Everlast PowerPro 256, PowerPro 236, PowerPro 164, PowerUltra 205P, PowerPro 205 Operator's Manual
EVERLAST
POWER ® SERIES
MULTIPROCESS TIG//SMAW/PLASMA CUTTER UNITS
P
r
o
2
5
6
Operator ’ s Manual
Includes AC/DC PowerPro and DC PowerUltra Units
Safety, Setup and General Use Guide
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Rev. 4 0516-12
IMPORTANT NOTICE:
This document has been prepared by Everlast Power Equipment INC. as general information
and does not contain and is not to be taken as containing any specific recommendation. The
document has been prepared in good faith and is professional opinion only. Information in this
document has been derived from third parties, and though Everlast believes it to be reliable as at
the time of printing. Everlast makes no representation or warranty as to the accuracy, reliability or
completeness of information in this document and does not assume any responsibility for updat-
ing any information or correcting any error or omission which may become apparent after the
document has been issued, Neither Everlast nor any of its agents has independently verified the
accuracy of the information contained in this document. The information is commercial in confi-
dence and not to be reproduced.
The recipient acknowledges and agrees that it must make its own independent investigation and
should consider seeking appropriate professional recommendation in reviewing and evaluating
the information. This document does not take into account the particular circumstances of the re-
cipient and the recipient should not rely on this document in making any decisions, including but
not limited to business, safety or other operations decisions. Except insofar as liability under any
statute cannot be excluded. Everlast and its affiliates, directors, employees, contractors and con-
sultants do no accept any liability ( whether arising in contract, tort or otherwise ) for any error or
omission in this document or for any resulting loss or damage ( whether direct, indirect, conse-
quential or otherwise) suffered by the recipient of this document or any other person relying on
the information contained herein. The recipient agrees that it shall not seek to sue or hold Ever-
last or their respective agents liable in any such respect for the provision or this document or any
other information.
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Serial number: __________________________
Model number: ____________________________
Date of Purchase: ___________________________
EVERLAST
Contact Information
Everlast US:
Everlast consumer satisfaction email: sales@everlastwelders.com
Everlast Website: everlastwelders.com
Everlast Technical Support: support@everlastwelders.com
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: sales@everlastwelders.ca
Everlast Website: everlastwelders.ca
Everlast Technical Support: sales@everlastwelders.ca
Telephone: 905-637-1637 9am-4:00pm EST M-F
10am-2pm EST Sat.
FAX: 1-905-639-2817
Everlast Austrailia:
Sydney: 5A Karloo Parade Newport NSW 2106 (02) 9999 2949
Port Macquarie: 4/18 Acacia Avenue Port Macquarie (02) 8209 3389
After hours support: 0413 447 492 Everlast Technical Support: support@pickproducts.com
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DearCustomer,
THANKS!Youhadachoice,andyouboughtanEverlast.Weappreciateyouasacustomer
andhopethatyouwillenjoyyearsofusefromyourwelder.
PleasegodirectlytotheEverlastwebsitetoregisteryourunitandreceiveyourwarrantyinformaon.Yourunitregistraonisimportantshouldanyinformaonsuchasproductupdatesorrecallsbeissued.Itisalsoimportantso
thatwemaytrackyoursasfaconwithEverlast
contactEverlastdirectlythroughthesalesdepartmentthroughthemaincustomerservicenumberinyourcountry.
Yourunitwillberegisteredandwarrantywillbeissuedandinfulleffect.Keepallinformaonregardingyourpurchase.In
warrantyserviceandreturned.
theeventofaproblemyoumustcontacttechnicalsupportbeforeyourweldercanbeacandidatefor
Please review the current online warranty statement and informaƟon 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
condiƟons.
Everlastoffersfulltechnicalsupport,inseveraldifferentforms.Wehaveonlinesupportavailablethroughemail,
andaweldingsupportforumdesignedforcustomersandnoncustomerinteracon.Technicaladvisorsareacveon
theforumdaily.Wealsodivideoursupportintotwodivisions:technicalandweldingperformance.
anissueorquesonconcerningyourunit,pleasecontactperformance/technicalsupportavailablethroughthe
maincompanyheadquartersavailableinyourcountry.Forbestservicecalltheappropriatesupportlineandfollow
upwithanemail,parcularlyifoffhours,oryoucannotreachalive
person,parcularlyduringheavycallvolumemes,holidays,andoffhours,leaveamessageandyourcallwillnormallybereturnedwithin24hours.Alsoforquickanswerstoyourbasicquesons,jointhecompanyownedforum
available
ons,andperhapsfindatopicthatalreadyaddressesyourquesonathp://www.everlastgenerators.com/
forums/.
