36
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 LLC does not accept liability for injury or damages, conse-
quential 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 to download your current war-
ranty information. Your unit registration is important should any information such as product up-
dates 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 pur-
chase. 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 web-
site of the Everlast division located in or nearest to your country. Print it for your records
and become familiar of its terms and 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 ques-
tions, join the company owned forum available through the website. You’ll 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 many questions by the advisors to clarify prob-
lems or issues that may seem very basic. However, diagnosis procedures MUST be followed to
begin the warranty process. Advisors can’t assume anything, even with experienced users, and
must cover all aspects to properly diagnose the problem. Depending upon your issue, it is advisa-
ble to have basic tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive
test meter with volt/ohm functions before you call.
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
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
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 255EXT (325EXT)
25 Ft. Water-Cooled 20F Series Torch Assembly

and
25 Ft. Air-Cooled 9F Series Torch Assembly
(Both with flex head and flex hose design)
Argon Regulator Heavy Duty Work Clamp
Consumable Kit
(Does not include Tungsten)
47K Ω
Foot Pedal Assembly Stick Electrode Holder
NOTE: Accessory and consumable appearance, style and quantity subject to change without notice.
9
PowerTIG 255EXT/325 EXT TIG/Stick Welder Specification
Process AC/DC GTAW-P/DC SMAW
Inverter Type Digital Microprocessor Controlled, IGBT Module
Minimum/Maximum Rated Output TIG (255) DC: 3 A/10.1 V- 250 A/20 V (325) DC: 3 A/10.1 V-320 A/22.8 V
(255) AC: 5 A/10.2 V- 250 A/20 V (325) AC: 5 A/10.2 V– 320 A/22.8 V
Minimum/Maximum Rated Output Stick (255) 20 A/20.8 V - 225 A/29 V (325) 20 A/20.8- 250 A/28 V
Start Type Solid State HF and Lift Start
HF Point Gap Non-Adjustable Gapless Solid-State Design
TIG Duty Cycle @ Rated Amps/Volts (255) 60% @ 250 A/ 20 V 100% @ 200 A/ 18 V
(325) 35% @ 320 A/22.8 V 60% @ 245 A/19.8 V 100% @ 190 A/ 17.6 V
Stick Duty Cycle @ Rated Amps/Volts (255) 60% @ 225 A/ 29.0 V 100% @ 175 A/ 27 V
(325) 35% @ 250 A/ 28 V 60% @ 200 A/ 28 V 100% @ 160 A/ 26.4 V
OCV (U0) 70 V
Voltage Input (U1) (255) Standard 220/ 240 V; 50/60Hz 1~3 ph (325) 220/240 3 ph
Maximum Inrush Amps (I1MAX) (255) 33.6 A @ 220 V 1 phase, 27 A @ 220V 3 phase (325) 29 A @ 220V 3 phase
Maximum Operating Amps (I1EFF) (255) 20 A @ 220V 1 phase, 16 @ 220V 3 phase (325) 18 A @ 220 V 3 phase
Gas Pre-Flow /Post Flow Time 0-25 Seconds/ 0-50 Seconds
Start Amps/End Amps Start: 5-250 A (AC/DC)

End: 3-250 A DC; 5-250 A AC
Up/Down Slope 0-25/0-25 Seconds
AC Wave Forms Advanced Square, Soft Square, Sine Triangular
AC Frequency Control 20-250 Hz
AC Balance Control 5-90% of Electrode Positive (EP +)
Pulse Frequency Hz (Pulses Per Second) .1-500 Hz DC

