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Everlast Lightning 225 MTS Operator's Manual
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Everlast Lightning 225 MTS Operator's Manual

Everlast Lightning 225 MTS Operator's Manual

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Publish Date: MAY 2025
EVLTNG225 Rev. 1.0
USA/North America
©Everlast Power Equipment
DC
125/225A
DC
150/275A
DC
100/185A
120/240V
1 Phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide
Operator's Manual
FUNCTION: MIG/ AC/DC TIG with Pulse Function/ DC Stick
PURCHASE DATE:
WELDER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:

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Summary of Contents for Everlast Lightning 225 MTS

  • Page 1 Publish Date: MAY 2025 EVLTNG225 Rev. 1.0 USA/North America ©Everlast Power Equipment 125/225A Safety, Setup and General Use Guide 150/275A 100/185A FUNCTION: MIG/ AC/DC TIG with Pulse Function/ DC Stick PURCHASE DATE: WELDER SERIAL NUMBER: OPTIONAL ACCESSORY SERIAL NUMBER: Operator’s Manual...
  • Page 2 TABLE OF CONTENTS SPECIAL NOTICE AND CALIFORNIA PROPOSITION 65 WARNING CUSTOMER GREETING AND EXPLANATION OF PROCEDURES WARRANTY AND CONTACT INFORMATION SAFETY DISCLAIMER AND HF WARNING SAFETY WARNINGS, DANGERS, CAUTIONS AND INSTRUCTIONS GENERATOR OPERATION, OPERATING VOLTAGE AND OTHER GENERAL INFORMATION DUTY CYCLE EXPLANATION STATEMENT SPECIFICATIONS: DUTY CYCLE, PERFORMANCE SPECIFICATIONS AND INPUT AMPERAGE INFORMATION 12,13 SETUP GUIDE: GETTING STARTED, UNPACKING YOUR UNIT, ASSEMBLY AND INSPECTION...

  • Page 3: California Proposition 65 Warning

    Due to multiple variables that exist in the welding field and the changing nature of it and of the Everlast product line it- self, Everlast Power Equipment INC. does not guarantee the accuracy, complete-...
  • Page 4 Many issues can be resolved over the phone. If the issue cannot be resolved over the phone/email, you may be given an op- tion to return the unit, or have a part shipped to you, at Everlast’s discretion. Keep in mind, you may be asked questions that seem basic, or ele- mentary to your knowledge base.

  • Page 5: Who Do I Contact

    Warranties and service policies and procedures vary from country to country and are maintained and supported by the region- al or in country distributor of Everlast welding equipment. USA Customers Only: For full details on the 5 year parts and labor warranty, 30 day satisfaction policy, terms of sale, and how to proceed with a war- ranty claim, please visit: https://www.everlastgenerators.com/standard-warranty.
  • Page 6 Safe operation and proper maintenance is your responsibility. Everlast is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and maintenance of your Everlast product, it is no substitute for observing safe welding practices and behavior. Safe welding and related cutting operations require basic knowledge, experience and ultimately the exercise of common sense.
  • Page 7 It is your responsibility to make certain that the use of this welder is restricted to per- sons who have read, understand and follow the warnings and instructions in this manual. If you or the operator needs further instruction, contact Everlast welding support at 1-877 755-9353 ext. 204 or seek qualified professional advice and training.
  • Page 8 Safety Warnings, Dangers, Cautions and Instructions DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these hazards are immediate while others are cumulative in their effect. Do not weld in enclosed spaces or in areas without adequate ventilation. Fumes and gases released in the welding and cutting operations can be toxic.
  • Page 9 Safety Warnings, Dangers, Cautions and Instructions CAUTION! Trip Hazards exist around welders. Cords, cables, welding leads and hoses pose a trip hazard. Be aware of their location and inform others of their location. Tape and se- cure them so they will stay out of high traffic areas. CAUTION! Welded metal can stay hot long after welding is completed.
  • Page 10 13,000 Surge Watt generators or larger. Operating the unit on under-powered generators and/or on generators not rated with 5% or less THD can damage your unit. The generator manufacturer determines this rating, not Everlast. Do not assume that a name brand generator, or a “new” generator provides clean power.

