Everlast PowerPlasma 60S User manual

EVERLAST
POWERPLASMA S SERIES
Operator’s Manual for the PowerPlasma S Series
(60-100 Amp Models)
Safety, Setup and General Use Guide
CC
IGBT
1
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PHASE
Rev. 5 0 000330-18
everlastwelders.com
1-877-755-9353 Specicaons and Accessories subject to change without noce.
329 Lileeld Ave. South San Francisco, CA 94080 USA
PAC
60-100 Amp S Series IGBT Inverter Platform Plasma Cutters

2
Table of contents
Secon……………………………………………………………..Page
Leer to the Customer ………………...………………….
Everlast Contact Informaon…………………………….
Safety Precauons…………………………………………....
Introducon and Specicaons…………………….…..
Unit Specicaons……………………….……………………
General Overview…………….…..…………………………..
General Use and Care………...……………………………..
Quick Setup Guide, Torch Connecon….…………….
Rear Panel Gas Connecon and Wiring.…………….
Compressor and Air Dryer Diagram..……..…………..
Front Panel Features and Controls……………………..
Rear Panel Features and Controls……………………….
Basic Theory and Funcon.………………………………...
PowerPlasma 60S Torch………………………………………
PowerPlasma 80S Torch……………………………………...
PowerPlasma 100S Torch…………………………………...
CNC Connector Pin-Out…...…………………………………
Troubleshoong……………………………………………..…..
Special Operang Note……………………………………….
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5
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NOTE: Product specifications and features are subject to change without notice. While every attempt
has been made to provide the most accurate and current information possible at the time of publica-
tion, this manual is intended to be a general guide and not intended to be exhaustive in its content re-
garding safety, welding, or the operation/maintenance of this unit. Everlast Power Equipment INC.
does not guarantee the accuracy, completeness, authority or authenticity of the information contained
within this manual. The owner of this product assumes all liability for its use and maintenance. Ever-
last Power Equipment INC. does not warrant this product or this document for fitness for any particular
purpose, for accuracy of performance or for particular suitability of application. Furthermore, Everlast
Power Equipment INC. does not accept liability for injury or damages, consequential or incidental, re-
sulting from the use of this product or resulting from the content found in this document or accept
claims by a third party of such liability.

3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast. We appreciate you as a customer and
hope that you will enjoy years of use from your welder.
Please go directly to the Everlast website to register your unit and receive your warranty information.
Your unit registration is important should any information such as product updates or recalls be is-
sued. It is also important so that we may track your satisfaction with Everlast products and services.
If you are unable to register by website, contact Everlast directly through the sales department via
the main customer service number in your country. Your unit will be registered and warranty will be
issued and in full effect. Keep all information regarding your purchase. In the event of a problem
you must contact technical support before your welder can be a candidate for warranty ser-
vice and returned.
Please review and download the official warranty statement, located on our website
www.everlastwelders.com. If you are not in the United States, visit the distributor’s website
warranty information nearest to your region or country. Print it for your records and become
familiar of its terms and conditions.
Everlast offers full technical support in several different forms. We offer domestic based phone sup-
port and online support. Online support is available through email and through our website contact
forms. We also provide a welding support forum designed for customers and noncustomer interac-
tion. Technical advisors are active on the forum on a regular basis. We also divide our support into
two divisions: technical and welding performance. Should you have an issue or question concerning
your unit, please contact performance/technical support available through the main company head-
quarters available in your country. For best service, call the appropriate support line and follow up
with an email. In the event you do not reach a live person, particularly during heavy call volume
times, holidays, or off hours, leave a message and your call will normally be returned within 24
hours. For quick answers to basic operating or service questions, join the company owned forum
linked through the US website. You should be able to find knowledgeable, helpful people and staff
available to answer your questions, and perhaps find a topic that already addresses your question at
http://www.everlastgenerators.com/forums/.
Should you need to call or write, always know your model name, purchase date and welder manu-
facturing inspection date. This will assure the quick and accurate customer service. REMEMBER:
Be as specific and informed as possible. Technical and performance advisors rely upon you
to carefully describe the conditions and circumstances of your problem or question. Take
notes of any issues as best you can. You may be asked a series of questions by the advisors
that are meant to clarify problems or issues. Some of these questions may seem basic or
fundamental, but even with experienced users technical advisors can’t assume that correct
operating procedures are being followed for proper operation, and must cover all aspects to
properly diagnose the problem. Depending upon your issue, it is advisable to have basic
tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive test meter with
volt/ohm functions before you call.
Please note: To establish a warranty claim and return a unit for repair or replacement, you
must call technical support first and go through basic diagnosis before an Return Authoriza-
tion will be issued.
Let us know how we may be of service to you should you have any questions.
Sincerely,
Everlast Customer Service

4
Serial number: ____________________________
Model number: ____________________________
Date of Purchase:__________________________
Contact Information
Everlast US:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
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: [phone]
Everlast Canada:
Everlast consumer satisfaction email: [e-mail]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [email protected]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Australia:
Sydney: 5A Karloo Parade Newport NSW 2106
[phone]
Port Macquarie: 2B Pandorea Place Port Macquarie
[phone]
After hours support: 0413 447 492
Everlast Technical Support: [email protected]

