Everlast PowerPlasa 150 H Operating manual

Operator’s Manual
Publish Date: NOV.2023
EVPPLSMA150HRev. 1
USA/North America
©Everlast Power Equipment
3 Phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide For
PowerPlasma 150H
FUNCTION: Plasma Cutter with Water Cooled Option
PURCHASE DATE:
PLASMA CUTTER MODEL NAME:
CNC OPTIONAL TORCH INFO:
PLASMA CUTTER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:
DC
150A
HF
START
HAND/
CNC

2
TABLE OF CONTENTS
SPECIAL NOTICE AND CALIFORNIA PROPOSITION 65 WARNING 3
CUSTOMER GREETING AND EXPLANATION OF PROCEDURES 4
WARRANTY AND CONTACT INFORMATION 5
SAFETY DISCLAIMER AND HF WARNING 6
SAFETY WARNINGS, DANGERS, CAUTIONS AND INSTRUCTIONS 7
GENERATOR OPERATION INFORMATION 10
SPECIFICATIONS 12
DUTY CYCLE AND CNC USE INFORMATION 13
BREAKER SIZING AND WIRING REQUIREMENTS 14
GETTING STARTED, UNPACKING YOUR UNIT AND INSPECTION 15
CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION 16
CONNECTION OF AIR COMPRESSOR, REGULATORS, AND BASIC REQUIREMENTS TO PLASMA CUT 17
CONNECTING THE PLASMA TORCHES, HAND AND CNC SETUP INFORMATION 18
FRONT PANEL VIEW AND COMPONENT ID 19
REAR PANEL VIEW AND COMPONENT ID 20
CONTROL PANEL LAYOUT 21
PLASMA CUTTING OPERATION WARNINGS AND SAFETY INFORMATION 23
EXPLANATION OF PLASMA FUNCTIONS AND TERMS 24
STARTING CUTS AND PIERCING INFORMATION 25
CORRECT CUT AND TRAVEL SPEED INFORMATION 27
PLASMA CUTTING TORCH PARTS AND ASSEMBLY LT150 /LTM150(Air-Cooled) 29
PLASMA CUTTING TORCH PARTS AND ASSEMBLY FY-A200/FYXF300 (Water-Cooled) 31
CNC CONNECTOR PINOUT AND CONNECTION INFORMATION 32
ADDITIONAL TORCH AND CNC INFORMATION 33
TROUBLESHOOTING ERROR CODES 34
TROUBLESHOOTING COMMON PLASMA CUTTING ISSUES 35

3
NOTICE:
Product Specications and features are subject to change without notice. While
every attempt has been made to provide the most accurate and current infor-
mation possible at the time of publication, this manual is intended to be a general
guide and not intended to be exhaustive in its content regarding safety, welding,
or the operation/maintenance of this unit. Due to multiple variables that exist in
the welding eld and the changing nature of it and of the Everlast product line,
Everlast Power Equipment INC. does not guarantee the accuracy, completeness,
authority or authenticity of the information contained within this manual or of any
information offered during the course of conversation or business by any Everlast
employee or subsidiary. 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 particular purpose, for performance/accuracy
or for suitability of application. Furthermore, Everlast Power Equipment INC. does
not accept liability for injury or damages, consequential or incidental, resulting
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.
WARNING!
California Proposition 65 Warning:
This product, when used for welding or cutting, produces fumes or gases which
contain chemicals known to the State of California to cause birth defects and, in
some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)
Warning: Cancer and/or Reproductive Harm
www.P65warnings.ca.gov