  • Page 11: Specifications

    6 minutes out of a 10 minute time period at the maximum output of the welder (225A MIG, 225A TIG and 185A Stick output operating on 240V). Everlast uses a maximum output rating to figure duty cycle on this unit. A duty cycle of 35% is considered to be a commercial duty cycle class welder and is suitable for daily commercial use for commercial manufacturing and repair.
  • Page 12 Input Voltage/ Hertz/ Phase Dual Voltage 120/240V (± 10%) 50/60 Hz 1 phase (For 208V use, the calibration of wire speed and the PowerSet mode will be affected. For 208V 1 phase use, call Everlast tech support before use.) Current Rating (Inrush Amps)
  • Page 13 (gasless) operation, a special (dedicated) flux-cored gun should be sourced local- ly. Everlast does not supply flux-cored guns for gasless operation. Extended use with self shielded flux- cored operation with the standard MIG guns can result in damage to the gun. If self shielded flux cored wire is used, perform light duty work only with the stock MIG gun.

  • Page 14: Getting Started

    NOTICE: Cosmetic damage claims made after 30 days will not be accepted. Assemble the front, middle, and rear handles with the supplied screws. Do Unless Everlast is contacted and informed of such delay with legitimate not overtighten. Handle assembly is optional for some non-portable and reason for such a required for a delay (i.e.
  • Page 15 Setup Guide The recommended Everlast/ NOVA Cart 375 LF has ample room for cool- CHECK FOR GAS LEAKS. ing built into the design of the cart. Never attempt to restrict air flow by This unit has two gas connections on the rear. Each connection should be attaching filters to the vents or altering the vents in any way.
  • Page 16 NEMA 6-50P outlet or make any electrical power connections or related determi- nations of electrical code. Everlast is in no way liable for any damag- es caused by improper connection of this welder. As a rule, your welder should be on a dedicated branch circuit not far from an elec- trical disconnect box.
  • Page 17 Setup Guide CONNECT YOUR UNIT TO SHIELDING GAS. IMPORTANT: This is a compression fitting! Do not use thread tape or pipe sealant on any cylinder, regulator or other unit connection. The residue Always wear safety glasses when installing a gas cylinder to the welder. and debris may get into the gas solenoid and cause operational issues.
  • Page 18 Setup Guide What Size Cylinder Do I Need? What Shielding Gas Should Be Used? Gas cylinders come in a wide ranges of sizes. Cylinders range from about 20 The Lightning MTS model is a synergic welder which incorporates on Cu. Ft. to over 300 Cu. Ft. capacity. For this unit, there are at least two different screen recommendations for the type of gas needed for each process.
  • Page 19 Setup Guide SELECT THE PROPER TIG POLARITY AND CONNECTIONS. almost always be connected to the left positive terminal of the machine when welding in DC Mode. The work clamp will then be connected to the Selecting the correct polarity for TIG is quite simple. To TIG weld any met- negative terminal on the right side.
  • Page 20 For dedicated Flux-Cored use or for extended periods of use, you use a Flux -Cored gun. Flux-Cored guns are available from after-market sources. Everlast does not provide Flux-Cored guns as optional equipment.
  • Page 21 There may also be problems for calibration. Use with NOTICE: Spool guns and push-pull guns connect in the same manner other brand guns not approved by Everlast will void the warranty. If a “will and are installed using the same connections and polarity. Both ver- fit”...
  • Page 22 Setup Guide the drive rolls out with the ones of correct size and type found in the con- How Do I Disassemble the MIG Gun? sumable bag. When not in use, keep these “spares” put up where moisture and dust cannot get to them. They will rust if not stored properly. 15 Series MIG gun The top drive rolls are actually idler rolls used to hold tension and keep the wire in the groove.
  • Page 23 NOTE: This unit is equipped with the 24 Series MIG Gun. However it can the drive roll is reinstalled, just lightly snug the screws with the screw also be used with any series Everlast MIG gun (For optional purchase driver. Do not over tighten.
  • Page 24 Setup Guide rotate the tension lever clock-wise. Different types of wires require differ- ent tensions. There is no exact tension that works for all wire types. How- ever, for steel wire, you will generally tension to at least 3 to 3.5 on the dial.
  • Page 25 This welder uses a common Euro Style Connection for the MIG gun. This Even though .023” Stainless wire is supported, it may not be available in allows any Everlast gun or any after market gun with the same connection all markets and will experience feeding difficulty in the standard gun. In to be connected to this unit.
  • Page 26 Setup Guide mer liners for aluminum, are color coded for wire diameter sizes. also cause damage to the gun head or outer conduit when it is removed. If so, the whole gun may need to be replaced if the damage is severe NOTICE: Push-Pull Guns typically use special graphene type black/gray enough.
  • Page 27 Setup Guide move the old liner or before trimming the new one. It is better to have to Remove the brass nut from the base fitting on Euro Connector. Hold retrim a new liner than to cut too much off. the base fitting while using a wrench to do this.
  • Page 28 Setup Guide SELECT THE PROPER TUNGSTEN TYPE FOR TIG. Purchasing Tungsten can be difficult. Local suppliers tend to put a premi- um price on Tungsten, and may be three times an online price direct from What Type of Tungsten Do I Use? a distributor.
  • Page 29 Choosing the proper grind angle is important to achieving the weld pene- tration, bead appearance, and arc-cone width that you desire. While there Everlast uses a HV start system on this unit. This system is able to han- is no true one-size-fits-all angle, there are some general rules of thumb to dle several different sizes of Tungsten.

