Everlast PowerPlasma i Series Operator's Manual
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Everlast PowerPlasma i Series Operator's Manual

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Publish Date: May 2021
EVPPLSMA62102 Rev. 1
USA/North America
©Everlast Power Equipment
DC
50A
60A
80A
&
100A
240V
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide For
PowerPlasma 62i, 82i, and 102i
Operator's Manual
FUNCTION: Plasma Cutter
PURCHASE DATE:
PLASMA CUTTER MODEL NAME:
CNC OPTIONAL TORCH INFO:
PLASMA CUTTER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:

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  • Page 1 Publish Date: May 2021 EVPPLSMA62102 Rev. 1 USA/North America ©Everlast Power Equipment Safety, Setup and General Use Guide For & PowerPlasma 62i, 82i, and 102i 100A FUNCTION: Plasma Cutter PURCHASE DATE: PLASMA CUTTER MODEL NAME: CNC OPTIONAL TORCH INFO: PLASMA CUTTER SERIAL NUMBER: OPTIONAL ACCESSORY SERIAL NUMBER: Operator’s Manual...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SPECIAL NOTICE AND CALIFORNIA PROPOSITION 65 WARNING CUSTOMER GREETING AND EXPLANATION OF PROCEDURES WARRANTY AND CONTACT INFORMATION SAFETY DISCLAIMER AND HF WARNING SAFETY WARNINGS, DANGERS, CAUTIONS AND INSTRUCTIONS GENERATOR OPERATION INFORMATION SPECIFICATIONS DUTY CYCLE AND CNC USE INFORMATION GETTING STARTED, UNPACKING YOUR UNIT AND INSPECTION CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION CONNECTION OF AIR COMPRESSOR, REGULATORS, AND BASIC REQUIREMENTS TO PLASMA CUT...

  • Page 3: Special Notice And California Proposition 65 Warning

    Due to multiple variables that exist in the welding field and the changing nature of it and of the Everlast product line, Everlast Power Equipment INC. does not guarantee the accuracy, completeness,...

  • Page 4: Customer Greeting And Explanation Of Procedures

    Many issues can be resolved over the phone. If the issue cannot be resolved over the phone/email, you may be given an op- tion to return the unit, or have a part shipped to you, at Everlast’s discretion. Keep in mind, you may be asked questions that seem basic, or ele- mentary to your knowledge base.

  • Page 5: Warranty And Contact Information

    Warranties and service policies and procedures vary from country to country and are maintained and supported by the region- al or in country distributor of Everlast welding equipment. USA Customers Only: For full details on the 5 year parts and labor warranty, 30 day satisfaction policy, terms of sale, and how to proceed with a war- ranty claim, please visit: https://www.everlastgenerators.com/standard-warranty.

  • Page 6: Safety Disclaimer And Hf Warning

    Safe operation and proper maintenance is your responsibility. Everlast is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and maintenance of your Everlast product, it is no substitute for observing safe welding practices and behavior. Safe welding and related cutting operations require basic knowledge, experience and ultimately the exercise of common sense.

  • Page 7: Safety Warnings, Dangers, Cautions And Instructions

    If you or the operator needs further instruction, contact Everlast welding support at 1- 877 755-9353 ext. 204 or seek qualified professional advice and training.
  • Page 8 Safety Warnings, Dangers, Cautions and Instructions DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these hazards are immediate while others are cumulative in their effect. Do not weld in enclosed spaces or in areas without adequate ventilation. Fumes and gases released in the welding and cutting operations can be toxic.
  • Page 9 Safety Warnings, Dangers, Cautions and Instructions CAUTION! Trip Hazards exist around plasma cutters. Cords, cables, welding leads and hos- es pose a trip hazard. Be aware of their location and inform others of their location. Tape and secure them so they will stay out of high traffic areas. CAUTION! Welded metal can stay hot long after welding is completed.

  • Page 10: Generator Operation Information

    WARNING! Never use the electrical power outlet on the back of this machine for anything other than powering an Everlast brand water cooler. This is a special outlet designed to produce 240V with limited amperage draw. No other device or brand should be used in conjunction with this unit’s outlet.

  • Page 11: Specifications

    Specifications Specifications PowerPlasma 62i PowerPlasma 82i PowerPlasma 102i Inverter Type Digitally Controlled IGBT Inverter Minimum/Maximum Rated Output 20A/88V - 60A/108V 20/88V-80A/112V 20A/88V-100A/120V Start Type Blow-Back Type, High Frequency Start Torch Type Manua l/ CNC Option iPT60 12 ft. /iPT60M 25 ft. iPT80 12 ft./ iPT80M 25ft.

  • Page 12: Duty Cycle And Cnc Use Information

    Specifications *Duty Cycle Duty Cycle is simply the amount of time out of a 10 minute period in which the unit can operate. For example, if this unit has a duty cycle of 60% at maximum output means that the unit can be operated for 6 minutes out of 10 minutes. This may be continuously, or intermittently during the 10 mi- nute period of time.
  • Page 13 Use the I1MAX and the I1EFF ratings listed above to determine the proper breaker and conductor (wire) sizing required. Everlast plasma cutters are designed around use in industrial wiring applications and are intended to be used with modern electrical systems.

  • Page 14: Getting Started, Unpacking Your Unit And Inspection

    Cosmetic damage claims after 30 days will not be accepted, unless Consumable Starter Kit for Plasma. Everlast is contacted and informed of such delay and reason for such Torch. 62i: iPT 60, 82i: iPT80, 102i: iPT 100. a required delay (i.e. Overseas in deployment).

