EVERLAST

Power Plasma Series

Plasma Cutters
Operator ’ s Manual for PowerPlasma® Series
Includes Models 50,60,60E,70,80

Safety, Setup and General Use Guide

1
Rev. 1 0606-09
Thank you for purchasing an everlast product. We ap-
preciate your patronage and hope that you will enjoy
years of use from our product.

Please go directly to the Everlast website to register

your unit and receive your warranty information.
Your unit registration is important should any infor-
mation such as product updates or recalls be issued.
It is also important so that we may track your satis-
faction with Everlast products and services. If you
are unable to register by website, contact Everlast di-
rectly through the consumer department at the main
number. Your unit will be registered and warrantee
will be issued and in full effect.

2
Serial number: __________________________
Model number: ____________________________
Date of Purchase___________________________

EVERLAST
Contact Information
Everlast consumer satisfaction email: sales@everlastwelders.com
Everlast Website: everlastwelders.com
Everlast Technical Support: Support@everlastwelders.com
Main toll free number: 1-877-755 WELD ( 9353 ) 9am—5pm PST M-F
11am-4pm PST Sat.

FAX: 1-650-588-8817

NOTES:

3
 Table of contents

Section……………………………………………….Page

General ...…………………………………………… 5
Safety Precautions..………………………………. 6
Introduction and Specifications………………… 9
Know Your Machine……………………………….. 14
2.1 Panel Face and Functions…………………… 14
2.2 Lower Panel and functions….……………… 15
Getting Started…………………………………….. 16
3.1 General Guidelines…………………………… 16
3.2 Compressor Selection……………………….. 16
3.3 Air Filter Installation and Selection……….. 16
3.5 Plasma Torches……..………………………... 17
3.7 Plasma Operation…….……………………….. 17
3.8 Helpful Hints..…….……………………………. 18
3.9 Gouging…………….…………………………… 19
3.10 Piercing………………………………………… 19
4.0 Troubleshooting……………………………….. 20

4
 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 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, op-
eration 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 an electrician if distur-
bance 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
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 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
gases which contains chemicals known to the State of California to cause birth de-
fects 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.

Proper maintenance is your responsibility. Make sure all equipment is properly main-
tained 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
PowerPlasma 60, 60E,70,80

PowerPlasma 60 PowerPlasma 60E

PowerPlasma 70 PowerPlasma 80
9
Section 1 Introduction and Specifications

used at the rated power setting . Over-

1.1 This manual has been compiled to give heating may occur if the duty cycle is ex-
an overview of operation and is designed to ceeded. On multi-voltage, multi-phased
offer information centered around safe, machines, note that the rated duty cycle
practical use of the machine. It is not in- will change.
tended to teach cutting technique. All
suggestions and techniques given are ap- 1.5 The unit should be stored in a dry
proximations and should be used as a gen- place for long term storage. Humid/wet
eral guide only. conditions can contribute to the eventual
decay of the circuitry in the machine. For
1.2 To ensure that your Everlast product is safety reasons, do not use this machine
in top condition, carefully inspect unit for directly in the rain or with soaked clothing
damage upon opening the box, looking for or protective gear.
damage on the surface of the unit and to
the machine itself and all its accessories. 1.6 Use only the provided handles to lift the
Do this immediately upon receipt of prod- unit. Do not suspend by cables or chains
uct. Any damage issues must be resolved or use fork trucks to lift the units. If neces-
right away. It is further recommended that sary, use two people to carry the unit.
the product be tested at the same time for
proper operation, even if it is to be stored 1.7 Make sure that the units cooling fan
for a while. Check to make sure all pas- and exhaust vents are kept free of obstruc-
sages, connections and fittings are clear of tion. Before every operation, inspect the
any packing material or other obstruction. unit for unexpected obstructions such as
Record the serial number on the page pro- insect and rat nests. From time to time, a
vided in this manual. Include purchase date cleaning of the machine with low pressure
for warranty reference. Serial numbers are air and a small plastic bristle brush is nec-
located on the rear of the machine. essary to ensure long life. On these occa-
sions only, unplug unit and remove cover
1.3 The PowerPlasma (includes 60E indus- to access interior. Concentrate efforts on
trial) units are used daily in the industry aluminum heat sinks and panel vents to
performing day to day fabrication and re- remove dust and dirt.
pair activities. The exceptional arc charac-
teristics are provided by the inverter based 1.8 Refer to the following pages to locate
technology that employs the use of reliable your particular unit and its specifications.
IGBT transistors technology from Ger- Note that product specifications are sub-
many. Lightweight inverters allow a ma- ject to change without notice due to prod-
chine to be finely tuned for precise arc uct improvements. If any additional infor-
characteristics, while consuming less mation is needed contact Everlast. Sche-
power than the larger transformer based matics are not offered due to the proprie-
machines. Power Plasma units allow non- tary information that they contain. How-
contact starts, thanks to Pilot Arc technol- ever, simple wiring diagrams may be ob-
ogy. The employment of the Pilot Arc sim- tained for basic diagnosis and may be ob-
plifies cutting oxidized metals, expanded tained from technical support.
metals and wire meshes by providing a self
energizing arc while the unit is not in close
contact with the base metal. It reduces
electrode fouling and allows for use in ar-
eas sensitive to high frequency.

