Everlast PowerPlasma 50 User manual

Rev. 2 0 00312-13
CC
IGBT
1
~
PHASE
DC
EVERLAST
everlastwelders.com
1-877-755-9353
Specicaons and Accessories subject to change without noce.
329 Lileeld Ave. South San Francisco, CA 94080 USA
PAC
IGBT DESIGN 50AMP PLASMA CUTTER
Operator’s Manual For
PowerPlasma 50
Safety, Setup and General Use Guide
EVERLAST
POWER PLASMA 50

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 S-45……………………………….……………..
Troubleshoong………………………………………………....
CNC Connector Pin-Out Appendix……………………….
3
4
5
9
10
11
11
12
13
14
16
17
22
23
24
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 infor-
maon. Your unit registraon is important should any informaon such as product updates or re-
calls 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 through the main customer service number in your country. Your unit will be regis-
tered 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 candi-
date for warranty service and returned.
Please review the current online warranty statement and informaon found on the web-
site of the Everlast division located in or nearest to your 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 have online support available
through email, and a welding support forum designed for customers and noncustomer interacon.
Technical advisors are acve on the forum daily. We also divide our support into two divisions:
technical and welding 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 service call the appropriate support line and follow up with an
email, parcularly during o hours, or in the event you cannot reach a live person. In the event
you do not reach a live person, parcularly during heavy call volume mes, holidays, and o hours,
leave a message and your call will normally be returned within 24 hours. Also,for quick answers to
your basic quesons, join the company owned forum available through the website. You’ll 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 manu-
facturing 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 many quesons by the advisors to clarify prob-
lems or issues that may seem very basic. However, diagnosis procedures MUST be followed to
begin the warranty process. Advisors can’t assume anything, even with experienced users, and
must cover all aspects to properly diagnose the problem. Depending upon your issue, it is advisa-
ble to have basic tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive
test meter with volt/ohm funcons before you call.
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___________________________
EVERLAST
Contact Information
Everlast US:
Everlast consumer sasfacon email: [email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [e-mail]
Everlast Support Forum: hp://www.everlastgenerators.com/forums/index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
11am-4pm PST Sat.
FAX: [phone]
Everlast Canada:
Everlast consumer sasfacon email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [e-mail]
Telephone: [phone]am-4:30pm EST M-F
10am-1pm EST Sat.
FAX: [phone]
Everlast Austrailia:
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: [email protected]

5
Everlast is dedicated to providing you with the best possible equipment and
service to meet the demanding jobs that you have. We want to go beyond deliv-
ering a satisfactory product to you. That is the reason we offer technical sup-
port to assist you with your needs should an occasion occur. With proper use
and care your product should deliver years of trouble free service.
Safe operation and proper maintenance is your responsibility.
We have compiled this operator’s manual, to instruct you in basic safety, oper-
ation and maintenance of your Everlast product to give you the best possible
experience. Much of welding and cutting is based upon experience and com-
mon sense. As thorough as this welding manual may be, it is no substitute for
either. Exercise extreme caution and care in all activities related to welding or
cutting. Your safety, health and even life depends upon it. While accidents are
never planned, preventing an accident requires careful planning.
Please carefully read this manual before you operate your Everlast unit. This
manual is not only for the use of the machine, but to assist in obtaining the
best performance out of your unit. Do not operate the unit until you have read
this manual and you are thoroughly familiar with the safe operation of the unit.
If you feel you need more information please contact Everlast Support.
The warranty does not cover improper use, maintenance or consumables. Do
not attempt to alter or defeat any piece or part of your unit, particularly any
safety device. Keep all shields and covers in place during unit operation should
an unlikely failure of internal components result in the possible presence of
sparks and explosions. If a failure occurs, discontinue further use until mal-
functioning parts or accessories have been repaired or replaced by qualified
personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves.
These waves may disturb sensitive electronic equipment such as televisions,
radios, computers, cell phones, and related equipment. High Frequency may
also interfere with fluorescent lights. Consult with a licensed electrician if dis-
turbance is noted. Sometimes, improper wire routing or poor shielding may be
the cause.
HF can interfere with pacemakers. See EMF warnings in following safety sec-
tion for further information. Always consult your physician before entering an
area known to have welding or cutting equipment if you have a pacemaker.
Safety Precautions

