Everlast PowerPlasma i Series User manual

EVERLAST
POWERPLASMA i SERIES
Operator’s Manual for the PowerPlasma 62i, 82i and 102i
Safety, Setup and General Use Guide
CC
IGBT
1
~
PHASE
Rev. 1 0 001212-19
Specications and Accessories subject to change without notice.
329 Littleeld Ave. South San Francisco, CA 94080 USA
PAC
everlastwelders.com
1-877-755-9353
60-100 Amp i Series Digital IGBT Plasma Cutters

2
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…………………………………
Innotec iPT 80 Torch…………………………………
Innotec iPT 100 Torch………………………………...
CNC Connector Pin-Out…...……………………….…
Troubleshooting and Error Codes……………………...
3
4
5
9
10
13
13
15
16
16
18
19
20
25
27
29
31
32
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.

4
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 i SERIES 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 series 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
Consumable and Fuse Kit
Work Clamp
iPT 60, 80 or 100 Innotec Torch
Section 1 Introduction and Specifications
240V to 120V Adapter

10
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 62i Specications
Inverter Type Digital IGBT
Minimum/Maximum Rated Output 20A/88V - 60A/108V
Start Type Blow-Back Type
Torch Type iPT60 12 ft.
Duty Cycle @ Rated Amps/Volts ( 40° C) (Output V/A) 60% @ 60A/ 104V 100% @ 50A/ 100V
OCV (U0) 240 V
Voltage Input (U1) 50/60Hz 1 Phase (±10%)
Maximum Inrush Amps (I1MAX) 41A
Maximum Rated Effective Amps (I1EFF) 32.4A
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) 5/8” (15.8mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Recommended Maximum Daily Average Cut Thickness
(Steel, CNC, Auto-Cutting Mechanisms) 3/8” (9.5mm) 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) 1” (25mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Max Severance Cut @ 3 IPM (75mm / min) (Steel, Hand Cut ) 1 1/4” (31mm) Decrease 35-40% for Aluminum and Stainless Steel (INOX).
Gouging Limit (approximate gouge depth/width) 1/8”x 3/16” (3mm x 4.5mm)
Minimum Water Ingress Protection Standard IP21S
Efciency >85%
Cooling Method Full time High Velocity Fan
Dimensions (approximate) 18” H x 10” W x 25” L (320mm x190mm x 355mm)
Weight (Bare Unit) 50 lbs. (21kg)
Generator Requirement 10,000 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

11
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 82i Specications
Inverter Type Digital IGBT
Minimum/Maximum Rated Output 20A/88V - 80A/112V
Start Type Blow-Back Type
Torch Type iPT80 12 ft.
Duty Cycle @ Rated Amps/Volts ( 40° C) (Output V/A) 60% @ 60A/ 112V 100% @ 63A/ 104V
OCV (U0) 240 V
Voltage Input (U1) 50/60Hz 220-240V 1 Phase (±10%)
Maximum Inrush Amps (I1MAX) 58.4A
Maximum Rated Effective Amps (I1EFF) 45.2A
CNC Port/ CNC Capable Yes (Order CNC package to receive plug for port, or order plug separately)
Air Post Flow Timer Adjustable, 0-60 Seconds
Air Compressor Requirement and Recommendations. Minimum of 4.5 - 5 CFM @ 90 PSI (127-142 lpm @ 6.2 bar)
Use a compressor with a minimum output of 7 CFM @ 90PSI (198lpm @ 6.2 bar), with 30-
60 gallon (114-227 Liters) 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 (6.2 bar) (This is incoming pressure from the air compressor, not operating, or (From
Compressor/Tank) 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) 1” (25mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Recommended Maximum Daily Average Cut Thickness
(Steel, CNC, Auto-Cutting Mechanisms) 5/8” (15mm) 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) 1 1/4” (31mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Max Severance Cut @ 3 IPM (75mm / min) (Steel, Hand Cut ) 1 7/16” (36mm) Decrease 35-40% for Aluminum and Stainless Steel (INOX).
Gouging Limit (approximate gouge depth/width) 3/16”x 3/16” (4.5mm x 4.5mm)
Minimum Water Ingress Protection Standard IP21S
Efciency >85%
Cooling Method Full time High Velocity Fan
Dimensions (approximate) 18” H x 10” W x 25” L (320mm x190mm x 355mm)
Weight (Bare Unit) 51 lbs. (21kg)
Generator Requirement 13,000 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