4
THANK YOU! We appreciate you as a valued customer and hope that you will enjoy years of use from your plasma cutter. We work to please the cus-
tomer by providing a well supported, quality product. To make sure that you receive the best quality ownership experience, please see below for im-
portant information and time sensitive details.
What to do right now:
1. Print your receipt from your conrmation email that should have been sent to you after your purchase and put it up for safe keeping. If you do not
have one, contact us at 1-877-755-9353 (US customers) or 1-905-570-1818 (Canadian Customers). You will need this if anything should ever
happen for original owner verication (if bought as a gift, original receipt will still be needed, or explanation sent to Everlast).
2. Read this manual! A large number of tech and service calls are a result of not reading the manual from start to nish. Do not just scan or casually
peruse this manual. There are different features and functions that you may not be familiar with, or that may operate differently than you expect.
Even if you have expertise in the eld of welding, you should not assume this unit operates like other brands or models you have used.
3. Carefully unpack and inspect all items immediately. Look for missing or damaged items. Please report any issues within 48 hours (72 hours on
weekend or holidays) of receiving your product,. Take pictures if you are able and contact us at 1-877-755-9353, ext. 207 if any issue is discov-
ered between 9 am and 5 pm Eastern Time M-F (US customers) or at 1-905-570-1818 (Canadian Customers) between 9am and 4 pm weekdays
except on Fridays when hours are from 9 am to 12pm Eastern. If outside of the US or Canada, contact your in-country/or regional distributor di-
rect at their service number.
What to do within the next 2-3 days:
1. Make sure your electrical system is up to date and capable of handling the inrush and rated current of the unit. Consult and use a licensed and
knowledgeable electrician. If you have downloaded this manual in expectation of delivery, get started now.
2. Make sure this machine is plugged in, turned on, and tested with every process and major feature, checking for proper function. You have a 30
day period to test and thoroughly check out the operation of this unit under our 30 day satisfaction period. If something is wrong, this policy co-
vers shipping on the unit (30 day satisfaction policy applies to the USA only for the 48 lower states and D.C., territories and provinces are exclud-
ed) or any incidental parts that may be needed to resolve any issue. After this 30 day period, if you nd something wrong with the unit, you will not
receive the benet of free shipping back and forth to resolve this issue. Your unit is still covered under the 5 year parts/labor warranty, but ship-
ping is covered by the customer after the 30 day period is over. The rst 30 days of operation with any electronic item is the most critical and if
any issue will happen, it will often happen during this time. This is why it is very important that you put this unit to work as soon as possible. Any
issue should be reported within 48 hours (72 if on the weekend or holiday). Everlast will not be liable for any shipping after that time.
What to do within the next 30 days:
Visit our website (US customers). Go to www.everlastwelders.com. Navigate to the resources tab and to the “product registration” page to register
your product. While keeping your receipt/proof of purpose is still required for verication of ownership, registering will help us keep your details
straight and establish a chain of ownership. Don’t worry, though, your warranty is still valid if you can’t do this. Remember: Always keep your receipt
even if you register. You may want to staple a copy to your manual.
What to do if you have a warranty issue or problem with the unit:
1. Unplug the unit. (Also do this before any maintenance or cleaning is done.)
2. Do not attempt a self-repair until authorized by an Everlast representative. This does not include performing routine maintenance such as point gap
adjustments or regular internal cleaning. Any third party repairs are not covered under warranty, and can further damage your unit.
3. Within 24-48hours, (or by the next working business day) you must contact U.S. tech support at 1-877-755-9353 ext 207(U.S. hours are 9 am to
5pm Eastern for tech support and 9 am to 5 pm Pacic for the business/sales ofce). If you are in Canada contact 1-905-570-1818 (Canada hours
are 9am to 4pm M-Th, 9am to 12pm Fri). Although phone contact is preferred to establish a warranty claim, you may send an email to
[e-mail] (US) or [e-mail] (Canada) along with your contact information and brief explanation of the issue and
ask for a follow up call. If you contact us via phone, and you do not reach a live person, please leave a brief message with the nature of your prob-
lem and your contact information. You should expect a call back within 24 hours. It is also a good idea to follow up the message with an email.
4. Be prepared with as much information as possible when you talk with a tech advisor, including a details of the failure, settings, and application of
the unit. NOTE: A Proof-Of-Purchase (receipt) is required before returning the unit for warranty or before warranty parts can be sent to you.
5. Keep in mind that, you may be asked to check a few basic things. Before you call, having a screwdriver and volt/ohm meter at hand is a good idea
and will save time. Many issues can be resolved over the phone. If the issue cannot be resolved over the phone/email, you may be given an op-
tion to return the unit, or have a part shipped to you, at Everlast’s discretion. Keep in mind, you may be asked questions that seem basic, or ele-
mentary to your knowledge base. These are not meant to question your knowledge, but rather to make sure nothing is overlooked. However the
tech chooses to proceed, please cooperate with the process, even if you think you know what the cause or issue is. You may be asked to check
something or open the unit during the diagnosis. This does not void the warranty! Opening the unit is a part of routine maintenance and cleaning.
This is an important step. The willingness of the customer to work with tech support can save lots of time and accelerate the warranty process. For

5
warranty to be honored, you will need to make sure that you follow these guidelines. Units that are returned without an RMA (issued by the tech
support department) may not be repaired under the warranty agreement and you may be charged for the repair and can result in a delayed repair
as well.
What to do if you need setup help, guidance, weld issue diagnosis or have general product compatibility questions.
Call us at 877-755-9353 ext. 204 for welding guidance and general welding issue diagnosis. Or email [e-mail] with the basic
issue you are having, along with your specic settings, and welding application.
Hey...wait, what is my warranty?
Warranties and service policies and procedures vary from country to country and are maintained and supported by the region-
al or in country distributor of Everlast welding equipment.
USA Customers Only: For full details on the 5 year parts and labor warranty, 30 day satisfaction policy, terms of sale, and how to proceed with a war-
ranty claim, please visit: https://www.everlastgenerators.com/standard-warranty. Accessories are covered by a separate warranty and detailed infor-
mation can also be found at the link above.
Canada Customers Only: For full details on the 3 year parts and labor warranty, terms of sale, and related policies and procedures, please visit: https://
www.everlastwelders.ca/terms.php.
Who do I contact?
USA Technical Support:
Email: [e-mail]
1-877-755-9353 ext. 207
9am-5pm Eastern (Closed holidays)
Monday-Friday
USA Welding Support and General Product Information:
Email: [e-mail]
1-877-755-9353 ext 204
9am-6:30 pm Eastern (Closed holidays)
Monday-Friday
USA Sales and Main Ofce:
Email: [e-mail]
1-877-755-9353 ext 201
9am-5pm Pacic (Closed holidays)
Monday-Friday
Canada Technical Support:
Email: [e-mail]
905-570-1818
9am-4pm Eastern Monday-Thursday
9am-12pm Eastern Friday
Canada Sales and Main Ofce:
Email: [e-mail]
905-570-1818
9am-4pm Eastern Monday-Thursday
9am-12pm Eastern Friday
Other Countries and Regions:
Visit the U.S. Website @ www.everlastwelders.com and click on the flag of the country or region represented that is closest to you. If your country or
region is not found, call the U.S. ofce at 1-650-588-8588 between the hours of 9am to 5pm Pacic, Monday through Friday.

6
Safe operation and proper maintenance is your responsibility.
Everlast is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and
maintenance of your Everlast product, it is no substitute for observing safe welding practices and behavior. Safe welding and related cutting
operations require basic knowledge, experience and ultimately the exercise of common sense. Welding does signicant hazards to your health
and life! Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even life depends upon it.
WARNING! If you do not have proper knowledge or capability to safely operate this machine, do not use this machine until proper
training has been received!
While accidents are never planned, preventing an accident requires careful planning. Stay alert!
Please carefully read this manual before you operate your Everlast unit.
The warranty does not cover damage or harm created by improper use. neglect of the machine or failure to follow safe operating practices.
NOTICE:
Welding and cutting operations may generate undesirable High Frequency (HF) and EMF
energy. This can interfere with surrounding electronic equipment such as computers,
routers, CNC equipment, televisions, radios, fluorescent lighting etc. If disturbance in
surrounding electrical and electronic equipment is noted, consult a licensed electrician to
help properly ground surrounding equipment to limit the interference. This machine may
cause GCFI and ground fault outlets to malfunction. This unit is designed to be operated
on a dedicated, properly grounded circuit.