6
SAFETY PRECAUTIONS
These safety precautions are for protection of safety and health. Failure to
follow these guidelines may result in serious injury or death. Be careful to
read and follow all cautions and warnings. Protect yourself and others.
Welding and cutting processes produce high levels of ultraviolet (UV) radiation that
can cause severe skin burn and damage. There are other potential hazards involved
with welding such as severe burns and respiratory related illnesses. Therefore ob-
serve the following to minimize potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even
under welding helmets to protect your eyes from flying sparks and debris. When chip-
ping slag or grinding, goggles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct
shade of filter installed. Always use a welding helmet in good condition. Discard any
broken or cracked filters or helmets. Using broken or cracked filters or helmets can
cause severe eye injury and burn. Filter shades of no less than shade 5 for cutting
and no less than shade 9 for welding are highly recommended. Shades greater than 9
may be required for high amperage welds. Keep filter lenses clean and clear for maxi-
mum visibility. It is also advisable to consult with your eye doctor should you wear
contacts for corrective vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless
fully protected by a filter screen, protective curtains or equivalent protective equip-
ment. If no protection is available, exclude them from the work area. Even brief expo-
sure to the rays from the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy.
Ear protection is necessary to prevent hearing loss. Even prolonged low levels of
noise has been known to create long term hearing damage. Hearing protection also
further protects against hot sparks and debris from entering the ear canal and doing
harm.
Always wear personal protective clothing. Flame proof clothing is required at all
times. Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose
clothing is tucked in neatly. Leather aprons and jackets are recommended. Suitable
welding jackets and coats may be purchased made from fire proof material from
welding supply stores. Discard any burned or frayed clothing. Keep clothing away
from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for ade-
quate foot protection. Canvas, polyester and other man made materials often found
in shoes will either burn or melt. Rubber or other non conductive soles are necessary
to help protect from electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient.
Gauntlet type welding gloves are available from your local welding supply companies.
Never attempt to weld with out gloves. Welding with out gloves can result in serious
burns and electrical shock. If your hand or body parts comes into contact with the
arc of a plasma cutter or welder, instant and serious burns will occur. Proper hand
protection is required at all times when working with welding or cutting machines!

7
SAFETY PRECAUTIONS
WARNING! Persons with pacemakers should not weld, cut or be in the welding area
until they consult with their physician. Some pacemakers are sensitive to EMF radiation
and could severely malfunction while welding or while being in the vicinity of someone
welding. Serious injury or death may occur!
Welding and plasma cutting processes generate electro-magnetic fields and radiation.
While the effects of EMF radiation are not known, it is suspected that there may be
some harm from long term exposure to electromagnetic fields. Therefore, certain pre-
cautions should be taken to minimize exposure:
 Lay welding leads and lines neatly away from the body.
 Never coil cables around the body.
 Secure cables with tape if necessary to keep from the body.
 Keep all cables and leads on the same side the body.
 Never stand between cables or leads.
 Keep as far away from the power source (welder) as possible while welding.
 Never stand between the ground clamp and the torch.
 Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible
need for respiratory equipment while welding or cutting. Always weld with adequate
ventilation. Never weld in closed rooms or confined spaces. Fumes and gases re-
leased while welding or cutting may be poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
 Stop immediately and relocate work if necessary until adequate ventilation is ob-
tained.
 Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, cop-
per, cadmium, lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product when used for welding or cutting produces fumes and gas-
es 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 Phosgene gas can be deadly. Consider all chemicals to have potential
deadly results if welded on or near metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain
regulations regarding high pressure cylinders can be obtained from OSHA or local
regulatory agency. Consult also with your welding supply company in your area for
further recommendations. The regulatory changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and
closed. Store chained so that overturn is not likely. Transporting cylinders incorrectly
can lead to an explosion. Do not attempt to adapt regulators to fit cylinders. Do not
use faulty regulators. Do not allow cylinders to come into contact with work piece or
work. Do not weld or strike arcs on cylinders. Keep cylinders away from direct heat,
flame and sparks.