.1-250 Hz AC Advanced Square Wave (AC)
.1-10 Soft Square, Triangular and Sine Wave (AC)
Pulse Amps (Ratio) 5-95%
Pulse Time On (Balance) 3-100%
Stick Arc Force Control 0-100%
Stick Surge Amp Control (Hot Start Intensity) 0-100%
Stick Surge Amp Duration (Hot Start Time) 0-2.0 Seconds
Minimum Water Ingress Protection Standard IP21S
Efficiency >/= 80%
Cooling Method Full Time High Velocity Fan with Tunnel design
Dimensions (approximate) 17.5” H X 9.25” W X 22” L
Weight (Bare Unit) (255) 60 lbs (325) 62 lbs
AC Easy Start Parameters (Default) AC Frequency : 120Hz AC Balance: 25% Preflow: .5 Post Flow: 4 Seconds Amps:
120 A (with pedal) Start amps: 50A End amps 50 A Upslope: 1 second,
Downslope: 3 seconds, (2T with torch switch)
DC Easy Start Parameters (Default) DC: Preflow .5 Postflow: 3 Seconds Amps: 90 A (with pedal) Start amps: 50 A End
amps: 50A, Upslope: 1 second Downslope 3 seconds (2T with torch switch)
Minimum Generator Requirement* (255EXT) 8500 Watts (325EXT) Not recommended (3 phase only)
* Generator must be certified as a clean power unit by its manufacturer with less than 10% total harmonic distortion.
10
General overview: The new, 255 EXT and 325 EXT TIG/ Do not restrict air flow or movement of air around the
Stick welders from Everlast are the latest in a new gen- welder. Allow a buffer distance of 2 ft from all sides if
eration of digital, GTAW –P/SMAW inverter welders. possible, with a minimum distance of at least 18”. Do
With a Siemens microprocessor and IGBT module de- not operate the welder immediately in the weld area
sign the welder offers stable arc performance as well as or the force of the fan will cause welding issues such as
convenient setup and use. Key features include: unstable arc, or porosity.
A. Siemens IGBT modules, microprocessor and an
overall plug and play design improve reliability and Do not mount in areas that are prone to severe shock
reduces down time for service and repair. or vibration. Lift and carry the welder by the handle.
B. Full bridge design features soft switching technolo-
gy which further extends IGBT component life and Do not direct metallic dust or any dirt intentionally to-
extends its capabilities. ward the machine, particularly in grinding and welding
C. Solid state High Frequency design for arc starting operations. Make sure the panel is protected from
has improved arc initiation at low amperages. damage while welding and cutting operations by flip-
D. Features automatic over-voltage, over current and ping down the clear protective cover.
duty cycle protection (over-heat) with self diagnos-
ing trouble code feature. Duty Cycle. The duty cycle has been determined for
E. 9 Channel program memory stores favorite the 255EXT and 325 EXT. For the 255 EXT, the duty
settings. cycle is rated for 60% at 250 Amps (TIG) and for the 325
F. Arc force control and Hot Start time and Hot Start EXT, 35% @ 320 Amps. The duty cycle is based off a 10
intensity controls expand stick welding ability. minute duty cycle rating at 40° C. This means that the
G. Four standard wave forms in AC offer increased unit is capable of being operated at the stated amps for
aluminum capability. 6 out of every 10 minutes without a break for cooling
H. Advanced AC Pulse and Standard AC/DC pulse down the unit. This does NOT mean that the 255EXT
increase weld capability on thin or heat sensitive can work 60% of any other length of time. A full 4 mi-
materials. nute rest should be given to the welder for maximum
I. Easy start-up feature offers simplified operation. life. Stick duty cycle is rated at 60% for the maximum
General Use and Care: The welders are good for use ratings of stick at 225 amps for the 255EXT and 35% at
maximum amp rating of 250 amps for the 325EXT.
Overheat, over current, over voltage, and under voltage
faults are indicated by a warning light accompanied
with an error code. Do not operate the unit until the
Figure 1. Basic Inverter design cause of the problem has been determined and cor-
in many industrial environments such as ship yards, rected. Do not shut down an overheated welder until it
fabrication shops, pipelines. However, care should be has safely cooled. Once the overheat condition has
taken to keep the unit out of direct contact with water been cleared, welding can resumed. Do not operate the
spray. The unit is rated IP21S, which rates it for light welder with the covers removed. In case of other trou-
contact with dripping water. It is a good idea to re- bles follow the trouble diagnosis section and/or call
move the welder from the vicinity of any water or Everlast Technical support.
moisture source to reduce the possibility of electrocu-
tion or shock. Never operate in standing water. This manual has been compiled to give an overview of
operation and is designed to offer information cen-
Every 1-2 months, depending upon use, the welder tered around safe, practical use of the welder. Weld-
should be unplugged, opened up and carefully cleaned ing is inherently dangerous. Only YOU, the operator of
with compressed air. Regular maintenance will extend this welder, can ensure that safe operating practices
help extend the life of the unit. are followed, through the exercise of common sense
practices and safety training. Do not operate this ma-
IMPORTANT: Before opening the unit for any reason, chine until you have fully read the manual, including
make sure the unit has been unplugged for at least 10 points of safety. If you do not have the skill, and/or
minutes to allow time for the capacitors to fully dis- knowledge to safely operate this welder, do not use
charge. Severe shock and/or death can occur. this welder until formal training regarding safe opera-
tion of this welder has been received.
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
WATER-COOLED TORCH
NOTE: Torch switch and foot pedal
control cannot be used at the same time.
18/20 SERIES TORCH
COOLANT IN (RED)
INPUT
!
WA OUTPUT
COOLANT OUT (BLUE)
WATER COOLER
(Optional) ARGON GAS LINE SHOULD BE TAGGED AS “Ar”. IF NOT, TAKE DRY, COM-
PRESSED AIR AND GENTLY BLOW THROUGH THE LINES TO DISCOVER
WHICH LINE EXHAUSTS THROUGH THE TORCH OR THROUGH THE RE-
TURN 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
QUICK SETUP GUIDE: STICK POLARITY AND CONNECTIONS
GAS CONTROL
TORCH (+) WORK (-)
13
QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING 255/325 EXT
(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
L2,WHITE; HOT (240V 1or 3 phase) L1,BLACK; HOT(240V 1 or 3 phase)
GAS
INLET
1~220 V
OR
NEMA 6-50P
3~220v
CLAMP 3 PHASE WIRE COLORS FOR 255/ 325 EXT:

GREEN: GROUND L3,RED; HOT(240V 3 phase only)
RED:L3
WHITE: L2
BLACK L1
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.

NEMA 6-50 PLUG IS NOT APPLICABLE TO 325EXT. UNIT
IS 3 PHASE ONLY. CONSULT LICENSED ELECTRICIAN.
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 ADDI-
TIONAL 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. ADDI-
TIONALLY, 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
FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT/325EXT
1. CLEAR PROTECTIVE PANEL COVER
2. CONTROL PANEL
GAS OUTLET CONTROL
3.POSITIVE CONNECTOR 7. NEGATIVE CONNECTOR

DINSE 35-70mm² DINSE 35-70mm²
4.GAS OUTLET 9MM QUICK CONNECT 5. 7-PIN CONTROL FOR PEDAL/TORCH SWITCH/AMPTROL
15
POWERTIG 255 EXT/325EXT PARAMETERS PURPOSE