7
Safety Warnings, Dangers, Cautions and Instructions
NOTICE. This unit manual is intended for users with basic knowledge and skillset in weld-
ing. It is your responsibility to make certain that the use of this plasma cutter is restricted to
persons who have read, understand and follow the warnings and instructions in this manu-
al. If you or the operator needs further instruction, contact Everlast welding support at 1-
877 755-9353 ext. 204 or seek qualied professional advice and training.
WARNING! High Frequency (HF) energy can interfere with the operation of pacemakers and
can damage pacemakers. Consult with your physician and pacemaker manufacturer before
entering an area where welding and cutting equipment is in operation and before using this
plasma cutter. Some pacemakers have limited shielding. Alert any users or customers of
this potential problem.
WARNING! Use approved safety glasses with wrap around shields and sides while welding
and working in the weld area or serious eye damage or loss of vision may result. Use a
grinding shield in addition to the safety glasses during chipping and grinding operations.
WARNING! When welding always use an approved welding helmet or shielding device
equipped with at least an equivalent of a shade 9 or greater. Increase the shade number
rating as amperage increase over 100 amps. Inspect helmet for cracks in lenses and in the
helmet. Keep lens covers in good condition and replace as necessary.
WARNING! Plasma utting operations carry inherent risks which include but not limited to
possible cuts burns, electrical shocks, lung damage, eye damage and even death. Take all
appropriate measures to use proper Personal Protective Equipment (PPE). Always use
leather welding gloves, closed toe (preferably reinforced or steel toe leather shoes, and long
-sleeved flame resistant clothing (i.e. denim). Do not wear Poly/Nylon blend materials.
DANGER! Plasma cutting poses shock and electrocution risks. Keep this welding equip-
ment dry. Do not cut in the rain or where moisture accumulates. Use dry, rubber soled
shoes, gloves and clothing when welding. Do not rest or contact work clamp (ground) when
welding. Keep all parts of the body insulated from the part being welded when possible. Do
not touch terminals, make connections or change consumables while the unit is on. Con-
sider all parts to be “live” at all times even if no live work is being performed.
CAUTION! Fires are possible but also preventable while welding. Always remove flammable
rags, papers, and other materials from the weld area. Keep rags stored in an approved flame
proof canister. Keep a fully charged re extinguisher at hand. Remove any fuels, oils,
paint, pressurized spray cans, and chemicals from the weld area. Make sure any smoke/re
detectors are function properly. Do not weld on tanks, drums or barrels, especially if pres-
surized or sealed. Do not weld on any container that previously held fuel or chemicals.
Make sure the weld area is clear of flammable materials such as grass or wood shavings
solvents and fuels. Do not wear frayed or loose clothing. Visually inspect and recheck the
work area after welding looking for smoldering debris or flames.
WARNING! Welding gas cylinders are under high pressure. Keep all gas cylinders upright
and chained to a cart or held safely in a safety holding pen. Never transport gas cylinders
in an enclosed car van or other vehicle. Transport gas cylinders securely. Keep all cylin-
ders capped while not in use or during transport. Replace the cap on the cylinder when it
is going to be more than 24 hours before use. Do not use or attempt to repair faulty regu-
lators. Never weld on gas cylinders. Keep gas cylinders away from direct sparks.

8
Safety Warnings, Dangers, Cautions and Instructions
DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these
hazards are immediate while others are cumulative in their effect. Do not weld in enclosed
spaces or in areas without adequate ventilation. Fumes and gases released in the welding
and cutting operations can be toxic. Use fans or respiration equipment to insure adequate
ventilation if you are welding in a shop or garage area. Do not weld on galvanized metal
under any circumstance. You may develop metal fume fever. Symptoms are similar to lu-
like symptoms. Seek medical advice and treatment if you are exposed to galvanized weld-
ing fumes.
If you experience any eye burning, nose or throat irritation while welding, these are signs
that you need more ventilation.
If you feel these symptoms:
• Stop work immediately and relocate work area with better ventilation.
• Wash and clean your face and hands.
• Stop work completely and seek medical help if irritation persists
DANGER! Never use brake cleaner or any chlorinated solvent to clean or degrease metal
scheduled to be welded or other related equipment in the area being welded. The heating
of this cleaner and its residue will create highly toxic phosgene gas. Small amounts of
this vapor are harmful and can lead to organ failure and death. If degreasing of a part is
necessary, use Acetone or an approved pre-weld cleaner. Use the proper personal protec-
tive equipment (PPE) when handling any cleaners/solvents.
DANGER! People with pacemakers should consult a physician and pacemaker manufactur-
er before welding. There is a potential for damage or serious malfunction resulting in
death. High Frequency energy (HF)/Electromagnetic Fields generated during welding can
interfere with pacemaker signals, even permanently damaging it. Some pacemakers offer
some shielding, but restrictions regarding amperage and HF starting of TIG arcs may be
placed upon the individual. Warn all potential bystanders that they should exit the work
area if they have a pacemaker or similar medical equipment before welding. Severe electri-
cal shock leading to injury or death may occur while using the plasma cutter if the user
becomes part of the circuit path. While the Amp output of the plasma cutter is limited, the
unit may produce an OCV of 300V or greater. Consult with a Physician if a pacemaker is
expected to be implanted.
DANGER! Never defeat or modify any safety guards or shields. Keep all safety covers and
shields in place.
Never place your ngers in or near a fan shroud or insert any object into the fan(s).
DANGER! Do not supply more than 100 PSI to the air-pressure regulator supplied with
this machine. If you do, the regulator may leak or explode, causing severe injury or
death. Use a separate regulator mounted at the air-compressor to control supply air pres-
sure. Never use an air compressor without a separate compressor mounted air regulator!