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 weld-
ing or cutting. Keep work surface dry. Do not use welder or plasma cutter in the rain
or in extremely humid conditions. Use dry rubber soled shoes and dry gloves when
welding or cutting to insulate against electrical shock. Turn machine on or off only
with gloved hand. Keep all parts of the body insulated from work, and work tables.
Keep away from direct contact with skin against work. If tight or close quarters ne-
cessitates standing or resting on work piece, insulate with dry boards and rubber
mats designed to insulate the body from direct contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their location and
make sure all personnel in area are advised of their location. Taping or securing ca-
bles with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodi-
cally check work area for smoldering embers or smoke. It is a good idea to have
someone help watch for possible fires while you are welding. Sparks and hot metal
may travel a long distance. They may go into cracks in walls and floors and start a fire
that would not be immediately visible. Here are some things you can do to reduce the
possibility of fire or explosion:
 Keep all combustible materials including rags and spare clothing away from area.
 Keep all flammable fuels and liquids stored separately from work area.
 Visually inspect work area when job is completed for the slightest traces of smoke
or embers.
 If welding or cutting outside, make sure you are in a cleared off area, free from
dry tender and debris that might start a forest or grass fire.
 Do not weld on tanks, drums or barrels that are closed, pressurized or anything
that held flammable liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling
hot pieces of metal. Remember to place hot metal on fire-proof surfaces after han-
dling. Serious burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Prop-
er maintenance is your responsibility. Make sure all equipment is properly maintained
and serviced by qualified personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding
parts. Touching uncovered parts inside machine can cause discharge of high
amounts of electricity. Do not allow employees to operate poorly serviced equipment.
Always check condition of equipment thoroughly before start up. Disconnect unit
from power source before any service attempt is made and for long term storage or
electrical storms.
Further information can be obtained from The American Welding Society (AWS) that
relates directly to safe welding and plasma cutting. Additionally, your local welding
supply company may have additional pamphlets available concerning their products.
Do not operate machinery until your are comfortable with proper operation and are
able to assume inherent risks of cutting or welding.

9
Introduction and SpecificationsSection 1
Consumable Starter Kit
S-45 Plasma Torch Work Clamp
Air Regulator
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 almost any local welding supply store.

10
Introduction and SpecificationsSection 1
PowerPlasma 50 Specicaons
FEATURE/SPEC. POWERULTRA 205P
INVERTER TYPE IGBT
INPUT VOLTAGE ±10%;PHASE/FREQUENCY 110/220V; 1PH/50-60Hz
MAXIMUM INPUT AMPS (I₁MAX) 34A @110V/ 40 A @ 220V
MAXIMUM INPUT RUNNING AMPS (I₁e) A @ 110V/ 31.3 A @ 220V
TIG DUTY CYCLE % @ AMPS 100% @ 40 A (PLASMA/220V)
60% @ 25 A (PLASMA/110V)
OUTPUT AMP RANGE
TIG: 5-200 A (220V)
Sck: 5-160 A (220V)
PLASMA: 20-50 A (220V)
10– 100 A (120V)*
20-27A (120V)*
OPERATING VOLTAGE RANGE
TIG: 10.4-18 V
Sck: 20.2-26.4 V
PLASMA: 88-100 V
OPEN CIRCUIT VOLTAGE TIG/STICK 60-80 V
PLASMA: 250 V
TIG TORCH 26 SERIES
PLASMA TORCH S-45 SERIES BLOWBACK START
CONSTANT CURRENT (CC) OUTPUT TYPE DC (±)
STICK CELLULOSE ROD CAPABLE 6010,6011 6011 ONLY (DC+)
INCLUDES
WORK CLAMP WITH CABLE (8
FT),STICK TORCH WITH CABLE
(8FT), TIG TORCH: 12 FT, PLAS-
MA S-45 12 FT, CONSUMABLE
STARTER KIT FOR TIG AND
PLASMA (NO TUNGSTEN)
DINSE CONNECTOR TYPE 25 Series
POST FLOW ADJUSTABLE 0-60Seconds
PROTECTION CLASS IP21S
INSULATION GRADE F

