Everlast PowerPlasma 52i User manual

EVERLAST
POWERPLASMA 52i
Operator’s Manual for the PowerPlasma 52i
Safety, Setup and General Use Guide
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Rev. 1 0 001122-19
1-877-755-9353 Specications and Accessories subject to change without notice.
329 Littleeld Ave. South San Francisco, CA 94080 USA
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everlastwelders.com
50 Amp Digital IGBT Plasma Cutter
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120/240V

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TABLE OF CONTENTS
Section………………………………..…………..Page
Letter to the Customer ………………...……………...
Everlast Contact Information……………………...……
Safety Precautions……………………………………
Introduction and Specications………………….…….
Unit Specications……………………….…………...
General Overview…………….…..…………………...
General Maintenance…...………...……………………
Quick Setup Guide, Torch Connection….………………
Compressor and Air Dryer Diagram..……..…………….
Quick Operating Tips and Warning…….……………….
Front Panel Features and Controls……………………..
Rear Panel Connections……………………………….
Operation…………..………………………………...
Innotec iPT 60 Torch…………………………………
CNC Connector Pin-Out…...……………………….…
Troubleshooting and Error Codes……………………...
Special Operating Notes………………………………
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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 information 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. Everlast Power Equipment INC.
does not guarantee the accuracy, completeness, authority or authenticity of the information contained within this manual. The
owner of this product assumes all liability for its use and maintenance. Everlast Power Equipment INC. does not warrant this prod-
uct 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.

3
Dear Customer,
THANKS! You had a choice, and you bought an Everlast Product. We appreciate you as a customer
and hope that you will enjoy years of use from your welder.
Please go directly to the Everlast website to register your unit and receive your warranty information.
Your unit registration is important should any information such as product updates or recalls be issued.
It is also important so that we may track your satisfaction with Everlast products and services. If you are
unable to register by website, contact Everlast directly through the sales department via the main cus-
tomer service number in your country/region. Your unit will be registered and warranty will be issued
and in full effect. Keep all information regarding your purchase. In the event of a problem you must
contact technical support before your welder can be a candidate for warranty service and returned.
Please review and download the ofcial warranty statement, located on our website
www.everlastwelders.com. If you are not in the United States, visit the distributor’s website warranty
information nearest to your region or country. Print it for your records and become familiar the terms
and conditions outlined in the warranty. Warranty terms vary from country to country and region to re-
gion. For this reason, the warranty is honored through the original national/regional branch of Everlast
that originally sold the unit only. If a product is purchased in one country or region, another country or
region is not responsible for the enforcement or backing the terms of the warranty and sale.
Everlast offers full technical support in several different forms. We offer domestic based phone support
and online support. Online support is available through email and through our website contact forms.
We also provide a welding support forum designed for customers and noncustomer interaction. Tech-
nical advisors are active on the forum on a regular basis. We also divide our support into two divi-
sions: technical and welding performance. Should you have an issue or question concerning your unit,
please contact performance/technical support available through the main company headquarters availa-
ble in your country. For best service, call the appropriate support line and follow up with an email. In
the event you do not reach a live person, particularly during heavy call volume times, holidays, or off
hours, leave a message and your call will normally be returned within 24 hours. For quick answers to
basic operating or service questions, join the company owned forum linked through the US website.
You should be able to nd knowledgeable, helpful people and staff available to answer your questions,
and perhaps nd a topic that already addresses your question at http:// www.everlastgenerators.com/
forums/.
Should you need to call or write, always know your model name, purchase date and welder manufac-
turing inspection 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 de-
scribe the conditions and circumstances of your problem or question. Take notes of any issues as best
you can. You may be asked a series of questions by the advisors meant to clarify problems or issues.
Some of these questions may seem basic or fundamental, but even with experienced users technical
advisors can’t assume that correct operating procedures are being followed for proper operation. They
must cover all aspects to properly diagnose the problem. Depending upon your issue, it is advisable to
have basic tools handy such as screwdrivers, wrenches, pliers, and even an inexpensive test meter with
volt/ohm functions before you call.
Please note: To establish a warranty claim and return a unit for repair or replacement, you must call tech-
nical support rst and go through basic diagnosis before an Return Authorization will be issued.