9
Safety Warnings, Dangers, Cautions and Instructions
CAUTION! Trip Hazards exist around plasma cutters. Cords, cables, welding leads and hos-
es pose a trip hazard. Be aware of their location and inform others of their location. Tape
and secure them so they will stay out of high trafc areas.
CAUTION! Welded metal can stay hot long after welding is completed. Burns may occur.
Always wear gloves or use tongs/pliers when handling welded or cut metal. Remember
the heat from the metal may catch other material on re. Always have a re-proof area
ready to place welded components until they fully cool. Use soap stone or a metal marking
marker to label the metal as “HOT” to serve as a reminder to all present in the area.
CAUTION! Welding and cutting operations generate high levels of ultraviolet (UV) radiation
which can burn and damage skin and eyes. The intensity is so high that exposed skin and
eyes can burn in a few minutes of exposure. Minimize direct skin and eye exposure to this
intense form of radiation by using proper PPE and sun screen where appropriate.
CAUTION! Do not allow bystanders. Do not allow others without proper Personal Protec-
tion Equipment (PPE) suitable for welding to stand in the welding area or to observe weld-
ing and welding related activities. If protection is not readily available, use a welding
screen to separate the welding area from the rest of the area. If no protection or screen is
available, physically exclude them from the welding area by a wall or other solid divider.
Keep all pets and young children away from the welding area.
CAUTION! Electromagnetic Fields can be generated by this plasma cutter and radiate into
the work place. The effect of EMF is not fully known. Exercise caution when welding by:
NOT draping welding leads (guns/cables) over your shoulders or arms, NOT coiling them
around your body, NOT inserting yourself directly between the cables, and by NOT con-
tacting the unit while welding. DO keep the work clamp connected as close as possible to
the area of the weld and directly to the object being welded whenever possible.
DANGER! Never touch connectors or ttings while this machine is turned on. Keep all
safety covers in place when not in use. Never remove or replace the plasma consumables
while the machine is turned On. Even though the torch is equipped with a “parts-in-place”
safety disconnect, it is possible that overheating of the torch, excessive wear or damage to
the consumables may cause this feature to malfunction. Make sure the brass safety cut out
pins on the torch head remain in good repair and that the spring loaded function remains
operational and keeps them fully extended when the torch cap is removed. The Open Cir-
cuit Voltage (OCV) while in plasma mode may exceed 300V. This is enough to cause
burns, injury severe electrical shock, injury and instant death.

10
WARNING!
Never use the electrical power outlet on the back of this machine for
anything other than powering an Everlast brand water cooler. This is
a special outlet designed for the special plasma cutter water cooler
normally used for CNC operation. No other device or brand should
be used in conjunction with this unit’s outlet. Do not attempt to
modify, or change this outlet for use with anything else other than an
Everlast brand water cooler designed for this unit. Severe damage,
re or injury may occur if other devices or other brand equipment is
connected.

11
HF INTERFERENCE WARNING!
This unit utilizes High Frequency to generate and sustain the Pilot arc.
This means that the unit is subject to emit emf/HF energy which may
cause damage to unshielded components. When using the unit near or
with electronic equipment such as computers and electronic and fluores-
cent lighting the use of this plasma cutter may interfere with the stable op-
eration of the control systems. The use of this unit should always comply
with local wiring codes, including operating on a separate, dedicated circuit
and proper ground(s).
This unit may cause damage to unshielded CNC cut tables and control
equipment unless the items are factory shielded and designed for use with
high amperage plasma CNC type cutting. This unit should only be used
with commercial CNC equipment that is fully shielded. Manufacturers of
high amperage CNC cutting equipment(more than 125A) usually shield
equipment from the possible effect of High Frequency. HF start is the nor-
mal type of plasma start for plasma units greater than 125A so the threat is
generally recognized and accounted for in larger commercial CNC sys-
tems. This unit should never be used with home-owner or non-
commercial CNC type tables and controls.
HF emissions can be controlled with use of proper shielding/ grounding
techniques and maintenance of the HF spark gap. If problems are experi-
enced in a commercial environment, call Everlast Tech Support for help di-
agnosing and reducing interference.

12
Specifications
Specifications PowerPlasma 150H
Inverter Type Digitally Controlled IGBT Inverter
Minimum/Maximum Rated Output 20A/88V - 150A/140V
Start Type High Frequency
Torch Type Manua l/ CNC Option Air-Cooled Innotec
Duty Cycle @ Rated Amps/Volts ( 40° C) (Output V/A) 60% @ 150A/ 140V 100% @ 115A/ 126V
OCV (U0) 300V
Voltage Input (U1) 480V 50/60Hz 3 Phase (±10%)
Maximum Inrush Amps (I1MAX) @ 240V 32.5A
Maximum Rated Effective Amps (I1EFF) 26A
CNC Port/ CNC Capable Yes, order CNC package. Use Water-Cooled Torch for best results for heavy duty use.
Air Pre Flow Timer (For better starts with HF) Adjustable, 0-10 Seconds
Air Post Flow Timer Adjustable, 0-60 Seconds
Up/Slope Down Slope Time Adjustable, 0-5S
Air Compressor Requirement and Recommendations.
NOTICE:
Pancake type and small oil-less compressors are not suitable.
9 CFM @ 90 PSI
Use a compressor with a minimum output of 9 CFM @ 90PSI (255lpm @ 6.2 bar), with 60 gallon
capacity (273l)or higher.
For CNC operation use 11 CFM @ 90 PSI (312 lpm @ 6.2 bar)
Duty Cycle/ Over Current Protection Yes
Minimum Operating/Cutting Air Pressure:
(Set and check air-pressure with “Air Test” engaged.)
NOTICE:
Low Air Pressure will interrupt output and display error code (E03).
Approximately 45 PSI (2.8 bar)
(safety cut-out threshold)
Recommended Cutting Air Pressure: 45-73PSI (65 to 72 for best results)
Maximum Supplied Air Pressure:
90 psi (6.2 bar) This is the incoming supply pressure from the air compressor, not operating,
(cutting) pressure. The air compressor MUST have a separate pressure regulator at the tank or inline
to control maximum supply pressure.
Recommended Maximum Daily Average Cut Thickness
(Steel, Hand Cut)
NOTICE:
Decrease 35% for Aluminum and Stainless Steel (INOX).
1.9” (48mm)
Recommended Maximum Daily Average Cut Thickness
(Steel with CNC and Auto-Cutting Mechanisms)
NOTICE:
Decrease 35% for Aluminum and Stainless Steel (INOX).
NOTICE:
CNC operation has limiting factors that reduces operation Average Cut Thickness capability. This includes duty
cycle, inability to manipulate torch for piercing duties, cut speed requirements/expectations.
1.75” (45mm)
Rated Maximum Quality Cut @ 10-12 IPM (@ 250-300mm / min)
(Steel, Hand Cut)
NOTICE:
Decrease 35-40% for Aluminum and Stainless Steel (INOX).
2” (50mm)
Max Severance Cut @ 3 IPM (75mm / min)
(Steel, Hand Cut )
NOTICE:
Decrease 35-40% for Aluminum and Stainless Steel (INOX).
2.25” (58mm)
Pre/Flow Post Flow Time 0-10 Seconds/ 0-60 Seconds
Pilot Arc Amperage 15-35A (Adjust for best operation for different optional torches. Set normally to 20-25A.)
Pierce Amperage 20-150A
Upslope/ Downslope Time 0-5 Seconds / 0-5 Seconds
Water Cooler (Optional) PowerCool 400
Minimum Water Ingress Protection Standard IP21S
Efciency >85%
Cooling Method Full-Time High Velocity Fan
Dimensions (approximate) 25.9” H x 11.25” W x 25.2” L (660mm x295mm x 640mm)
Weight (Bare Unit) 119 lbs. (54kg)
Minimum Storage/ Minimum Operating Temperature Storage: -10°F/-23°C Operating: 14°F/-10° C