1.4 Be careful to observe duty cy-

cles of the machine posted in this
manual and on the machine itself.
A duty cycle is a rating of percentage of
time out of 10 minutes the machine can be
10
 Section 1 Introduction and Specifications

PowerPlasma Models
Table 1.1
MODEL PowerPlasma 50

Power Voltage 1 x220/230/240V ± 10%;50/60Hz

Input Current 39A

Rated Output Current 50A

Current Range 20-50A
Open Current Voltage 200V
Rated Duty Cycle @ 50 Amps 60%

Start Type/Operation Pilot Arc/ ⅛” Standoff or Drag

Air Pressure 70-90 psi > 5.0 cfm*

Rated Quality Cut /Severance 11/16 inches (17 mm)/ 7/8 inch (22 mm)
After Flow Time 10 Seconds
Outline Dimensions 18X8.25X12.25 inches (460X210X310 mm)

MODEL PowerPlasma 60

Power Voltage 1 x220/230/240V ± 10%;50/60 Hz

Input Current 50A

Rated Output Current 60A

Current Range 20-60A
Open Current Voltage 200V
Rated Duty Cycle @ 60 Amps 60%

Start Type/Operation Pilot Arc/ ⅛” Standoff or Drag

Air Pressure 60-100 psi >5.7 cfm*
Rated Quality Cut/ Severance Cut 1 inch (25 mm)/ 1 ¼ inches (32 mm)
After Flow Time 10 Seconds
Outline Dimensions 22X8.6X14 inches (560 × 220 × 360 mm)

11
Section 1 Introduction and Specifications

PowerPlasma Models

PowerPlasma 60E
MODEL
(Industrial/ Large frame)
Power Voltage 3 x 220/230/240V ± 10%;50/60Hz

Input Current 28.9A

Rated Output Current 60A
Current Range 20-60A
Open Current Voltage 200V
Rated Duty Cycle 60%

Start Type/ Operation Pilot Arc/ ⅛” Standoff or Drag

Air Pressure Requirements 65 -100 psi >5.3 cfm*
Rated Quality Cut/Severance Cut 1 inch (25mm) 1 ⅜ inches (35 mm)
After Flow Time 10 Seconds
Outline Dimensions (20.5X10.25X21.25 inches) 520X260X540

MODEL PowerPlasma 70
Power Voltage 1 x220/230/240V ± 10%;50/60Hz
Input Current 58A
Rated Output Current 70A
Current Range 20-70A
Open Current Voltage 200V
Rated Duty Cycle @ 70 Amps 60%

Start Type/ Operation Pilot Arc/ ⅛” Standoff or Drag

Air Pressure 65-100 psi > 6.5 cfm*
Rated Quality Cut/ Severance Cut 1 ⅛ inches (29 mm)/ 1 ½ inches (38 mm)
After Flow Time 10 Seconds
Outline Dimensions 22X8.6X14 inches (560 × 220 × 360 mm)

12
Section 1 Introduction and Specifications

PowerPlasma Models

MODEL POWERPLASMA 80

Power Voltage 1 x220/230/240V ± 10%;50/60Hz

Input Current 70A

Rated Output Current 80A
Current Range 20-80A
Open Current Voltage 200V
Rated Duty Cycle 60%