MAIN PANEL FEATURES
1. Protective Cover N/A Clear hinged cover protects panel from damage. Keep closed during welding opera-
tions.
2. Main Control Panel Digital The main control features digital adjustment. It offers features that include Easy Start
Up, Pulse, Advanced AC pulse, Stick welding feature, VRD Stick welding feature, Stick
Hot Start, Arc force control, Lift start Tig, HF start TIG, 2T/4T/Pedal/Amptrol Control,
and error code diagnosis.
3. Positive Connector DINSE 35-70mm² Location of the positive terminal connection. This is a standard 35 series connector.
For Stick: Torch Connection (most electrodes). For TIG: Work Clamp Connection.
4. Gas Outlet Quick Connect 9mm Connects the gas to the TIG torch. To connect: Push the torch fitting into the connect-
or until the collar slides forward with a click. To Release: Slide the outer collar back.
5. Control Connector 7 Pin Connect the foot pedal , amptrol or torch switch to this socket to control the welder.
(Panasonic type) Only one control connector can be plugged in at one time. If the torch has a torch
switch feature or hand amptrol feature, tie the loose connector back or leave it hang-
ing while using the pedal.
6. Negative Connector DINSE 35-70mm² Location of the negative terminal connection. This is a standard 35 series connector.
For Stick: Work clamp Cocnnection. For TIG: Torch connection.
NOTES:
16
23
24
22
2 21
7
6
11
5 12
4 8 13
3 14
10
9
18
15a
19
15b
20
16 17
POWERTIG 255EXT/325EXT PARAMETERS PURPOSE
1. Memory Function 1-9 The unit has 9 programs which allow the operator to select parameters then save the
settings to the selected program channel. To operate, use the selector button to select the
desired program number where the program is to be stored. The red select light will be lit,
indicating that the welder is in the programming mode. Enter the desired program parame-
ters. After all parameter changes have been made, press the selector button and hold for 3
seconds and release. The green save button will light, indicating the function has been saved.
After approximately 2 seconds, the save light will go out, and the unit will default back to the
red select light. Any additional adjustments made after this will need to be resaved.
2. Easy Start Up Menu Normal, AC,DC The welder includes two Easy Start Up modes, one for AC and one for DC. The Easy Start Up
features for AC and DC have been pre-programmed with parameters that are generally usa-
ble in most situations. Most parameter adjustments are blocked and are non adjustable in
these modes. Amperage, and control functions are adjustable. Select Normal to allow
standard setup. Suited for quick welds and repairs or novice use.
3. Pre-Flow 0-25 Seconds Pre-Flow sets the gas flow time before the arc starts after the trigger or pedal is pressed.
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. Use enough time so that first “blast” of argon is settled.
(about .3-.5 seconds) Pre-flow delays the arc start by the amount of time set.
4. Start Amps 5-250 A (AC/DC) Serves as the 2T/4T beginning arc start amp value while using the torch switch, pedal or
amptrol. Allows the arc to be started at a different value than the selected maximum or
minimum welding amps while using the torch switch, foot pedal or hand amptrol. Typically
used to start the weld puddle more quickly/slowly. This feature is usually turned to the
minimum amp setting (5 amps) while the foot pedal is in use. However, It can be used to
create a “hot” TIG start with the pedal, or used to improve arc starting.
17
5. Upslope 0-25 Seconds Upslope ramps amps “up” from the start amp value to the welding amp value while
starting the weld puddle. For best operation, value should be set to 0 with foot pedal in
use. If used with an hand amptrol, without a separate switch to control slope in 2T/4T
mode, then the upslope should be also be set to 0. If slope is set while in use with the
foot pedal, sluggish or slow amp acceleration after the arc is struck will result.
6. Welding Amps AC: 5-250 Amps Welding amps define the top limit of amps at which the machine has been programmed to
DC: 3-250 Amps operate. Used with the foot pedal and amptrol, this is the maximum limiting value at the
upper limit of the range of travel. With the torch switch this is the destination, or maxi-
mum current reached after up slope has occurred. When used with pulse, Welding Amps
represents the high amp stage of the pulse cycle. When used with Advanced AC Pulse,
this represents the AC, high amp stage of the pulse.
7. Pulse Time On (Balance) 5-95% of Welding Defines the duty cycle (balance) of the pulse, by dividing or skewing the amount of time
Amp (Peak) 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 repre-
sented by a % of total time the pulse spends in the pulse amp stage of the cycle during one
full pulse. The feature can be used to increase or decrease pulse amp time relative to the
welding amp time of the cycle to help manage heat input. This functions the same in both
Standard and Advanced AC pulse modes.
8. Pulse Amps (%) 3-100% of Governs the lower( base or background current) amp value during the pulse cycle as a
Welding amps percent of welding amps. In Advanced AC Pulse mode this also represents the DC—
(negative) low amp stage of the pulse cycle.
9. Pulse Frequency , Hertz DC: Represented by Hertz (Hz), the pulse frequency defines the actual number of times each
(Pulses per second ) .1-500 Hz second the pulse makes one complete cycle between welding amps (peak/high amp value)
AC Advanced Square.: and pulse amps (background/low amp value). This is also commonly referred to as Pulses
.1-250Hz Per Second (PPS). Low pulse frequencies are ideal for timing the point where filler metal is
AC Soft Square: added. This helps improve appearance and uniformity. Higher pulse frequencies are use-
.1-10 Hz ful for welding seams and edges of thin material. Also it is useful for overall heat input
AC Triangular: control for thicker metals. Higher pulse frequencies are highly useful for automated weld-
.1-10 Hz ing processes. WARNING: WELDING AT HIGH PULSE FREQUENCIES INCREASES THE DECI-
AC Sine: BEL /NOISE LEVEL OF THE ARC. HEARING PROTECTION IS HIGHLY RECOMMENDED!
.1-10 Hz In Advanced mode, the function of the frequency is essentially the same, and represents
Advanced AC Pulse: the number of times per second that the welder cycles completely between AC (Welding
.1-10 Hz Amps/Peak current) and DC- (Pulse amps/base current).
10. AC Frequency 20-250 Hz Governs the number of times per second that the current alternates 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 pene-
tration on thicker materials. Ideal adjustment range is usually between 100-150 Hertz. For
comparison most transformer welders in the US operate on 60 Hz. Greater arc control
and stability can be achieved through the higher frequency range offered by this welder.
Lower Frequencies will widen and soften the arc and reduce the level of control. WARN-
ING: INCREASING THE AC FREQUENCY ALSO INCREASES THE DECIBEL/NOISE LEVEL OF
THE AC WELDING ARC. HEARING PROTECTION SHOULD BE WORN!
11. AC Balance 10-90% of EP Defines the percent of Electrode Positive (EP) used during AC welding to provide cleaning
action. 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. Too much cleaning action will
result in tungsten balling or splitting. Too little cleaning can result in dirty, sooty welds
and even a dull weld appearance. Simply put, as the percent increases, greater cleaning
will occur, but less penetration will be achieved. NOTE: This is expressed as a percent of
full Electrode Positive polarity. This unit uses 100% Electrode Positive as the reference,
which is opposite (a reciprocal value) from some brands of TIG welders with this adjust-
ment. Using the welder in excess of 50% EP can ball and vaporize the tungsten. For most