13
Specifications
Duty Cycle
Duty Cycle is simply the amount of time out of a 10 minute period in which the unit can operate. For example, if this unit has a duty cycle of 60% at
maximum output means that the unit can be operated for 6 minutes out of 10 minutes. This may be continuously, or intermittently during the 10 mi-
nute period of time. This rating standard (United States) is based on a maximum ambient temperature of 40 C. Operating above this point, or at lower
temperatures with high humidity may reduce the duty cycle rating. Of course, the duty cycle may increase somewhat as ambient temperature drops.
Regardless, this unit’s duty cycle is not controlled by a timer. Rather, this unit is equipped with a heat sensor located on a heat sink near the critical
power components of the plasma cutter. If the operating temperature of the unit is exceeded, welding output will stop and an over-temperature warning
light/error code will be displayed on the panel. If a duty cycle event is registered, do not turn the unit off! Allow the plasma cutter to continue to run at
idle for at least 10-15 minutes until the temperature has fallen enough to reset the sensor and over-temperature warning light. Even if the unit resets,
allow the unit to cool for a full 15 minutes, or the duty cycle will be more quickly triggered since the unit resets just below the heat threshold. The fan
(s) must continue to run for a full 15 minutes to cool the unit properly after the duty cycle shut down has occurred. After 15 minutes of cooling, you
may switch the unit off if you are nished welding. If the unit does not automatically reset after 15 minutes, turn the unit off. Wait for 15 seconds be-
fore turning the machine back on. If the unit does not reset, contact technical support for further advice and assistance. As a best practice, when you
have completed welding and have been welding continuously for extended periods of time, keep your unit on for 10 additional minutes without welding
to allow it to cool.
The intentional and/or repeated triggering of the duty cycle protection feature on this unit will shorten the lifespan of the unit’s electronics and can
weaken internal components. The effect of overheating your unit repeatedly takes a cumulative toll on the unit.
NOTICE: These units are tested by an international and independent certifying agency for their ability to sustain the claims of duty cycle, under lab in-
duced conditions which are typically more stringent than average shop conditions.
DUTY CYCLE AND CNC USE
When considering this unit for use with CNC applications, keep in mind that CNC applications may require nearly a 100% duty cycle. For this reason,
the unit should be used at or near the 100% Duty Cycle Amperage rating of the unit, and not at the full maximum amperage. See the specication chart
for this rating. This does not mean the unit cannot be used at the maximum Amp rating of the unit (the 60% Duty cycle rating), but it does mean that
special attention should be taken when cutting parts that may require over ten minutes of cut time to complete, or when rapidly cutting one part after
the other at maximum settings, without sufcient cooling time between parts being cut.
Keep in mind that the 100% duty cycle Amp rating does not mean that this unit will cut continuously for an
innite period of time. The duty cycle is based on a clearly dened 10 minute window of time. For example,
a 100% duty cycle does not mean the unit will cut continuously for 25 minutes without a rest for cooling. It
only means it will cut up to 10 minutes at the rated amperage without having to rest a cool. This means that
after the 10 minute time period has expired, the unit may overheat if the unit continues to cut without a rest.
But in practical terms, though, when using at much lower amperage than the 100% rating, continuous or
near continuous cutting may be possible in some circumstances. Additionally, ambient operating condi-
tions and other factors such as cleanliness of the internal parts can affect the duty cycle positively or nega-
tively. This unit regulates duty cycle by means of a thermo-sensor rather than a timer, so duty cycle may
vary disproportionately at times, and is not a completely linear function.

14
Specifications
Breaker Sizing and Wiring Requirements
Before installation of this unit in any facility, always consult a licensed local electrician familiar with the requirements of properly wiring a plasma cutter
into the electrical supply. Refer to the National Electric Code (NEC) and local codes. If needed, refer the electrician to Article 630 of the NEC during
consultation to determine proper application and wiring needs. Use the I1MAX and the I1EFF ratings listed above to determine the proper breaker and
conductor (wire) sizing required. Everlast plasma cutters are designed around use in industrial wiring applications and are intended to be used with
modern electrical systems. Household wiring may need to be upgraded before this plasma cutter may be installed. Additional HF protection and isola-
tion may be needed if this plasma cutter interferes with the operation of electrical/electronic equipment.
IMPORTANT: Do not modify plasma cutter wiring. This unit meets the standards for conductor sizing on the power cable and takes into account power
cable length, duty cycle and rated current.
NOTICE:
If any electrical disturbance is noticed as a result of the high frequency interference that is possible with the operation of the inverter switching and
operation, the HF service bolt should be connected directly to a 12 gauge wire that is bonded directly to an outside copper ground rod driven into
moist soil. Additionally, all metal items including any metal frame or sheeting of the building should be connected and grounded to separate copper
ground rods driven into the ground at 10 foot intervals around the perimeter of the building. This includes items such as tables, carts, rack material,
metal surrounds, etc. that may act as “antenna” to radiate/absorb HF energy. Additionally, all cords and welding leads should be twisted together and
run directly to the work without coils or excess cabling. Normally, this will not be required, but it is supplied in the case of any interference that may be
observed. This is usually observed in older or non standard installations where grounding and ground isolation is a problem.
WARNING!
Never connect the torch or work clamp to the machine while the machine is switched on. Never torch any
tting or torch connector while the unit is switched on. Touching the connectors while running may result in
severe shock, burns or electrocution. Always switch the machine off before changing consumables or touch-
ing any of the cutting parts (consumables) of the torch.