11
General overview: The PowerPlasma 50 ulizes the latest
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 volt-
age models only) with limited output up to 27 amps.
This design allows the unit to be used in many dierent
circumstances and applicaons. The PowerPlasma 50 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 along with duty cycle
and overcurrent protecon which will shut down output
of the plasma cuer unl the condion is resolved. The
OK-to-cut light is a feature which can be used by the op-
erator at a glance to determine if the air pressure is in
the opmum range. This unit employs the use of a blow
back design start which incorporates a pilot arc. 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
back to the unit. To prevent consumable burn out and
torch damage, the pilot arc is reduced to 22-27 amps.
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 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 to-
ward the machine, parcularly in grinding and welding
operaons. Make sure the panel is protected from dam-
age.
NOTE: When servicing unit, remove rear plasc panel
rst, the remove metal cover. DO NOT REMOVE FRONT
PLASTIC PANEL! THE FRONT PANEL IS INTEGRAL TO THE
FRAME OF THE UNIT. REMOVING THIS PANEL IS TIME
CONSUMING AND UNECESSARY.
Duty Cycle. The duty cycle has been determined for the
PowerPlasma at 60% @ 50 amps on 240 V operaon.
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 operat-
ed at the max amps for the stated percent of me out of
10 minutes without a break to cool down the unit. For
the remainder of the 10 minute me period, the welder
should rest for maximum 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 welder unl it
has safely cooled. Once the overheated condion has
cleared, cung may resume. Do not operate the unit
with the covers removed. Only cycle the power switch to
reset the unit IF the light has not gone out aer 10
minutes. 120V operaon may reduce duty cycle in some
situaons and will necessarily reduce output. A heavier
duty torch is recommended to accommodate high duty
cycle use (> 40% at maximum amps). The S-75 torch will
provide the durability needed for high duty cycle use and
performance when used at or near the Plasma cuer’s
maximum duty cycle or in rough service condions. You
can contact Everlast to purchase a larger torch or source
one through a Tramet dealer.
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. The weld-
ing industry is inherently dangerous. Only YOU, the opera-
tor of this Plasma cuer, can ensure that safe operang
pracces are followed, through the exercise of common
sense pracces and training. Do not operate this machine
unl you have fully read the manual, including the safety
secon. If you think that you do not have the skill or
knowledge to safely operate the plasma cuer, do not use
this welder unl formal training is received.
Introduction and Specifications
Section 1

12
FUSE TORCH
WORK PIECE
TO WORK (+)
35 SERIES CONNECTOR
QUICK SETUP AND USE GUIDESection 2
QUICK SETUP GUIDE: PLASMA CONNECTIONS
NOTES:
1) Aempt to operate only when “OK to Cut” light is ON.
2) See torch manual included in this manual for parts idencaon.
3) Do not exceed 90 psi air supply pressure or failure of components may result.
4) Adjust torch operaon pressure to 72 psi (5 bar) for best results with unit set to “constant ow”. If supplied, use the ow meter as de-
picted in the torch manual to properly set the air pressure and ow.
5) When using lower amperage levels, the nozzles will need to be changed out for ones with a smaller diameter orice. Everlast is the OEM
supplier of the torch but not the manufacturer. Smaller diameter nozzles are available through Tramet authorized distributors. A
symptom of a consumable that is too large, is a wandering arc or spuering.
6) Do not aempt to cut with the work clamp removed. The unit will produce the pilot arc without the work clamp connected. The pilot
arc is not designed to cut and excessive use will burn up the consumable and the torch. Keep the pilot arc engaged for lile as possible.
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, and the arc is present,
likely it is an issue with a poor connecon of the work clamp. Poor connecon of the work piece can cause the pilot arc not to 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 workpiece, clamp and even the DINSE connector on the panel. Repair if necessary. If this does not resolve the pilot arc
transfer issue, contact Everlast.
S-45 Torch (-)