  • Page 30: Front Panel View

    Component Identification and Explanation Front Panel View Component Identification Function/Component Note Protective Cover Keep cover down and in place during welding activities and while in storage. Euro-Style Quick MIG Connector Connect the MIG gun to this connector. (Only one gun may be connected at a time.) Connect the Spool Gun to this connector.
  • Page 31 Water Cooler Outlet This outlet is to be used with Everlast 240V rated water coolers only. Do not use with any other application. Do not operate with 120V (240V 1Ph, 4A max)

  • Page 32: Control Panel Layout

    Component Identification and Explanation Control Panel Layout Component Identification Function/Component Note 1. Welding Process Selector Press left or right arrow key connected to the process selector LEDs to navigate back and forth to select the desired weld pro- cess. The LED will light to indicate which weld process has been selected. See Quick Setup Section. 2.

  • Page 33: Manual Control

    • Settings may not be perfect for all positions/applications/users. Everlast PowerSet is a “next-level” form of Synergic programming which • Presets may takes away from Pro user’s ability to tailor the settings to incorporates color coded graphics and a limited adjustment range. Over- individual needs or worksite applications.

  • Page 34: Starting-Up The Welder

    If any malfunction of the control screen or the welder is observed, Make sure all fittings are tight and that your gas cylinder valve is fully contact Everlast Tech Support. open. Put on proper safety equipment (PPE) and fire resistant clothing.
  • Page 35 Component Identification and Explanation GENERAL INFORMATION ON SETUP AND USE. Selecting the Process. Quick Steps to Setting-Up the Welder. The main display in the upper area serves to display the status, or value of a function or parameter. (1a) At the top of the panel (1) use the process selector buttons to select the •...
  • Page 36 Component Identification and Explanation of the unit. In the PowerSet mode, only one line may be displayed due to the simplified input design. When a parameter or a function is selected, the screen will display the value or status of the function in two places: At the top of the screen in the main display area.
  • Page 37 Component Identification and Explanation from gray to green and will display additional parameters related to Why Are Some Settings Limited or Blank? the function. When the items are green and the blank areas filled by There are two basic reasons some settings are limited in adjustment or additional parameter information, they are then adjustable.
  • Page 38 Component Identification and Explanation USING THE PROGRAM MENUS AND MEMORY FUNCTION. process is not selected at the top of the selector. (The selected pro- gram will override the process selector and display the saved program The memory function on this machine allows the user to save and name up and process.) to 30 different programs.
  • Page 39 Component Identification and Explanation distinctive without exceeding the character limit. Once the program has been entered, rotate the adjustment knob (3)to save selection or press cancel to exit the screen. If cancel is selected the program will not be saved on that line and the name or status of the line will not be changed.
  • Page 40 Inox), Ar Gas (100% Argon for Aluminum), or No Gas (For Flux- Cored on Steel) in wire feeding modes. 10. Inductance. IMPORTANT NOTICE FOR EXISTING EVERLAST MIG OWNERS AND USERS: This improves the wet-in of the weld. A high Manual/PowerSet Mode. This indicates which mode the machine is setting will result in a very poor arc, with a high pitch.
  • Page 41 WFS/Amps to the control knob on the gun. will be set to 0% or 100% after testing the range of function. If the 15. Units. Everlast recognizes that there is a need to provide different unit is used at extremes for Inductance, bad arc quality will result.
  • Page 42 Component Identification and Explanation DC TIG MANUAL MENU Main Right Display, Default Amp Display. Adjust with right adjustment knob. By default this display area indicates the Amperage. In adjust- The TIG manual menu is arranged similarly to the MIG menu and some of ment mode, the function or parameter selected will display and the the features and parameters overlap.
  • Page 43 Component Identification and Explanation 12. Spot/Stitch Timer. The Spot timer must be turned on for the Stitch function to appear to the right of the Spot Timer function. When Spot is turned off as shown in the picture above, the Stitch function is no longer selectable and the space will turn gray and will remain blank.
  • Page 44 Component Identification and Explanation AC TIG MANUAL MENU ment mode, the function or parameter selected will display and the display numbers/letters will turn red to indicate adjustment mode. The TIG manual menu is arranged similarly to the MIG menu and some of After 5 seconds of no input or adjustment of any parameter or func- the features and parameters overlap.