15
Setup Guide
Getting Started
UNPACK YOUR UNIT.
Upon arrival, you will need to completely unpack your unit, and check
things over. This is a time sensitive matter. Do not delay or hold the plas-
ma cutter unopened in the box. First, make sure the unit is opened from
the top. Be careful with using knives and sharp objects so you won’t cut
cords and cables inside the boxes. Lay all items out and inspect them.
You should have the following in your box:
1. Plasma cutter with built in water line connections for optional water
cooler use.
2. Air-Regulator with built in water trap/particulate lter.
3. 200A Work Clamp (approx. 9.5 ft with cable).
4. Consumable Starter Kit for Plasma.
5. Torch, Air-Cooled Innotec LT150, Optional Water-Cooled machine
torch.
When you receive your package, inspect the unit for damage. Check for
the presence and general condition of the accessories. Some slight rub-
bing or chafng of some of the accessories may be present, but this is
considered normal. Most notably, the torch may appear to be used or
red. This is because it has been live tested in the factory for proper oper-
ation before putting into the box. If any item is damaged or missing,
please inform Everlast within 72 hours of product receipt. See pages 4 and
5 for more details. Assemble the handle with the supplied screws. Do not
overtighten the screws.
POWER UP AND TEST YOUR UNIT.
You will need to fully test the unit as soon as possible. Within 72 hours
after receipt of the unit, be sure to have every thing you need at hand to
test the unit. Make sure the correct input power, wiring, and plug congu-
ration is being used. Then, power up your machine without any accesso-
ries installed. Allow the unit to idle for 15 minutes. Check and observe
operation of knobs, controls and buttons, cycling through each as re-
quired. Make sure the fan is running at full speed. After the test is com-
pleted, turn the unit off, connect the accessories, shielding gas (customer
supplied) and conduct live testing of all the functions and features of the
machine. For testing and cutting make sure work clamp is connected di-
rectly to the part being welded (work). Check for arc starting and stability.
If problems are observed, contact Everlast. See page 5 for more infor-
mation. NOTICE: Cosmetic damage claims after 30 days will not be ac-
cepted, unless Everlast is contacted and informed of such delay and rea-
son for such a required delay (i.e. Overseas in deployment).
CHECK FOR LEAKS.
Be sure to check for gas and water leaks before attempting to cut. Con-
nect all the air and water lines and tighten and recheck any related clamps,
plugs and ttings. If you hear or suspect air leaks, use warm, soapy water
(or a dedicated leak testing solution available from welding suppliers) and
spray on all rear external connections. If any leaks are present, bubbles
will form around the area of the leak. Tighten any clamps or ttings found
to be leaking on the air and water tubing connecting the unit and torch to
the air compressor and optional water cooler . If the regulator is leaking,
make sure the pressure is not more than 90 psi, and tighten the small
screws on the regulator with a screw driver. If too much air pressure is
applied, the regulator may have blown internal and external O-rings.
Check and remedy if the regulator persists leaking. If the problem cannot
be remedied, or internal leak is suspected contact Everlast. NOTICE: A
small drop in set pressure and operating pressure (while cutting) is nor-
mal. This does not indicate a leak. This drop should never be more than 4
to 5 psi and is usually less than 3 psi. Setting the unit one LED light over
the target pressure will offset this drop and allow the unit to perform satis-
factorily while cutting. If the pressure drops more than 3 to 5 psi, this
usually indicates the supply hose is too long or too small for the length it
is running before reaching the unit. Always keep the supply hose as short
as possible. Use 1/2” air hose or larger for best results.
DISTANCE YOUR PLASMA CUTTER FROM YOUR WORK.
As a best practice technique, be sure to locate your plasma cutter away
from the immediate area you are welding. Sparks and debris thrown by
the plasma cutting process can enter the unit and cause damage. Do not
intentionally cut with the plasma cutter on the work station or in the imme-
diate area of the cut. This includes any grinding or milling operations that
may occur in the area. With CNC operation, keep the cutter out of the
immediate area of the cut table. Keep in mind the fan draws air in from
the rear and exhausts out the front and the sides of the unit.
GIVE YOUR PLASMA CUTTER SPACE TO COOL.
The plasma cutter needs room to cool itself. Place the unit in a place that
will allow 18” from all sides to allow for proper cooling. The plasma cutter
pulls air in from the rear, and pushes it through the unit’s heat sinks to
cool the electronics. The air is then exhausted through the front panel and
side louvers of the unit. If any of sides is blocked or restricted, the duty
cycle will be reduced, and overheating will occur, leading to possible
damage if the restriction is severe enough. Never attempt to restrict air
flow by attaching lters to the vents or by modifying your fans for “on
NOTICE:
The unit comes with a basic consumable starter kit, designed to get
you only through a couple days of plasma cutting. You should have
5 standard 150A cutting tips and electrodes. You will need to pur-
chase a more extensive kit soon after receiving and using your unit.
If you don’t order extra consumables soon after you receive this
unit, you may run out more quickly than you expect. This kit con-
tains stand-off type, non-shielded consumables that are sized for
the maximum Amp operation of the unit are designed for stand-off
cutting. Lower Amp operation, gouging or drag cutting will require
the purchase of additional consumables (See torch parts page for
amp ratings and sizes). Additionally, some miscellaneous parts may
be found together with the consumable kit which may include fas-
teners, and some items for the air regulator required for assembly.
If you think you are missing a needed part, check the consumable
kit bag before calling Everlast for replacement.
PowerPlasma 150H