welds, no more than 45% cleaning is needed. Ideally, start with 30% EP for a reference
point, and fine tune the cleaning by adjustment this point in increments of 5%.
18
12. Down Slope 0-25 Seconds Down Slope will ramp amps “down” from the welding amp value to the end amp value to
give time to fill the crater left at the end of the weld bead. For best operation, value should
be set to 0 with foot pedal in use. If used with a hand amptrol, without a separate switch to
control slope in 2T/4T mode, then the upslope should be set to 0 as well. When using the
foot pedal or amptrol without a separate control switch, the arc may flare at the end of the
weld after the weld has been lowered to the minimum amp level if the value has not been
set to 0. Can also be used in the 4T mode to help with heat control by briefly tapping the
switch to cool off the weld before tapping it again to restart the up slope sequence before
the arc reaches the end amp stage.
13. End Amps AC: 5-250 Amps Sets the final or minimum current before the arc is terminated. Used for filling craters at the
DC: 3-250 Amps ends of the weld and crack prevention. When using the foot pedal, this should be set to the
lowest amp value (3 for DC; 5 for AC) or arc may suddenly get hot at the end of the weld.
14. Post Flow 0-50 Seconds Controls the amount of time in seconds that the argon flows after the arc has terminated.
Provides proper shielding during cooling to prevent rapid oxidation of the weld which results
in porosity. Use 1-2 seconds post flow time for every 10 amps.
15a. HF TIG/ Lift TIG/Stick/ N/A This selects TIG or stick mode. It also selects the type of TIG start. The Process selector
VRD Stick Process Selector offers the choice of Lift Tig (for DC only) which requires contact with the metal to initiate the
arc and High Frequency Start which allows non contact starting of the arc (for AC and DC).
When in HF mode, the unit relies upon a gapless solid state HF module to start the arc, which
is a more reliable and trouble free design than traditional point gap HF design. The lift start
function on the EXT models provides a cold electrode for safety, and prevents accidental
starts. This requires that the pedal or torch switch must be used to energize the arc. HF
refers to the start type only. The inverter design of the welder eliminates the need for a
constant HF overlay in AC.
15b. HF TIG/ Lift TIG/Stick/ N/A This selects the stick process or the VRD stick process. A Voltage Reduction Devices (VRD) is
VRD Stick Process Selector required in some situations to reduce the risk of electrocution. The VRD reduces the Open
Circuit Voltage (OCV) below 20 volts (±3V) for safer operation until the arc is struck and low
resistance is sensed. The VRD can make starting more difficult in some situations, and re-
quires a brief contact with the metal to start the weld. Rusty metals, or painted surfaces may
make starting more difficult by offering too high of a resistance value for the unit to sense an
arc strike attempt. When using the VRD Stick mode, a slight delay in arc starting may be
noticed. A firm scratching action may be necessary.
16. Parameter Selector N/A The push button selector is used to scroll left to right through different panel settings.
17. Parameter Adjuster N/A The control knob is used increase or decrease parameter values. To increase adjustment
speed, push in on the knob while turning.
18. 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 arc force amperage.
19. Hot Start Time 0-2 Seconds Sets the length of time that the Hot Start is active while starting the arc. Used to reduce
(Surge Amp Time) sticking of the electrode during the arc strike phase.
20. Hot Start Amps % 0-100% Controls 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. The
% represents the percent of additional hot start amps available.
21. TIG Pulse Mode Selector Pulse OFF The unit features two pulse modes. The standard mode is available in AC and DC modes. The
Standard Pulse Advanced AC mode, works only in AC. Pulse is used to control heat input on metals by puls-
Advanced AC Pulse ing amperage between a high (Peak) and low (Base or background) amp value. The high amp
stage is represented as Welding Amps. The low amp stage is represented as Pulse Amps. The
Advanced AC pulse pulses between AC and DC– polarity to control heat input on thin alumi-
num. In advanced mode, AC is assigned the welding amps stage of the pulse, and DC– is
assigned the pulse amps stage of the pulse. Both the standard and Advanced pulse modes
have the same features of pulse time on, pulse frequency and pulse amps. Other than
changing the polarity in Advanced AC pulse mode, the two pulses are similar in adjustment.
19
22. 2T/4T/ Pedal/Amptrol 2T, 4T, Pedal, This selects the operation of the torch switch, pedal, or hand amptrol.
Selector Pedal with 2T,
Pedal with 4T To operate with the torch switch, select 2T or 4T. For 2T operation, simply press and hold the
switch. The panel program will cycle automatically. When the switch is released, the arc will
downslope and terminate with post gas flow. When in 4T mode, the switch is pressed, and
held to start the pre-flow and the start amps part of the cycle. When released, upslope be-
gins and continues until the amps are raised to the preset welding amps. When pressed and
held again, downslope starts and ramps down to the end amp stage (crater current). When
released, the arc terminates, and post flow begins. If desired, before the downslope finishes,
the switch may be tapped again to start the up slope again.
To operate with the foot pedal, select pedal mode. The features such as start amps,
upslope, down slope, and end amps will function with the pedal. Be sure to lower these
features to the minimum values when the foot pedal is in use, unless a desired effect is
needed. The start amp feature can be particularly useful as a brief “hot start” tig setting
which provides an initial burst of amps to be to rapidly develop a puddle.
To operate with a hand amptrol, select Pedal, and then press the selector additionally to
select the 2T or 4T feature light. Both the Pedal and the 2T or 4T pedal will be lit. The
starting and ending of the arc will be the same as the standard 2T or 4T mode, except the
amps can be adjusted while welding with the amptrol. However, some amptrols have only a
a switch that is built into the amptrol mechanism, and is not controllable independently of
the amperage. When this type of amptrol is used, the unit should be placed into standard
pedal mode for proper operation.
23. AC Waveform/DC selector DC The unit features AC/DC operation, with 4 standard wave forms available in AC for specialized
AC welding needs. The advanced square wave is the default mode and is the best all around
Advanced Square mode with excellent wet in, and arc controllability . Soft Square wave and Sine wave mimic
Soft Square the feel and effect of the transformer welders. The Soft square wave is similar to Square
Triangular wave transformers, and have a smooth, buttery feel, but maintains good control over the arc.
Sine The Sine wave is similar to much older sine wave transformer TIG welders. This offers the
softest arc, and affords less control than other modes. The Triangular wave is designed for
rapid wet in, and high speed travel on the metal. It also features rapid freeze of the puddle.
DC mode is the standard mode used for all metals except aluminum and magnesium. Alumi-
num and Magnesium should be welded in AC only.
24. Data Indicator Amps The unit features a single main display. The data in the display is always accompanied by a
Seconds corresponding LED light which indicates the function being represented. This also includes a
Percent self diagnosing function which displays an error code and a corresponding warning light.
Hertz
Warning
On
20
REAR PANEL FEATURES AND CONTROLS
1. WATER COOLER RECEPTACLE

