Everlast Power plasma 50s User manual

Rev. 2 0 00327-18ETL

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

50 Amp IGBT Plasma Cutter

Operator’s Manual For

PowerPlasma 50S

Safety, Setup and General Use Guide

EVERLAST

POWER PLASMA 50S

IGBT

PHASE

PAC

120/240V

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, Plasma Connecons…..………..

Quick Setup Guide, Rear Connecon for Plasma…

Front Panel Features and Controls……………………..

Rear Panel Features and Controls……………………...

Plasma Funcon and Operaon………………………....

Plasma Torch PT60/iPT60..………………….……………..

Troubleshoong………………………………………………....

CNC Connector Pin-Out Appendix……………………….

NOTE: Product Specicaons and features are subject to change without noce. While every aempt has

been made to provide the most accurate and current informaon possible at the me of publicaon, this manu-

al is intended to be a general guide and not intended to be exhausve in its content regarding safety, welding,

or the operaon/maintenance of this unit. Everlast Power Equipment INC. does not guarantee the accuracy,

completeness, authority or authencity of the informaon contained within this manual. The owner of this

product assumes all liability for its use and maintenance. Everlast Power Equipment INC. does not warrant this

product or this document for tness for any parcular purpose, for performance/accuracy or for suitability of

applicaon. Furthermore, Everlast Power Equipment INC. does not accept liability for injury or damages, conse-

quenal or incidental, resulng from the use of this product or resulng from the content found in this docu-

ment or accept claims by a third party of such liability.

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 informaon. Your

unit registraon is important should any informaon such as product updates or recalls be issued. It is also

important so that we may track your sasfacon with Everlast products and services. If you are unable to

number in your country. Your unit will be registered and warranty will be issued and in full eect. Keep all

informaon regarding your purchase. In the event of a problem you must contact technical support before

your welder can be a candidate for warranty service and returned.

Please review and download the ocial warranty statement, located on our website

www.everlastwelders.com. If you are not in the United States, visit the distributor’s website warranty in-

formaon nearest to your region or country. Print it for your records and become familiar of its terms and

condions.

Everlast oers full technical support in several dierent forms. We oer domesc based phone support 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on. Technical advisors

are acve on the forum on a regular basis. We also divide our support into two divisions: technical and weld-

ing performance. Should you have an issue or queson concerning your unit, please contact performance/

technical support available through the main company headquarters available in your country. For best ser-

vice, call the appropriate support line and follow up with an email. In the event you do not reach a live per-

son, parcularly during heavy call volume mes, holidays, or o hours, leave a message and your call will nor-

mally be returned within 24 hours. For quick answers to basic operang or service quesons, join the compa-

ny owned forum linked through the US website. You should be able to nd knowledgeable, helpful people

and sta available to answer your quesons, and perhaps nd a topic that already addresses your queson at

hp://www.everlastgenerators.com/forums/.

Should you need to call or write, always know your model name, purchase date and welder manufacturing

inspecon date. This will assure the quick and accurate customer service. REMEMBER: Be as specic and

informed as possible. Technical and performance advisors rely upon you to carefully describe the condi-

ons and circumstances of your problem or queson. Take notes of any issues as best you can. You may

be asked a series of quesons by the advisors meant to clarify problems or issues. Some of these ques-

ons may seem basic or fundamental, but even with experienced users technical advisors can’t assume

that correct operang procedures are being followed for proper operaon, 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 funcons before you

call.

Please note: To establish a warranty claim and return a unit for repair or replacement, you must call tech-

nical support rst and go through basic diagnosis before an Return Authorizaon will be issued.

Let us know how we may be of service to you should you have any quesons.

Sincerely,

Everlast Customer Service

Serial number: ____________________________

Model number: ____________________________

Date of Purchase:__________________________

Contact Informaon

Everlast US:

Everlast consumer sasfacon email: [email protected]om

Everlast Website: everlastwelders.com

Everlast Technical Support: [email protected]

Everlast Support Forum: hp://www.everlastgenerators.com/forums/index.php

Main toll free number: 1-877-755 WELD (9353)

Hours:

9am-5pm PST M-F

11am-4pm PST Sat.