12
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 102i Specications
Inverter Type Digital IGBT
Minimum/Maximum Rated Output 20A/88V - 100A/120V
Start Type Blow-Back Type
Torch Type iPT100 12 ft.
Duty Cycle @ Rated Amps/Volts ( 40° C) (Output V/A) 60% @ 100A/ 120V 100% @ 80A/ 112V
OCV (U0) 250 V
Voltage Input (U1) 50/60Hz 1 Phase (±10%) (3 Phase 240V or 480V Optional)
Maximum Inrush Amps (I1MAX) 78A @ 220V 1 Phase (Optional 45A @ 220V 3 Phase)
Maximum Rated Effective Amps (I1EFF) 60A @ 220V 1 Phase (Optional 35A @ 220V 3 Phase)
CNC Port/ CNC Capable Yes (Order CNC package to receive plug for port, or order plug separately)
Air Post Flow Timer Adjustable, 0-60 Seconds
Air Compressor Requirement and Recommendations. 7 CFM @ 90 PSI (200 lpm @ 6.2 bar)
Use a compressor with a minimum output of 9 CFM @ 90PSI (250lpm @ 6.2 bar), with 60
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 (6.2 bar) (This is incoming pressure from the air compressor, not operating, or (From
Compressor/Tank) 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) 1 1/4” (31mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Recommended Maximum Daily Average Cut Thickness
(Steel, CNC, Auto-Cutting Mechanisms) 7/8” (22mm) 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) 1 1/2” (38mm) Decrease 35-40% for Aluminum and Stainless (INOX).
Max Severance Cut @ 3 IPM (75mm / min) (Steel, Hand Cut ) 1 3/4” (44mm) Decrease 35-40% for Aluminum and Stainless Steel (INOX).
Gouging Limit (approximate gouge depth/width) 3/16”x 1/4” (4.8mm x 6mm)
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) 52 lbs. (24kg)
Generator Requirement 17,500 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

13
Section 1 Introduction and Specifications
NOTICE:
This manual has been compiled to give an overview of operation and is designed to offer information centered around safe, practi-
cal use of the plasma cutter. Welding and cutting operations are inherently dangerous. Only the operator of this Plasma cutter can
ensure that safe operating practices are being followed, through the exercise of common sense practices and training. Do not
operate this machine until you have fully read the manual, including the safety section. If you do not have the skill or knowledge
to safely operate the plasma cutter, do not use this plasma cutter until formal training is received. To prevent re, always be aware
of your surroundings.
GENERAL PRODUCT INFORMATION:
The PowerPlasma i series units utilize the latest in digital inverter design technology. The digital design is a major revision of the
former analog inverter designs of their predecessors. This has simplied internal design of the units. It has improved reliability
and reduced weight. Cutting operations are more accurately managed for increased performance and consumable life.
New features have been added which help the user to more easily achieve quality cut results. The addition of both the digital air
pressure meter and colored LED lights help the user to achieve the best air pressure for the selected operating mode.
The new gouging feature on the PowerPlasma 62i is suitable for light gouging activities. This is perfect for delicately removing
bad welds and defects on thin plate metals 1/4”or under in a single pass. The PowerPlasma 82i and 102i are ne for heavier goug-
ing requirements. The softer arc and lower air pressure allow the arc to smoothly remove around 5 lbs. of metal per hour. Spe-
cial, larger consumables will be required to perform gouging activities in addition to the starter kit provided. These must be
sourced and purchased separately.
POWER INPUT:
This unit may be operated on 208-240V single phase input. For Wiring and Breaker requirements, consult the Article 630 of the
National Electric Code (NEC) for special information concerning proper wiring and breaker sizing of duty-cycle limited welding/
cutting machines. Use the I1MAX and I1EFF ratings supplied on page 10 in this manual to determine correct breaker and wire sizing.
Always consult a licensed electrician before wiring this unit to new or existing service. Never attempt to adapt this unit to work with
existing dryer or range plugs. Do not use on long or undersized extension cords.
GENERAL MAINTENANCE 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 cutter from the vicinity of any water or moisture source to reduce the
possibility of electrocution or shock. Never operate this plasma cutter in standing water.
IMPORTANT: Before opening the unit for any reason, make sure the unit has been unplugged for at least 10 minutes to allow time
for the capacitors to fully discharge. Severe shock and/or death can occur.
Every 1-2 months, depending upon use, the plasma cutter should be unplugged, opened up and carefully cleaned with dry com-
pressed or canned air. To open, remove rear plastic cover and main cover. Do not remove the front plastic cover. Regular mainte-
nance will extend the life of the unit. Carefully descale metal particles from the fan blades to prevent vibration and fan damage (if
buildup is present).
•Do not restrict air flow or movement of air around the plasma cutter. Allow a minimum clearance of at least 18” (500mm) on
all sides.
•Lift and carry the welder by the handle. Do not mount in areas that are prone to severe shock or vibration.
•Do not operate the unit immediately next to the weld/cut area. Allow at least 6 feet separation.
•Do not direct metallic dust or any dirt intentionally toward the machine, particularly in grinding and welding operations. Make
sure the control panel is protected from damage.