13
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 REGULATOR 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 SPITTING,
POPPING AND RAPID CONSUMABLE WEAR. THE REGULATOR/FILTER THAT IS INCLUDED IS NOT SUFFICIENT TO REMOVE ALL MOISTURE. IT
SERVES ONLY AS A WATER TRAP AND FINE SEDIMENT FILTER. ANY AIR COMPRESSOR SYSTEM PRODUCES MOISTURE IN ALMOST ANY ENVIRON-
MENT REGARDLESS OF HUMIDITY LEVELS. DAILY DRAINING OF THE AIR COMPRESSOR IS RECOMMENDED AS WELL. THE AIR SUPPLIED TO THE
PLASMA 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 INSTALLED 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 DRYER/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)
2
1
4NOTE: WHEN ASSEMBLING AIR REGULATOR NOTICE THE MARKING S THAT
ARE STAMPED ON TOP OF THE REGULATOR HOUSING FOR AIR FLOW DIREC-
TION. AIR FLOW DIRECTION WILL BE NOTED AS IN/OUT OR 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 REGU-
LATOR WITH “IN” OR THE ARROW POINTING TO THE MIDDLE OF THE REGULA-
TOR. ALSO THE BRASS PLUG INCLUDED WITH THE ACCESSORY PACKAGE
SHOULD BE MOUNTED IN THE CENTER HOLE.
PUSH TO CONNECT

14
FUSE TORCH
WORK PIECE
9. CENTRAL CONNECTOR
2. ON/TEMP/O.C./OK-TO-CUT
3. AMP CONTROL
1. AMP DISPLAY
QUICK SETUP AND USE GUIDESection 2
FRONT PANEL FEATURES AND CONTROLS
11. AIR PRESSURE
4. CNC/MANUAL CUT SWITCH
5. POST FLOW TIME
6. CONSTANT FLOW/TIMED FLOW SWITCH
7. WORK CLAMP (25 SERIES)
8. FUSE
10. AIR PRESSURE ADJUSTMENT