Shouldyouneedtocallorwrite,alwaysknowyourmodelname,purchasedateandweldermanufacturinginspec-
on
possible.Technicalandperformanceadvisorsrelyuponyoutocarefullydescribethecondionsandcircumstancesofyourproblemorqueson.Takenotesofanyissuesasbestyoucan.You
theadvisorstoclarifyproblemsorissuesthatmayseemverybasic.However,diagnosisproceduresMUSTbefollowedtobeginthewarrantyprocess.Advisorscan’tassumeanything,evenwithexperiencedusers,andmust
coverallaspectstoproperlydiagnosetheproblem.
.
Letusknowhowwemaybeofservicetoyoushouldyouhaveanyquesons.
Sincerely,
EverlastCustomerService
throughthewebsite.You’llfindknowledgeable,helpfulpeopleandstaffavailabletoansweryourques-
date.Thiswillassurethequickandaccuratecustomerservice.REMEMBER:Beasspecificandinformedas
productsandservices.Ifyouareunabletoregisterbywebsite,
Shouldyouhave
person.Intheeventyoudonotreachalive
maybeaskedmanyquesonsby
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TABLE OF CONTENTS
Section……………………………………………….Page
General ...……………………………………………
Safety Precautions..……………………………….
Introduction and Specifications…………………
Know Your Machine………………………………..
2.1 Panel Face and Functions……………………
2.2 Lower Panel and Functions….……………...
2.3 Rear Panel ……………………………………..
Getting Started……………………………………..
3.1 General Guidelines……………………………
3.2 Shielding Gas Selection………………………
3.3 Regulator/Flow meter Selection……………
3.4 Regulator Connection………………………...
3.5 Regulator Adjustment………………………..
3.6 Machine Setup………………………………….
3.7 Tungsten Selection……………………………
3.8 TIG Torch………………………………………..
3.9 TIG Welding Principles and Guide…………
3.13 MMA (Stick Welding)…………………………
3.16 Plasma Torch …………………………………
3.17 Plasma Cutting Principles………………….
4.0 Trouble Shooting……………………………….
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5
GENERAL
Everlast is dedicated to providing you with the best possible equipment and
service to meet the demanding jobs that you have. We want to go beyond delivering a satisfactory product to you. That is the reason we offer technical support to assist you with your needs should an occasion occur. With proper use
and care your product should deliver years of trouble free service.
Safe operation and proper maintenance is your responsibility.
We have compiled this operator’s manual, to instruct you in basic safety, operation and maintenance of your Everlast product to give you the best possible
experience. Much of welding and cutting is based upon experience and common sense. As thorough as this welding manual may be, it is no substitute for
either. Exercise extreme caution and care in all activities related to welding or
cutting. Your safety, health and even life depends upon it. While accidents are
never planned, preventing an accident requires careful planning.
Please carefully read this manual before you operate your Everlast unit. This
manual is not only for the use of the machine, but to assist in obtaining the
best performance out of your unit. Do not operate the unit until you have read
this manual and you are thoroughly familiar with the safe operation of the unit.
If you feel you need more information please contact Everlast Support.
The warranty does not cover improper use, maintenance or consumables. Do
not attempt to alter or defeat any piece or part of your unit, particularly any
safety device. Keep all shields and covers in place during unit operation should
an unlikely failure of internal components result in the possible presence of
sparks and explosions. If a failure occurs, discontinue further use until malfunctioning parts or accessories have been repaired or replaced by qualified
personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves.
These waves may disturb sensitive electronic equipment such as televisions,
radios, computers, cell phones, and related equipment. High Frequency may
also interfere with fluorescent lights. Consult with an electrician if disturbance is noted. Sometimes, improper wire routing or poor shielding may be the
cause.
HF can interfere with pacemakers. See EMF warnings in following safety section for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.
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SAFETY PRECAUTIONS
These safety precautions are for protection of safety and health. Failure to
follow these guidelines may result in serious injury or death. Be careful to
read and follow all cautions and warnings. Protect yourself and others.