14
Section 1 Introduction and Specifications
DUTY CYCLE:
The duty cycle of this unit has been tested and established at 60% at full Amp Output. This duty cycle has been established under the standard
rating temperature of 104 F (40 C). If you are not familiar with Duty Cycle ratings, duty cycle is the percent of time out of a 10 minute time
period at which a welder or plasma cutter can operate continuously without overheating. Lowering output increases duty cycle. It is possible to
achieve a 100% duty cycle by lowering the output Amps. However, 100% duty cycle is still based off a 10 minute time period and does not
mean it has an “innite” duty cycle. Theoretically, if the machine were to go 11 minutes of uninterrupted operation even at a 100% Duty Cycle
level of operation, you could incur an overheat condition. Duty cycle on this machine is not controlled by a timer, but rather by one or more
temperature sensors strategically located on the heat sink(s) of the machines internal circuitry. If an overheat is detected the cutting output will be
interrupted. A code of “E01” will be displayed. If this happens, allow the unit to continue to run and cool for at least 15 minutes. Do not turn
the unit off during this time! If the unit does not automatically reset after this time, cycle the machine off and back on to clear the code. If the
code does not clear at this time, contact Everlast for further remedy. Intentionally and repeatedly triggering the duty cycle can damage the unit
over time. This type of damage becomes apparent during repair and service and is not covered under warranty.
CNC Use and Duty Cycle Concerns:
CNC use demands more out of plasma cutter than normal hand cutting operations. Always be aware of your Amp output level and use patterns
during CNC operation. If operating in CNC mode for thick, long cuts, or when doing repeated and rapid high input Amp demand activities, i.e.
rapid, successive starts, consider lowering the Amp output of the machine to at least the 100% duty cycle rating of this unit for best results. (See
page 10 for exact duty cycle specications). Of course this lowers maximum cut capacity, but it is also part of the reason why CNC cutting has
lower stated cut capacities across most all brands of plasma cutters.
Occasionally, you may exceed the duty cycle cutting through thick materials or with constant use. This usually causes no harm. However, if you
are regularly exceeding the duty cycle, this is a sign that you may need to use a larger plasma cutter or your unit may need to be cleaned and/or
serviced.
OVER/UNDER VOLTAGE/CURRENT:
This unit is equipped with a over/under voltage/current device which senses under or over voltage conditions caused by poor power supply or
internal faults and shuts down output. If you observe an error code “E02” immediately turn the machine off. Evaluate the input power supply for
proper voltage. Also inspect the suitability of any extension cords for service. If code does not clear, after remedying common issues stated
below, contact Everlast. Do not continue to try to clear the code if it does not appear to have been corrected.
Common Items That Can Trigger the Over/Under Voltage Current:
•Operating on too long or undersized extension cord or service wiring. Damaged wiring.
•Improperly grounded service/ power supply.
•Operating on too small of a generator or on a generator not rated as “Clean Power” (5% or less THD).
•Too long of a cutting arc.
•Excessively worn or missing consumables or damaged torch head.
•Internal machine fault. (If code cannot be cleared after correcting other issues, call Everlast.)
GENERATOR REQUIREMENTS AND OPERATION
This unit may be run on a generator. (See pages 10, 11, and 12 for respective generator wattage requirements.) However, the generator must
provide “clean power”. Clean power is dened as having 5% or less Total Harmonic Distortion (THD). This is a rating given by the manufacturer
of the generator, and not Everlast. This is similar to the power normally supplied at a wall outlet. This represents a sine wave (AC) that is most-
ly free of voltage spikes and electronic noise. Many general purpose (GP) generators are not rated to produce clean power and are designed for
emergency or construction use with resistive loads such as lights or heaters. These generators can damage the plasma cutter. If damage does
not occur immediately, the effect can be cumulative, depending on how “dirty” the power actually is. Damage created by running this unit off a
generator, or welder/generator not rated for clean power output by its manufacturer will not be covered under warranty. If you are in doubt about
your generator or welder/generator, contact the manufacturer. Everlast does not keep an authorized list of generator brands or models. Howev-
er, if the manufacturer rates its generator for 5% or less THD, this is sufcient to meet our standards. However, do some additional research on
the brand and model of the generator to make certain there are no issues, recalls or reported equipment (electronics in particular) damage related
to malfunctioning generators from the manufacturer.
The generator should be properly grounded, according to the generator manufacturer instructions.
Never leave the unit on or connected while starting the generator. Never stop the generator while the unit is on or connected. Severe damage
will occur. This includes running the generator low on or out of fuel. This damage is not covered under warranty, even if the unit is rated as
“clean powered”. Always allow the generator to warm up before plugging the unit in and using it. A cold engine may not develop or maintain
proper RPM needed to provide stable, clean power even if the unit is rated to be “clean power”. Never use economy idle (ECO mode), or auto
idle modes with this unit. Always use maximum idle when this unit is turned on.

