Everlast PowerArc 200STi Operator's Manual

EVERLAST

POWERARC 200ST

i

Operator’s Manual for the PowerARC 200STi

Safety, Setup and General Use Guide

Rev. 2. 1 00-181215– Jan. 2019

DC Stick/DC TIG Inverter Welder

CC

GTAW

SMAW

IGBT

1

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PHASE

DC

everlastwelders.com

1-877-755-9353

380 Swi Ave. South San Francisco, CA 94080 USA

Specicaons and accessories subject to change without noce.

120V
240V

2

Table of Contents

Section…………………………………………………….Page

Letter to the Customer ………………...…………………..
Everlast Contact Information……………………………….
Safety Precautions……………………………………….…
Section 1: Specications…….……………………………..
Section 2: General Setup and Operation………………….
General Description, Purpose and Features……………...

Front Panel..…………………………………….………......

Rear Panel …….…………………………………………....

Stick Welding Conguration………..……………………...
TIG Torch Conguration.…………………………………..

Wire Connection…………………………………………....

Stick Operation Technique/Information…………………...
Basic TIG Operation…………………..……………………
TIG ARC Start and TIG Tips………...……………………..
Tungsten Preparation…………….………………………...
Kit Contents…..……………………………………………..
TIG Torch Assembly………………………………...……..
Trouble Shooting……………………………………………

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4
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9
10
10

14

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16
17
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19
20
22
23
24
25
26

NOTE: Product Specicaons and features are subject to change without noce. Every aempt has been
made to ensure this manual’s contents is accurate at me of publicaon. However, certain descripons, quan­es, appearance and specicaons of the product in this manual are subject to change without noce or up­date of this manual. This manual is intended to be a general guide and not intended to be exhausve in its
content regarding safety, welding, or the operaon/maintenance of this unit. Everlast Power Equipment INC.

does not guarantee the accuracy, completeness, authority or authencity of the informaon 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 tness for any parcular purpose, for per­formance/accuracy or for suitability of applicaon. Furthermore, Everlast Power Equipment INC. does not
accept liability for injury or damages, consequenal or incidental, resulng from the use of this product or re­sulng from the content found in this document or accept claims by a third party of such liability.

3

Dear Customer,

THANKS! You had a choice, and you bought an Everlast. 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 infor­maon. Your unit registraon is important should any informaon such as product updates or re­calls be issued. It is also important so that we may track your sasfacon 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 eect. Keep all informaon regarding your purchase.

In the event of a problem you must contact technical support before your welder can be a candi­date for warranty service and returned.

Please review the current online warranty statement and informaon found on the web­site of the Everlast division located in or nearest to your country. Print it for your records
and become familiar of its terms and condions.

Everlast oers full technical support, in several dierent forms. We have online support available
through email, and a welding support forum designed for customers and noncustomer interacon.
Technical advisors are acve on the forum daily. We also divide our support into two divisions:
technical and welding performance. Should you have an issue or queson 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, parcularly if o hours, or you cannot reach a live person. In the event you do not reach a
live person, parcularly during heavy call volume mes, holidays, and o hours, leave a message
and your call will normally be returned within 24 hours. Also for quick answers to your basic ques­ons, join the company owned forum available through the website. You’ll nd knowledgeable,
helpful people and sta available to answer your quesons, and perhaps nd a topic that already
addresses your queson at hp://www.everlastgenerators.com/forums/.

Should you need to call or write, always know your model name, purchase date and welder manu­facturing inspecon date. This will assure the quick and accurate customer service. REMEMBER:

Be as specic and informed as possible. Technical and performance advisors rely upon you to
carefully describe the condions and circumstances of your problem or queson. Take notes of
any issues as best you can. You may be asked many quesons by the advisors to clarify prob­lems or issues that may seem very basic. However, diagnosis procedures MUST be followed to
begin the warranty process. Advisors cannot 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 funcons before you call.

Let us know how we may be of service to you should you have any quesons.

Sincerely,

Everlast Customer Service

4

Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________

Everlast US:
Everlast consumer sasfacon email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Welding Support: [e-mail]
Everlast Support Forum: hp://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353)

Sales: Ext 201 9am—5pm PST M-F

Tech Support: Ext 207 9am—5pm EST M-F
Welding Support: Ext 204 9am—5pm EST M-F

FAX: [phone]

Everlast Canada:
Everlast consumer sasfacon email: [e-mail]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]

Telephone: [phone]am-4:30pm EST M-F

FAX: [phone]

Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
Aer hours support: 0410 661 334
Everlast Technical Support: [e-mail]

Other Numbers (Please record here for your records):

5

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

Safe operaon and proper maintenance is your responsibility.

We have compiled this operator’s manual to instruct you in basic safety, operaon and
maintenance of your Everlast welder to give you the best possible experience. Much of the
welding related acvies you will encounter are based upon experience and common sense.
As thorough as this welding manual may be, it is not a substute for either. Exercise extreme
cauon and care in all acvies related to welding. Your safety, health and even life depends
upon it. While accidents are never planned, prevenng an accident requires careful planning.
Please carefully read this manual in its enrety before you operate your Everlast unit. This
manual is not only intended to outline the funcons of the machine, but to assist you in ob-

taining the best performance out of your unit. Do not operate the unit unl you have read

this manual and are thoroughly familiar with the safe operaon of the unit. If you feel you
need more informaon about operang your unit, please contact Everlast Support.

