background image

18 

Section 2 

REAR PANEL FEATURES AND CONTROLS CONTINUED 

1. 

Never operate the plasma cutter on a generator that is not certified by its manufacturer to be “clean” power, which is less than 10% 
total harmonic distortion.  Less than 5% is preferred.  Operating the unit on square wave output or modified sine wave generators is 
strictly prohibited.   Contact the manufacturer of the generator for this information.  Everlast does not have an “approved” list of gener-
ators.  But, if the generator is not listed as clean power by its manufacturer,  then operation is prohibited.  Generators that do not at 
least meet the operating input requirements of the plasma cutter  are also forbidden to be used with the welders.  Surge amp capability 
of the generator should equal or exceed the  maximum inrush demand of the plasma cutter.   But the  surge capability should not be 
used as the only factor.  The regular, running output of the generator should match  or exceed the running or “rated” demand of the 
welder.   Any damage done by operating the unit on a generator not specified by its manufacturer to be “clean”, will not be covered 
under warranty.  This also includes suspect power sources where voltage is below 208 V and above 250 V.  

2. 

To properly size the breaker, the I1MAX  should be used in determining breaker size.  To size the wiring, the I1EFF   rating should be 
used to help determine the proper wire size.  The NEC in Article 630.11 allows a derating of the wire size based off of duty cycle.   The 
requirements are different than the requirements for most other 240V electrical products. However, consult a licensed electrician and 
local codes before installing any wiring or breakers. 

FEATURE 

PARAMETERS 

PURPOSE 

1.  CNC Connection 

N/A 

This allows the unit to be used with a CNC machine and provides the basic inputs for CNC opera-
tion.  See pin-out section located in the back of this manual. 

2.  2-Pole Power Switch 

On/Off 

The breaker switch contains 2 poles for power.  It serves as the On/Off switch for  the cutter.   
Always turn the cutter on and off by the switch first before using any disconnect switch.   

3.  Power Cable 

220/240 V 
1 phase 
(110 X2) 

The PowerPlasma S series uses 220/240 V power, including good quality 208 V power.  The wiring 
contains 3 separate wires. Everlast uses standard wire color codes  and sizes for welders plasma 
cutters.  Standard wire colors are L-1 black (hot),  L-2 white (hot), and green (ground) for 1 phase 
220/240 V.  Do not attempt to use a 4 wire 1 phase 220/240 connection.  

NOTE: In many home 

circuits, red and black are the power wires.  But in standard welding/ plasma cutting  circuitry, 
white and black are hot wires.  Green is always the ground in both circuits.  There is NO neutral 
in a standard welder circuit.  The units are shipped with a standard NEMA 6-50P.  

Always con-

sult a licensed electrician who is aware of local codes before attempting any wiring of the welder 
or of the power circuits.   Everlast is not responsible for any mis-wiring or damage caused to the 
unit by incorrectly wiring the welder.  If additional help is needed, contact Everlast.  

WARNING:  

DO NOT CONNECT THE PLASMA CUTTER TO  ANY OTHER VOLTAGE  OR PHASE ,  OR SEVERE 
DAMAGE WILL RESULT!  

4.  GAS  Input Connection 

Push to connect 

The gas input line is connected to the  Regulator assembly via the clear tubing provided in the 
accessory package.  To attach, simply push the tubing into the connector until it is firmly seated 
then give a slight tug to make sure it has been captured correctly by the fitting.  Make sure that 
the tubing shoulder is squarely cut and not cut at an angle.  An uneven or angular cut will cause 
leaking at the connector.  If the tubing must be removed, simply push on the outer plastic collar 
back while holding the tubing firmly in the other hand. 

5.  HF Ground Bolt 

N/A 

HF energy can be devastating to surrounding electronic equipment. Although this unit does not 
use HF energy to operate, it can serve as a direct drain should any EMF interference is suspected. 

6. Regulator Assembly 

N/A 

The regulator assembly serves as both a filter/water trap, and an air regulator.  The water trap  
with the fine sediment filter is self draining.  It is not designed to dry the air, but rather serves the 
purpose of catching any  residual slug of water that may be present in the air  line and filtering 
any trash or sediment that passes into the bowl of the regulator.   It is not designed to serve as an 
air dryer.  A separate air dryer must be placed between the regulator and the air compressor.   
During the assembly of the regulator, be sure to screw the 1/4” automotive quick connect into 
the side that is  stamped on top with “IN” or that has been stamped with an arrow pointing to 
the center of the regulator.  The small brass plug should screw into the center of the regulator 
and the remaining push-to-connect fitting should be screwed into the remaining hole. Then, 
connect the clear tubing to the push-to- connect.  Make sure the shoulder of the tubing has been 
cut squarely or the connection may leak as a result.  Screw the regulator bracket to the back of 
the plasma cutter first before attaching the regulator to the bracket.  Make sure the screws  lo-
cated in the accessory bag are the proper length and are inserted with the accompanying  lock 
and flat washers.  To adjust the regulator, simply pull the knob up slightly until it clicks, and ro-
tate the knob clockwise to increase the pressure or counter clockwise to decrease the pressure.  
To lock in the setting, push the knob down until it clicks.  Do not exceed 90 psi supply pressure.  
Do not exceed 85 psi on the plasma cutter side of the regulator or internal leakage may result. 
Operating air pressure should be set between 70 and 75 psi while in to “Test” mode. 

QUICK SETUP AND USE GUIDE 

Summary of Contents for PowerPlasma 60S

Page 1: ...werPlasma 60S 70S and 80S Safety Setup and General Use Guide CC IGBT 1 PHASE Rev 3 0 00215 13 EVERLAST everlastwelders com 1 877 755 9353 Specifications and Accessories subject to change without notic...