  • Page 15: Connecting Your Unit To The Power Source And Wiring Information

    If you are not qualified to make these connections, don’t. Everlast is in no way liable for any damag- es caused by improper connection of your plasma cutter. Your plas- ma cutter should be on a dedicated branch circuit not far from an electrical disconnect box.

  • Page 16: Connection Of Air Compressor, Regulators, And Basic Requirements To Plasma Cut

    CNC use, special shielded consumables are available for most of the Innotec® iPT series torches. Since Everlast does directly manufacture the plasma torches, every consumable configuration for every torch may not be stocked or available. For these or other special applications, consult OEM distributors of the iPT/PT/PTM series torches in the North American Markets.

  • Page 17: Connecting The Plasma Torches, Hand And Cnc Setup Information

    While Everlast does not outright prohibit Out of square torches cause a lot of issues with beveled cuts. If you...

  • Page 18: Front Panel View And Component Id

    If fuse is stuck or holder is damaged, contact Everlast Support. Euro Central Connector Connect the torch to this connector. For details concerning pinout and torch compatibility, contact Everlast Support for more information. Screws (paired set on side panel, near rear) Connect the argon regulator bracket to this location.

  • Page 19: Rear Panel View And Component Id

    CNC control cable. Do not remove or re-pin CNC connector on the unit. Do not solder directly to the unit connector. If you do not have the accompanying plug that mates to the rear in the packaging for CNC cutters, contact Everlast.
  • Page 20 More commonly the supply hose is too small for the length of run and amount of air consumption. Use a minimum of 3/8” air hose for lengths up to 25 ft. Contact Everlast Support for assistance if needed.

  • Page 21: Plasma Cutting Operation Warnings And Safety Information

    Component Identification and Explanation Plasma Cutter Function Important Information and Warnings: DANGER! Never touch any of the bare portions of the torch power connectors, fuse, consumables or torch control while the unit is switched on and torch is connected. Severe injury or death may occur if the torch trigger is accidentally activated or becomes damaged.

  • Page 22: Explanation Of Plasma Functions And Terms

    Component Identification and Explanation Explanation of Functions and Plasma Cutting Terms where from 1/2 to 2/3 of the torch rated capacity. Cutting can still be What Air Pressure do I use to cut? performed, but starting a cut in the middle of the metal is no longer an option.

  • Page 23: Starting Cuts And Piercing Information

    Component Identification and Explanation How do I edge start a plasma cut? How do I pierce start a plasma cut? Edge starts are the best type of start to promote consumable Piercing starts often result in rapid consumable wear and and torch life.

  • Page 24: Consumable Information, Correct Cut And Travel Speed Information

    Everlast is not the manufacturer of the Innotec iPT series torches and TRAVEL does not offer all possible consumable types available for the torch series.
  • Page 25 Component Identification and Explanation What kind of dross am I seeing? What other problems am I like to encounter? Dross identification can help you determine what is wrong with your Frequently, more than one problem may exist. Closely evaluating cuts. Use the guide below to help you improve your cut quality. all issues can help narrow down cutting problems.
  • Page 26 Component Identification and Explanation How Do I Use a Lead-in? What is Kerf? When cutting an object, particularly a pattern shape, where the torch must pierce or re-fire in-line at an When you make a cut, a certain amount intersection of a cut, a lead-in cut should be employed. A lead-in is a cut that is made in the disposable of material is removed from the cut.

  • Page 27: Plasma Cutting Torch Parts And Assembly Powerplasma 62I And Ipt60 Torch

    Component Identification and Explanation (OPTIONAL)
  • Page 28 Component Identification and Explanation...

  • Page 29: Plasma Cutting Torch Parts And Assembly Powerplasma 82I And Ipt80/Iptm80 Torch

    Component Identification and Explanation...
  • Page 30 Component Identification and Explanation...

  • Page 31: Plasma Cutting Torch Parts And Assembly Powerplasma 102I And Ipt100/Iptm100 Torch

    Component Identification and Explanation...
  • Page 32 Component Identification and Explanation...

  • Page 33: Cnc Connector Pinout And Connection Information

    The Plasma cutter currently comes configured for 50 to 1 voltage divider for the THC. This is a 1 to 3V operating range. Some CNC tables are configured for 50 to 1 voltage divider but are calibrated based on particular brand with a higher arc voltage range than Everlast and many other brands supply on the standard volt/amp curve.

  • Page 34: Additional Torch And Cnc Information

    It can also theoretically affect duty cycle ratings. If you desire to use another torch with this machine, consult with Everlast before changing. There are some appropriate options.

  • Page 35: Troubleshooting Error Codes

    OVER CURRENT. Check to make sure input power cable is correct length and size. Internal unit fault or low input voltage. Possible issue running on generator with dirty power. Identify cause, plug directly into the receptacle. Cycle the switch one time. If the code does not clear, call Everlast Tech Support.

  • Page 36: Troubleshooting Common Plasma Cutting Issues

    Cup and/or nozzle is melting or cracking. Improper cutting technique/excessive piercing. Power input circuit breaker trips repeatedly. Improperly sized circuit. Internal issue. Contact Everlast. Arc “Blows Out” when ready to cut. Too high of air pressure. Wrong size consumable for amperage being used.

This manual is also suitable for:

Powerplasma 62iPowerplasma 82iPowerplasma 102i

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