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Section 1
General overview: The PowerPlasma 50 utilizes the latest
in inverter design technology. It's a portable dual voltage
plasma cutter with an output of 50 amps on 240V 1
phase power. It can also be used with 120 V (dual volt-
age models only) with limited output up to 27 amps.
This design allows the unit to be used in many different
circumstances and applications. The PowerPlasma 50 is
also equipped with a CNC port (see appendix) for light or
moderate CNC work. A separate CNC torch may be
bought for this type of operation. The arc start incorpo-
rates a blow back design with an automatic pilot arc.
The blow back design of the torch is depicted in detail
located in the torch section of this manual. This unit
features low air pressure protection along with duty cycle
and overcurrent protection which will shut down output
of the plasma cutter until the condition is resolved. The
OK-to-cut light is a feature which can be used by the op-
erator at a glance to determine if the air pressure is in
the optimum range. This unit employs the use of a blow
back design start which incorporates a pilot arc. The pilot
arc is designed for scouring the surface of the metal and
creating a path for continuity. The unit itself provides the
pilot arc through a ground path inside the torch head
back to the unit. To prevent consumable burn out and
torch damage, the pilot arc is reduced to 22-27 amps.
Once the pilot arc establishes continuity, arc intensity
and amps increase as the arc transfers to the metal.
General Use and Care: Care should be taken to keep the
unit out of direct contact with water spray. The unit is
rated IP21S, which rates it for light contact with dripping
water. It is a good idea to remove the plasma cutter
from the vicinity of any water or moisture source to re-
duce the possibility of electrocution or shock. Never op-
erate in standing water.
Every 1-2 months, depending upon use, the plasma
cutter should be unplugged, opened up and carefully
cleaned with compressed air. Regular maintenance will
extend the life of the unit.
IMPORTANT: Before opening the unit for any reason,
make sure the unit has been unplugged for at least 10
minutes to allow time for the capacitors to fully dis-
charge. Severe shock and/or death can occur.
Do not restrict air flow or movement of air around the
plasma cutter. Allow a buffer distance of 2 ft from all
sides if possible, with a minimum distance of at least 18"
clearance. Do not operate the unit immediately in the
weld/cut area.
Do not mount in areas that are prone to severe shock or
Introduction and Specifications
vibration. Lift and carry the welder by the handle.
Do not direct metallic dust or any dirt intentionally to-
ward the machine, particularly in grinding and welding
operations. Make sure the panel is protected from dam-
age.
NOTE: When servicing unit, remove rear plastic panel
first, the remove metal cover. DO NOT REMOVE FRONT
PLASTIC PANEL! THE FRONT PANEL IS INTEGRAL TO THE
FRAME OF THE UNIT. REMOVING THIS PANEL IS TIME
CONSUMING AND UNECESSARY.
Duty Cycle. The duty cycle has been determined for the
PowerPlasma at 60% @ 50 amps on 240 V operation.
The duty cycle is based off a 10 minute duty cycle rating at
40° C. This means that the unit is capable of being operat-
ed at the max amps for the stated percent of time out of
10 minutes without a break to cool down the unit. For
the remainder of the 10 minute time period, the welder
should rest for maximum life. The temperature light will
come on and the unit will automatically stop cutting when
an overheat condition has occurred. Stop trying to cut
immediately. Heat will continue to be generated by and
transferred to the electronics after welding has ceased.
Cutting in humid, or hot conditions can affect duty cycle
as well. Do not shut down an overheated welder until it
has safely cooled. Once the overheated condition has
cleared, cutting may resume. Do not operate the unit
with the covers removed. Only cycle the power switch to
reset the unit IF the light has not gone out after 10
minutes. 120V operation may reduce duty cycle in some
situations and will necessarily reduce output. A heavier
duty torch is recommended to accommodate high duty
cycle use (> 40% at maximum amps). The S-75 torch will
provide the durability needed for high duty cycle use and
performance when used at or near the Plasma cutter's
maximum duty cycle or in rough service conditions. You
can contact Everlast to purchase a larger torch or source
one through a Trafimet dealer.
This manual has been compiled to give an overview of
operation and is designed to offer information centered
around safe, practical use of the plasma cutter. The weld-
ing industry is inherently dangerous. Only YOU, the opera-
tor of this Plasma cutter, can ensure that safe operating
practices are 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 think that you do not have the skill or
knowledge to safely operate the plasma cutter, do not use
this welder until formal training is received.
11
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