  • Page 45 Component Identification and Explanation the torch while welding without a foot pedal. See more detailed 2T/4T cially for relatively short tack welds. Remote information and explanation found later in this manual for 13. Pulse. The pulse is used to help control heat input and warping by illustrated examples.
  • Page 46 Component Identification and Explanation puddle. Additionally, at 50% Positive polarity the etched area created thing but very thin gauge metals. At higher Amperage on thick mate- by the cleaning effect that Positive polarity creates, will be unaccepta- rials there will be issues with proper wet-in and penetration. Weld bly wide.
  • Page 47 Component Identification and Explanation DC Stick Manual Menu: ment knob. By default this display area indicates the Amperage. In adjustment mode, the function or parameter selected will display and The stick manual menu is simplest menu of all the manual menus. Howev- the display numbers/letters will turn red to indicate adjustment mode.
  • Page 48 Component Identification and Explanation In Manual Welding Modes, What Are the Welder’s Default Settings? The welder is designed to include many extra features and functions in the Manual mode that aren’t included with basic welders. These extra features are meant to give the user the maximum amount of control over the weld performance.
  • Page 49 Component Identification and Explanation Using the PowerSet Menus. ommendations as well for single pass. The unit does offer higher settings and may recommend a gas change as the wire speed and voltage enter the The PowerSet function is an advanced synergic function designed to pro- Globular and Spray transfer range to perform single pass welds (MIG C25 vide the user with a simplified set up process by using a combination of process selection).
  • Page 50 Component Identification and Explanation pearance. For Volts, Amps and Wire Feed Speed, the graphic appears MIG, TIG, and Stick PowerSet Information. as shown above in the picture. As the user makes progresses further MIG/Flux-Cored: away from the recommended adjustment, the graphic will also change color, turning from green to yellow and finally to red.
  • Page 51 Smaller diameter wires need less burn-back time. Voltage Input Confirmation. Voltage Input Confirmation. This confirms Inductance. IMPORTANT NOTICE FOR EXISTING EVERLAST MIG the voltage that is to be supplied to the machine. The correct Voltage OWNERS AND USERS: Inductance improves the wet-in of the weld. A is 240V.
  • Page 52 The correct Voltage 13. Units. Everlast recognizes that there is a need to provide different is 240V. If 220, 230, or 208V is supplied at the outlet, the Voltage will units of measures to different industries and regions of the world.
  • Page 53 Component Identification and Explanation which is a synergic, more automated mode. In PowerSet mode, settings dictate how the welder’s amperage and screen programming many functions may not be available for adjustment and will be pre- are set and controlled. Depending upon the remote selection choice, set.
  • Page 54 Component Identification and Explanation achieve an accurate setting of Amps. If the exact thickness is not DC Stick: listed, use the next lower standard thickness and adjust Amps up as Stick performance relies upon the proper selection of the rod type/class to needed.
  • Page 55 Component Identification and Explanation some functions may not be available for adjustment and will be preset for best general performance. If optimum performance is not achieved, discontinue use of PowerSet and use the full manual set- ting to achieve better results. Right Side Display.
  • Page 56 Component Identification and Explanation NOTICE: The following sections cover MIG, Synergic PowerSet MIG, TIG, and Stick terms, definitions, and basic operation. Some of the terms overlap from process to process and serve essentially the same functions. Take note that some terms will repeat from process to process, but will be described in a way that is specific to the process being used.
  • Page 57 Component Identification and Explanation Using The Trigger/Torch Switch Remote Functions Operating the 2T/4T Remote Function The Remote Torch Control function works with both the MIG and TIG pro- cesses. The Trigger (MIG) and Switch (TIG) function is designed to allow the user to program the welder so that the stages of the weld cycle can be controlled via operation of the torch switch.
  • Page 58 Component Identification and Explanation use the Pedal in any torch trigger or other remote function setting or mal- function of the weld cycle will occur. To control the amperage, the maxi- mum amperage is set on the screen. The pedal then controls the range of amperage from minimum set amperage up to the maximum Amperage set on the panel.
  • Page 59 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms EXPLANATION OF GENERAL WELDER FUNCTIONS. If large amounts of spatter are present, the puddle seems fluid (appears wet) and the wire speed is within the targeted range, decrease volts a little Volt and Amp Settings (Short Circuit MIG).
