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
CC
IGBT
1
~
PHASE
DC
PAC
DV
120/240V

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, 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……………………….
3
4
5
9
10
11
11
12
13
14
16
17
23
24
25
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.

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 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
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 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

4
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: [phone]
Everlast Canada:
Everlast consumer sasfacon email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [email protected]a
Telephone: [phone] Hours:
9am-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]
Aer hours support: 0413 447 492
Everlast Technical Support: [e-mail]

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 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!

7
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.

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 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.

9
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

10
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.

11
General overview: The PowerPlasma 50S ulizes the lat-
est in inverter design technology. It’s a portable dual
voltage plasma cuer with an output of 50 amps on
240V 1 phase power. It can also be used with 120 V (dual
voltage models only) with limited output up to 25 amps.
This design allows the unit to be used in many dierent
circumstances and applicaons. The PowerPlasma 50S is
also equipped with a CNC port (see appendix) for light or
moderate CNC work. A separate CNC torch may be
bought for this type of operaon. The arc start incorpo-
rates a blow back design with an automac pilot arc.
The blow back design of the torch is depicted in detail
located in the torch secon of this manual. This unit
features low air pressure protecon safety shut down-
along with duty cycle and overcurrent protecon which
will shut down output of the plasma cuer unl the con-
dion is resolved. The OK-to-cut light is a feature which
can be used by the operator to determine, at a glance, if
the air pressure is within the safe working range. The
pilot arc is designed for scouring the surface of the metal
and creang a path for connuity. The unit itself provides
the pilot arc through a ground path inside the torch head
and back to the unit. To prevent consumable burn out
and torch damage, the pilot arc is reduced to 22-27 amps
when acvated. Once the pilot arc establishes connuity,
arc intensity and amps increase as the arc transfers to the
metal.
General Use and Care: Care should be taken to keep the
unit out of direct contact with water spray. The unit is
rated IP21S, which rates it for light contact with dripping
water. It is a good idea to remove the plasma cuer
from the vicinity of any water or moisture source to re-
duce the possibility of electrocuon or shock. Never op-
erate this plasma cuer in standing water.
Every 1-2 months, depending upon use, the plasma
cuer should be unplugged, opened up and carefully
cleaned with compressed air. Regular maintenance will
extend the life of the unit.
IMPORTANT: Before opening the unit for any reason,
make sure the unit has been unplugged for at least 10
minutes to allow me for the capacitors to fully dis-
charge. Severe shock and/or death can occur.
Do 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 operate the unit immediately in the
weld/cut area. Do not mount in areas that are prone to
severe shock or vibraon. Li and carry the welder by
the handle. Do not direct metallic dust or any dirt inten-
onally toward the machine, parcularly in grinding and
welding operaons. Make sure the control panel is pro-
tected from damage.
NOTE: When servicing unit, remove rear plasc panel by
removing the screws in the plasc rear panel. Then re-
move the main metal cover to gain interior access. DO
NOT REMOVE FRONT PLASTIC PANEL OR ITS SCREWS!
THE FRONT PANEL IS INTEGRAL TO THE FRAME OF THE
UNIT. REMOVING THE FRONT PANEL IS TIME-
CONSUMING AND UNECESSARY. DO NOT REMOVE ANY
SWITCHES OR CONTROLS.
Duty Cycle. The duty cycle has been determined for the
PowerPlasma at 60% @ 50A while operang on240 V
(60% @ 25A while operang on 120V). 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 connu-
ously at the maximum amps for 6 minutes out of 10
minutes without a break to let the unit cool. For the re-
mainder of the 10 minute me period, the welder should
rest for maximum service life. The temperature light will
come on and the unit will automacally stop cung when
an overheat condion has occurred. Stop trying to cut
immediately. Heat will connue to be generated by and
transferred to the electronics aer welding has ceased.
Cung in humid, or hot condions can aect duty cycle
as well. Do not shut down an overheated unit unl it has
me to safely cool. If the duty cycle is exceeded, the over
temperature indicator will be lit and the unit will stop
cung. In this case allow the unit to cool for a minimum
of 15 minutes before resuming work. Once the overheat-
ed condion is sasfactorily remedied, the unit may be
safely shut down or cung may resume. Cycle the power
switch to reset the unit if needed. Do not operate the
unit with the covers removed. When using for CNC pur-
poses, use cauon to prevent overheang. The best way
to prevent overheang in CNC applicaons is to use the
unit at a lower amperage output to increase duty cycle
me and to extend the cung life of the consumables.
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. Welding
and cung operaons are inherently dangerous. Only the
operator of this Plasma cuer can ensure that safe oper-
ang pracces are being followed, through the exercise of
common sense pracces and training. Do not operate
this machine unl you have fully read the manual, in-
cluding the safety secon. If you do not have the skill or
knowledge to safely operate the plasma cuer, do not use
this plasma cuer unl formal training is received. To
prevent re, always be aware of your surroundings.
Introduction and SpecificationsSection 1

