Everlast PowerTIG 255EXT – 255 Amp Dual-Voltage AC/DC TIG & Stick Welder

Advanced AC/DC TIG performance for demanding aluminum, stainless, steel, titanium, and production welding.
The Everlast PowerTIG 255EXT combines powerful output with precise digital control for professional welders who need dependable performance across thin sheet, heavy plate, and repeat production work. With dual-voltage 120V/240V operation, four AC waveforms, Advanced AC Pulse, programmable memory, and strong Stick welding capability, it is built for serious fabrication without unnecessary setup complexity.

Whether you are fine-tuning the arc for thin aluminum, increasing penetration on thicker material, or saving proven settings for repeat jobs, the PowerTIG 255EXT gives you the control needed to produce consistent, high-quality welds.

Why Welders Choose the PowerTIG 255EXT

• Powerful AC/DC TIG Output: Handles precision sheet-metal work, aluminum fabrication, and demanding production applications.
• Four AC Waveforms: Adjust arc feel, penetration, cleaning action, and heat input to match the job.
• Advanced AC Pulse: Helps increase penetration on thicker aluminum while reducing warping and burn-through on thin material.
• True Low-Amp Control: Starts as low as 3 amps DC and 5 amps AC for delicate welding work.
• Dual-Voltage Flexibility: Operates on 120V or 240V power for shop, field, and mobile applications.
• Professional Stick Performance: Includes adjustable Hot Start, Arc Force, and E6010 capability.

Advanced AC Waveform Control

• Advanced Square Wave: Produces a focused, responsive arc with strong penetration and precise puddle control.
• Soft Square Wave: Delivers a smoother arc with a softer, more traditional welding feel.
• Triangular Wave: Reduces average heat input to help control distortion on thin aluminum.
• Sine Wave: Produces a smooth, quiet arc with familiar transformer-style characteristics.

Key Features

• Digital microprocessor control
• Heavy-duty IGBT power modules
• 120V/240V dual-voltage operation
• Low output down to 3 amps DC and 5 amps AC
• 2T, 4T, foot pedal, and torch-mounted amperage control modes
• Four selectable AC waveforms
• Adjustable AC frequency and AC balance
• Standard pulse up to 500 Hz in DC and 250 Hz in AC
• Advanced AC Pulse up to 10 Hz
• Two Easy Start modes for faster AC or DC setup
• Programmable memory for repeat welding parameters
• HV Start with electronic control for smoother starts and reduced maintenance
• Lift Start capability
• Dedicated gas purge button for setup without initiating the arc
• Spot-weld timer for repeatable tacking and sheet-metal work
• Adjustable Stick Hot Start time and intensity
• Adjustable Stick Arc Force control
• VRD function for applications where reduced open-circuit voltage is required
• E6010 and cellulose-electrode capability
• Built-in receptacle for the Everlast PowerCool 300 water cooler
• Fan-On-Demand cooling system
• Simplified menu design with no hidden setup menus

What’s Included

• 9 Series Air-Cooled TIG Torch with 12.5' Cable and 35 Series DINSE Connector
• 20 Series Water-Cooled TIG Torch with 12.5' Cable and 35 Series DINSE Connector
• Two TIG Torch Switches with 12.5' Cables and 7-Pin Female Plugs for 2T/4T Operation
• Stick Electrode Holder with 10' Cable and 35 Series DINSE Connector
• Ground Clamp with 10' Cable and 35 Series DINSE Connector
• Power Pedal TIG Deluxe 22K
• RH-191 Argon Regulator with Hose
• 6' Input Power Cable with NEMA 6-50 Plug
• Starter Consumable Kit

Note: Tungsten electrodes, water cooler, and welding cart are not included.

Ideal Applications

• Production welding and fabrication
• Precision aluminum fabrication
• Motorsports and off-road fabrication
• Automotive restoration and customization
• Aerospace and aircraft fabrication
• Prototype development
• Industrial maintenance
• Shipyard work
• Pipe and pipeline applications
• Farm and ranch maintenance
• Educational welding programs
• Professional and advanced home shops

Recommended Materials

• Aluminum
• Steel
• Stainless steel
• Chrome-moly
• Titanium
• Copper
• Nickel alloys
• Most weldable metals

TIG Welding Capacity

On 240V Power:

• Steel, Single Pass: Up to approximately 3/8"
• Steel, Multi-Pass: Up to approximately 1"+
• Aluminum, Single Pass: Up to approximately 3/8"
• Aluminum, Multi-Pass: Up to approximately 1"+

On 120V Power:

• Maximum TIG Output: 150 amps
• Steel, Single Pass: Up to approximately 3/16"
• Steel, Multi-Pass: Up to approximately 7/16"
• Aluminum, Single Pass: Up to approximately 3/16"
• Aluminum, Multi-Pass: Up to approximately 3/8"

Minimum Recommended Material Thickness:

• Steel: Approximately .004"
• Aluminum: Approximately .005"

TIG capacity figures are based on accepted industry practices for quality single- and multi-pass welding. Advanced AC Pulse may improve performance on thicker aluminum when properly adjusted. Actual results depend on joint design, material condition, shielding gas, operator technique, and application requirements.

Stick Welding Capacity

• Minimum Electrode Diameter: 1/16"
• Maximum Electrode Diameter on 240V: Up to approximately 3/16"
• Maximum Electrode Diameter on 120V: Up to approximately 3/32"
• Maximum Stick Output on 120V: 120 amps
• E6010 Capability: Supported, although performance may be limited when operating on 120V

Maximum electrode diameter depends on electrode classification, manufacturer recommendations, welding position, and application.

Power & Generator Requirements

• 120V or 240V input power
• Use only generators certified by the manufacturer as producing clean power
• Total harmonic distortion must be less than 5%
• Minimum for 120V Operation: 4,200 surge watts
• Minimum for 240V Operation: 10,500 surge watts
• Recommended for Best Performance: 12,500 surge watts or greater

Who Is the PowerTIG 255EXT Best For?

The PowerTIG 255EXT is best for welders who need more power and control than a basic AC/DC TIG machine provides. Its combination of high output, low-amp control, four AC waveforms, Advanced AC Pulse, memory, and professional Stick controls makes it well suited for aluminum fabrication, motorsports, aerospace work, production welding, and shops that regularly move between thin and heavy materials.

Frequently Asked Questions

Can the PowerTIG 255EXT weld aluminum?
Yes. It provides full AC TIG capability with adjustable AC frequency, AC balance, four selectable waveforms, and Advanced AC Pulse.

What is the benefit of Advanced AC Pulse?
Advanced AC Pulse can improve penetration on thicker aluminum while helping reduce heat input, warping, and burn-through on thinner material.

How is this different from a basic AC/DC TIG welder?
The PowerTIG 255EXT offers greater control through four AC waveforms, high-frequency pulse, programmable memory, true low-amp operation, Easy Start modes, and advanced Stick settings.

Can it run on standard 120V power?
Yes. It operates on both 120V and 240V. Maximum output is reduced to 150 amps in TIG mode and 120 amps in Stick mode when using 120V power.

Does it include both air-cooled and water-cooled TIG torches?
Yes. The package includes a 9 Series air-cooled torch and a 20 Series water-cooled torch. The required water cooler is sold separately.

Does it include a foot pedal?
Yes. The Power Pedal TIG Deluxe 22K is included.

Can it weld with E6010 electrodes?
Yes. The PowerTIG 255EXT supports E6010 and other cellulose electrodes, although E6010 performance may be limited when operating on 120V.

Can I save frequently used settings?
Yes. Programmable memory allows proven welding parameters to be saved for faster setup and more repeatable production work.