Page 2: ...e at the time of publication this manu al is intended to be a general guide and not intended to be exhaustive in its content regarding safety welding or the operation maintenance of this unit Everlast...

Page 3: ...nical support available through the main company headquarters available in your country For best service call the appropriate support line and follow up with an email particularly during off hours or...

Page 4: ...om forums index php Main toll free number 1 877 755 WELD 9353 9am 5pm PST M F 11am 4pm PST Sat FAX 1 650 588 8817 Everlast Canada Everlast consumer satisfaction email sales everlastwelders ca Everlast...

Page 5: ...t Do not operate the unit until you have read this manual and you are thoroughly familiar with the safe operation of the unit If you feel you need more information please contact Everlast Support The...

Page 6: ...equip ment If no protection is available exclude them from the work area Even brief expo sure to the rays from the welding arc can damage unprotected eyes Always wear hearing protection because weldi...

Page 7: ...y burning of the eyes nose or throat are signs that you need to increase ventilation Stop immediately and relocate work if necessary until adequate ventilation is ob tained Stop work completely and se...

Page 8: ...ion Keep all combustible materials including rags and spare clothing away from area Keep all flammable fuels and liquids stored separately from work area Visually inspect work area when job is complet...

Page 9: ...tion 1 12 ft S 75 Trafimet Torch Work Clamp NOTE Accessory and consumable style and quantities are subject to change without notice Regulator Assembly with Bracket PowerPlasma 60S 70S and 80S Consumab...

Page 10: ...uirement 5 CFM 90 psi 30 60 gallon reserve 6 CFM 90 psi 30 60 gallon reserve 7 CFM 90 psi 30 60 gallon reserve Duty Cycle Over Current Protection Yes Yes Yes Minimum Operating Air Pressure Safety Cut...

Page 11: ...hich rates it for light contact with dripping water It is a good idea to remove the welder from the vicinity of any water or moisture source to reduce the possibility of electrocution or shock Never o...

Page 12: ...12 QUICK SETUP AND USE GUIDE Section 2 QUICK SETUP GUIDE CONNECTIONS WORK TORCH CENTRAL CONNECTOR...

Page 13: ...TUBING IMPORTANT TO PREVENT AIR LEAKS MAKE SURE TUBING ENDS ARE SQUARELY CUT AND FULLY INSERTED TO RELEASE TUBING PRESS GENTLY ON PLASTIC COLLAR SO THAT IT COMPRESSES INTO HOUSING AND THEN PULL TUBIN...

Page 14: ...ND COMMONLY AVAILABLE IS THE REPLACEABLE DESSICANT TYPE USED FOR AUTOMOTIVE PAINTING DAMAGE DONE TO THE TORCH AND THE PLASMA CUTTER INCLUDING BUT NOT LIMITED TO SHORTING CORROSION AND DETERIORATION OF...

Page 15: ...T 4T LOCK 3 AIR PRESSURE GAUGE 2 AIR PRESSURE OK TO CUT 1 AMP DISPLAY QUICK SETUP AND USE GUIDE Section 2 FRONT PANEL FEATURES AND CONTROLS 10 PILOT ARC OPERATION 4 AMP CONTROL 5 CENTRAL CONNECTOR FUS...

Page 16: ...propriate to cool the torch and the consumables Post flow time will depend upon the amps and length severity of use A post flow time of 3 5 seconds post flow for every 10 amps is suggested 9 2T 4T Tri...

Page 17: ...S INLET 1 220 V 1 220 VAC 2 2 POLE POWER SWITCH 5 HF GROUND BOLT 4 GAS INLET 3 POWER CABLE 1 220 240V QUICK SETUP AND USE GUIDE Section 2 REAR PANEL FEATURES AND CONTROLS 1 CNC CONNECTION 6 REGULATOR...

Page 18: ...Always con sult a licensed electrician who is aware of local codes before attempting any wiring of the welder or of the power circuits Everlast is not responsible for any mis wiring or damage caused...

Page 19: ...AVEL 1 16 EDGE START 40 60 TRAVEL 1 PIERCE START 2 3 Piercing starts often result in rapid consumable wear and excess blow back of molten metal de posited onto torch and consumables This should be don...

Page 20: ...h cut Lowering the air pressure below 65 psi to try to get the torch to cut will only result in a lazy wandering arc TIP For longer consumable life do not use the pilot arc unnecessarily Select the 3...

Page 21: ...SULTS OF CUT AT FAST SPEED SIGNIFICANT SOFT POROUS DROSS RESULTS OF CUT AT SLOW SPEED VERTICAL CUT LINES RESULTS OF TOO MUCH CURRENT OR TOO MUCH STAND OFF HEIGHT SIDE VIEW MELTED TOP EDGE RESULTS OF W...

Page 22: ...tion of a cut a lead in cut should be employed A lead in is a cut that is made in the disposable part also known as a drop of the object to lead into the main part of the cut so that the destructive f...

Page 23: ...75 torch nor is it affiliated with Trafimet other than its role as an OEM supplier of torches on PowerPlasma S Series units Not all items accessories and parts depicted are available directly through...

Page 24: ...e this voltage Pins 4 and 6 provide the divided arc voltage This is selectable by adding a jumper on the CNC circuit board to create either 1 16 th or 1 50th of the raw arc voltage It may be used by s...

Page 25: ...e Wrong consum ables Poor quality aftermarket consumables Premature wear on consumables Short consuma ble life Uneven wear of consumables melting of cup Moisture oil contamination of consumable Excess...

Page 26: ...26...

Reviews: