Everlast PowerPlasa 150 H Use Manual
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Everlast PowerPlasa 150 H Use Manual

Everlast PowerPlasa 150 H Use Manual

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Publish Date: NOV.2023
EVPPLSMA150HRev. 1
USA/North America
©Everlast Power Equipment
DC
150A
HF
START
HAND/
CNC
3 Phase
Welders, Plasma Cutters, Multi-Process
Safety, Setup and General Use Guide For
PowerPlasma 150H
Operator's Manual
FUNCTION: Plasma Cutter with Water Cooled Option
PURCHASE DATE:
PLASMA CUTTER MODEL NAME:
CNC OPTIONAL TORCH INFO:
PLASMA CUTTER SERIAL NUMBER:
OPTIONAL ACCESSORY SERIAL NUMBER:

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Summary of Contents for Everlast PowerPlasa 150 H

  • Page 1 Publish Date: NOV.2023 EVPPLSMA150HRev. 1 USA/North America ©Everlast Power Equipment 150A Safety, Setup and General Use Guide For START HAND/ PowerPlasma 150H FUNCTION: Plasma Cutter with Water Cooled Option 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 BREAKER SIZING AND WIRING REQUIREMENTS GETTING STARTED, UNPACKING YOUR UNIT AND INSPECTION CONNECTING YOUR UNIT TO THE POWER SOURCE AND WIRING INFORMATION...

  • 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 for the special plasma cutter water cooler normally used for CNC operation. No other device or brand should be used in conjunction with this unit’s outlet.
  • Page 11 CNC type tables and controls. HF emissions can be controlled with use of proper shielding/ grounding techniques and maintenance of the HF spark gap. If problems are experi- enced in a commercial environment, call Everlast Tech Support for help di- agnosing and reducing interference.

  • Page 12: Specifications

    Specifications Specifications PowerPlasma 150H Inverter Type Digitally Controlled IGBT Inverter Minimum/Maximum Rated Output 20A/88V - 150A/140V Start Type High Frequency Torch Type Manua l/ CNC Option Air-Cooled Innotec Duty Cycle @ Rated Amps/Volts ( 40° C) (Output V/A) 60% @ 150A/ 140V 100% @ 115A/ 126V OCV (U 300V Voltage Input (U1)

  • Page 13: 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 14: 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 15: Getting Started, Unpacking Your Unit And Inspection

    If any item is damaged or missing, spray on all rear external connections. If any leaks are present, bubbles please inform Everlast within 72 hours of product receipt. See pages 4 and will form around the area of the leak. Tighten any clamps or fittings found 5 for more details.

  • Page 16: Connecting Your Unit To The Power Source And Wiring Information

    If you are not qualified to make these connec- brass screen over windows and open doors to prevent High Frequency tions, don’t. Everlast is in no way liable for any damages caused by leakage to nearby areas.

  • Page 17: Connection Of Air Compressor, Regulators, And Basic Requirements To Plasma Cut

    Setup Guide Getting Started CONNECT THE AIR COMPRESSOR What do I need to be able to plasma cut? Connect Regulator To Cylinder And Unit. The unit comes with everything you need as far as a basic starter kit for consumables, torch and regulator. However, you will need to supply a few things on your own.

  • Page 18: Connecting The Plasma Torches, Hand And Cnc Setup Information

    Slight the optional machine torch. While Everlast does not outright prohibit bevels caused while cutting around circles are normal, but a change...

  • Page 19: Front Panel View And Component Id

    Component Identification and Explanation Front Panel View Number Component Identification Component Note Protective Cover Keep cover down and in place during welding activities and in storage. Negative Terminal (-) Connect the work clamp to this terminal. (DINSE 15/25 Type, 3/8” nominal dia.) Pilot Arc Thumbscrew The torch pilot arc is connected here.

  • Page 20: 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 21: Control Panel Layout

    Check for obstructions and cleanliness of the unit. Reset the machine by cycling the power switch after Display Area/ 15 minutes if the light does not clear automatically. If the Over-Temperature light does not clear after reset, contact Everlast Multiple Warning LED’s...
  • Page 22 Component Identification and Explanation Control Panel Layout Number Component I.D. Value Component Note This graphline includes all adjustable functions of the welder. These assist in both hand cutting and CNC cutting by offering a program- mable control of the Plasma Cutter as it operates throughout the cut cycle. From Left to Right order: •...

  • Page 23: 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, consumables or torch control connetor 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 24: Explanation Of Plasma Functions And Terms

    Component Identification and Explanation Explanation of Functions and Plasma Cutting Terms What Air Pressure do I use to cut? Lead-In/Lead Out. Lead ins or Lead Outs are simply cuts that are made at the beginning or end of the cut that will not be used in the The unit should maintain between 65 and 72 PSI while actively cutting.

  • Page 25: 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 26 Everlast offers OEM size and configuration of consumables originally supplied with the torch for replacements and do not offer all configurations or sizes. Everlast is not the manufacturer of the available plasma torches and TRAVEL does not offer all possible consumable types available for the torch series.

  • Page 27: Correct Cut And Travel Speed Information

    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 28 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 29: Plasma Cutting Torch Parts And Assembly Lt150 /Ltm150(Air-Cooled)

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

  • Page 31: Plasma Cutting Torch Parts And Assembly Fy-A200/Fyxf300 (Water-Cooled)

    Component Identification and Explanation...

  • Page 32: 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 33: Additional Torch And Cnc Information

    How do I set my plasma cutter CNC cutting? Can you help provide support advice my CNC table? You may be looking for CNC cut charts and tables for use. Currently, Everlast does not produce such information. There are numerous brands and types of systems on the market, many are here today, gone tomorrow.

  • Page 34: Troubleshooting Error Codes

    Troubleshooting Error Codes TROUBLE CODE WITH WARNING LIGHT/UNIT DIAGNOSIS STOPS WELDING BUT IS TURNED ON. OVER TEMPERATURE/ DUTY CYCLE EXCEEDED. Allow unit to rest for 15 minutes while running. The unit should reset. If it does not or condition reoccurs, check for obstacles near unit blocking cooling.

  • Page 35: Troubleshooting Common Plasma Cutting Issues

    Too high of air pressure. Wrong size consumable for amperage being used. During CNC use, arc fires inconsistently Too much clamping pressure on CNC torch or torch clamped too low. Gas (Air) continues to flow Dirty or stuck solenoid. Can be serviced and cleaned. Contact Everlast for instructions.

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