5
Everlast is dedicated to providing you with the best possible equipment and service to meet
the demanding jobs that you have. We want to go beyond merely delivering a sasfactory
product to you. That is the reason we oer free technical support to assist you with your
needs should an occasion occur. In the event that you need a repair, or have an issue, please
call tech support to iniate a warranty claim and an Return Authorizaon number if needed.
With proper use and care your product should deliver years of trouble free service.
Safe operaon and proper maintenance is your responsibility.
We have compiled this operator’s manual to instruct you in basic safety, operaon and
maintenance of your Everlast product to so you may enjoy the best possible operang experi-
ence. Most welding and cung is based upon experience and common sense. As thorough as
this welding manual may be, it is no substute. Exercise extreme cauon and care in all acvi-
es related to welding or cung. Your safety, health and even life depends upon it. While
accidents are never planned, prevenng an accident requires careful planning.
Please carefully read this manual before you operate your Everlast unit. This manual is not
only wrien for the safe use of the machine, but also to assist in obtaining the best perfor-
mance out of your unit. Do not operate this unit unl you have read this manual and you are
thoroughly familiar with the safe operaon of the unit. If you feel you need more informaon
please contact Everlast Support.
The warranty does not cover improper use, maintenance or consumables. Do not aempt to
alter or defeat any safety device of your unit. Keep all shields and covers in place during unit
operaon should an unlikely failure of internal components result in the possible presence of
sparks and explosions. If a failure occurs, disconnue further use unl malfunconing parts or
accessories have been repaired or replaced by qualied personnel.
Note on High Frequency electromagnec disturbances:
Certain welding and cung processes generate High Frequency (HF) energy. These energy
waves may disturb sensive electronic equipment such as televisions, radios, computers, cell
phones, and related equipment. High Frequency may also interfere with uorescent lights.
Consult with a licensed electrician if a disturbance is noted. Somemes, improper wire roung
or poor shielding may be the cause.
HF can interfere with pacemakers. See EMF warnings in following safety secon for further
informaon. Always consult your physician before entering an area known to have welding or
cung equipment if you have a pacemaker.
Safety Precautions

6
SAFETY PRECAUTIONS
These safety precauons are for protecon of safety and health. Failure to follow
these guidelines may result in serious injury or death. Be careful to read and follow all
cauons and warnings. Protect yourself and others.
Welding and cung processes produce high levels of ultraviolet (UV) radiaon that can cause se-
vere skin burn and damage. There are other potenal hazards involved with welding such as severe
burns and respiratory related illnesses. Therefore observe the following to minimize potenal acci-
dents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even under weld-
ing helmets to protect your eyes from ying sparks and debris. When chipping slag or grinding, gog-
gles and face shields may be required.
When welding or cung, always use an approved shielding device, with the correct shade of lter
installed. Always use a welding helmet in good condion. Discard any broken or cracked lters or
helmets. Using broken or cracked lters or helmets can cause severe eye injury and burn. Filter
shades of no less than shade 5 for cung and no less than shade 9 for welding are highly recommend-
ed. Shades greater than 9 may be required for high amperage welds. Keep lter lenses clean and
clear for maximum visibility. It is also advisable to consult with your eye doctor should you wear con-
tacts for correcve vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cung operaon unless fully protected
by a lter screen, protecve curtains or equivalent protecve equipment. If no protecon is availa-
ble, exclude them from the work area. Even brief exposure to the rays from the welding arc can
damage unprotected eyes.
Always wear hearing protecon because welding and cung can be extremely noisy. Ear protec-
on is necessary to prevent hearing loss. Even prolonged low levels of noise has been known to cre-
ate long term hearing damage. Hearing protecon also further protects against hot sparks and debris
from entering the ear canal and doing harm.
Always wear personal protecve clothing. Flame proof clothing is required at all mes. Sparks and
hot metal can lodge in pockets, hems and cus. Make sure loose clothing is tucked in neatly. Leather
aprons and jackets are recommended. Suitable welding jackets and coats may be purchased made
from re proof material from welding supply stores. Discard any burned or frayed clothing. Keep
clothing away from oil, grease and ammable liquids.
Leather boots or steel toed leather boots with rubber booms are required for adequate foot pro-
tecon. Canvas, polyester and other man made materials oen found in shoes will either burn or
melt. Rubber or other non conducve soles are necessary to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cung or handling met-
al. Simple work gloves for the garden or chore work are not sucient. Gauntlet type welding gloves
are available from your local welding supply companies. Never aempt to weld with out gloves.
Welding with out gloves can result in serious burns and electrical shock. If your hand or body parts
comes into contact with the arc of a plasma cuer or welder, instant and serious burns will occur.
Proper hand protecon is required at all mes when working with welding or cung machines!