The warranty does not cover improper use, maintenance or consumables. Do not aempt to
alter or defeat any piece or part of your unit, parcularly any safety device. Keep all shields
and covers in place during unit operaon should an unlikely failure of internal components
result in the possible presence of sparks and explosions. If a failure occurs, disconnue fur­ther use unl malfunconing parts or accessories have been repaired or replaced by qualied
personnel.

Note on High Frequency electromagnec disturbances:

Certain welding and cung processes generate High Frequency (HF) waves. These waves may
disturb sensive electronic equipment such as televisions, radios, computers, cell phones, and
related equipment. High Frequency may also interfere with uorescent lights. Consult with
an electrician if disturbance is noted. Somemes, improper wire roung or poor shielding
may be the cause.

HF can interfere with pacemakers. See EMF warnings in following safety secon for further
informaon. Always consult your physician before entering an area known to have welding or
cung equipment if you have a pacemaker.

Safety Precautions

6

These safety precauons are for protecon of safety and health. Failure to follow
these guidelines may result in serious injury or death. Be careful to read and follow all
cauons and warnings. Protect yourself and others.

Welding and cung processes produce high levels of ultraviolet (UV) radiaon that can cause se­vere skin burn and damage. There are other potenal hazards involved with welding such as severe

burns and respiratory related illnesses. Therefore, always wear Proper Personal Protecve Equip­ment (PPE) and observe the following to minimize potenal 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 ying sparks and debris. When chipping slag or grinding, gog-

gles and face shields may be required.

When welding or cung, always use an approved shielding device, with the correct shade of lter
installed. Always use a welding helmet in good condion. Discard any broken or cracked lters or

helmets. Using broken or cracked lters or helmets can cause severe eye injury and burn. Filter
shades of no less than shade 5 for cung and no less than shade 9 for welding are highly recommend­ed. Shades greater than 9 may be required for high amperage welds. Keep lter lenses clean and
clear for maximum visibility. It is also advisable to consult with your eye doctor should you wear con­tacts for correcve vision before you wear them while welding.

Do not allow personnel to watch or observe the welding or cung operaon unless fully protected
by a lter screen, protecve curtains or equivalent protecve equipment. If no protecon is availa-

ble, exclude them from the work area. Even brief exposure to the rays from the welding arc can
damage unprotected eyes.

Always wear hearing protecon because welding and cung can be extremely noisy. Ear protec­on is necessary to prevent hearing loss. Even prolonged low levels of noise has been known to cre-

ate long term hearing damage. Hearing protecon also further protects against hot sparks and debris
from entering the ear canal and doing harm.

Always wear personal protecve clothing. Flame proof clothing is required at all mes. Sparks and
hot metal can lodge in pockets, hems and cus. Make sure loose clothing is tucked in neatly. Leather
aprons and jackets are recommended. Suitable welding jackets and coats may be purchased made
from re proof material from welding supply stores. Discard any burned or frayed clothing. Keep
clothing away from oil, grease and ammable liquids.

Leather boots or steel toed leather boots with rubber booms are required for adequate foot pro­tecon. Canvas, polyester and other man made materials oen found in shoes will either burn or

melt. Rubber or other non conducve soles are necessary to help protect from electrical shock.

Flame proof and insulated gauntlet gloves are required whether welding or cung or handling met­al. Simple work gloves for the garden or chore work are not sucient. Gauntlet type welding gloves

are available from your local welding supply companies. Never aempt 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 cuer or welder, instant and serious burns will occur.

Proper hand protecon is required at all mes when working with welding or cung machines!

Safety Precautions

7

WARNING! Persons with pacemakers should not weld, cut or be in the welding area unl they

consult with their physician. Some pacemakers are sensive to EMF radiaon and could severely
malfuncon while welding or while being in the vicinity of someone welding. Serious injury or death

may occur!

Welding and plasma cung processes generate electro-magnec elds and radiaon. While the
eects of EMF radiaon are not fully known, it is suspected that there may be some harm from long
term exposure to electromagnec elds. Therefore, certain precauons 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 cung processes pose certain inhalaon risks. Be sure to follow any guidelines from
your chosen consumable and electrode suppliers regarding possible need for respiratory equipment
while welding or cung. Always weld with adequate venlaon. Never weld in closed rooms or con­ned spaces. Fumes and gases released while welding or cung may be poisonous. Take precauons
at all mes.
Any burning of the eyes, nose or throat are signs that you need to increase venlaon.

• Stop immediately and relocate work if necessary unl adequate venlaon is obtained.

• Stop work completely and seek medical help if irritaon and discomfort persists.

WARNING! Do not weld on galvanized steel, stainless steel, beryllium, tanium, copper, cadmium,

lead or zinc without proper respiratory equipment and or venlaon.