12
FUSE TORCH
WORK PIECE
TO WORK (+)
DINSE STYLE CONNECTOR
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: PLASMA CONNECTIONS
1. Only aempt to make cuts when the “OK to Cut” light is lit. Absence of the light indicates low or no air pressure.
2. See torch manual included in this manual for parts idencaon and assembly order.
3. Do not exceed 90 psi air supply pressure or internal leaks or failure of air supply components may result.
4. Adjust torch operaon pressure to 75 psi (5 bar) for best results with unit set to “constant ow.”
5. When using the plasma cuer at amp levels lower than 40 amps, the nozzle (p ) will need to be changed out for one with a smaller
diameter orice. While Everlast is the supplier of the torch, it is not the manufacturer. Everlast has a considerable inventory of standard
replacement consumables and consumable kits. In the event addional sizes or styles of consumables are needed that Everlast does not
stock, these are available locally and online through authorized distributors of Tec.mo/Innotec PT/iPT series of torches. A symptom of a
consumable that is too large is a weak or wandering arc with spuering.
6. Do not aempt to cut with the work clamp removed. The unit is capable of creang a pilot arc without the work clamp connected. The
pilot arc is not designed as a cung ame. Excessive use of the Pilot arc will accelerate wear of the consumable and the torch. Keep the
pilot arc engaged as briey as possible. Use the “p saver” funcon to keep the pilot arc from re-engaging aer it starts the arc to reduce
wear. If you noce that the unit does not cut but only scars the surface or cuts less than 1/8” into the metal slowly, it is likely to be an
issue with poor connecon of the work clamp. Poor connecon of the work clamp to the piece to be cut can cause the pilot arc to not
transfer properly. Have someone safely look at the display while aempng a cut. The display should briey drop below 30 amps and
then return to the preset amperage level. If it remains below 30 amps (usually 22-27 amps or so) the pilot arc is not transferring. Stop
and examine the work piece, clamp and even the DINSE connector on the panel. Repair if necessary. If this does not resolve the pilot
arc transfer issue, contact Everlast.
iPT60 (-)

13
STOP:
DO NOT FIRE THE TORCH WITH THE TRIGGER TO SET THE OPERATINGAIR PRESSURE. USE THE
“CONSTANT FLOW” FEATURE TO SET CUTTING PRESSURE. DO NOT CHANGE CONSUMABLES
WHILE THE UNIT IS SWITCHED ON. SERIOUS SHOCK, BURN OR INJURY MAY RESULT IF THE
CUP-IN-POSITION SENSOR IN THE TORCH HEAD WERE TO STICK OR MALFUNCTION!
Having trouble setting your unit for best cutting? Try the following:
•Keep your standoff to less than 1/8”. Do not drag the torch directly on the metal.
•Always use dry air. Drain compressor daily to improve effectiveness of air dryers and
to prevent them from prematurely failing.
•Don’t greatly lower air pressure to try to reduce kerf or cut thinner material. Always
reduce nozzle orifice size to match amperage. See Torch pages for different con-
sumable sizes.
•Use this as a general rule of thumb for good hand cutting speed and quality:
1. For the first 1/8” of thickness, use 20 amps.
2. After the first 1/8” add 10 amps for every 1/8” after that.
3. For Stainless and Aluminum, use settings that are 40% higher.
QUICK SETUP AND USE GUIDESection 2