7
SAFETY PRECAUTIONS
WARNING! Persons with pacemakers should not weld, cut or be in the welding area unl they
consult with their physician. Some pacemakers are sensive to EMF radiaon and could severely
malfuncon while welding or while being in the vicinity of someone welding. Serious injury or death
may occur!
Welding and plasma cung processes generate electro-magnec elds and radiaon. While the
eects of EMF radiaon are not known, it is suspected that there may be some harm from long term
exposure to electromagnec elds. Therefore, certain precauons should be taken to minimize expo-
sure:
• Lay welding leads and lines neatly away from the body.
• Never coil cables around the body.
• Secure cables with tape if necessary to keep from the body.
• Keep all cables and leads on the same side the body.
• Never stand between cables or leads.
• Keep as far away from the power source (welder) as possible while welding.
• Never stand between the ground clamp and the torch.
• Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cung processes pose certain inhalaon risks. Be sure to follow any guidelines from
your chosen consumable and electrode suppliers regarding possible need for respiratory equipment
while welding or cung. Always weld with adequate venlaon. Never weld in closed rooms or con-
ned spaces. Fumes and gases released while welding or cung may be poisonous. Take precauons
at all mes.
Any burning of the eyes, nose or throat are signs that you need to increase venlaon.
• Stop immediately and relocate work if necessary unl adequate venlaon is obtained.
• Stop work completely and seek medical help if irritaon and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, tanium, copper, cadmium,
lead or zinc without proper respiratory equipment and or venlaon.
WARNING! This product when used for welding or cung produces fumes and gases which con-
tains chemicals known to the State of California to cause birth defects and in some cases cancer.
(California Safety and Health Code §25249.5 et seq.)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas. Release of Phos-
gene gas can be deadly. Consider all chemicals to have potenal deadly results if welded on or near
metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain regulaons re-
garding high pressure cylinders can be obtained from OSHA or local regulatory agency. Consult also
with your welding supply company in your area for further recommendaons. The regulatory changes
are frequent so keep informed.
All cylinders have a potenal explosion hazard. When not in use, keep capped and closed. Store
chained so that overturn is not likely. Transporng cylinders incorrectly can lead to an explosion. Do
not aempt to adapt regulators to t cylinders. Do not use faulty regulators. Do not allow cylinders to
come into contact with work piece or work. Do not weld or strike arcs on cylinders. Keep cylinders
away from direct heat, ame and sparks.

8
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 cung. Keep work surface dry. Do not
use welder or plasma cuer in the rain or in extremely humid condions. Use dry rubber soled shoes
and dry gloves when welding or cung to insulate against electrical shock. Turn machine on or o
only with gloved hand. Keep all parts of the body insulated from work, and work tables. Keep away
from direct contact with skin against work. If ght or close quarters necessitates standing or resng
on work piece, insulate with dry boards and rubber mats designed to insulate the body from direct
contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their locaon and make sure all
personnel in area are advised of their locaon. Taping or securing cables with appropriate restraints
can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cung. Always keep re exnguish-
ers close by and addionally a water hose or bucket of sand. Periodically check work area for smol-
dering embers or smoke. It is a good idea to have someone help watch for possible res while you are
welding. Sparks and hot metal may travel a long distance. They may go into cracks in walls and oors
and start a re that would not be immediately visible. Here are some things you can do to reduce the
possibility of re or explosion:
• Keep all combusble materials including rags and spare clothing away from area.
• Keep all ammable fuels and liquids stored separately from work area.
• Visually inspect work area when job is completed for the slightest traces of smoke or embers.
• If welding or cung outside, make sure you are in a cleared o area, free from dry tender and
debris that might start a forest or grass re.
• Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held amma-
ble liquid or material.
Metal is hot aer welding or cung! Always use gloves and or tongs when handling hot pieces of
metal. Remember to place hot metal on re-proof surfaces aer handling. Serious burns and injury
can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper mainte-
nance is your responsibility. Make sure all equipment is properly maintained and serviced by qualied
personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding parts. Touching
uncovered parts inside machine can cause discharge of high amounts of electricity. Do not allow em-
ployees to operate poorly serviced equipment. Always check condion of equipment thoroughly
before start up. Disconnect unit from power source before any service aempt is made and for long
term storage or electrical storms.
Further informaon can be obtained from The American Welding Society (AWS) that relates directly
to safe welding and plasma cung. Addionally, your local welding supply company may have addi-
onal pamphlets available concerning their products. Do not operate machinery unl your are com-
fortable with proper operaon and are able to assume inherent risks of cung or welding.

9
Introduction and SpecificationsSection 1
iPT 60/80/100 Torch
Work Clamp
NOTE: Accessory and consumable style and quanes are subject to change without noce.
Regulator Assembly with Bracket
PowerPlasma 60S/80S/100S
Consumable Starter Kit
(Qty. and items may vary)