WARNING! This product when used for welding or cung produces fumes and gases which con-

tains 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 Phos-

gene gas can be deadly. Consider all chemicals to have potenal 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. Unchained cylinders

may be damaged in fall and can cause damage, injury or death. Certain regulaons 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 recommendaons. The regulatory changes are frequent so
keep informed.

All cylinders have a potenal explosion hazard. When not in use, keep capped and closed. Store
chained so that overturn is not likely. Transporng cylinders incorrectly can lead to an explosion. Do
not aempt to adapt regulators to t 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, ame and sparks. Do not transport without safety caps in place.

Safety Precautions

8

WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do

not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground
clamp. Do not stand in water or damp areas while welding or cung. Keep work surface dry. Do not
use welder or plasma cuer in the rain or in extremely humid condions. Use dry rubber soled shoes
and dry gloves when welding or cung to insulate against electrical shock. Turn machine on or o
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 ght or close quarters necessitates standing or resng
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 locaon and make sure all

personnel in area are advised of their locaon. Taping or securing cables with appropriate restraints

can help reduce trips and falls.

WARNING! Fire and explosions are real risks while welding or cung. Always keep re exnguish-

ers close by and addionally a water hose or bucket of sand. Periodically check work area for smol­dering embers or smoke. It is a good idea to have someone help watch for possible res while you are
welding. Sparks and hot metal may travel a long distance. They may go into cracks in walls and oors
and start a re that would not be immediately visible. Here are some things you can do to reduce the
possibility of re or explosion:

• Keep all combusble materials including rags and spare clothing away from area.

• Keep all ammable 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 cung outside, make sure you are in a cleared o area, free from dry tender and

debris that might start a forest or grass re.

• Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held amma-

ble liquid or material.

• Keep cylinders turned o when not in use.

• Turn o all cylinders and remove regulators when the machine is expected not to be used for

more than 24 hours. Do not transport cylinders uncapped.

Metal is hot aer welding or cung! Always use gloves and or tongs when handling hot pieces of
metal. Remember to place hot metal on re-proof surfaces aer handling. Serious burns and injury
can result if material is improperly handled. Immediately label all recently welded or cut material as
“Hot” with soapstone or a marker suitable for marking metal, when le unaended.

WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper mainte-

nance is your responsibility. Make sure all equipment is properly maintained and serviced by qualied

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 em-
ployees to operate poorly serviced equipment. Always check condion of equipment thoroughly
before start up. Disconnect unit from power source before any service aempt is made and for long
term storage or electrical storms. The warranty does not cover lightening strike damage.

Further informaon can be obtained from The American Welding Society (AWS) that relates directly
to safe welding and plasma cung. Addionally, your local welding supply company may have addi­onal pamphlets available concerning their products. Do not operate machinery unl your are com­fortable with proper operaon and are able to assume inherent risks of cung or welding.

Safety Precautions

9

PERFORMANCE AND FEATURE COMPARISON

Specifications Section 1

Specification PowerARC 200ST

i

Inverter Type Digitally Controlled IGBT

Input Voltage (±10); Phase/Frequency 120/240V; 1PH/50-60Hz

Maximum Inrush Amps(I1max) 39.2A @120V/ 36.8A @ 240V

Maximum Eecve (rated running) Amps (I1e) 24A @ 120V/ 22A @ 240V

Duty Cycle @ Rated Amps/Volts

120V:
35% @ 120A/ 24.8 V
60% @ 90A/ 23.6 V

100%@ 55A/ 22.8 V

240V:
35%@ 200A/ 28V
60% @ 160A/26.4V
100%@130A/25.2V

DC Output Range

120V:
5-120A, 20.2-24.8V

240V:
5-200A, 20.2-28V

Open Circuit Voltage 70 V

Li TIG/ HF Start Feature Live Li use with manual gas valve torch. No gas solenoid. No HF Start.

TIG Pulse No Pulse

Welding Accessory Package

INCLUDES: Electrode holder (sck) with 10 cable and connector work
clamp with 10  cable and connector. Regulator and Foot Pedal oponal.

Current Output Type DC (±)

Cellulose Electrode Capable (6010,6011) Yes, selectable buon for E6010 operaon.

DINSE Connector Type 35/50mm² (DINSE 35 STYLE)

Hot Start Adjustable Intensity (0-100%) and Duraon (0-2 Seconds).

Arc Force Control Adjustable (0-100%)

Voltage Reducon Device (VRD) for Sck Not Equipped.

An-Sck Funcon Not Equipped.

Maximum Rod Diameter (Sck Electrode) 120V: 3/32” -1/8” 240: 5/32”-3/16” (depending on electrode type.)

Dimensions 6.5”W x 11.5”H x 16.5”L (165mm W x 292mm H x 420mm L)

Weight 26 Lbs. (11 KG) Bare Unit Weight.

Protecon Class IP21S

Insultaon Grade F

Input Cable Length 6 .

Minimum Recommended Generator Surge Was

9000 Was. Must be clean power output rated by the generator manufac­turer. (clean power is considered ≤5% THD) or warranty is void.

IMPORTANT:

This unit is DC output only. Although technically possible, DC TIG is not recommended for welding aluminum or magnesium.