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Serial number: ____________________________
Model number: ____________________________
Date of Purchase___________________________
Everlast USA:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.com
Everlast Technical Support: [email protected]
Everlast Welding Support: [email protected] Everlast Support
Forum: http://www.everlastgenerators.com/forums/ index.php
Main toll free number: 1-877-755 WELD (9353) 9am—5pm PST M-F
FAX: [phone]
Everlast Canada:
Everlast consumer satisfaction email: [email protected]
Everlast Website: everlastwelders.ca
Everlast Technical Support: [email protected]
Telephone: [phone]am-4:30pm EST M-F
Everlast Australia:
Port Macquarie 4/18
Acacia Ave.
Port Macquarie NSW 2444
(02) 6581 23888
After Hours Support
0431 016 416
Sales: [email protected]
Support: [email protected].au

5
Safety Precautions
Everlast is dedicated to providing you with the best possible equipment and service to meet the de-
manding job requirements that you may have. We want to go beyond delivering a satisfactory prod-
uct to you. That is the reason we offer free technical and basic welding support to assist you with
your needs, should an occasion occur where it is needed. 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, operation and maintenance
of your Everlast product to give you the best possible operator/owner experience. Welding and re-
lated cutting operations require basic experience and common sense. 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. Stay alert!
Please carefully read this manual before you operate your Everlast unit. This manual, if read in full,
can assist the user in obtaining helpful information concerning the safe operation of this unit. Do not
operate the unit until you have read this manual and you are thoroughly familiar ith the safe operation
of the unit. If you feel you need more information please contact Everlast Support. The content of
this manual is not meant to be an exhaustive primer on welding. It is written to an audience that, if
not professional, will have at least some basic knowledge of welding terms and practices.
The 5 year warranty does not cover improper use, maintenance, accessories or consumables. Acces-
sories are covered by a separate warranty (length varies), which is also listed on our website along
with the full terms of the welder warranty. Consumables have no warranty.
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 malfunctioning parts or accessories have been repaired or replaced by qualied personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves. These waves may dis-
turb 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 elec-
trician if disturbance is noted. Sometimes, improper wire routing or poor shielding may be the
cause.
WARNING! HF can interfere with pacemakers. See EMF warnings in following safety section for fur-
ther information. Always consult your physician before entering an area known to have welding or
cutting equipment if you have a pacemaker.

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 observe 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 chipping 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
lter installed. Always use a welding helmet in good condition. Discard any broken or cracked
lters or helmets. Using broken or cracked lters or helmets can cause severe eye injury and
burn. Filter shades of no less than shade 5 for cutting and no less than shade 9 for welding are
highly recommended. Shades greater than 9 may be required for high amperage welds. Keep
lter lenses clean and clear for maximum visibility. It is also advisable to consult with your eye
doctor should you wear 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 lter screen, protective curtains or equivalent protective equipment. If no
protection is available, exclude them from the work area. Even brief exposure to the rays
from the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy. Ear pro-
tection 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 re 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 adequate 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 electri-
cal shock.
Flame proof and insulated gauntlet or cuffed type gloves are required whether welding or cut-
ting or handling metal. Simple work gloves for the garden or chore work are not sufcient.
Gauntlet type welding gloves are available from your

7
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 elds 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 elds. Therefore, certain precautions should be taken to mini-
mize exposure:
•Lay welding leads and lines neatly away from the body.
•Never coil cables around the body or limbs.
•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 conned spaces. Fumes and gases released 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 obtained.
Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, copper, cadmium,
lead or zinc without proper respiratory equipment and or ventilation.
WARNING! The use of this product can expose you to chemicals such as lead, which is known to
the State of California to cause birth defects, reproductive harm and cancer. Proposition 65 Warn-
ing. For more information visit: www.P65Warnings.ca.gov
DANGER! Do not weld or cut around Chlorinated solvents or degreasing areas. Release of Phos-
gene 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 re-
garding high pressure cylinders can be obtained from OSHA or local regulatory agency. Consult
also with your welding supply company in your area for further 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 t cylinders. Do not use faulty regulators. Do not allow cylin-
ders 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.
Safety Precautions

8
WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do not use frayed,
cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground clamp. Do not stand in water or
damp areas while welding or 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 necessitates 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 cables with appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep re extinguishers close by and
additionally a water hose or bucket of sand. Periodically check work area for smoldering embers or smoke. It is a
good idea to have someone help watch for possible res while you are welding. Sparks and hot metal may travel a
long distance. They may go into cracks in walls and floors and start a re that would not be immediately visible.
Here are some things you can do to reduce the possibility of re or explosion:
• Keep all 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 re.
• 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 re-proof surfaces after handling. Serious burns and injury can result if material is improperly
handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Proper maintenance is your respon-
sibility. Make sure all equipment is properly maintained and serviced by qualied personnel. Do not abuse or misuse
equipment. Remove any faulty cords, plugs or electrical equipment from service or access.
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.
If operating on a generator: Always switch off and disconnect the unit before shutting the unit down. Never start the
generator with the unit switched on or connected. Failure to do so may result in damage to the unit. This damage is
not covered under warranty. Make sure that any required generator grounding is performed properly and to the man-
ufacturer’s recommendations.
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 con-
cerning their products. Do not operate machinery until your are comfortable with proper operation and are able to
assume inherent risks of cutting or welding.
Safety Precautions