Welding and cutting processes produce high levels of ultraviolet (UV) radiation that
can cause severe skin burn and damage. There are other potential hazards involved
with welding such as severe burns and respiratory related illnesses. Therefore observe the following to minimize potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even
under welding helmets to protect your eyes from flying sparks and debris. When chipping slag or grinding, goggles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct
shade of filter installed. Always use a welding helmet in good condition. Discard any
broken or cracked filters or helmets. Using broken or cracked filters or helmets can
cause severe eye injury and burn. Filter shades of no less than shade 5 for cutting
and no less than shade 9 for welding are highly recommended. Shades greater than 9
may be required for high amperage welds. Keep filter lenses clean and clear for maximum visibility. It is also advisable to consult with your eye doctor should you wear
contacts for corrective vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless
fully protected by a filter screen, protective curtains or equivalent protective equipment. If no protection is available, exclude them from the work area. Even brief exposure to the rays from the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy.
Ear protection is necessary to prevent hearing loss. Even prolonged low levels of
noise has been known to create long term hearing damage. Hearing protection also
further protects against hot sparks and debris from entering the ear canal and doing
harm.
Always wear personal protective clothing. Flame proof clothing is required at all
times. Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose
clothing is tucked in neatly. Leather aprons and jackets are recommended. Suitable
welding jackets and coats may be purchased made from fire proof material from
welding supply stores. Discard any burned or frayed clothing. Keep clothing away
from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for adequate foot protection. Canvas, polyester and other man made materials often found
in shoes will either burn or melt. Rubber or other non conductive soles are necessary
to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient.
Gauntlet type welding gloves are available from your local welding supply companies.
Never attempt to weld with out gloves. Welding with out gloves can result in serious
burns and electrical shock. If your hand or body parts comes into contact with the
arc of a plasma cutter or welder, instant and serious burns will occur. Proper hand
protection is required at all times when working with welding or cutting machines!
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SAFETY PRECAUTIONS
continued
WARNING! Persons with pacemakers should not weld, cut or be in the welding area
until they consult with their physician. Some pacemakers are sensitive to EMF radiation
and could severely malfunction while welding or while being in the vicinity of someone
welding. Serious injury or death may occur!
Welding and plasma cutting processes generate electro-magnetic fields and radiation.
While the effects of EMF radiation are not known, it is suspected that there may be
some harm from long term exposure to electromagnetic fields. Therefore, certain precautions should be taken to minimize exposure:
Lay welding leads and lines neatly away from the body.
Never coil cables around the body.
Secure cables with tape if necessary to keep from the body.
Keep all cables and leads on the same side the body.
Never stand between cables or leads.
Keep as far away from the power source (welder) as possible while welding.
Never stand between the ground clamp and the torch.
Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible
need for respiratory equipment while welding or cutting. Always weld with adequate
ventilation. Never weld in closed rooms or confined spaces. Fumes and gases released while welding or cutting may be poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
Stop immediately and relocate work if necessary until adequate ventilation is 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
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.
8
et seq
.)
SAFETY PRECAUTIONS
continued
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly
grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not
stand, lean or rest on ground clamp. Do not stand in water or damp areas while welding or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain
or in extremely humid conditions. Use dry rubber soled shoes and dry gloves when
welding or cutting to insulate against electrical shock. Turn machine on or off only
with gloved hand. Keep all parts of the body insulated from work, and work tables.
Keep away from direct contact with skin against work. If tight or close quarters necessitates standing or resting on work piece, insulate with dry boards and rubber
mats designed to insulate the body from direct contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their location and
make sure all personnel in area are advised of their location. Taping or securing cables with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodically check work area for smoldering embers or smoke. It is a good idea to have
someone help watch for possible fires while you are welding. Sparks and hot metal
may travel a long distance. They may go into cracks in walls and floors and start a fire
that would not be immediately visible. Here are some things you can do to reduce the
possibility of fire or explosion:
Keep all combustible materials including rags and spare clothing away from area.
Keep all flammable fuels and liquids stored separately from work area.
Visually inspect work area when job is completed for the slightest traces of smoke
or embers.
If welding or cutting outside, make sure you are in a cleared off area, free from
dry tender and debris that might start a forest or grass fire.
Do not weld on tanks, drums or barrels that are closed, pressurized or anything
that held flammable liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling
hot pieces of metal. Remember to place hot metal on fire-proof surfaces after handling. Serious burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. 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.
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