16
demand” service.
CONNECT YOUR UNIT TO THE OUTLET.
This unit is designed for 480V 3 phase use only. Do not attempt to con-
nect this unit to any other power source.
This unit is designed for commercial use and is not intended for home-
owner or small shop use where single phase power may be present. In
addition, all three phases must be used. This cannot be used with single
phase 480V, two conductor conguration.
NOTICE:
There are special rules centered around wiring an outlet for service
with a welding machine. The National Electric Code under Article 630
has developed specic regulations for wiring electrical service for
welding equipment. These are different than for other types of service
such as a stove or dryer in a household or even in a commercial appli-
cation. You need to consult and/or employ a locally licensed industrial
electrician familiar with industrial wiring codes and techniques before
installing this unit to make sure all national and local codes and regu-
lations are followed. If you are not qualied to make these connec-
tions, don’t. Everlast is in no way liable for any damages caused by
improper connection of your plasma cutter. Your plasma cutter should
be on a dedicated branch circuit not far from an electrical disconnect
box. Importantly, it should not share circuits with other shop or house-
hold items. If possible the unit should be wired direct into a discon-
nect. If this is not possible then use a suitable 480V 3 phase rated
plug capable of supporting the rated amperage of this machine that is
connected direct to a disconnect device that is on a dedicated branch.
In addition, OSHA rules governing line de-energizing may apply to
installation and maintenance of this machine.
Lockout or disconnect power to the disconnect box before connecting
the input conductors. Connect the green ground wire rst before con-
necting any other wire. This unit does use a breaker type switch that
turns the unit on and off and which provides a disconnect at the ma-
chine, but cannot easily be locked out to prevent use, and does not
prevent flow of power to the plasma cutter itself.
Setup Guide
Getting Started
Wire Conguration 3 Phase 480V
ADVISORY:
This unit uses an High Frequency (HF) mechanism to create a pilot arc
without touching the steel. This can cause interference with unshielded
electronics in proximity to the plasma cutter. It may also interfere with
operation of lower tiered CNC plasma tables that are unshielded.
Even with shielding some disturbances may be noticed. If this is the case,
consider grounding all metal objects in the affected area of at least fty feet
at regular distances prescribed by your electrician. This includes tables,
pipes, racks, plumbing, conduits and power boxes. If being used in a
metal building, every panel should be connected via a braided copper wire.
Use a braided 12 gauge wire to connect all objects, providing a direct
ground to earth via a copper ground rod driven in the ground to the out-
side the building. Space every fty feet. Ground rods must be driven in
moist earth to be effective.
It may also be necessary to create a “Faraday” cage made of copper or
brass screen over windows and open doors to prevent High Frequency
leakage to nearby areas.
The plasma cutter also provides a ground bolt in the rear to provide an
easy way to ground the case as well. This must be grounded when
grounding other metal items in the vicinity.
Regardless of perceived interference, always keep the plasma cutter away
from communication cables and commercial powerlines. Separate them
from the plasma cutter by at least 50 feet. This includes power heads.
This work should only be completed by a qualied
electrician familiar with industrial applications and the
rules and agencies governing them.

17
Setup Guide
Getting Started
CONNECT THE AIR COMPRESSOR
What do I need to be able to plasma cut?
The unit comes with everything you need as far as a basic starter kit
for consumables, torch and regulator. However, you will need to
supply a few things on your own.
1. You will need a suitable air-compressor and at least 1/2” supply
line hose. 5/8” supply may be required for long distances. The
input side on the regulator is the standard industrial 1/4” quick
connect tting. Suitable units should follow recommendations
found in the product specication recommendations. Compres-
sors supplying less than 9 CFM @ 90 psi with less than a 60
gallon reserve capacity are not suitable for this unit.
2. You will need to be able to regulate your air at the air compres-
sor. Do not use the pressure switch on the air compressor to
control the air pressure. A gate or ball valve installed on the air
compressor is not enough either. You will need an adjustable
regulator which will control the air pressure at the tank. The
regulator that you install on the unit is to be used to regulate
actual cutting pressure. You need to be able to regulate the
supply pressure down to 90PSI at the air-compressor. If you
supply more than 100PSI to the cutter’s regulator, you may
damage the regulator.
3. You will need a separate air-dryer. Moisture is the enemy of any
plasma system and will destroy consumable life and eventually
torch as well. The regulator/lter included with the unit is not
sufcient to remove moisture from the system. It is designed to
trap particulates and slugs of water created by the coupling/
decoupling process. A refrigerated system is not necessary.
We recommend you look at the cartridge type systems that have
replaceable elements for a budget alternative. If these are not
available, consider at least having a replaceable paint gun dryer
mounted inline and monitor the moisture it traps and replace it
often.
4. You will need additional consumables with different sizes to
match the cut Amperage. The stock consumables are designed
for use at the maximum amperage of the machine. The orice in
the plasma tip is specically designed for a narrow range of
Amps. To see that range, check the plasma torch pages of this
manual, and each tip diameter corresponds to a specied amp
range. Lowering air pressure to try to compensate for lower
Amps results in poor quality cuts and inconsistent arc behavior.
Always match the consumable size to the Amperage being used.
NOTICE: For direct on-the-metal drag cutting and CNC use,
special shielded consumables.
IMPORTANT:
Do not reverse air flow direction on the regulator! Make sure the
arrow stamped on top of the regulator coincides with the direction of
air flow. If flow direction is reversed, it can cause operational issues.
Connect Regulator To Cylinder And Unit.
1
2
3
4
0
5
Connect tubing to lower rear of the unit.
Air Dryer
Regulator