FAX: 1-650-588-8817

Everlast Canada:

Everlast consumer sasfacon email: [email protected]

Everlast Website: everlastwelders.ca

Everlast Technical Support: [email protected]a

Telephone: 905-637-1637 Hours:

9am-4:30pm EST M-F

10am-1pm EST Sat.

FAX: 1-905-639-2817

Everlast Australia:

Sydney: 5A Karloo Parade Newport NSW 2106

(02) 9999 2949

Port Macquarie: 2B Pandorea Place Port Macquarie

(02) 8209 3389

Aer hours support: 0413 447 492

Everlast Technical Support: support@pickproducts.com

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

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 cautions 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!

SAFETY PRECAUTIONS

WARNING! Persons with pacemakers should not weld, cut or be in the welding area unl they con-

sult with their physician. Some pacemakers are sensive to EMF radiaon and could severely mal-

func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 contains

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.

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 con-

tact.

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nguishers

close by and addionally a water hose or bucket of sand. Periodically check work area for smoldering

embers or smoke. It is a good idea to have someone help watch for possible res while you are weld-

ing. 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 maintenance

is your responsibility. Make sure all equipment is properly maintained and serviced by qualied per-

sonnel. 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.

Introduction and SpecificationsSection 1

Consumable Starter Kit

iPT 60 Plasma Torch

Work Clamp

NOTE: Accessory and consumable style and quanes are subject to change without noce. Consumable starter kits provide only enough

consumables to get started. Extra consumables can be purchased through Everlast or through other local and online iPT 60 Innotec dis-

tributors. Full consumable kits are sold through Everlast. Various diameter consumables for lower amp use are available.

Air Filter/Water Trap

PowerPlasma 50S

240V to 120V adapter

PowerPlasma 50S Speccaons

Inverter Type IGBT

Minimum/Maximum Rated Output 110V: 20A/88V-25A/90V 220V: 20A/88V - 50A/100V

Start Type Blow-Back Type

Torch Type iPT60 12 .

Duty Cycle @ Rated Amps/Volts ( 40° C)

(Output V/A)

220V: 60% @ 50A/ 100V 100% @ 40A/ 96V

110V: 60% @ 25A/ 90V 100% @ 20A/ 88V

OCV (U0) 200 V

Voltage Input (U1) Dual Voltage: 120V/ 240V; 50/60Hz 1 Phase

Maximum Inrush Amps (I1MAX) 110V: 32.1A 220V: 35.8A

Maximum Rated Eecve Amps (I1EFF) 110V: 24.9A 220V: 27.9A

CNC Port Yes

Air Post Flow Timer Adjustable, 0-50 Seconds

Minimum Air Compressor Requirement 4.5 - 5 CFM @ 90 psi/

25 gallon tank

Duty Cycle/ Over Current Protecon Yes

Minimum Operang Air Pressure

(Safety Cut-Out Threshold)

35 psi

Recommended Operang Air Pressure

(Set with Air Flow set “Test”)

70-75 psi

Maximum Supplied Air Pressure

(From Compressor/Tank)

90 psi

Recommended Maximum Average Cut Thickness

(Hand Torch/Daily Use)

1/2”

Recommended Daily Maximum

Average Cut Thickness (CNC)

1/4”

Rated Maximum Quality Cut @

10-12 IPM (Steel)

3/4”

Max Severance Cut @ 3 IPM (Steel ) 1”

Minimum Water Ingress Protecon Standard IP21S

Eciency >85%

Cooling Method Full Time High Velocity Fan with Tunnel design

Dimensions (approximate) 12.5” H X 7.5” W X 14” L

Weight (Bare Unit) 35 lbs

Generator Requirement 8,500 W Clean Power (less than 10% total harmonic distoron)

Minimum Storage/ Minimum Operang Temperature Storage: -10°F/-23°C Operang: 14°F/-10° C

Introduction and SpecificationsSection 1

Decrease maximum cut thickness values for aluminum and stainless by approximately 35-40%.

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.

Use the inrush amps value to size breaker. Use the rated eecve current to size wiring. Consult the NEC for details concerning wiring plasma cuers and welders.