5. 3-POLE POWER SWITCH
220/240 V WATER COOLER ONLY!
1~220 VAC
4. POWER CABLE 1/3 ~ 220/240V*
1~220 V
GAS
OR
INLET
3~220v
2. HF GROUND BOLT
3. ARGON GAS INLET
*325EXT 3 ~ 220/240V or 460/480V (Special order)
21
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 1 phase 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 envi-
ronment 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 dis-
rupt 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.
3. 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 through-
out 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 The PowerTIG 255 EXT can used with either one or three phase 220/240 V power, including
1 and 3 phase. good quality 208 V power. The 325 EXT can be used with only 220/240V 3 phase (unless
special ordered with other voltage input). The wiring for the 255/325 EXT contains 4 sepa-
rate 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.
(Applies to 255 EXT only). 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 and match up wire colors. 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 255 EXT 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 mis-wiring the welder. If additional
help is needed, contact Everlast. WARNING: DO NOT CONNECT THE WELDER TO 460/
480 V 1 OR 3 PHASE POWER , UNLESS SPECIALLY ORDERED FOR THIS VOLTAGE OR SE-
VERE DAMAGE WILL RESULT TO THE WELDER! CONSULT THE SIDE PANEL ON THE WELD-
ER WITH SPECIFICATIONS IF IN DOUBT. THE SIDE OR BACK PANEL (LOCATION VARIES)
SPECIFIES THE CORRECT VOLTAGE/PHASE AS WELL AS SPECIFIC AMP REQUIREMENTS.
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 connect-
ed to 3 phase power (255 EXT only).
NOTES:
1. The gas input connection should be checked for tightness periodically, especially if the machine is moved.
22
Section 3 Basic theory and function
Welder Function Summary and Explanations. The standard pedal mode incorporates the same fea-
tures of the sequencer. When used, it is similar in
1. 2T/4T/Pedal sequencer. The 2T/4T feature al- operation to the 2T mode with the same settings.
lows operation of the welder without a foot pedal. However, all features except pre-flow and post flow
In many circumstances, a foot pedal is not practical would should be programmed for the minimum allow-
for use. So, the 2T/4T function has been created to able value so the functions do not interfere with nor-
allow programming of the welder to simulate the mal pedal operation. But if a TIG “hot start” is needed
activities of the foot pedal while providing more to improve arc transfer, or develop an instant puddle,
accurate control. The “T” refers to the number of the start amp feature can be used. Any other feature
travels of the remote switch installed on the torch such as down slope can be used as well, for any special
required to operate the programming. 2T is essen- application or need . However, be sure to remember
tially a “press and hold” operation and all program- to reset these features to the minimum values when
ming is cycled automatically. Releasing the switch they are not required, or undesirable operation such
begins the final stage of programming. 4T operates as arc flares, sluggish operation may occur after releas-
differently in the fact that each touch activates a ing the foot pedal.
different stage of the programming, allowing for NOTE: The welder features an additional 2T and 4T
greater control. Also, in 4T,while actually welding mode when the pedal light is on . This is actually de-
at full amps, no finger contact with the switch is signed for use with a hand amptrol (47k or 50k Ω).
required. Following the graphic lines below, you However, to work correctly, a torch switch must be
can visually trace and learn the activity and func- used in conjunction with the amptrol to control the arc
tion of each part of the welding cycle. In either 2T cycle. A momentary on/off button should mounted
or 4T operation the programming can be reset to separately to activate the arc cycle if none is provided.
“upslope” before reaching the end amp stage by Some aftermarket torch amptrols have a built in
pressing the switch once more. Setting a long switch that automatically activates when the amptrol
down slope improves the use of this reset function. amperage is increased. In this case, the amptrol should
See the graphics below for further explanation. be used in the foot pedal mode, or 2T pedal mode only
The up and down arrows indicate the switch travel depending upon amptrol switch configuration. Ever-
direction. last sells torches with built in amptrols that are de-
signed for use with our units in the amptrol 2T and 4T
mode. Torches with both a separate torch switch and
2T Torch Operation Effect on Weld Cycle
amptrol functions just as it would with the regular 2T
WELD AMPS WELD AMPS
or 4T cycle, except the amperage can be adjusted at
DO
the torch while welding, once the welding cycle has