Start Type/ Operation Pilot Arc/ Standoff or Drag

Air Pressure 65-100 psi >7.0 cfm*
Rated Quality Cut/ Severance Cut 1 ¼ inches (32 mm) 1 ⅝ inches (42 mm)
After Flow Time 10 Seconds
Outline Dimensions 22X8.6X14 inches (560 × 220 × 360 mm)

* Actual requirement of Cubic Feet Per Minute of air and actual air pressure
used varies depending upon the metal thickness, metal type, and whether
gouging or cutting. Gouging requirements use less pressure. If continuous cut-
ting and gouging is done within the duty cycle requirements of the machine, cfm
requirements will increase significantly.

13
Section 2 Know Your machine

2.1 Panel Face. The following numerically 6. Air Pressure Gauge. Dual scaled.
referenced items refer to controls and fea-
tures found on the front panel. 7. Air Pressure Regulator. Rotate knob to
increase or decrease air pressure. Note
1. Amp Meter. Registers preset amper- that changes and variations of pressure
age. It is accurate within ± 7%. may occur while compressor is running.
Adjustment of the supply side regulator
2. Power Indicator. Illuminates when may be necessary to reduce variations of
power is on and plugged in. pressure. 60E knob is on the back of unit.

3. Low Air Pressure Warning. Illuminates 8. Auto/Standard Switch. Controls the

when air pressure fails below safe operat- function of the trigger on the torch. Use the
ing level. Discontinue use until pressure torch in standard mode for simple cutting
returns to safe operating levels. operations by pressing and holding the

6
2
1 3 5
4

9 8

trigger to initiate cutting. Use the Auto-

If frequent warnings occur, check for matic mode to “lock” on the cutting power
broken, kinked or leaking lines inter- by pressing and releasing the trigger.
nally and externally. If no fault is found, Press and release the trigger again, to de-
consider upgrading to a larger air com- activate the arc. This is helpful for long
pressor. cuts, CNC or track torch applications.

4. Over Current Warning. Illuminates 9. Cutting/Test Switch. Cutting mode acti-

when duty cycle has been exceeded. vates the post flow automatically. If mak-
ing long or thick cuts, additional after flow
5. Cutting Amperage. Selects cutting am- to cool the torch may be needed. If so, se-
perage. Cutting Amperage will be deter- lect Test position for additional manual
mined by thickness and type of metal. Re- post-flow or to check for positive flow of
duction of amperage will improve quality of air. After cool down or testing, return the
cuts on thinner materials without over- switch to the cutting position to resume
melting and refusing of cut pieces. normal post-flow timing.
14
Section 2 Know Your machine
continued
2.2 Lower Panel. The lower front panel is de- 2.3 Rear Panel. The following depiction is a
picted below. Each terminal or lug should be typical rear panel view.
kept free of dirt or obstructions.
Image 2.2
1 2 3
Image 2.3 Rear Panel

1 2 3 4 5
1. Work Piece. The ground clamp is at-
tatched to this jack by aligning the tabs on the
plug and the receptacle and giving a slight
twist clockwise.

2. Fuse. This fuse is connected to the pilot 4

arc. If the fuse blows, then the pilot arc will
not initiate. Check this fuse first for any prob-
lems associated with the pilot arc. Replace
the fuse with the same rated fuse only.

3. Control. The switch control from the torch

connects to this connector. Screw the con-
nector together firmly. Some models may
have more than the four pins pictured.\