9
Regulator/Water Trap/Filter Assembly
POWERPLASMA 52i PACKAGE CONTENTS
NOTICE! Accessory and consumable style and quantities are subject to change without notice. Consumable starter kits provide only enough consumables to get
started. Extra consumables can be purchased through Everlast or through other local and online iPT 60 Innotec distributors. Full original consumable kits are sold
through Everlast. Various diameter consumables for lower amp use are available. The unit comes with a spare 30 Amp glass-type (slow-blow) fuse for the pilot
arc. Set this fuse aside where you can nd it. Replacement fuses may be bought locally (use part number printed on fuse for reference) or directly from Everlast.
Consumable and Fuse Kit
Work Clamp
iPT 60 Innotec Torch (12 ft.)
Section 1 Introduction and Specifications
240V to 120V Adapter

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Section 1 Introduction and Specifications
NOTICE:
When evaluating a plasma cutter for daily service, do not consider maximum severance cut values as criteria for routine use. These maximum specications are intended for occasional
situations that might require such a cut. Plan the unit’s daily use around the recommended average cut thickness for best results and speed. This is an industry standard recommenda-
tion and is not unique to Everlast PowerPlasma models. CNC cut thickness recommendations are further reduced by duty cycle, travel speed expectations, and straight-down piercing
limitations. Everlast’s performance specications are based on reasonable environmental conditions with well maintained units, and cutting with new consumables using optimum air
pressure. Actual performance results may vary in the eld due to variable conditions, power supply, air pressure, air quality, consumable wear etc.
Use the I1MAX value to size the breaker. Use the I1EFF current to size wiring. Consult the NEC Article 630 for details concerning wiring and breaker requirements.
PowerPlasma 52i Specications
Inverter Type Digital IGBT
Minimum/Maximum Rated Output 120V: 20A/88V-25A/90V 240V: 20A/88V - 50A/100V
Start Type Blow-Back Type
Torch Type iPT60 12 ft.
Duty Cycle @ Rated Amps/Volts ( 40° C) (Output V/A) 240V: 60% @ 50A/ 100V 100% @ 40A/ 96V
120V: 60% @ 25A/ 90V 100% @ 20A/ 88V
OCV (U0) 200 V
Voltage Input (U1) Dual Voltage: 120V/ 240V; 50/60Hz 1 Phase (±10%)
Maximum Inrush Amps (I1MAX) 110V: 32.1A 220V: 35.8A
Maximum Rated Effective Amps (I1EFF) 110V: 24.9A 220V: 27.9A
CNC Port/ CNC Capable Yes (Order CNC package to receive plug for port, or order plug separately)
Air Post Flow Timer Adjustable, 0-50 Seconds
Air Compressor Requirement and Recommendations. 4.5 - 5 CFM @ 90 PSI (127-142 lpm @ 6.2 bar)
Use a compressor with a minimum output of 5.3 CFM @ 90PSI (150lpm @ 6.2 bar), with
30 gallon (114 Liter) capacity or higher recommended for best operation. Pancake type
and small oil-less compressors are not suitable.
Duty Cycle/ Over Current Protection Yes, Self-diagnosing feature. (See code references at the end of this manual.)
Minimum Operating Air Pressure Approximately 43 PSI (2.7 bar) (safety cut-out threshold)
Use pressure indicated by target LED color. Varies by process.
(Set and check air-pressure with “Air-Check” engaged)
Low/High Pressure indicated by Error Code E03.
Maximum Supplied Air Pressure 90 psi (This is incoming pressure from the air compressor, not operating, or (From Com-
pressor/Tank) cutting pressure.) The air compressor MUST have a separate pressure regu-
lator at the tank or inline to control maximum supply pressure.
Recommended Maximum Daily Average Cut Thickness
(Steel, Hand Cut) 1/2” (12mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Recommended Maximum Daily Average Cut Thickness
(Steel, CNC, Auto-Cutting Mechanisms) 1/4” (6mm) Note: 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.
Rated Maximum Quality Cut @ 10-12 IPM (@ 250-300mm / min)
(Steel, Hand Cut) 3/4” (19mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Max Severance Cut @ 3 IPM (75mm / min) (Steel, Hand Cut ) 1” (25mm) Decrease 35-40% for Aluminum and Stainless Steel (INOX).
Gouging Limit (approximate gouge depth/width) 1/8”x 3/16” (3mm x 4.8mm)
Minimum Water Ingress Protection Standard IP21S
Efciency >85%
Cooling Method Full time High Velocity Fan
Dimensions (approximate) 12.5” H x 7.5” W x 14” L (320mm x190mm x 355mm)
Weight (Bare Unit) 35 lbs. (16kg)
Generator Requirement 8,500 W Clean Power (≤5% total harmonic distortion/Clean Power Output Rated)
Minimum Storage/ Minimum Operating Temperature Storage: -10°F/-23°C Operating: 14°F/-10° C