10
Specicaon PowerPlasma 60S PowerPlasma 80S PowerPlasma 100S
Inverter Type IGBT IGBT IGBT
Minimum/Maximum Rated Output 20 A/88 V - 60 A/108 V 20 A/88 V-80 A/112 V 20/88V
Start Type Blow-Back Type Blow-Back Type Blow-Back Type
Torch Type Innotec iPT60 Innotec iPT80 Innotec iPT100
Duty Cycle @ Rated Amps/Volts ( 40° C)
(Output V/A)
60% @ 60 A/ 104V
100% @ 50 A/ 100 V
60% @ 80 A/112 V
100% @ 63 A/104 V
60% @ 100 A/ 120V
100% @ 80A/112V
OCV (U0) 240 V 240 V 250V
Voltage Input (U1) Standard 220/ 240 V;
50/60Hz 1 Ph
Standard 220/ 240 V;
50/60Hz 1 Ph
Standard 220/240V;
50/60Hz 1 Ph(3 Ph. Opt)
Maximum Inrush Amps (I1MAX) 41 A @ 240 V 58.4 A @ 240 V 78A/45A @ 240V 1Ph/3Ph
Maximum Rated Eecve Amps (I1EFF) 32.4 A @ 240 V 45.2 A @ 240 V 60/35 @ 220V 1ph/3ph
CNC Port Yes Yes Yes
Air Post Flow Timer Adjustable Adjustable Adjustable
Minimum Air Compressor Requirement 5.5 CFM @ 90 psi/
30-60 gallon reserve
7 CFM @ 90 psi/
30-60 gallon reserve
8 CFM @ 90 psi/
60 gallon reserve
Duty Cycle/ Over Current Protecon Yes Yes Yes
Minimum Operang Air Pressure
(Safety Cut-Out Threshold)
35 psi 35 psi 35 psi
Recommended Operang Air Pressure
(Set with Air Flow set to “Constant Flow”)
70-75 psi 70-75 psi 70-75 psi
Maximum Permissible Stac Air Pressure
(Without air owing)
85 psi 85 psi 85psi
Maximum Supplied Air Pressure
(From Compressor/Tank)
90 psi 90 psi 90 psi
Recommended Daily Maximum Average Daily
Cut Thickness (Hand Torch)
5/8” 1” 1 1/4”
Recommended Daily Maximum Average Cut
Thickness (CNC)
3/8” 5/8” 7/8”
Rated Maximum Quality Cut @10-12 IPM
(Steel)
1” 1 1/4” 1 3/8”
Max Severance Cut @ 3 IPM (Steel ) 1 1/4” 1 7/16” 1 5/8”
Minimum Water Ingress Protecon Standard IP21S IP21S IP21S
Eciency >85% >85% >85%
Cooling Method Full Time High Velocity Fan
with Tunnel Design
Full Time High Velocity Fan
with Tunnel Design
Full Time High Velocity Fan
with Tunnel Design
Dimensions (approximate) 18” H X 10” W X 25” L18” H X 10” W X 25” L18” H X 10”W X 25”l
Weight (Bare Unit) 55 lbs 55 lbs 58 lbs
Introduction and SpecificationsSection 1
Decrease maximum cut thickness values for aluminum and stainless by approximately 40%.
When evaluang a plasma cuer for daily service, do not consider maximum severance cut values as criteria for roune use! These maximum specicaons are intended for occasional
situaons that might require such a cut. Plan the unit’s daily use around the recommended average cut thickness for best results and speed. This is an industry standard recommendaon
and is not unique to Everlast PowerPlasma models. CNC cut thickness is further reduced as it is typically a 100% duty cycle operaon which will require a lower maximum amp seng.
Plasma performance specicaons are based on reasonable environmental condions with well maintained units, and cung with new consumables using opmum air pressure. Actual
performance results may vary in the eld due to variable condions, power supply, air pressure, air quality, consumable wear etc.

11
General overview: The new, redesigned PowerPlasma S
series are non-high frequency start machines. The “blow
-back” type start that is used is generally safe for use in
CNC applicaons and is ideal for general use. The elimi-
naon of the HF points within the unit also improves
reliability and removes the need for regular HF point gap
maintenance. Blow-back type start involves a rear-ward
movement of the electrode within the torch head when
forced by the air pressure. When air pressure is applied
the movement of the electrode o its seated posion
against the inner surface of the circuit grounded nozzle
creates a spark, energizing the plasma stream. This type
start means that it has a pilot arc design so that cung
can be done on any metal surface without having to con-
tact to strike an arc and is ideal for cung items like ex-
panded metal or uneven surfaces. There are several
other key features on the PowerPlasma S series:
A. IGBT construcon is designed to improve reliability
while providing power. By using mostly non proprie-
tary components long term serviceability is ensured.
B. Full bridge design features so switching technology
which further extends IGBT component life and ex-
tends its capabilies.
C. The Italian designed PT/iPT series of torches fea-
tures a “blowback” design with a Euro-type Central
connector. These oer improved consumable life
with a patented “back striking” design.
D. The Tip Saver feature further improves consumable
life by liming the pilot arc on me to 3 seconds. A
normal mode is also available for extended cung
on expanded/perforated metal and irregular surfac-
es. In the p saver mode, once the pilot arc has
been engaged for 3 seconds the pilot arc will exn-
guish and the trigger must be cycled to restrike.
E. Manual post-ow control is a unique feature with
Everlast and provides beer post ow control of the
air so consumable life is increased and the torch can
be cooled for an extended period of me if desired.
F. OK-to-Cut light stays lit while the plasma cuer is
within the minimum air pressure limits needed for
the torch to funcon without causing torch damage.
If the light goes out, the automac shut down ter-
minates the output of the unit unl the air pressure
is back to a sustainable level. Minimum air pressure
is set around 35 psi. Keep in mind this air pressure is
not ideal, but will prevent premature torch failure.
General Use and Care: The Plasma cuer is designed for
use in many industrial environments such as ship yards,
fabricaon shops and pipelines. However, care should
be taken to keep the unit out of direct contact with wa-
ter spray. The unit is rated IP21S, which rates it for light
contact with dripping water. It is a good idea to remove
the welder from the vicinity of any water or moisture
source to reduce the possibility of electrocuon or shock.
Never operate in standing water. This unit has a high
open circuit voltage further necessitang safe operang
pracces. The operator should be careful to prevent
splashing/spraying water in the direcon of the plasma
cuer. Every 1-2 months, depending upon use, the welder
should be unplugged, opened up and carefully cleaned
with dry, compressed air. Regular maintenance will ex-
tend the life of the unit. Always protect the unit from low
temperatures ( <-10°F/-23°C). Do not operate below 15°
F/9°CDo not restrict air ow or movement of air around
the plasma cuer. Allow a buer distance of 2 . from all
sides if possible, with a minimum distance of at least 18”
clearance. Do not direct metallic dust or any dirt inten-
onally toward the machine, parcularly in grinding and
cung operaons. Every three months, remove the cover
and blow out the interior with compressed air to remove
buildup (use safety glasses to protect your eyes). Before
opening the unit for service, make sure the unit has been
unplugged for at least 10 minutes to allow me for the
capacitors to fully discharge. Severe shock and/or death
can occur. During use and storage, make sure the panel
is protected from damage during welding and cung op-
eraons by ipping down the clear protecve cover.
Duty Cycle. The duty cycle for the PowerPlasma S series
units are rated for 60% while operang at the maximum
amps ouput. The duty cycle is based o a 10 minute duty
cycle rang at 40° C. This means that the unit is capable of
being operated at the maximum stated amps for 6 out of
every 10 minutes without a break to cool down the unit.
This does NOT mean that the unit can work 60% of any
greater length of me. A full 4 minute rest is needed for
maximum life. The temperature light will come on and
the welder will automacally stop welding when an over-
heat condion has occurred. Heat will connue to be
generated by and transferred to the electronics aer
cung has ceased. If an overheat event occurs, allow the
unit to cool for 15-20 minutes before reseng the unit.
Do not shut down an overheated cuer before resuming
cung. Operaon in humid, or hot condions can aect
duty cycle as well. Once the overheated condion has
cleared, reset the unit by cycling the power switch to o
and then back on. Do not operate the plasma cuer with
the covers removed for safety and overheang concerns.
IMPORTANT:
This manual has been compiled to give an overview of
operaon and is designed to oer informaon centered
around safe, praccal use of the plasma cuer. Do not
operate this machine unl you have fully read the manu-
al, including the safety secon.
Introduction and Specifications
Section 1