4. Pilot Arc. The Pilot Arc is responsible for

establishing an arc once the trigger is
pressed. Pilot arcs do not require touching
the electrode to the work piece. Also,they
reduce fouling of the electrode tips for im-
proved cuts. Connect the pilot arc by un- 5 6
screwing the knob on the pilot arc stud. 1. Serial Number. Record in manual.
Place the pilot arc wire from the torch (with
the round ring), on the stud and tighten screw 2. Machine Specifications. This information
thumb tight. supersedes any specifications offered in the
manual when specification changes occur
5. Torch. Connect the main torch hose to from time to time.
this fitting. Tighten firmly to seat the fittings.
Do not use any type of thread sealant. Using 3. Double Pole Power Switch. This heavy
thread sealant will prevent the necessary duty switch powers the unit. Flipping the
metal to metal contact required to power the switch turns the unit on or off.
torch once the pilot arc initiates. If a leak is
observed, remove the torch and inspect the 4. Fan. Allow 12 inches of clearance between
threads and seat. If a fault or defect is found the fan and any object that could restrict air
in the threads, contact Everlast. If the seat is flow. This includes walls and workbenches.
found to be plugged, carefully clean the seat
(with the unit unplugged) with a small instru- 5. Air Inlet. Connect to regulator.
ment such as a small pick to remove the ma-
terial found to be plugging the port 6. Power Cord.
15
Section 3 Getting started

3.1 These are general guidelines for use

and maintenance for your PowerPlasma that can develop inside the supply lines
unit. Take into account all safety rules and between the unit and the air compressor.
recommendations first before operation
and service. Do not let untrained person- Many types of air dryers/filters are readily
nel operate or service equipment in any available. Refrigerated systems are highly
way. effective, yet expensive. Other less effec-
tive but acceptable forms of dryers include
3.2 Compressor selection. desiccant dryers, water separators and
Proper Air Compressor selection is critical cyclone filters. Additionally, filters that
to providing trouble free operation of your trap particulates and oil may be required
Power Plasma unit. Issues such as maxi- depending upon your compressor type and
mum air pressure and cubic feet per min- age. These dyers are available everywhere
ute at full rated air pressure are important air compressors are sold and in some auto
when selecting an appropriate air com- part stores.
pressor to supply the needed air to cut ef-
fectively. Listed in the earlier chapter for Be sure to service the air dryers on a regu-
your machine is the cubic feet per minute lar and frequent basis. Drain water from
(cfm) and air pressure (psi) requirement. air compressors frequently as well. Humid
These are minimum requirements needed days and rapid changes in temperatures
to allow your machine to operate in aver- can accelerate the accumulation of water
age circumstances. Rarely, less pressure in air compressors and air lines.
and cfm may be required for certain short Image 3.3 Commonly available air dryers.
burst activities. However, if you intend to
fully use your unit to its potential, then you
will need to use an air compressor that is
capable of exceeding the posted minimum
requirements. Many times this means hav-
ing a separate 220V circuit available to
power the air compressor. However,
there are quite a few newer compressors
capable of meeting the minimum air re-
quirements for the PowerPlasma 50 for av-
erage use that run on 110V.

3.3 Air Filter and Air Dryer Selection.

Every PowerPlasma Unit must be oper-
ated with at least one air dryer con-
nected to the air suppy line. Failure to use
an air dryer will void the warranty! Most
units include one air dryer. Moisture in the
air supply is the number one cause of pre- 3.4 Powering the Unit. It is important that
mature consumable failure. Moisture can all extension cords and circuits be rated
destroy a contact tip or electrode in a mat- for the appropriate amperage of your unit.
ter of seconds if it is present at high levels. Consult the specifications for requirements
It can stick solenoids and ruin other com- of the unit. Underrated circuits and exten-
ponents as well. It is advisable to actually sion cords can lead to over heating and
employ at least two air dryers in the sys- eventual failure of the unit itself. If cor-
tem. One should be installed at the unit rectly wired and rated circuits are repeat-
and the other should be installed at the edly tripped and the unit acts irregularly,
compressor. If only one is to be installed, discontinue use and contact Everlast.
then the air dryer should be installed at the
machine itself to eliminate the moisture
16
 Section 3 Getting started

3.5 Plasma Torch. Becoming familiar with a 3.6 Plasma Principles. Before any weld-
Plasma torch is a necessary step to becoming ing or cutting takes place, it is necessary to
proficient at Plasma put on protective gear and familiarize yourself
Everlast Cutting. Refer to the with safety precautions.
following image for a
typical Plasma torch Plasma Cutting is an efficient and simple way
Eve
breakdown for the to cut multiple metal types. The super sonic
rlas
t Plasma 50 and 60-80 plasma stream, generated by ionized pressur-
torch assemblies. ized air, is capable of rapidly burning metal
Image 3.8a without overheating the surrounding area.
PowerPlasma Torches
This is helpful for preventing warpage and
preventing the formation of Heat Affected
Zones (HAZ) in the metal.