14
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: REAR CONNECTIONS FOR PLASMA OPERATION
Compressor and Dryer Diagram
GAS
INLET
NOTES: A SEPARATE AIR DRYER BETWEEN THE AIR COMPRESSOR AND FILTER ASSEMBLY MUST BE INSTALLED. 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 SPIT-
TING, POPPING AND RAPID CONSUMABLE WEAR. THE 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. DAILY DRAINING OF THE AIR COMPRESSOR IS RECOMMENDED AS WELL. THE AIR SUPPLIED TO THE PLAS-
MA CUTTER SHOULD BE OF SIMILAR QUALITY USED FOR AUTOMOTIVE PAINTING. DIFFERENT STYLES OF DRYERS ARE AVAILABLE. THE MOST
INEXPENSIVE AND COMMONLY AVAILABLE 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 INTERNAL LINES
AND COMPONENTS) AS A RESULT OF EXCESS MOISTURE IS NOT COVERED UNDER WARRANTY. ADDITIONALLY, A FILTER SHOULD BE IN-
STALLED IN-LINE OR AT THE COMPRESSOR THAT WILL FILTER ANY EXCESS OIL OR OIL BLOW-BY FROM THE LINE IF NECESSARY. DO NOT USE
WITH OILING SYSTEMS DESIGNED TO AUTOMATICALLY LUBRICATE AIR TOOLS. IT IS ADVISABLE TO USE THE PLASMA CUTTER WITH A NEW
AIR HOSE/LINE THAT IS FRESH WITHOUT MOISTURE OR LUBE CONTAMINATION. IF 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. FAILURE TO USE THE PROPER DRY-
ER/FILTER IS THE NUMBER ONE CAUSE OF CUTTING ISSUES.
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 w ngs
(Customer Supplied)
21
4NOTE: WHEN ASSEMBLING AIR FILTER NOTICE THE MARKINGS THAT ARE
STAMPED ON TOP OF THE REGULATOR HOUSING FOR AIR FLOW DIRECTION.
AIR FLOW DIRECTION WILL BE NOTED AS IN OR OUT. IT MAY BE STAMPED
WITH A SMALL ARROW FOR AIR FLOW DIRECTION. THE QUICK CONNECT 1/4”
MALE AUTOMOTIVE COUPLING SHOULD BE MOUNTED ON THE SIDE OF THE
FILTER STAMPED WITH “IN” MARKING OR WITH THE ARROW POINTING TO THE
MIDDLE OF THE FILTER. ALSO, THE BRASS PLUG INCLUDED WITH THE ACCES-
SORY PACKAGE SHOULD BE MOUNTED IN THE CENTER HOLE.
PUSH TO CONNECT

15
FUSE
TORCH
WORK PIECE
10. CENTRAL CONNECTOR
1. ON/TEMP/O.C./OK-TO-CUT
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS
12. AIR PRESSURE
5. AMP CONTROL
4. POST FLOW TIME
3. CONSTANT FLOW/TIMED FLOW
8. WORK CLAMP (25 SERIES)
9. FUSE
11. AIR PRESSURE ADJUSTMENT
2. AMP DISPLAY
6. 2T/4T TRIGGER LATCH
7. NORMAL/TIP SAVER