E
W
P
DO
SLO
N
P
WN
SL
SLO
reached the normal welding stage of the cycle.

O
UP
PE
SLO
UP
START AMPS END AMPS

PE
PREFLOW POST FLOW
= UP ON SWITCH Everlast 26 series hand amptrol torch

= DOWN ON SWITCH 2. Easy Start Modes (AC and DC). The unit is
equipped with a separate AC and DC easy start mode.
4T Torch Operation Effect on Weld Cycle This mode allows the operator to get started welding
quickly and easily without having to worry about cor-
rectly setting the unit up. The unit is preprogrammed
WELD AMPS DO for good, all around performance in either AC or DC
W
N
SL modes. The amperage is preset, but can be adjusted if
PE
O PE
SLO
START AMPS END AMPS desired. Torch switch or pedal control can be select-
UP
PREFLOW POST FLOW ed, but most other features are locked into an opti-
mized general purpose setting. This feature is useful
for novice welders, and for customers wanting quick
start up of the units without an extensive setup proce-
dure.
23
have little or no way to change the ratio of EN to EP,

3. AC Wave Forms. The wave form control is a which results in welding with a molten ball at the tip
useful feature for achieving a desired type of arc of the tungsten and a less stable arc. Electrode nega-
performance in AC mode. There are 4 wave forms tive (EN) provides penetration in the TIG welding pro-
to choose from. The standard, default wave form cess. Electrode positive (EP) creates a strong reverse
is the advanced square wave. This wave form is flow of electricity that breaks up the weld-resistant
excellent for all types of welding, and offers quick oxidation that covers aluminum and magnesium com-
puddle wet-in, and good arc stability. The triangu- ponents. It also places a lot of heat on the tungsten.
lar wave form is useful in situations where a fast In a “balanced” wave where both EP and EN are equal
freezing puddle is desired, particularly on thin alu- in time length (50%), penetration is reduced and over-
minum. The soft square wave, offers a buttery arc, cleaning results in wide etch lines running parallel to
with a smooth, easy feel similar to the feel of a the side of the weld. Not all welds conditions will be
standard square wave transformer-based welder. alike so more cleaning is required at times than others.
The sine wave form mimics older transformer Similarly, more penetration will be required at times
welders. This is the softest wave form, and offers than others. Ordinarily, about 30-35% electrode posi-
less arc definition and control than other wave tive is considered an ideal amount (65-70% electrode
forms. This is preferred by some older more expe- negative). This means that more heat is put into the
rienced welders. When using various wave forms, work than on the tungsten and a sharper point can be
only the Advanced Square wave offers a relatively used. Cleaning is still sufficient at that level. Good re-
high pulse frequency, 250 Hz, in the standard pulse sults can be achieved with about 30% EP or less. The
mode. All other wave forms are limited to a maxi- cleaning action is still significant even at these levels.
mum of 10 Hz. Advanced pulse mode limits the Ideally, the cleaning action should be adjusted until a
pulse frequency to 10 Hz for other wave forms. \ small amount of frosting can be seen no more than
1/8” distance from the edge of the weld. If a piece of
4. AC Frequency. The AC frequency only applies to metal is particularly heavily oxidized or dirty, more
the AC mode. Standard transformer welders typi- cleaning action will be required. If too much cleaning
cally have a fixed frequency of 60 Hz which is es- action is used, the tungsten will begin to ball and even
sentially the line input frequency supplied by the may start to burn away. If this much cleaning action is
power company. But with inverters, the capability truly needed, then switch to a larger sized tungsten
of AC frequency adjustment is practically limitless that can handle the increased heating level. Signs of
due to the IGBT components that create its own too little cleaning action while welding aluminum are
frequency. Frequency adjustment capability is use- sooty, black or dull looking welds. A dedicated stain-
ful to help improve directional control of the arc, less brush and suitable aluminum cleaner such as ace-
and to focus the arc so that a narrower bead profile tone should still be used before welding any type of
can be achieved. Also, at higher frequencies, the aluminum to help break up the heaviest oxide layer so
puddle agitation is greater which improve the less EP is needed and better penetration can be
breakup of undesirable oxides. All wave forms can achieved. Even if the aluminum has a mirror like
be adjusted from 20-250 Hz shine, it is still oxidized.
Cleaning/Frosted Area of Aluminum
30% EP
Narrow bead/etching/sharp tungsten
`
200 Hz 60 Hz 50% EP
Wider bead/etching/rounded tungsten
5. AC Balance. The AC output is formed by rapidly
alternating polarity between electrode negative
and electrode positive, creating something that 65% EP
resembles a wave when viewed on an oscilloscope. Wide bead/etching/balled tungsten
Normally, with standard transformer welders, both
standard sine wave and even square wave welders
24
EXAMPLE: AC EP (+) BALANCE Parameter Notes:
1 Hz (one full AC cycle)
EP 50%
EN 50% 50%
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.
NOTE:
1. Due to the rapid switching of the inverter, High
Frequency (HF) is not needed except to start the
arc. The HF TIG only refers to the initial arc start,
and can be used for DC as well. In a transformer
welder, the HF could be switched to continuous 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 with aluminum, you
should only operate the AC mode with the HF start
selected. Lift start is recommended only for DC, or
for AC when a copper scratch block is used and the
arc is transferred. Lift start would be used in areas
that are sensitive to electronic interference such as
hospitals or computer/CNC equipment.
2. 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.
3. If arc wandering in AC is a problem, reduce cleaning
percent, then if it continues, reduce gas flow and
then check for drafts or for poor work clamp con-
nection. Also check for highly oxidized or dirty
aluminum or a faulty work clamp or connection.
4. AC controls only apply to AC operation, and do not
affect the settings on DC.
5. Too slow of travel speed will increase the etch-
ing/cleaning area.
25
6. Standard Pulse. (AC and DC) The pulse creates two

EXAMPLE 1
amp values, a high and a low value that cycle back and
Welding Amps: 100 amps,
forth between each other while welding. The upper
PulseAmps: 50%
amperage is called the “welding amps” (sometimes
Pulse Time On: 50%
called peak current) and the lower amperage is called
AMPS DC Pulse Frequency: 1 Hz
“pulse amps “ (sometimes called background or base
current). This creates a situation where penetration Pulse Time ON
Welding Amps
can be achieved without overheating the metal, par-
ticularly on metals that are prone to structural deteri- 100
Pulse Amps
oration or burn through. In effect you are creating an
50
average of amps. The PowerTIG series feature three
adjustable parameters concerning the pulse: Pulse Hz
DC
1S 2S 3S
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 EXAMPLE 2
pulse amp knob. However, when you adjust the pulse Welding Amps: 100 amps
amps, you are actually defining a fixed ratio of amps. AMPS
Pulse Amps: 50%
This is expressed as a percentage of Welding Amps. Pulse Time On : 50%
The display is not synchronized with the pulse so it DC Pulse Frequency: 25Hz
samples at a set rate that is independent of pulse 100
changes, which yields randomly fluctuating numbers.
As you increase amperage, the pulse will maintain the 50
same ratio of amps you have selected. To adjust the
pulse amps to a desired setting using an example of DC
100 Welding Amps, setting the pulse amps to 50% 1S
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.
2. Pulse Frequency. Pulse speed or frequency as it is EXAMPLE 3

referred to is measured in the unit standard “Hertz”. Welding Amps: 100 amps
AMPS
Simply, it is the number of pulses per second that oc- Pulse Amps: 25%
cur. Pulse frequency controls the arc constriction and Pulse Time On: 75%
also help with heat management. DC Pulse Frequency: 3 Hz
100
3. Pulse Time On (Balance). Pulse Balance is the per-

centage (%) of time that the pulse stays in the pulse
25
amp stage of the cycle. Increasing the Pulse time on
DC
can increase the duration the pulse amp stage of the 1S
cycle to decrease heat. Pulse Balance is also common-
ly referred to as pulse duty cycle. For welding purpos-
es the term “Pulse Time On” is used here.
Setting up the pulse is not a process with a fixed ad-