15
Section 2 Quick Setup Guide
QUICK SETUP GUIDE: CONNECTIONS
TORCH (-)
PILOT ARC FUSE(30A SLOW BLOW)
WORK (+)
CENTRAL CONNECTOR
DINSE TYPE 35 CONNECTOR
OPTIONAL MACHINE (CNC) TORCH (-)

16
Section 2 Quick Setup Guide
IMPORTANT:
A separate air dryer between the air compressor and lter assembly must be installed, usually at the compressor or right before the regulator. This is a customer
supplied item. Failure to install a separate air dryer/lter will greatly decrease consumable life. It can also lead to contamination in the torch head which will cause
failure. Moisture in a plasma system is detrimental to all parts, including the solenoid and torch head. The included lter/water trap is designed mainly to catch
dirt and moisture created during the coupling and uncoupling process, or minute amounts of moisture that may escape the separate dryer/lter. Multiple styles of
dryers/lters are available in a wide range of prices from a few dollars to several hundred dollars. A simple, economic desiccant type dryer used in automotive
paining is enough to get started. Damage caused by operating the unit without the additional dryer/lter is not covered under warranty! Never use this plasma
cutter with an oiler system, or with a worn air compressor which uses excessive oil. For best results, if installing this unit on an older system, install a new hose
and plumbing components after the air dryer before connecting to the unit.
• Drain the air compressor on a daily basis after use. Do not supply more than 90 psi to the plasma cutter from the compressor. If the air pressure on the
front gauge drops too far to maintain a good cut or falls signicantly out of spec while cutting, increase the size of the supply hose/line to the plasma cutter
in lieu of increasing supply pressure.
Plasma Connections:
Compressor and Dryer Diagram
Air Dryer/Oil Filter
(Customer Supplied)
Regulator Assembly with
Built-in Water Trap
and Dirt Filter (Included)
Compressor and Air hose with
Fittings
(Customer Supplied)
Gas Inlet
1~220 VAC
1~220 V
Compressor Regulator
(Customer Supplied)
1
2
3
4
NOTICE:
When assembling the regulator/air lter/water trap, take note of the markings
stamped on the top of the housing. There will be markings to indicate air flow
direction. The quick connect 1/4” Industrial style coupling should be mounted
on the side of the lter stamped with the IN marking or with the arrow pointing to
the middle of the lter. Depending upon the style supplied with your unit, there
may be an open middle connection in between the inflow and outflow ttings. In
this case there is a brass plug that must be screwed into this tting. The brass
plug, if not in the lter box, is included with the consumable and spare parts
bag. If you cannot located this plug, contact Everlast for replacement plug.
1/4” Industrial Style Quick
Connector (Included)