15
POWERPRO FEATURES PARAMETERS PURPOSE
1. Amp Display N/A Indicates amperage while cung. While adjusng the amperage with the torch switch con-
nected relays selected amperage. When pilot arc is engaged, it is normal for the amps to drop
on the display. Typical readout while pilot arc is engaged is <30 amps.
2. On/Temp/ Duty Cycle/ OK
to Cut
On/O On indicator should always be on while the unit is plugged in and the power switch is switched
on. The Duty Cycle/ Over Current light is a dual colored LED. The color will appear red/amber if
duty cycle is reached and welding/cung will be interrupted. The unit should automacally
reset if this light comes on. If the unit does not reset, manually cycle the power switch aer 10
minutes. Do not turn o the unit unl it has had sucient me to cool. If it appears Green,
then it is likely an overcurrent situaon has occurred. Cycle the power switch to reset the ma-
chine. The light should go o. If it does not, and will not weld, contact Everlast. The OK to cut
light remains amber colored (color may vary) while the air pressure is above the minimum
threshold pressure threshold. This is not a warning light, but rather it gives the operator assur-
ance at a glance that the pressure is within tolerable limits to prevent torch damage. Addion-
ally when the pressure falls below this threshold (approx. 35 psi) the unit will stop cung auto-
macally. Cung will resume once the pressure rises above the minimum threshold. If the
light is on, however, it does not indicate the pressure is at opmal levels. Further tuning of the
air pressure may be needed. See below.
3. Amp Control N/A Controls amperage output.
4. CNC/Manual Switch This switch allows the user to select the torch operaon for a simple remote trigger with a semi
automac CNC device such as a track torch. It also allows manual, press and hold cung when
set to “manual”. When selected for CNC, the operaon of the torch only requires a simple
touch of the trigger or remote device to acvate the arc. Once acvated the switch can be
released and the unit will connue cung. To stop, simply press and release the switch again.
This feature is ed only to the front pins on the central connector only and does not operate in
conjuncon with the CNC port on the rear. These two funcons are separate, with dierent
intended forms of operaon. For manual cung, simply press and hold the trigger. For safest
use, do not operate the torch manually with the switch in the CNC mode. The torch will stay
ignited unl the trigger is cycled again. This can cause confusion if in an emergency situaon.
5. Post Flow Control 0-60 Seconds
(approximate)
Sets the post ow me of the air. Time is approximate only and can vary somewhat from the
maximum limit posted from unit to unit. Consider the maximum seng mark a reference guide
only. Use approximately 1-3 seconds of air ow for every 10 amps. More for extended cuts.
6. 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 with the ow tube. This prevents accidental arc iniaon while the air pressure is
being set. 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.
7. Work Piece 25 series Locaon of the posive terminal connecon for the work clamp cable. DINSE-style connector.
8. Fuse This fuse protects the operaon of the pilot arc and circuits of the machine should there be an
overcurrent 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 fuse or damage may result to the machine.
9. Central Connector 9 mm This serves as a unied, quick connecon for the torch. The Central connector is a universal
style connecon and is available as a retrot on many dierent brands through Tramet. The
connector carries power and the torch switch signal.
10. Air Pressure Adjustment 90 psi supply
pressure max.
70-75 psi
operang
pressure
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 pressure 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.
14. Air Pressure Gauge. 90 psi max
supply
65-75 oper-
ang
Used to measure air supply pressure.. Supply pressure should not exceed 90 psi. Adjust oper-
ang pressure while air is owing with gauge provided, or adjust to 72 psi and increase or de-
crease 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

16
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. 2-POLE POWER SWITCH
4. GAS INLET

17
FEATURE PARAMETERS PURPOSE
1. 2-Pole Power switch On/O The breaker switch has 2 poles. It serves as the On/O switch for the welder. Always
turn the welder on and o by the switch rst before using any disconnect. The Water
cooler outlet on the rear remains live aer the switch is turned o.
3. 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
welders in the US and Canada. Other countries vary plug conguraon as well as input.
As a dual voltage unit, when used with 120V supply connect the pigtail adapter to
reduce the input. When using on 120V, make sure the breaker and wiring is sized
properly for use or damage to the machine can result. Consult licensed electrician
before operang on 120V to conrm wiring and breaker suitability.
4. Gas Input Connecon 1/4-5/16” The unit is supplied with tubing which connect this ng to the air lter. 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 per-
pendicular. Reinstall the tubing.
5. HF Ground Bolt N/A Normally this circuit 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 build-
ing should be grounded as well, including pipes, tables, and even metal siding. HF
energy has been known to bleed back into the power grid and disrupt electronic devic-
es 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.
6. Air Filter Assembly 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 sup-
plied). 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.
QUICSection 2
REAR PANEL FEATURES AND CONTROLS CONTINUED
NOTES
1. The gas input connecon should be checked for leaks periodically, especially if the machine is moved.
2. Never operate welder 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 genera-
tor 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 welder. But the surge capabil-
ity 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 welder on a generator not specied by its manufacturer to be “clean”, 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.