12
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: CONNECTIONS
WORK (+) TORCH (-)
CENTRAL CONNECTOR

13
QUICK SETUP AND USE GUIDESection 2
GAS
INLET
1~220 VAC
1~220 V
IMPORTANT: ALWAYS CONSULT A LICENSED ELECTRICIAN AND LOCAL CODES BEFORE RE
-WIRING YOUR WELDER OR ATTEMPTING TO MAKE ANY ELECTRICAL CONNECTION.
NEMA 6-50P
L2,WHITE; HOT (240V 1 PHASE) L1,BLACK; HOT (240V 1 PHASE)
QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING
(US/Canada)
SUPPLIED PLUG IS A NEMA 6-50P, THE STANDARD PLUG FOR
MOST 1 PHASE 240 V WELDERS IN THE US AND CANADA.
1
2
3
4
PUSH TO CONNECT TUBING
IMPORTANT: TO PREVENT AIR LEAKS, MAKE SURE TUBING ENDS ARE SQUARELY CUT
AND FULLY INSERTED. TO RELEASE TUBING: PRESS GENTLY ON PLASTIC COLLAR SO
THAT IT COMPRESSES INTO HOUSING AND THEN PULL TUBING OUT.
GREEN GROUND (220/240V 1 PHASE)
NOTE: WHEN ASSEMBLING AIR REGULATOR NOTICE THE MARKINGS THAT ARE STAMPED
ON TOP OF THE REGULATOR HOUSING FOR AIR FLOW DIRECTION. AIR FLOW DIRECTION
WILL BE NOTED AS IN/OUT OR BE STAMPED WITH A SMALL ARROW FOR AIR FLOW DI-
RECTION. THE QUICK CONNECT 1/4” MALE AUTOMOTIVE COUPLING SHOULD BE MOUNT-
ED ON THE SIDE OF THE REGULATOR WITH “IN” OR THE ARROW POINTING TO THE MID-
DLE OF THE REGULATOR. ALSO THE BRASS PLUG INCLUDED WITH THE ACCESSORY
PACKAGE SHOULD BE MOUNTED IN THE CENTER HOLE.
Not Pictured: L3,RED; HOT (240V 3
PHASE Opt. for PP 100S) Use a 3 phase
rated plug for this applicaon or wire
all wires directly to panel.

14
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: REAR CONNECTIONS AND WIRING
Compressor and Dryer Diagram
GAS
INLET
1~220 VAC
1~220 V
NOTE: A SEPARATE AIR DRYER BETWEEN THE AIR COMPRESSOR AND REGULATOR ASSEMBLY MUST BE IN-
STALLED. IT SHOULD BE INSTALLED AS CLOSE TO THE PLASMA CUTTER AS PRACTICAL. THIS IS A CUSTOMER
SUPPLIED ITEM. THIS WILL REDUCE CUTTING ISSUES SUCH AS SPITTING, POPPING AND RAPID CONSUMABLE
WEAR. THE REGULATOR/FILTER THAT IS INCLUDED IS NOT SUFFICIENT TO REMOVE ALL MOISTURE. IT SERVES
ONLY AS A WATER TRAP AND FINE SEDIMENT FILTER. ANY AIR COMPRESSOR SYSTEM PRODUCES MOISTURE IN
ALMOST ANY ENVIRONMENT REGARDLESS OF HUMIDITY LEVELS. DRAIN THE AIR COMPRESSOR DAILY. THE AIR
SUPPLIED TO THE PLASMA CUTTER SHOULD BE OF SIMILAR QUALITY USED FOR AUTOMOTIVE PAINTING. DIF-
FERENT STYLES OF DRYERS ARE AVAILABLE. THE MOST INEXPENSIVE AND COMMONLY AVAILABLE AIR DRYER IS
THE REPLACEABLE DESSICANT TYPE USED FOR AUTOMOTIVE PAINTING. DAMAGE DONE TO THE TORCH AND
THE PLASMA CUTTER (INCLUDING BUT NOT LIMITED TO: SHORTING, CORROSION AND DETERIORATION OF IN-
TERNAL LINES AND COMPONENTS) AS A RESULT OF EXCESS MOISTURE IS NOT COVERED UNDER WARRANTY.
ADDITIONALLY, A FILTER SHOULD BE INSTALLED IN-LINE OR AT THE COMPRESSOR THAT WILL FILTER ANY EX-
CESS OIL OR OIL BLOW-BY FROM THE LINE IF NECESSARY. DO NOT USE THE PLASMA CUTTER WITH OILING SYS-
TEMS DESIGNED TO AUTOMATICALLY LUBRICATE AIR TOOLS. FOR BEST RESULTS, USE THE PLASMA CUTTER
WITH A NEW AIR SUPPLY HOSE GUARANTEE THE AIR SUPPLY IS INITIALLY WITHOUT MOISTURE OR LUBE CON-
TAMINATION. IF THE AIR PRESSURE DROPS FROM THE COMPRESSOR TO THE CUTTER MORE THAN 5-10 PSI, OR
AIR FLOW IS INSUFFICENT, INCREASE TO A LARGER SIZE DRYER, FILTER OR AIR HOSE. FAILURE TO USE THE PROP-
ER DRYER OR FILTER IS THE NUMBER ONE CAUSE OF CUTTING ISSUES RELATED TO CONSUMABLE WEAR.
Air Dryer/Oil Filter
(Customer Supplied)
Regulator Assembly with
built-in water trap
and dirt lter (Included)
1/4” Automove Universal style
quick connector (Included)
Compressor and Air hose with-
ngs (Customer Supplied)