17
Section 2 Quick Setup Guide
STOP!
To set the air pressure, use the “Air-Check” feature to initiate air flow, then adjust the pressure while air is continually flowing.
Do not re the torch to initiate air flow. Firing the torch without cutting signicantly increases consumable wear.
STOP!
• Turn the unit off to check and change torch consumables. Shock, burn, injury or death may result if the torch trigger were
accidentally pressed during removal.
• Turn the unit off to check and change pilot arc fuse. Failing to do so may result in shock, burn, injury or death.
• Do not become a ground path while using this unit. This means you need to insulate/isolate yourself from the work piece
while cutting. Refrain from touching or contacting the cutting tip while performing cut operations.
• Cutting wet or damp material may increase your chances for shock or electrocution. Sweat can also increase your chances
of shock/electrocution.
• Do not exceed 90 P.S.I. (6.2 bar) input supply pressure (from compressor).
GENERAL OPERATING TIPS
• Keep your standoff to less than 1/8”.
• Do not drag the torch directly on the metal unless using drag consumables. (Available from some OEM suppliers of the
Innotec iPT series torches.)
• Always use dry air. Install inline air dryer. Do not rely on the supplied water trap/lter. Drain compressor daily to improve
effectiveness of air dryers and to prevent them from prematurely failing.
• Don’t greatly air pressure to try to reduce kerf or cut thinner material. Always reduce nozzle orice size to match amperage.
• See the Torch information page for different consumable sizes and amp ratings. Use this as a general rule of thumb for
good hand cutting speed and quality: For the rst 1/8” of thickness, use 20 amps. After the rst 1/8” add 10 amps for every
1/8” after that. For Stainless and Aluminum, use settings that are 40% higher.
• Do not attempt to operate with work clamp removed. Always connect the work clamp directly to the part being cut.
• Excessive pilot arc operation drastically reduces consumable life. Grind the area where the work clamp is attached for best
contact. Use the Tip Saver function to extend consumable life when auto restarting is not necessary. Use the Auto Restart
function for hand cutting expanded metal or while cutting intricate CNC components. If the unit only lightly cuts or gouges
the surface, the pilot arc is staying on too long and continuity to the cut is not being detected. This can blow your pilot arc
fuse and cause the torch not to strike unless touched to the metal. If this happens, change the fuse and make sure your work