  • Page 60 Component Identification and Explanation comes quickly with a little practice. Pushing can result in shallower pene- MIG and TIG welding requires a well prepped surface to obtain a sound tration but the molten puddle is easier to see and the arc sits easily on the weld.
  • Page 61 Component Identification and Explanation Suggested Maximum Amperage for wires in Short Circuit Mode: • In Steel spray-arc, the wire can handle higher Amperages, but will require a change in shielding gas for proper spray with minimum spatter and maximum control. If higher Amperages are used, or even nearing the maximum settings listed below the wire may tend to go into a more spatter prone globular transfer if a spray compatible gas is not used.
  • Page 62 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms Key Notes to Remember About Synergic MIG Welding • Always adjust Amps before adjusting Arc Trim to control the weld. • Set Arc Trim to –1.0 and adjust up or down from there in increments of .1.
  • Page 63 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms Arc Length and Contact Tip to Work Distance in Welding. Joint Preparation Keeping a tight, short arc for TIG and Stick is important to prevent inclu- sions in the weld, especially while weaving. It helps control the puddle. V-GROOVE (60-80°) DOUBLE V-GROOVE Keep arc length ≤...
  • Page 64 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms Drag or Push MIG? MIG Welding is fairly simple. Just keep travel angle and direction in mind when welding. A push angle is often recommended for short circuit MIG and Spray Arc Welding for the least amount of spatter and bead profile. Push is always recommended for welding Aluminum and Pulsed MIG.
  • Page 65 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms The TIG arc start can be performed in three basic ways. technically is considered an HV start, it electronically simulates the HF start. The first and primary arc starting method used is High Voltage Start. HV start is a contactless start which is performed by holding the Tungsten off The second method is Lift Start which requires direct, purposeful contact the metal about 1/8”...
  • Page 66 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms AC Balance (TIG). This is the relative amount of time during one AC cycle length of the MIG weld. The Arc Trim actually controls the average pulse (1 Hz) that the machine spends in either positive or negative polarity. For voltage and is represented by a relative scale (-5 to +5).
  • Page 67 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms broken. The other type of lift start is a “remote lift start”. It functions essen- NOTICE: tially the same except, the tungsten is not electrically live and the torch The HF on an inverter is not continuous.
  • Page 68 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms used, increase to 1 to 2 seconds. of a weld chart. Consider the PowerSet settings to be the weld chart on this unit, but expressed in a digital format. PowerSet (MIG/ Flux-Cored/TIG/Stick).
  • Page 69 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms pulse parameter, whether it be frequency, balance, or Pulse Amperage will welding setting, up to the maximum welding setting selected on the panel. skew the effect of the pulse. Keep this in mind when making changes and When used in pedal mode, many weld cycle parameters will not be availa- make only small changes to one parameter at a time to dial in the desired ble for adjustment since the pedal itself controls those functions manually.
  • Page 70 Component Identification and Explanation Explanation of Parameters, Functions and Welding Terms sized spot welds along a object while tacking up an object for fitment. Up-Slope (MIG/TIG). Upslope is the duration in time that it takes for the programming to transition the TIG Start Amperage (or MIG Wire Feed Speed) from the TIG Start Amp/ MIG Start WFS value to the Welding Amp value.
  • Page 71 Component Identification and Explanation Wireless Foot Pedal Option Can I Use a Remote Wireless Pedal? The Lightning series is able to be used with the NOVA wire less pedal system. This system is composed of the pedal and internal transmitter and the external dongle receiver.
  • Page 72 Component Identification and Explanation North SN24 SERIES MIG TORCH PARTS BREAKDOWN (MB24KD Style) North SN 24 Series MIG Gun (MB24KD Style) Item Part Number Description 200300 Gas Cone/Nozzle 12.5mm EB2206 Contact Tip .6mm M6x8x26 (.023” Heavy Style) EB2208 Contact Tip .8mm M6x8x28 (.030” Heavy Style) EB2209 Contact Tip .9mm M6x8x28 (.035”...
  • Page 73 Component Identification and Explanation North SN36 SERIES MIG TORCH PARTS BREAKDOWN (MB36KD Style) *Denotes Standard Build for Most Sales Regions...
  • Page 74 26 Series Air-Cooled Welding Torch (Typical Type) Parts and Assembly. DC: 200A @ 60% Duty Cycle; AC: 175A @ 60% Duty Cycle Typical Everlast and NOVA Torch Assembly (17,18, 26 Series) (Some parts may not appear exactly the same but are equal in assembly order and type.) Tungsten not included, but available in select Consumable Kits on the website at www.everlastwelders.com.