16
POWERPLASMA 50S PARAMETERS PURPOSE
2. On/Temp/ Over/ OK to Cut On/O On indicator should always be on while the unit is plugged in and the power switch is switched on. If
the duty cycle is reached the “TEMP” light will come on and welding/cung will be interrupted. If this
happens, let the unit cool for 15 minutes before resuming cung. Do not turn o the unit. Aer 15
minutes the unit may be reset by cycling the on/o switch or, if desired, shut down completely by turn-
ing the power switch to o. When the “OVER” light comes on, the unit has experienced an electrical
issue due to over or under current/voltage. The unit will also cease cung, but the fan should connue
to run. Check the wiring for proper conecons, output, gauge and length. Once remedied, reset the
unit by cycling the on/o switch. If the “Over” light does not clear, contact Everlast. The OK-TO-CUT
light remains on while the air pressure is above the minimum threshold pressure. This is not a warning
light, but rather it gives the operator assurance that the pressure is within tolerable limits to prevent
torch damage. When the air pressure falls below this threshold (approx. 35 psi) and the light goes out,
the unit will stop cung automacally. Cung will resume once the pressure rises above the minimum
threshold and the light will be relit. If the OK-TO-Cut light is on, however, it does not indicate the pres-
sure is at opmal levels and further adjustment may be needed.
2. Amp Display N/A Indicates selected amperage. When cung operaon changes to reect real me amp output. When
pilot arc is engaged, it is normal for the amps to drop on the display. Typical readout while pilot arc is
engaged is less than 30A. Some variaon in output is normal while cung.
3. Constant Flow/Timed Flow N/A When set to constant ow, the air will connue to ow indenitely to allow the air pressure to be set, or
the ow gauge to be installed to allow the ow/pressure to be adjusted to the opmum level without
having to re the torch. The “Timed ow” is the normal posion used for cung. Cung should not be
aempted in the constant ow posion.
4. Post Flow Control 0-50 Seconds
(approximate)
Sets the post ow me of the air aer cung. The post ow Time is approximate only. Consider the
maximum seng mark a reference guide only. Use approximately 1-3 seconds of air ow for every 10
amps. Use more for extended cuts.
5. Amp Control N/A Controls amperage output. On 120V amps will be adjustable from 20A to 25A. On 240V amps will be
adjustable from 20-50 amps. 120V operaon will require use of smaller consumables for a stable arc.
Lowering air pressure cannot substute for using a correctly sized consumable.
6. 2T/4T Trigger Latch This switch should normally be set to 2T. The 2T/4T Trigger latch feature allows the operator to change
the way the torch trigger funcons. In 2T mode, operaon is a simple, press-and-hold operaon. This
allows you to keep cung as long as the torch trigger is held down. In 4T mode, this is good for extend-
ed cuts or for use with a momentary remote cut switch for use while using a track torch or other similar
device. To operate, press the torch trigger (or remote switch) quickly and release. The unit should re
and cut. The torch switch does not need to be held down. To terminate the arc, press the switch or
buon again and the arc will stop. Use the 4T seng cauously! Always be aware of which seng you
are using.
7. Normal/Tip Saver N/A This feature allows you to select the exact way the pilot arc will funcon. The Tip Saver funcon limits
the amount of me the pilot arc stays on and also prevents the pilot arc from automacally relighng if
the cut is lost. When in Tip Saver mode, the unit will light the pilot arc only once. Each me the cut
connuity is lost, it will not relight. In Normal mode, the unit will operate the pilot arc, re-engaging the
pilot arc automacally when the cut is lost or when connuity cannot be maintained, such as cung
expanded metal, or rusted/oxidized metal.
8. Work Piece 25 series Locaon of the posive terminal connecon for the work clamp cable. DINSE-style connector.
9. Fuse This fuse protects the operaon of the pilot arc and circuits of the machine should there be an overcur-
rent or feedback onto the system. If the display ceases to operate or pilot arc quits check the fuse.
Extra fuses are provided in the accessories kit. If no fuse is available, a standard glass type automove
fuse will work. Be sure to match the amperage of the fuse. Do not exceed the amp rang of the origi-
nal fuse or damage may result to the machine.
10. Central Connector 9 mm This serves as a unied, quick connecon for the torch. The Central connector is a universal style con-
necon and is available as a retrot on many dierent brand. The connector carries power and the
torch switch signal.
11. Air Pressure Adjustment 90 psi max supply
70-75 psi operang
To increase pressure, pull knob out unl it clicks (about 1/4”). Then, rotate knob clockwise to increase
pressure, counterclockwise to decrease pressure. Press in to lock. Do not supply the unit with MORE
than 90 psi from the compressor. Do not operate the torch with more than 75 psi for opmum results.
The torch manufacturer recommends a pressure seng of 72-73 psi (5 bar) Instead of lowering pres-
sure to use less amperage, change nozzle to a smaller orice size. However for some situaons lower air
pressure may yield sasfactory cuts, down to 65 psi. Do not lower air pressure just to make low amp
cuts. Use a nozzle with a smaller orice.
12. Air Pressure Gauge. 0-150psi Used to measure air supply pressure.. Supply pressure should not exceed 90 psi. Adjust operang
pressure while air is owing with gauge provided, or adjust to 72 psi and increase or decrease pressure
from there to achieve opmum cung results. If air pressure drops more than 10 psi from compressor
to unit air pressure gauge, check for internal kinks or leaks in tubing.
Section 2
FRONT PANEL FEATURES AND CONTROLS CONTINUED
QUICK SETUP AND USE GUIDE

17
GAS
INLET
1~220 V
3. HF GROUND BOLT
2. POWER CABLE 1 ~ 120/240V
QUICK SETUP AND USE GUIDESection 2
REAR PANEL FEATURES AND CONTROLS
5. REGULATOR ASSY. 1. BREAKER/ POWER SWITCH
4. GAS INLET