4 3.7 Simple and easy steps to cutting correctly

2 with an Everlast PowerPlasma® Cutter.
5
Ev

1
er

1. Set Amperage and Air pressure to suit the

la
st

units specifications.
3 4 Place the torch cutting
1 2 tip directly on the edge
5
Ev

of the metal. Alterna-

er

tively, you may allow

la

Image 3.8b
up to 1/8 inch of stand-
st

Typical Everlast Torch Parts

off to prevent extra
wear and blow back of material.

1. Cup. Screws to torch body. It focus the 2. Press trigger to begin cutting. Hold torch
gas in the plasma stream. Replace when ei- trigger down to continue
ther severely burned or cracked. cutting in Standard
mode. To cut in Auto-
2. Cutting Tip. Directs the plasma flame to matic mode, press trig-
the base metal. Either screws to torch or sits ger to allow arc to start
inside cup, depending upon model. Check tip and release trigger to
frequently for wear or burn through. continue cutting.

3. Swirl Ring. Rapidly spins air into a tornado 3. Once Plasma stream is established and
like stream to create plasma. Not found on all sparks exit the bottom of
torch designs. If your torch (S-series in par- the piece of metal being
ticular) has a swirl ring, it must be used. cut, slowly move the
torch forward into the cut.
4. Electrode. This forms the arc needed to Depending upon torch ori-
create the plasma head. Often when tip is entation, you may pull,
burned or worn, the plasma cutting ability of push or move side-to-side
the unit becomes limited. Check condition to make the cut. Grip the
when changing out cutting tips. torch only tight enough to
keep the trigger pressed. A tight grip will re-
5. Torch Body. Keep the body of the torch in sult in uneven cutting. Glide the hand gently
good condition. Inspect often for cracks and across the metal, maintaining a drag style cut
burns in the torch body to prevent electrocu- or a standoff. Use standoff wheels or ring if
tion. Make sure that the switch is functioning necessary on long cuts. If the torch tip sticks
properly. Do not oil or grease the switch. or fouls excessively, revert to standoff cutting.
17
Section 3 Getting started
continued
4. Continue cutting following the desired 7. Allow post/after flow cooling to occur.
path of cut. Make sure Post flow will continue for
that the sparks are exiting up to a half a minute after
the piece of metal at a 10- Post Flow the cut is completed. If ad-
15 degree angle. If the ditional cooling is required
sparks are exiting straight because of heavy cutting or
down, then the cutting extended cutting, switch
speed is too slow. In- the post flow switch to
crease cutting speed until “Test” to start manual cooling of the torch.
a change of the spark an- After the torch is sufficiently cooled, return
gle is observed. If exces- the switch to cutting mode to discontinue
sive slag is building up on the bottom of the the post/after flow cooling cycle.
metal (more than 1/8 inch) then either in-
crease amperage, travel speed or air pres- 3.8 Helpful Hints for cutting.
sure. Sometimes excessive slag build up on
the bottom of the cut occurs because the 1. Make several practice cuts first. Adjust
machine has reached its severance limit. the amperage and air pressure throughout
Occasionally excessive slag can be caused the range to see the effects it has on the
by rusty or contaminated metal. Note that cut. Each machine will have a slightly dif-
cutting thicknesses posted in the specifica- ferent range or “sweet spot”.
tion page are specifically for mild carbon
steel under ideal circumstances. Stainless, 2. Use a substantial flat piece of metal to
Aluminum and other metals have reduced make a long, clean cut. Attempting to cut
ratings cut ratings. Cutting capacity of odd objects or make short cuts cannot
these metals are generally 10-20% less than really train proper technique. It will also be
mild steel. difficult to ascertain the quality of the cut.