18
2
4
5
6
7
ITEM DESCRIPTION
1Amps. Use to set and control Amp output. While cutting, the amps are displayed dynamically (live).
2Cutting Pressure. This displays selected cutting pressure and indicates the ideal pressure for cutting. The center green LED indicates the target pres-
sure, indicated by the center inverted arrow ( ). The farther away from the target pressure the unit is adjusted, the light colors will change to yellow and
red. The pressure required will be different for cutting and gouging modes. If the pressure falls below the target pressure while cutting, increase pres-
sure slightly so that the LED to the right of the arrow is lit. This will allow the target pressure to be correct while cutting. This happens when long
lengths of hose, or undersized hose/plumbing is used to connect to the unit. If the hose is resized and shortened, the pressure drop will be less. Large
variations in compressor cut-in/kickout pressures can also affect this. Make sure that you use an adequate size compressor as listed in the specications
on page 10. If there is a signicant loss of pressure, there may be an internal restriction to the pressure circuit or leak. Contact Everlast.
3Post-Flow. The post-flow adjustment adjusts the amount of time that air flows after the torch has nished cutting. This is important for extending your
torch and consumable life. The higher the amperage and the longer the unit cuts, the more post flow is required. As a rule of thumb, use 1 to 2 seconds
of post flow for every 10 amps. Longer post flow times may be used in cases where long, uninterrupted cuts are being performed.
4Air Check. This is used to set and adjust cutting air pressure. Select the button to open the solenoid without having to re the torch. Adjust air pressure
to the target pressure. The gas will continue to flow until the button is reselected. Do not use the torch trigger and post flow cycle to set the cutting air
pressure.
5a Lock Off/ On. “Lock” refers to the trigger function. With the “Lock-off” selected press and hold the torch trigger to cut. The arc will stay on as long as
the trigger is held down. This is the best method for short or detailed cutting. To use the “Lock-on” mode, press and release the torch trigger to start the
cut. The arc will be on when the trigger is released. Press and release the torch trigger again to stop the cut and begin the post flow cycle. This can be
used on long cuts with track torches or pipe beveling devices. Warning! Selecting Lock On can create a dangerous situation if the user is not alert and
informed of its operation.
5b CNC Operation. This turns on the CNC circuit and the rear control socket.
6a Auto Restart. In this mode, the pilot arc is designed to switch back on automatically if cut continuity is lost. Once continuity is regained, the cutting arc
will re-energize and the pilot arc will shut off. This cycle will happen continuously as long as it is needed.
Use this mode to cut expanded or rusty metal or in CNC mode. This mode results in more rapid wear of the consumables.
6b Tip Saver Start. In this mode the torch supplies the pilot arc for approximately 3 seconds before terminating the arc. This limits pilot arc on time and
helps save consumables. Use this mode if you are hand cutting or cutting in CNC mode on long, continuous cuts. If the cut is lost, the torch must be
retriggered to restart the cut.
6c Gouge. This feature is designed to quickly remove excess weld material or to correct defective welds or blemishes in metal. The torch is held at an
shallow angle to the weld or area and the arc strikes the metal blowing a layer of metal away. The arc is less aggressive. Lower air pressure must be
used along with large, special consumables (available separately from most OEM suppliers of the Innotec iPT series torch) designed for gouging. This
unit is designed for light gouging only. See Specications, page 10.
7Information/Warning LED’s. The far left LED conrms that the unit is switched to On and remains lit continuously. The lightning symbol indicates an
over/under current/voltage condition and is accompanied by error code E02. The thermometer symbol indicates that the unit has surpassed the duty
cycle and has over heated and is accompanied by error code E01. The broken round symbol indicates there the torch cap is not in place or making
adequate contact with the base. It is accompanied by error code E04. Additional Error codes that occur without an accompanying LED can be found on
the last page of this manual. With any error code, the output will be interrupted until it is corrected. In some cases, the machine may need to be reset by
turning it off and back on again.
Section 2 Quick Setup Guide
Front Panel Controls
13