18
POWERPLASMA 50S PARAMETERS PURPOSE
1. Breaker/ Power switch On/O The breaker switch serves as the On/O switch for the Plasma Cuer. Always turn the unit on
and o by the switch rst before using any disconnect.
2. Power Cord 120/240 V
1 phase, 50/60 Hz.
The unit is prewired with a standard NEMA 6-50 plug. This is the standard plug for 240V 1
phase welders and plasma cuers in the US and Canada. Other countries vary plug congura-
on as well as input. When used with 120V supply connect the 240V-120V adaptor supplied
with the plasma cuer. This will automacally step down the unit for 120V operaon. No inter-
nal wiring changes will be needed. When using on 120V, make sure the breaker and wiring is
sized properly for use or damage to the machine can result. Consult a licensed electrician before
operang on 120V to conrm wiring and breaker suitability when operang at maximum 120V
output. Do not aempt to rewire the plasma cuer. Use the standard plug provided.
3. Gas Input Connecon 1/4-5/16” The unit is supplied with tubing which connect this ng to the air lter. Some models: The
push to connect design allows easy connecon of the Cuer. Cut the tubing squarely before
installaon to reduce the chance of leaking. If you suspect leaking, test the connecon with a
soluon of mild soapy water. If bubbles are seen, disconnect the tubing by sliding the plasc
collar on the ng that surrounds the tube and remove the tube. (A small bladed screw driver
may be used to gently push the collar back if needed. Do not use a lot of pressure. Once the
tubing is installed, it will be held rmly unl the collar releases. Do not jerk the tubing.) Then cut
the edges so the shoulder is cut fully perpendicular. Reinstall the tubing.
4. HF Ground Bolt N/A Normally this connecon is not required with the blow back start design. However, a small
amount of HF energy may sll be emied. If electronic interference is observed, this bolt should
be grounded directly to an outside source. All metal parts inside the building should be ground-
ed as well, including pipes, tables, and even metal siding. HF energy has been known to bleed
back into the power grid and disrupt electronic devices further down the grid. It is recommended
that a small, separate ground wire (minimum 14 gauge) be aached at this point while in use.
5. Air Filter Assembly N/A The lter helps remove ne parculates and large drops of water. A separate air dryer must be
installed inline to prevent rapid torch and consumable wear (Customer supplied). The lter
assembly is not designed to remove moisture from the air, only large drops of water that may be
created in the coupling and uncoupling process. Everlast does not warranty damage caused to
torches or consumables by moisture. Residual moisture in the line also can contaminate the
system, causing problems while TIG welding. The number one issue experienced with Plasma
cung, that causes many dierent symptoms, is the presence of moisture in the air line.
Section 2
NOTES:
1. The gas input connecon and internal air connecons should be checked for leaks periodically, especially if the machine is moved or has been over-pressurized
from the air compressor (more than 90 psi).
2. Never operate this unit 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% is preferred. Operang the unit on square wave output or modied sine wave generator 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
plasma cuer. 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 plasma cuer on a generator not specied by its manufacturer to be “clean” (less than 10% total harmonic distoron of
the sine wave), will not be covered under warranty. This also includes suspect power sources where voltage is below 208 V and above 250 V. For 120V use, it
should be within 110-130 V. For 240V operaon, the generator size should be no less than 8500 maximum was.
QUICK SETUP AND USE GUIDE
REAR PANEL FEATURES AND CONTROLS CONTINUED

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 nger under the yellow safe-
ty and squeeze the trigger. Wait for 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 nger
under the yellow safety and squeeze the trig-
ger. 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 builds inside the torch to
create the pressure needed to force the electrode o the nozzle seat. This me will be longer with torches with
longer cables. If the torch does not light aer 3 seconds, let go of the trigger and restart. If start/arc is errac check
nozzle and electrode for ghtness and wear. If the pilot arc will not re-re automacally, select “normal” on panel.

20
FLAME AT FAST TRAVEL SPEED
TRAVEL
FLAME AT SLOW TRAVEL SPEED
TRAVEL
Basic theory and function
Section 3
FLAME AT NORMAL 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: To extend consumable life do not use the pilot arc longer than necessary. Use the p
saver 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” so the pilot arc reres 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.