5. Exit the cut by pausing briefly to allow

the spark stream to catch
up and to be directed
straight down. This is usu-
ally the most challenging
part of the cut because the
bottom of the cut needs to
be even with the top before
exiting or the cut piece will
remain stuck to the parent
piece of metal. Carefully work the plasma
stream to the very edge of the cut.
Image 3.11 Practice Cuts Using Different
6. Release the trigger to break the arc in Settings.
the Standard mode setting.
In the Automatic mode set- 3. Keep torch straight in cut. Do not lean
ting, repress the trigger or tilt the torch. The ergonomic design of
and release to discontinue Everlast’s torches eases this problem.
the arc. However, fatigue is a common cause for
Caution! Breaking the poor, uneven cuts.
arc in the auto mode by lifting the arc away
will not satisfactorily terminate the arc and 4. Keep consumables checked for wear.
will restart the pilot arc. Precautions must Tip wear can decrease cutting capacity and
be taken in this mode or serious injury can cut quality at an imperceptible rate until
occur. cutting ability is significantly affected.
18
Section 3 Getting started
continued
3.9 Gouging.
Everlast PowerPlasma Cutters are able to
perform light to medium gouging, depend-
ing upon the type of metal with the stan-
dard cutting tip and electrode. To gouge,
simply lower the air pressure until the low
air pressure warning light comes on.
When the light illuminates, allow the air
pressure to stabilize and increase the air
pressure 5-10 pounds above the warning
light threshold.
Lean the torch at a 30-35 degree angle to
the work piece and begin to gouge. If you
experience problems, experiment with the
air pressure to accomplish the desired
type of gouge. For certain applications, a
special gouging tip may be required. For
this special need, contact Everlast in ad-
vance of the expected time of need to de-
termine availability of special gouging
electrodes.

3.10 Piercing.

Occasionally, the need will arise to pierce

directly down into a piece of metal to initi-
ate a cut with out the benefit of starting on
the edge of the material. This is known as
piercing. To pierce, simply start the torch
with a 1/8 inch stand-off at the desired
spot. If possible, lean the torch at a slight
angle so that blowback does not become
a problem and will not foul the tip. Make
sure that you tilt the torch away from the
piece being cut out to prevent marring.
Allow the torch to slowly burn its way
through the metal. As the torch plasma
stream burns down through the plate,
straighten the torch into the cutting posi-
tion. As sparks begin to exit the bottom,
you may shorten the stand-off and begin
your cut. Excessive use of piercing will
significantly reduce consumable life, par-
ticularly with an inexperienced operator.
Do not attempt to pierce an object that is
thicker than 50-60% of the rated cut ca-
pacity to ensure long torch life.

Note that piercing can produce a lot

of blowback of molten metal. Protec-
tive gear is absolutely required, espe-
cially face shields and fire proof clothing.

19
Section 4 Trouble Shooting

TROUBLE: CAUSE/SOLUTION

Machine will not turn on. Check cords and wiring. Check circuit
breaker. If no fault is found, contact
Everlast Support.

Machine runs, but will not cut. Check for a good ground. Make sure
ground cable and PlasmaTorch is se-
curely fastened to lug and receptacle.
Check that the Auto/Standard switch is
in the correct position for type of use de-
sired (see Auto/Standard operation).
Pilot Arc will not energize. Check machine fuse. Contact Everlast
Support for further remedy.

Electrodes and tips are rapidly con- Inadequate air flow. Water in air supply.
sumed. Poor cutting technique. Return to stand-
off cutting of no more than 1/8 inch.
Heavy slag on the underside of the cut Travel speed too slow. Either increase
with complete cut through. cutting speed or reduce cutting amper-
age to fit metal thickness. Too much
standoff (more than 1/8 inch).
Cut is beveled on one side. All plasma cutters tend to leave a slightly
beveled side (up to 5 degrees). However,
decreasing the standoff and increasing
air pressure can help reduce or eliminate
problems. Always orient bevel toward
parent piece so that part remains true.
Air pressure warning light illuminates Internal leakage around air fittings.
while there is adequate pressure dis- Though typically an easy fix, consult with
playing on pressure gauge. Everlast Support for instructions if
needed.
Cut quality is poor. Check and adjust settings. Increase/
decrease air pressure. Check for con-
sumable wear.
Over current LED illuminates. Duty cycle exceeded. Allow machine to
cool. Make sure fan is not blocked.

Unstable Arc. Poorly grounded unit or worn electrode.

Other issues. Contact Everlast Support.

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