Everlast PowerPlasma 25i XTR Operator's Manual
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Everlast PowerPlasma 25i XTR Operator's Manual

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Publish Date: May 2021
EVPPLSMA25IXTR Rev. 1
USA/North America
©Everlast Power Equipment
DC
25A
120V
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide
Operator's Manual
FUNCTION: Plasma Cutter
PURCHASE DATE:
PLASMA CUTTER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:

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Summary of Contents for Everlast PowerPlasma 25i XTR

  • Page 1 Publish Date: May 2021 EVPPLSMA25IXTR Rev. 1 USA/North America ©Everlast Power Equipment Safety, Setup and General Use Guide FUNCTION: Plasma Cutter PURCHASE DATE: PLASMA CUTTER SERIAL NUMBER: OPTIONAL ACCESSORY SERIAL NUMBER: Operator’s Manual 120V Welders, Plasma Cutters, Multi-Process...

  • 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 USE INFORMATION BREAKER SIZING AND WIRING REQUIREMENTS GETTING STARTED, UNPACKING YOUR UNIT AND PRESET 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 25i XTR Inverter Type Digitally Controlled IGBT Inverter Minimum/Maximum Rated Output 10-25A/ 84-90V Start Type Blow-Back Type, High Frequency Start Torch Type Innotec iPT25 CNC Ready No. Do not use with CNC equipment Duty Cycle @ Rated Amps/Volts (40° C) (Output V/A)

  • Page 12: Duty Cycle And 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, this unit has a duty cycle of 35% at maximum output. This means that the unit can be operated for 3.5 minutes out of 10 minutes. This may be continuously, or intermittently during the 10 minute period of time.

  • Page 13: Breaker Sizing And Wiring Requirements

    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 Preset Information

    (work). Check for arc starting and stability. If prob- Consumable Starter Kit for Plasma. lems are observed, contact Everlast. See page 5 for more infor- Regulator. Pressure Gauge and Tubing (4a) mation. NOTICE: Cosmetic damage claims after 30 days will not be Torch.
  • Page 15 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

    Always match the consumable size to the Amperage being used. NOTICE: 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 Torch, Setup Information

    Setup Guide Getting Started The PowerPlasma 25i XTR torch connects via a threaded coupler. WARNING! This coupler provides both gas and power to the torch. The torch also has a separate torch switch connection (Center, two pin con- THIS UNIT HAS AN OCV OF 400V! nector) and a separate pilot arc wire( Black thumbscrew).

  • Page 18: Front Panel View And Component Id

    Component Identification and Explanation Front Panel View Number Component Identification Component Note Carry Strap Use this adjustable strap only to carry the unit. Do not use this strap to suspend the unit. Gas and Power Connection This terminal is the main connection for the torch. It provides both air and cutting power to the fitting. Tight- en lightly (<1/8”...

  • Page 19: Control Panel Layout And Id

    Then turn the unit back on. If the fault does not clear, this indicates possible internal damage. Discontinue use immediately and call Everlast.

  • Page 20: Rear Panel View And Component Id

    Component Identification and Explanation Rear Panel View Number Component Identification Component Note Power Switch This switch turns the unit on and off. Air Regulator Mounting Holes The two mounting holes are used to locate the air regulator bracket. Attach the bracket before installing the regulator. Ground Service Bolt For use in a combined effort to mitigate any electrical interference that may be caused by the operation of this unit.

  • 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 performed, but starting a cut in the middle of the metal is no longer What Air Pressure Do I Use to Cut? an option. If piercing starts are attempted near the maximum capaci- ty of the machine, wear will greatly accelerate on all torch consuma- The unit should maintain between 55 and 65 PSI while actively cutting.

  • 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 25I Xtri And Ipt25 Torch

    Component Identification and Explanation iPT 25 Torch...
  • Page 28 Component Identification and Explanation iPT 25 Torch...

  • Page 29: Additional Torch And Cutting Advice/Information

    It can also theoretically affect duty cycle ratings. If you desire to use another torch with this machine, consult with Everlast before replacing or changing your torch.

  • Page 30: 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.

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