19
Section 2 Quick Setup Guide
ITEM DESCRIPTION
1Breaker Switch. This switch serves as the main power switch for the unit. If a severe fault or short takes place, this breaker switch will trip. If the break-
er trips, nd and rectify fault before attempting to power the unit back on. If the breaker does not reset, contact Everlast.
2Fan. Keep the fan area clear and allow a minimum of 18” (500mm) clearance for proper air circulation and maximum duty cycle. The fan should run
continuously.
3Regulator/Filter/Water Trap. This regulates the cutting pressure of the unit. To adjust: Pull up rmly but gently on the regulator knob until the detent
clicks (about 1/8” or 3mm). Rotate clockwise to increase pressure. Rotate counterclockwise to decrease pressure. Observe the pressure and indicator
lights on the front of the machine to reach the ideal pressure for the process you have selected. Push the knob back down after adjusting to lock-in the
pressure setting. WARNING! Do not supply more than 90 psi to the regulator or damage and/or severe injury may occur.
4Gas Inlet. The gas inlet has a push-to-connect type tting. When initially installing, make sure the connecting tubing from the regulator to the inlet is
squarely cut on the end so that a good seal is formed. If the tubing must be removed, the outer collar must be pressed in gently to release the tubing.
Hold the collar while removing the tubing.
5Ground Bolt. This is to be used in cases where High Frequency (H.F.) interference is being caused or where a bonded ground is indicated by code. This
should be connected directly to an outside copper clad rod driven into the ground with at least a # 12 gauge wire connecting the two together. All metal
parts inside the building should be grounded as well, including pipes, tables, and even metal siding to help prevent stray H.F. emissions from causing
interference or damage to the electronics and surrounding equipment.
6NEMA 6-50 Power Plug. This is the standard 240V, single phase plug used for welders/plasma cutters in North America. This plug has only three
wires and is used by all manufacturers for this type application. This unit requires and uses no neutral. There are two power legs and one ground
(middle U-shaped, or rounded prong). Do not attempt to rewire or adapt this plug for other applications. Consult with a licensed electrician before
installing power service to the unit. Refer to Article 630 of the NEC for information concerning wiring of welders and plasma cutting units.
7. CNC Socket. The CNC socket is provided with the standard signals required to work with most CNC control systems. The mating plug is optional, but it
included as standard equipment in the CNC package version of this unit. Contact Everlast to purchase this connector without the CNC package.
Rear Panel Connections
Gas Inlet
1~220 VAC
1~220 V
7
2
1
3
4
5
6

20
0°-15°
TRAVEL
1/16”
EDGE START
40°-60°
TRAVEL
1
PIERCE START
2
3
Section 3 Operation
NOTICE:
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 off the nozzle seat. This may take up to a second, especially when using longer torches or marginal air
supply systems. Restarting the arc in tip saver mode requires retriggering the torch. If the torch does not light after 3 seconds, let go of the
trigger and press it again. If the start or arc is erratic check nozzle and electrode for tightness and wear.
IMPORTANT:
If you use a standoff guide with the torch, it must be adjusted to provide no more than 1/8” standoff, less if possible. Long standoff heights
reduce cut capacity and quality. It also promotes rapid consumable wear and can prevent the pilot arc from transferring.
EDGE STARTS
Edge starts are the best type of start to promote
consumable and torch life. This reduces blow back
of molten material and allows a smooth gradual start
of the arc and maximizes cutting capacity.
1) Line up the hole on the tip of the electrode on
the edge of the cut. Hold torch perpendicular to
the cut initially, about 1/16” off 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 penetrate
all the way through the metal.
3) As the torch penetrates the flame all the way
through the metal, tilt the torch so there is a
slight lead in the flame if metal is thin. If the
metal being cut is thick, keep holding torch in a
nearly vertical position.
4) Begin moving the torch in the direction of the
cut. Maintain 1/16” standoff height.
5) Move the torch fast enough so the sparks and
flame trail from the bottom edge at an angle of
no more than 30° and no less than 10° from
perpendicular to the metal. Excess angle of
sparks/flame indicate too fast of travel speed or
practical cut capacity has been reached. Little
or no angle indicates too slow of travel speed.
PIERCE STARTS
Piercing starts often result in rapid consumable wear
and excess blow back of molten metal deposited onto
torch and consumables. This should be done only as
necessary on thicker material.
1) Tilt the torch in the direction of travel or to-
ward the side of the metal to be discarded or
wasted at a 40° to 60° angle. Slide the yellow
safety lock and squeeze the trigger. Wait for arc
to start.
2) Once the arc starts, wait for the arc to transfer
from pilot arc to the cutting arc.
3) As the flame penetrates through the metal (at a
sloped angle) rotate the torch slowly to the
vertical position. 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 direction of the
cut. Maintain 1/16” standoff height.
5) Move the torch fast enough so the sparks and
flame trail from the bottom edge at an angle of
no more than 30° and no less than 10° from
perpendicular to the metal. Excess angle of
sparks/flame indicate too fast of travel speed or
practical cut capacity has been reached. Little
or no angle indicates too slow of travel speed.