18
Setup Guide
Getting Started
The PowerPlasma 150H uses a multi-point connection. These con-
nections also include water cooled connections for the optional water
cooler and water cooled torch. But whether the torch is air cooled or
water cooled, the connection of the torch is essentially the same.
With the water cooler, the water cooler water supply line connects in
the rear and the torch water cooled lines connect in the front.
The standard unit is equipped with an Innotec HF LF150 series torch.
The torch supports a wide range of amperages when the correct size
and type of consumables are used.
When operating with CNC plasma tables, Everlast discourages the
use of hand held torches, and recommends that the user purchase
the optional machine torch. While Everlast does not outright prohibit
their use with CNC systems, it should be noted that hand torches are
more prone to wearing out prematurely and failure. While the con-
sumables are the same between the hand torch and the machine
torch, there are slight differences internally that make the machine
torch more suitable for longer life. Machine torches have straight
sides which can be easily measured and squared. The hand torch
has a slight angle and bevel to the torch head, which makes getting it
truly perpendicular to the torch piece much more difcult. Even
prefabricated adapters and hand torch holders are notorious for slip-
ping or holding the torch at a angle other than a true 90 . While
squaring the machine torch, make sure that the plate is not warped
by checking the torch on opposite sides rst with a speed square or
machinist’s square. If one side reads square and the other side
does not, then it is likely you have a warped plate, or loose holder.
After checking the initial two opposing sides, rotate 90 clockwise
around the torch circumference and check the torch for squareness
in that direction. Then check the opposing side. Once square, check
all sides again for squareness. If the torch needs a major adjustment
in one direction, you will need to check the other direction for
squareness, since adjustment with some torch holders allows move-
ment in all directions.
Out of square torches cause a lot of issues with beveled cuts. If you
notice a cut that is beveled in one direction of travel, you should
suspect a warped plate, cutting deck or an out of square torch. Slight
bevels caused while cutting around circles are normal, but a change
in direction of travel can change the amount of bevel and the direc-
tion of the bevel.
Squaring the Machine Torch
How Do I Connect The Torch?
Hand Torch
Work Clamp
Work
DINSE 15/25
Adapter
Central Connector
Square the torch on all four sides to ensure the torch and the
plate are level. Check at every 90 °, all the way around the
torch. Recheck all sides after any adjustment has been
made.
0
90
180
270 Torch
1 2 3 4 5
1. Work Clamp Connection
2. Pilot Arc Wire Connection
3. Torch Switch/Control (Not used for CNC applications)
4. Cool Water to Torch (For optional Water-Cooled torch only)
5. Main Power and Air Line (Air and Water Cooled torches)

19
Component Identification and Explanation
Number Component Identification Component Note
1Protective Cover Keep cover down and in place during welding activities and in storage.
2Negative Terminal (-)
(DINSE 15/25 Type, 3/8” nominal dia.)
Connect the work clamp to this terminal.
3Pilot Arc Thumbscrew The torch pilot arc is connected here. This provides the autolighting and relighting of the torch. If this is not
connected the torch cannot function properly.
4Torch Water Line Connector
(Raise Cover to Access)
Connect the water line of the optional water cooled torch to this connector. When the water cooling mode is
selected, this line must run through the plasma cutter instead of directly from the cooler. If no water flows
through this line, the Plasma Cutter will sense a no-flow situation and will not cut. If this happens, an E04
code will be displayed simultaneously as conrmation. The return line is connected directly to the water
cooler from the torch however. Be sure not to mix up the air and water lines or damage to the torch will
result. Make sure your lines are connected correctly before use and that the water is connected at the rear.
5Main Torch Connector
(Raise Cover to Access)
The unit may be operated with a water cooled or an air cooled torch. This is the main torch connector where
air and power is supplied to the torch. Do not mix up the main torch connection and the water cooler con-
nection or damage will result to the torch.
6Torch Switch Control Connector The torch switch of the Plasma cutter connects to this tting for hand cutting. CNC cutting and arc activation
is controlled through the rear socket.
Front Panel View
3
1
2 6
4
5
WARNING!
Never connect the torch or work clamp to the machine while the machine is switched on. Never touch any tting or torch connector while the unit is
switched on. Touching the connectors while the machine is switched on may result in severe shock, burns or electrocution.

20
Component Identification and Explanation
Rear Panel View
Number Component Identification Component Note
1 Power Switch This is the main powerswitch. Thisshould be used for powering the machine on and off.T his switch doubles as the main power
switch and disconnect switch. If this switch trips and the welder power turns off, a signicant internal event or failure of the
switch may have occurred. If this occurs, immediately remove from service and mark/tag according to regulations and contact
Everlast Tech Support for further diagnosis and/or repair options.
2Cooler Plug This plug is to be used only for powering the optional watercooler. Never modify or adapt this plug for any use. Use only with
Everlast water coolers designed for this unit.
3CNC Connector and Dust Cap For use with CNC controllers. Locate and use the mated plug (supplied in CNC version packaging). Solder the mated plug pins
directly to CNC control cable. Do not remove or re-pin CNC connector on the unit. Do not solder directly to the unit connector.
If you do not have the accompanying plug that mates to the rear in the packaging for CNC cutters, contact Everlast.
4HF Ground Service Bolt For use in a combined effort to help mitigate any electrical interference that may be caused by the operation of this unit.
5Air input connector (from regulator) This is a push-to-connect tting. The regulator tubing should be inserted here from the regulator supplied with the unit and
customer-installed on the rear of machine. Before inserting tubing, trim tubing so that the end is cut completely square. This
will help prevent leaks and line blow-offs.
6Water-Cooler Input Connection The blue water cooler out line should be connected at this connection. The Red in connection on the cooler should be connect-
ed directly to the cooler. This input connection provides a flow alert warning and interrupt and should not be bypassed.
7Fan The fan should be kept clean and clear of obstruction. Keep at least 18” away from any objects that may block air flow and
exchange of cool air.
8Input Cable*
North America only: The unit is wired for 480V 3 phase use. The unit must be installed in accordance with article 630 of the
NEC. It must be used on a dedicated circuit and cannot share operation or duty with any other power connection. While this
unit may be connected to a 480V 3 phase outlet, it is recommended to connect directly to a disconnect box.
*NOTICE: Always consult national codes and a licensed industrial electrician before wiring this welder to any service.
1
2
6
5
7
3
4
8