15
WORKPIECE TORCH
6. FUSE
3. AIR PRESSURE GAUGE
2. AIR PRESSURE OK TO CUT
1. AMP DISPLAY
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS
4. AMP CONTROL
5. CENTRAL CONNECTOR
FUSE
7. WORK
9. 2T/4T LOCK
10. PILOT ARC OPERATION
11. AIR FLOW FUNCTION
12. ON/TEMP/O.C
8. AIR POST FLOW

16
Section 2
FRONT PANEL FEATURES AND CONTROLS CONTINUED
QUICK SETUP AND USE GUIDE
PowerPlasma S Features Parameters Purpose
1. Amp Display 20-60 (60S)
20-80 (80S)
Displays selected amperage unl cut starts. Once cut starts, then amps display dynamically by dis-
playing the actual output amps while cung. While Pilot arc is engaged or when cut starts, the
amps will drop to 20-30 amps unl connuity is sensed and cung arc takes over and the pilot arc
disengages.
2. Air Pressure OK to Cut LED On/O This light should remain on as long as there is sucient cung pressure to protect the torch from
melng. Once the air pressure drops below the minimum threshold of approximately 35 psi, the
light will go out, indicang the pressure is too low. If the light goes out the unit will automacally
prevent the torch arc from being acvated and there will be no power to the torch. The unit will not
cut unl the minimum air pressure is sased.
3. Air Pressure Gauge. 0-150 psi The gauge registers up to 150 psi, but air pressure from the compressor to the cuer should never
be set above 90 psi. Air pressure to the torch while cung should ideally be around 75 psi.
4. Amp Control Innite Adjusts and selects desired operang amperage.
5. Central Torch Connector N/A The central torch connector is an all-in-one connector. This is a universal style connecon which
allows greater interchangeability of torches. It also greatly simplies torch connecon. When in-
stalling the connector, line up the locang tab on the torch side with the slot on the connector on
the machine side connector. Fully insert the coupling and then ghten the collar nut on the torc-
side ng hand ght. Do not use tools to ghten. Do not over ghten.
6. Fuse 30 A
(Slow Blow Type)
This fuse protects the unit from overloads of the pilot arc. If the pilot arc ceases to operate, check
the fuse and replace it if it is faulty. This is a standard glass type automove fuse which can be
sourced locally. Do not use a higher rang than what the old fuse is rated for or damage can occur.
7. Work Piece Connector N/A The work lead (somemes referred to as “ground”) is used to complete the circuit. The torch pilot
arc may acvate, but the unit will not actually cut if the work lead is not connected to the work
piece. If an arc is present but the unit will not easily cut or is very slow or poor cung any material,
check and make sure work lead is connected and is connected to a clean spot on the work.
8. Air Post Flow 0-60 Seconds Select a post ow me that is appropriate to cool the torch and the consumables. Post ow me
will depend upon the amps and length/severity of use. A post ow me of 1 second post ow for
every 10 amps is suggested.
9. 2T/4T Trigger lock 2T/4T 2T is the normal posion while cung. To operate, simply press and hold the switch and cut nor-
mally. Release the switch when the cut is nished. The 4 T seng allows the torch to be locked on
during use. To cut in 4T mode, simply press and hold the trigger to start the arc. Release the trigger
to connue cung. Once the arc is ready to be terminated slowly press and release the switch
again. Cauon: Use 4T cauously. This feature can leave the torch acvated if the torch is improp-
erly withdrawn from the cung area. But is useful for long cuts or when mechanical cung requir-
ing remote acvaon of the torch, i.e. a linear track torch or a pipe bevel track cuer.
10. Pilot Arc Funcon Tip Saver/
Normal
This allows the user to choose the best pilot arc mode to save consumables. The 3 second pilot arc
will only engage the pilot arc for 2-3 seconds before it shuts the arc o. To re-re the pilot arc in p
saver mode, release the trigger and press it again. Normal mode allows the pilot arc to automacal-
ly re-engage aer cung connuity is lost, i.e. cung expanded metal.
11. Air Flow Funcon Test/Normal Select “Test” to set air ow/air pressure for the torch. The operang pressure should always be set
while this is in Test since it does not require the torch to be live. This allows the air to ow constant-
ly unl the switch is placed back into the normal, med mode. To set the air pressure, turn the
torch unl the nozzle is facing up, then place the ow tube (clear plasc tube with ball in it) over
the nozzle. Select “Test” on the machine. With the air owing, adjust the air pressure/ow up or
down unl the ball is oang in the sight window of the ow tube. If no ow tube is present or
provided with your unit, then simply set the air pressure while “Test” is selected unl it is some-
where between 70-75 psi. Pressure over or under this can result in an unstable arc.
12. On/ Temp/ Over Current On or O These indicate the status of the machine and indicate if any fault is present. If duty cycle is exceed-
ed, the Duty Cycle light will come on and cung will be interrupted, but the unit will connue to run
and the fan will cool. Once the light goes o cung may resume. Aer 5-10 minutes, if the light
does not go o and cung is sll prevented, the cycle the machine o and then back on. If the Over
Current light is on, recheck all wiring and connecons and make sure the correct wire size and wiring
has been used. Purposefully creang too long of an arc may also cause this or it could be a side-
eect of hing the duty cycle limit of the machine. Cycle the machine on and o. If the light clears
and cung resumes, the fault has been cleared. If the unit will not work and/or the light remains
on, contact Everlast Tech Support.

17
GAS
INLET 1~220 V
1~220 VAC
2. 2-POLE POWER SWITCH
5. HF GROUND BOLT
4. GAS INLET
3. POWER CABLE 1 ~ 220/240V
QUICK SETUP AND USE GUIDESection 2
REAR PANEL FEATURES AND CONTROLS
1. CNC CONNECTION
6. REGULATOR ASSY.

18
Section 2
REAR PANEL FEATURES AND CONTROLS CONTINUED
1. Never operate the plasma cuer on a generator that is not cered by its manufacturer to be “clean” power, which is less than 10%
total harmonic distoron. Less than 5% THD is preferred. Operang the unit on square wave output or modied sine wave generators
is strictly prohibited. Contact the manufacturer of the generator for this informaon. Everlast does not have an “approved” list of
generators. But, if the generator is not listed as clean power by its manufacturer, then operaon is prohibited. Generators that do not
at least meet the operang input requirements of the plasma cuer are also forbidden to be used with the unit. Surge amp capability of
the generator should equal or exceed the maximum inrush demand of the plasma cuer. But the surge capability should not be used
as the only factor. The regular, running output of the generator should match or exceed the running or “rated” demand of the welder.
Any damage done by operang the unit on a generator not specied by its manufacturer to be “clean”, will not be covered under war-
ranty. This also includes suspect power sources where voltage is below 208 V and above 249 V.
2. To properly size the breaker, the I1MAX should be used in determining breaker size. To size the wiring, the I1EFF rang should be used
to help determine the proper wire size. The NEC in Arcle 630.11 allows a derang of the wire size based o of duty cycle. The re-
quirements are dierent than the requirements for most other 240V electrical products. However, consult a licensed electrician and
local codes before installing any wiring or breakers.
PowerPlasma S Features Parameters Purpose
1. CNC Connecon N/A This allows the unit to be used with a CNC machine and provides the basic inputs for CNC opera-
on. See pin-out secon located in the back of this manual.
2. 2-Pole Power Switch On/O The 2 pole breaker switch serves as the On/O switch for the cuer. Always turn the cuer on
and o by the switch rst before using any disconnect switch.
3. Power Cable with Plug 220/240 V
1 phase
(110 X2)
Plug:
NEMA 6-50P
The PowerPlasma 60S and 80S S will operate on 220/240 V 50/60 Hz power, including good quali-
ty 208 V power. The wiring contains 3 separate wires. Everlast uses standard sized wiring and
correct plugs (NEMA 6-50P) for welders and plasma cuers in the US and Canada. (Other coun-
tries will vary according to regional requirements). Standard wire colors are L-1 black (hot), L-2
white (hot), and green (ground) for 1 phase 220/240 V. Do not aempt to use a 4 wire 1 phase
220/240 connecon. NOTE: In many home circuits, red and black are the power wires. But in
standard welding/ plasma cung circuitry, white and black are hot wires. Green is always the
ground in both circuits. There is NO neutral in a standard welder circuit. The units are shipped
with a standard NEMA 6-50P plug. Always consult a licensed electrician who is aware of local
codes before aempng any wiring of the welder or of the power supply circuits. Everlast is not
responsible for any mis-wiring or damage caused to the unit by incorrectly wiring the welder. If
addional help is needed, contact Everlast. Disconnect the plasma cuer when not in use.
4. Gas Input Connecon N/A The gas input line is connected to the regulator assembly via the clear tubing provided in the
accessory package. To aach, simply push the tubing into the connector unl it is rmly seated
then give a slight tug to make sure it has been captured correctly by the ng. Make sure that
the tubing shoulder is squarely cut and not cut at an angle. An uneven or angular cut will cause
leaking at the connector. If the tubing must be removed, simply push on the outer plasc collar
back and retract the tubing while holding it in the other hand.
5. HF Ground Bolt N/A High Frequency (HF) energy can be devastang to surrounding electronic equipment. Although
this unit does not use HF energy to start the arc, normal HF generated by the unit may cause
slight interference with electronic items. This bolt can serve as a direct drain should any EMF
interference is suspected.
6. Regulator Assembly N/A The regulator assembly serves as both as an air lter, water trap, and pressure regulator. The
water trap with the ne sediment lter is self draining. It is not designed to dry the air, but ra-
ther serves the purpose of catching any residual slug of water that may be present in the air line
and ltering any trash or sediment that passes into the bowl of the regulator. It is not designed
to serve as an air dryer. A separate air dryer must be placed between the regulator and the air
compressor. During the assembly of the regulator, be sure to screw the 1/4” automove quick
connect into the side that is stamped on top with “IN” or that has been stamped with an arrow
poinng to the center of the regulator. The small brass plug should screw into the center of the
regulator and the remaining push-to-connect ng should be screwed into the remaining hole.
Then, connect the clear tubing to the push-to- connect. Make sure the shoulder of the tubing has
been cut squarely or the connecon may leak as a result. Screw the regulator bracket to the back
of the plasma cuer rst before aaching the regulator to the bracket. Make sure the screws
located in the accessory bag are the proper length and are inserted with the accompanying lock
and at washers. To adjust the regulator, simply pull the knob up slightly unl it clicks, and ro-
tate the knob clockwise to increase the pressure or counter clockwise to decrease the pressure.
To lock in the seng, push the knob down unl it clicks. Do not exceed 90 psi supply pressure.
Do not exceed 85 psi on the plasma cuer side of the regulator or internal leakage may result.
Operang air pressure should be set to about 75 psi while in to “Test” mode.
QUICK SETUP AND USE GUIDE

19
Edge Starts are the best type of start if possible
to promote consumable and torch life. This re-
duces blow back of molten material and allows a
smooth gradual start of the cut.
1. Line up the hole on the p of the electrode
on the edge of the cut. Hold torch perpen-
dicular to the cut inially, about 1/16” o
the metal. Slide the yellow safety lock and
squeeze the trigger. Wait for arc to start.
2. Once the arc starts, wait for the arc to pene-
trate all the way through the metal.
3. As the torch penetrates its ame all the way
through the metal, lt the torch so there is a
slight lead in the ame if metal is thin. If it is
thick, keep holding torch in a nearly vercal
posion.
4. Begin moving the torch in the direcon of
the cut. Maintain 1/16” stando height.
5. Move the torch fast enough so the sparks
and ame trail from the boom edge at an
angle of no more than 30° and no less than
10° from perpendicular to the metal. Excess
angle of sparks/ame indicate too fast of
travel speed or praccal cut capacity has
been reached. Lile or no angle indicates
too slow of travel speed.
IMPORTANT: If you use a stando guide with the torch, it must be adjusted to provide no more than 1/8” stando, less if possible. Long stand-
o heights reduce cut capacity and quality. It also promotes rapid consumable wear and can prevent the pilot arc from transferring.
Basic theory and function
Section 3
0°-15°
TRAVEL
1/16”
EDGE START
40°-60°
TRAVEL
1PIERCE START
2
3
Piercing starts oen result in rapid consumable
wear and excess blow back of molten metal de-
posited onto torch and consumables. This
should be done only as necessary.
1. Tilt the torch in the direcon of travel or
toward the side of the metal to be discarded
or wasted at a 40° to 60° angle. Slide the yel-
low safety lock and squeeze the trigger. Wait
for arc to start.
2. Once the arc starts, wait for the arc to trans-
fer from pilot arc to the cung arc.
3. As the torch penetrates it ame at an angle
rotate the torch slowly to the vercal posi-
on, as the arc penetrates the metal. Tilt the
torch from 0°-15° for thin metal cuts, or hold
it nearly perpendicular for thicker metal cuts.
4. Begin moving the torch in the direcon of the
cut. Maintain 1/16” stando height.
5. Move the torch fast enough so the sparks
and ame trail from the boom edge at an
angle of no more than 30° and no less than
10° from perpendicular to the metal. Excess
angle of sparks/ame indicate too fast of
travel speed or praccal cut capacity has
been reached. Lile or no angle indicates
too slow of travel speed.
The design of the blow back start may cause a slight delay in the arc as the air pressure must built inside the torch
tubing and head to create the pressure needed to force the electrode o the nozzle seat. This may take up to a sec-
ond. Restarng the arc in p saver mode requires retriggering the torch. If the torch does not light aer 3 seconds,
let go of the trigger and press it again. If the start or arc is errac check nozzle and electrode for ghtness and wear.

20
Basic theory and function
Section 3
FLAME AT NORMAL TRAVEL SPEED
TRAVEL
FLAME AT FAST TRAVEL SPEED
TRAVEL
FLAME AT SLOW TRAVEL SPEED
TRAVEL
NOTE: When stepping down amps to cut thinner material, you must change to small-
er orice nozzle. Nozzles are oered in dierent sizes which are appropriate for dier-
ent amp levels. Too large of a diameter orice will result in arc instability and a rough
cut. Lowering the air pressure below 65 psi to try to get the torch to cut will only re-
sult in a lazy, wandering arc.
TIP: For longer consumable life do not use the pilot arc unnecessarily. Select the 3 second
pilot arc feature and do not re the torch unless you are near the metal and ready to cut.
For expanded metal cung be sure to select “Normal” to re-re the pilot arc automacally.
IMPORTANT: Check consumables regularly for wear and change them out before
they are completely worn. Allowing the consumables to wear unl they quit working
may damage related torch components, creang a more costly repair.