justment 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
26
50-75% Pulse Amp setting is typically used to help

with timing the addition of filler metal to the weld 8. Arc Force Control/Surge Amp Control. When stick weld-
puddle. A higher pulse frequency level with variations ing, arc force is used to help improve weldability of certain
in Pulse Time On and a narrow/wider ratio can be used metals and welding rods. The arc force boosts current flow
to prevent burn through and speed up welding on thin to match the demands of arc length and position. As an arc
materials. It can also help maintain a proper bead on a is held shorter, voltage tends to drop so extra amps are
thin edge weld or prevent burn through on extremely introduced to help maintain a steady arc. Surge amps boost
thin metal. A fast pulse speed will make fine ripples in the starting amperage briefly to heat up the welding elec-
the weld while a slow pulse speed will give a much trode and weld area so the arc starts cleanly, without stick-
more coarse, but visually appealing result. There are ing or porosity. Both controls are inactive while welding in
limitless ways to adjust the pulse. Keep in mind TIG mode.
though, that the basic purpose of the pulse is to aver-
age the heat input while maintaining penetration. 9. Foot Pedal. 47k Ω. Select 2T on the panel. Select maxi-
mum amp value desired on the panel. The foot pedal will
7. Advanced Pulse (AC only). The Advanced Pulse is a only control amps up to the range governed on the front
feature not typically found on most pulse type TIG panel. If more amperage is needed raise the amp level on
welders. In the “advanced” mode, the unit pulses the panel. The foot pedal also controls both Welding
current back and forth between AC and DC – polarity. Amps, and Pulse Amps through the ratio established by
This is designed primarily for use with welding alumi- selecting the pulse Amp % on the panel. Welding with
num, and is accessible only when used in AC mode. pulse and the foot pedal takes practice, as it will seem the
The purpose of Advanced Pulse mode is to create a welder is welding at less amps than it is. Always set the
quick freezing puddle, and offer more definition of the panel amps to about 25% more than what should be need-
puddle ripples. It is also useful for controlling cleaning ed. Increasing the amps more than this margin on the pan-
width, and for heat input control on thin gauge alumi- el will reduce the accuracy of the foot pedal by lowering the
num. AC is assigned as the welding amps setting resolution of the foot pedal. Be sure to turn the start/end
(pulse peak), and the DC— is assigned as the pulse amps and up/down slope to the minimum setting or it will
amps % ( base value). Otherwise, the pulse frequency, interfere with pedal operation. The pedal cannot override
and pulse time on are adjusted the same and perform the start/end amp and slope controls. For more accurate
the same function as the standard pulse mode adjust- and responsive control, Everlast offers a US made foot pe-
ments. Occasionally during use, a slight wobble of the dal available as an additional option. Do not attempt to
arc may be seen as it pulses between AC and DC—. control stick function with the foot pedal.
This is usually observed if the frequency is set low and
the metal is highly oxidized, the arc length is too long, 10. Water-cooled/ Air-cooled torch. (20 and 9 series) A
or the work clamp is not connected securely. If this water cooler is necessary for use with the water- cooled 20
happens, readjust the work clamp, re-clean the metal series torch and to reach the maximum current potential of
and /or shorten the arc length. If pulsing slowly, the the unit. Using a water-cooled torch even briefly without
filler should be added on the audible AC stage of the water can seriously and permanently damage your torch.
pulse as this is the hotter stage of the pulse. Note: The The Power Cool 300 may be purchased separately from
graph below has been simplified for clarity. It is de- Everlast which is designed to cool the torch up to the maxi-
signed to show the relationship and interaction be- mum amp capacity of the welder. If you are not have a
tween the AC and DC parts of the pulse and does not water cooler or have not purchased a water cooler, you will
depict the effect of AC frequency cycling between — need to use the air-cooled (gas -cooled) 9F series torch that
and + polarity during the pulse cycle. is included with the unit. Keep in mind that the 100% duty
AMPS cycle mark on the 9 series is 125 amps DC, and 85 amps
AC. The torch may be used at slightly higher amperages but
Pulse Time ON Welding Amps (AC) the torch duty cycle will be reduced and the potential to
100
overheat and damage the torch exists. Overheated torches
Pulse Amps (DC-) are not warrantable. All consumables should be inter-
50
changeable with other brand torches with similar 9 or 20
designations. They should be available for local purchase.
Pulse Hz
Time No special consumables are required. Although a small
1S 2S 3S starter kit of consumables is included, you will need more
27
consumables fairly quickly. No Tungsten is included
with the starter kit. Actual starter kit contents may
vary.
11. DINSE style connector. Everlast uses a 35-70mm²

connector for both negative and positive connectors,
which is a standard connector within the welding indus-
try. 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.
12. 7 pin remote/foot pedal connector. This 7 pin con-

nector is available from Everlast should it become dam-
aged. See Pin-out reference found in the appendix of
this manual.
13. Argon quick connect. This is a 9 mm size quick con-

nect nipple. These are commonly available from Ever-
last 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.
14. Low amp starts. The units have been configured to

be able to start at approximately 5 amps AC/DC. After
the arc is started in DC, amps may be reduced to the
minimum 3 amp minimum level. Start Amps may also
be increased for a “hot start” while in TIG mode if re-
quired.
15. Argon Regulator. The argon regulator is listed in

SCFH for North American markets. (subject to change).
NOTE ABOUT THE FOOT PEDAL MODE:

While using the foot pedal, and some hand amptrols,
the welder will revert back to the minimum amp
setting on the welder after the arc is terminated and it
will not show maximum set amps. It will only show
maximum set amps while the unit is being adjusted for
amperage. While welding the display will read actual
weld amperage. After 3-4 seconds the display will de-
fault back to the minimum amp reading. When using
2T or 4T control modes, the amps will register the max-
imum set amps until the arc is started. To see the
maximum set amperage in the pedal mode without
the arc on, simply make a small adjustment in the
main adjustment knob while the Welding Amps light is
lit. The unit will revert to the “setting” mode and dis-
play selected maximum amperage.
28
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 arc. Create a slight

truncation on the tip for higher
2.5 – 3 X Ø (DIAMETER)  amp use for best arc stability.
>50 A 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 RE-
SULT. 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.
29
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 Operation of TIG

