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EVERLAST
POWERPLASMA i SERIES
60-100 Amp i Series Digital IGBT Plasma Cutters
CC
PAC
IGBT
1
~
PHASE
Operator's Manual for the PowerPlasma 62i, 82i and 102i
Safety, Setup and General Use Guide
Rev. 1
0 001212-19
everlastwelders.com
Specifications and Accessories subject to change without notice.
1-877-755-9353
329 Littlefield Ave. South San Francisco, CA
94080 USA
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Summary of Contents for Everlast PowerPlasma i Series
- Page 1 EVERLAST POWERPLASMA i SERIES 60-100 Amp i Series Digital IGBT Plasma Cutters IGBT PHASE Operator’s Manual for the PowerPlasma 62i, 82i and 102i Safety, Setup and General Use Guide Rev. 1 0 001212-19 everlastwelders.com Specifications and Accessories subject to change without notice.
- Page 2 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 fitness for any particular purpose, for performance/accuracy or for suitability of application. Furthermore, Everlast Power Equipment INC.
- Page 3 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.
- Page 4 Date of Purchase___________________________ Everlast USA: Everlast consumer satisfaction email: sales@everlastwelders.com Everlast Website: everlastwelders.com Everlast Technical Support: tech@everlastwelders.com Everlast Welding Support: performance@everlastwelders.com 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: 1-650-588-8817 Everlast Canada: Everlast consumer satisfaction email: sales@everlastwelders.ca...
- Page 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.
- Page 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.
- Page 7 Safety Precautions WARNING! Persons with pacemakers should not weld, cut or be in the welding area until they consult with their physician. Some pacemakers are sensitive to EMF radiation and could severely malfunction while welding or while being in the vicinity of someone welding. Serious injury or death may occur! Welding and plasma cutting processes generate electro-magnetic fields and radiation.
- Page 8 Safety Precautions 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.
- Page 9 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...
- Page 10 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.
- Page 11 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.
- Page 12 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.
- Page 13 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 simplified internal design of the units. It has improved reliability and reduced weight.
- Page 14 “clean power”. Clean power is defined 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.
- Page 15 Section 2 Quick Setup Guide QUICK SETUP GUIDE: CONNECTIONS DINSE TYPE 35 CONNECTOR CENTRAL CONNECTOR PILOT ARC FUSE(30A SLOW BLOW) WORK (+) TORCH (-) OPTIONAL MACHINE (CNC) TORCH (-)
- Page 16 The brass plug, if not in the filter box, is included with the consumable and spare parts bag. If you cannot located this plug, contact Everlast for replacement plug. IMPORTANT: A separate air dryer between the air compressor and filter assembly must be installed, usually at the compressor or right before the regulator.
- Page 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 fire the torch to initiate air flow. Firing the torch without cutting significantly increases consumable wear. STOP! •...
- Page 18 Make sure that you use an adequate size compressor as listed in the specifications on page 10. If there is a significant loss of pressure, there may be an internal restriction to the pressure circuit or leak. Contact Everlast.
- Page 19 Breaker 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, find and rectify fault before attempting to power the unit back on. If the breaker does not reset, contact Everlast.
- Page 20 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.
- Page 21 When stepping down amps to cut thinner material, you must change to smaller orifice nozzle. Nozzles are offered in different sizes which are made for different amp levels. See the torch parts page for amp range and size of consumables. Everlast offers OEM size and configuration of consumables originally supplied with the torch for replacements and do not offer all configurations or sizes.
- Page 22 Section 3 Operation RESULTS OF CUT AT CORRECT SPEED, RESULTS OF CUT AT FAST SPEED AIR PRESSURE AND TORCH ANGLE ROUGH, DISTINCT CUT LINES SPACED FAR APART SMOOTH, EVEN CUT LINES WITH A S REARWARD SWEEP NOTICEABLE SMALL, HARD DROSS MINIMAL EASY TO CLEAN DROSS RESULTS OF TOO MUCH CURRENT RESULTS OF CUT AT SLOW SPEED...
- Page 23 Section 3 Operation AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING OUT A DISK SHAPED OBJECT AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING HOLE IN AN OBJECT NOTICE: When cutting an object, particularly a pattern shape, where the torch must pierce or re-fire in-line at an intersection of a cut, a lead -in cut should be employed.
- Page 24 Section 3 Operation GOUGING TRAVEL GOUGING Gouging is used to remove metal, usually a weld or surface defect by “washing” away the surface metal with an arc flame. Gouging should be performed with a consumable with a large diameter orifice or special gouge consumable with a large diameter orifice. These consumables are available from some OEM suppliers of the Innotec iPT series torch.
- Page 25 Section 3 Operation (OPTIONAL)
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- Page 31 If the controller has a pin for ground this is likely the pin to use. *Everlast does not endorse or recommend these brands and is not affiliated with them in anyway. They are mentioned as a common reference only. For specific recommendations regarding connection, contact the manufacturer of the CNC equipment/controllers. There are numerous makers of CNC equipment for plasma cutting and Everlast does not offer technical support for individual manufacturers.
- Page 32 Torch switch wire is loose. Problem with Central connector. Torch is not properly connected. IGBT or PCB bad, contact Everlast. Over current/Duty cycle Error Code. Machine runs, but no output. Duty cycle exceeded or Over current. Allow machine to cool. Reset main power switch after full cool down period.
- Page 33 Section 3 Troubleshooting Having trouble setting up your unit for best cutting? Try the following: Keep your standoff to less than 1/8” distance from the work piece. • Always use dry air. Drain compressor daily to improve effectiveness of air dryers and to prevent •...