18
Edge Starts are the best type of start if possible
to promote consumable and torch life. This re-
duces blow back of molten material and allows a
smooth gradual start of the cut.
1. Line up the hole on the p of the electrode
on the edge of the cut. Hold torch perpen-
dicular to the cut inially, about 1/16” o
the metal. Slide the yellow safety lock and
squeeze the trigger. Wait for arc to start.
2. Once the arc starts, wait for the arc to pene-
trate all the way through the metal.
3. As the torch penetrates its ame all the way
through the metal, lt the torch so there is a
slight lead in the ame if metal is thin. If it is
thick, keep holding torch in a nearly vercal
posion.
4. Begin moving the torch in the direcon of
the cut. Maintain 1/16” stando height.
5. Move the torch fast enough so the sparks
and ame trail from the boom edge at an
angle of no more than 30° and no less than
10° from perpendicular to the metal. Excess
angle of sparks/ame indicate too fast of
travel speed or praccal cut capacity has
been reached. Lile or no angle indicates
too slow of travel speed.
IMPORTANT: If you use a stando guide with the torch, it must be adjusted or bent to provide no more than 1/8” stando, less if possible.
Long stando 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
1
PIERCE START
2
3
Piercing starts oen result in rapid consumable
wear and excess blow back of molten metal de-
posited onto torch and consumables. This
should be done only as necessary.
1. Tilt the torch in the direcon of travel or
toward the side of the metal to be discarded
or wasted at a 40° to 60° angle. Slide the yel-
low safety lock and squeeze the trigger. Wait
for arc to start.
2. Once the arc starts, wait for the arc to trans-
fer from pilot arc to the cung arc.
3. As the torch penetrates it ame at an angle
rotate the torch slowly to the vercal posi-
on, as the arc penetrates the metal. Tilt the
torch from 0°-15° for thin metal cuts, or hold
it nearly perpendicular for thicker metal cuts.
4. Begin moving the torch in the direcon of the
cut. Maintain 1/16” stando height.
5. Move the torch fast enough so the sparks
and ame trail from the boom edge at an
angle of no more than 30° and no less than
10° from perpendicular to the metal. Excess
angle of sparks/ame indicate too fast of
travel speed or praccal cut capacity has
been reached. Lile or no angle indicates
too slow of travel speed.
The design of the blow back start may cause a slight delay in the arc as the air pressure must built inside the torch
tubing and head to create the pressure needed to force the electrode o the nozzle seat. This may take up to two
seconds. Restarng the arc with the post ow going may not cause a delay. If the torch does not light aer 3 sec-
onds, let go of the trigger and press it again. If start/arc is errac check nozzle and electrode for ghtness and wear.

19
Basic theory and function
Section 3
FLAME AT NORMAL TRAVEL SPEED
TRAVEL
FLAME AT FAST TRAVEL SPEED
TRAVEL
FLAME AT SLOW TRAVEL SPEED
TRAVEL
NOTE: When stepping down amps to cut thinner material, you must change to small-
er orice nozzle. Nozzles are oered through Tramet in dierent sizes which are ap-
propriate for dierent amp levels. Too large of a diameter orice will result in arc in-
stability and a rough cut. Lowering the air pressure below 65 psi to try to get the torch
to cut will only result in a lazy, wandering arc.
TIP: For longer consumable life do not use the pilot arc unnecessarily. Select the 3 second
pilot arc feature and do not re the torch unless you are near the metal and ready to cut.
For expanded metal cung be sure to select “Normal” to re-re the pilot arc automacally.
IMPORTANT: Check consumables regularly for wear and change them out before
they are completely worn. Allowing the consumables to wear unl they quit working
may damage related torch components, creang a more costly repair.
15-30

20
Basic theory and function
Section 3
MINIMAL EASY TO CLEAN DROSS
RESULTS OF CUT AT CORRECT SPEED,
AIR PRESSURE AND TORCH ANGLE
NOTICEABLE SMALL, HARD DROSS
RESULTS OF CUT AT FAST SPEED
SIGNIFICANT SOFT, POROUS DROSS
RESULTS OF CUT AT SLOW SPEED
VERTICAL CUT LINES
RESULTS OF TOO MUCH CURRENT OR
TOO MUCH STAND OFF HEIGHT
(SIDE VIEW)
MELTED TOP EDGE
RESULTS OF WORN CONSUMABLE OR
LOW AIR PRESSURE
(SIDE VIEW)
SEVERLY ANGLED CUT AT TOP
SMOOTH, EVEN CUT LINES WITH A S REARWARD SWEEP ROUGH, DISTINCT CUT LINES SPACED FAR APART