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 .
3. Plug in Torch and select 4T or 2T mode with the selector OR plug in foot pedal and pedal with selector OR plug in amptrol and select pedal 2T or 4T.
4. If using the torch switch select start/end amps to increase or decrease amps for starting and ending the weld.
5. If using the torch switch, select up/ down slope to increase/decrease the ramp up or ramp down time of the amperage.
6. Adjust maximum amps to the recommended amperage. Generally use 1 amp per .001”.
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.
30
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 or Stick VRD with the HF/Lift Start/Stick/ VRD selector button
3. Make sure electrode holder is hooked into the positive connector and the work clamp is hooked the nega-
tive connector.
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.
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. Adjust Hot Start (%) to create a hotter start than the actual weld current to prevent rod sticking and im-
prove starting reliability. Increase duration (Hot Start Time) to prolong surge until starting is improved.
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.
VRD Function will decrease OCV while machine is idle and cause a slight delay in start.
31
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” 130-175
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.
(slightly radioactive) 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.
32
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”
17
9 15
14
16
NO. TYPICAL PARTS FOR 9/20 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 #4, 5,6, or 7 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) (Water IN, 20 series) 1
14 Power Connector 1
15 Protective Cove (Denim, synthetic rubber or nylon) 1
16 Gas IN (9 series) / Water OUT (20 Series)
17 Gas IN (20 series only)
33
7 PIN CONNECTOR FOR 47K Ω FOOT PEDAL
To Pedal or Torch Switch

Bridge to 7
Bridge to 6
To Pedal or Torch Switch
NOTE:
The new digital EXT models are designed to accept multiple potentiometers
values, but the performance of different ohm pedals cannot be guaran-
teed. Some resolution or range may be lost. But, the pedals must still be
wired correctly and 7 pin plugs with the correct wiring must be used.
34
Section 3 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 or No “spark”. Too long of stand off. Failed HF module. Contaminated
tungsten. No tungsten or stick out too short.
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 amper-
age or increase tungsten size.
Porosity of the Weld. Discolored weld color. Tungsten Low flow rate of shielding gas. High flow rate of shielding
is discolored. 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, espe-
cially in Aluminum. Too short of post flow time. Check
tungsten stick out.
Over current/Duty cycle LED illuminates. Machine runs, Duty cycle exceeded or Over current. Allow machine to
but no output. 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.
35
Section 4 Trouble codes
TROUBLE CODE WITH WARNING LIGHT/UNIT DIAGNOSIS

STOPS WELDING BUT REMAINS ON.
801 OVER OR UNDER VOLTAGE/ Check power input cable for length/size, check input voltage
802 OVER TEMPERATURE/ DUTY CYCLE EXCEEDED. Allow unit to rest for 10 minutes. Check for obstacles, clean
welder, and heat sinks. (make sure unit is unplugged for 30 minutes before cleaning)
804 OVER CURRENT/ Check to make sure cable is correct length and size. Internal unit fault or low voltage
805 TORCH SWITCH IS STUCK CLOSED/ Turn off welder immediately and check switch.
OTHER CONTACT EVERLAST
36
Notes:
37

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EVERLAST

POWERTIG 255 EXT

Operator’s Manual for the PowerTig 255 EXT

Everlast Customer Service

Safe operation and proper maintenance is your responsibility.

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

Note on High Frequency electromagnetic disturbances:

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

PowerTig 255EXT (325EXT)

25 Ft. Water-Cooled 20F Series Torch Assembly

Argon Regulator Heavy Duty Work Clamp

Inverter Type Digital Microprocessor Controlled, IGBT Module

Start Type Solid State HF and Lift Start

HF Point Gap Non-Adjustable Gapless Solid-State Design

Gas Pre-Flow /Post Flow Time 0-25 Seconds/ 0-50 Seconds

Start Amps/End Amps Start: 5-250 A (AC/DC)

Up/Down Slope 0-25/0-25 Seconds

AC Wave Forms Advanced Square, Soft Square, Sine Triangular

AC Frequency Control 20-250 Hz

AC Balance Control 5-90% of Electrode Positive (EP +)

Pulse Frequency Hz (Pulses Per Second) .1-500 Hz DC

Pulse Amps (Ratio) 5-95%

Pulse Time On (Balance) 3-100%

Stick Arc Force Control 0-100%

Stick Surge Amp Control (Hot Start Intensity) 0-100%

Stick Surge Amp Duration (Hot Start Time) 0-2.0 Seconds

Minimum Water Ingress Protection Standard IP21S

Efficiency >/= 80%

Dimensions (approximate) 17.5” H X 9.25” W X 22” L

Weight (Bare Unit) (255) 60 lbs (325) 62 lbs

QUICK SETUP GUIDE: TIG CONNECTIONS

9/17 SERIES TORCH

COOLANT OUT (BLUE)

TORCH (+) WORK (-)

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

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

CLAMP 3 PHASE WIRE COLORS FOR 255/ 325 EXT:

NOTE: LITERS/MINUTE (lpm)

PLUG NOT INCLUDED! TO BE SUPPLIED BY CUSTOMER.

FRONT PANEL FEATURES AND CONTROLS POWERTIG 255EXT/325EXT

1. CLEAR PROTECTIVE PANEL COVER

GAS OUTLET CONTROL

3.POSITIVE CONNECTOR 7. NEGATIVE CONNECTOR

POWERTIG 255 EXT/325EXT PARAMETERS PURPOSE

POWERTIG 255EXT/325EXT PARAMETERS PURPOSE

REAR PANEL FEATURES AND CONTROLS

1. WATER COOLER RECEPTACLE

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

REAR PANEL FEATURES AND CONTROLS CONTINUED

the torch while welding, once the welding cycle has

reached the normal welding stage of the cycle.

START AMPS END AMPS

PREFLOW POST FLOW

= UP ON SWITCH Everlast 26 series hand amptrol torch

have little or no way to change the ratio of EN to EP,

EXAMPLE: AC EP (+) BALANCE Parameter Notes:

1 Hz (one full AC cycle)

Standard transformer welder balance: 50% EN/EP