  • Page 75: Troubleshooting

    Weld is dirty/oxidized, or porous. fan activity. Solenoid is sticking. Listen for audible click of gas solenoid. If no click is heard, then contact Everlast Support. Clean weld properly. Increase pre flow or For Flux Core, a certain amount of spatter, post flow.
  • Page 76 Check gas flow. Adjust for higher flow of gas. Listen for audible click Weld is dirty/oxidized, or porous. activity. Solenoid is sticking. Too short of pre- of gas solenoid. If no click is heard, then contact Everlast Support. Clean flow or post-flow. weld properly. Increase pre flow or post flow.
  • Page 77 Arc length too short with anti-stick turned on. Turn off anti-stick. Unstable Arc. Arc length is too long Shorten arc length and increase arc force. Metal is indirectly connected through table or Connect work clamp directly to item being welded. other item. Other. Contact Everlast.

  • Page 78: Error Codes

    If this does not clear after releasing the switch, turn off unit immediately and check torch switch for stuck contact. If the pilot arc or HF Start is engaged without attempting to cut or weld for more than 3 seconds this will activate. OTHER CONTACT EVERLAST...

  • Page 79: Maintenance

    11. Clean bezel vents and fan blades. Fan blades accumulate build-up which can cause reduced cooling efficiency, vibration and eventually failure. 12. Once cleaned, reassemble unit in reverse order. IMPORTANT: Never remove the front cover or upper operator’s panel unless instructed by Everlast.