Owner’s Manual & Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures� Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number)� Keep this manual and the receipt in a safe and dry place for future reference� 14e Visit our website at: http://www.harborfreight.
Table of Contents Safety Safetye��������������������������������������������������������� 2 Specifications.............................................. 5 Setup........................................................... 6 Operationr���������������������������������������������������� 8 Maintenances���������������������������������������������� 12 Troubleshooting.......................................... 13 Circuit Diagram........................................... 17 Parts List and Diagram...............
• When possible, move the work to a location well away from combustible materials. If relocation is not possible, protect the combustibles with a cover made of fire resistant material. • Remove or make safe all combustible materials for a radius of 35 feet (10 meters) around the work area. Use a fire resistant material to cover or block all open doorways, windows, cracks, and other openings. • Enclose the work area with portable fire resistant screens. Protect combustible walls, ceilings, floors, etc.
11. Safety Proper cylinder care. Secure cylinders to a cart, wall, or post, to prevent them from falling. All cylinders should be used and stored in an upright position. Never drop or strike a cylinder. Do not use cylinders that have been dented. Cylinder caps should be used when moving or storing cylinders. Empty cylinders should be kept in specified areas and clearly marked “empty.” 12. Never use oil or grease on any inlet connector, outlet connector, or cylinder valves. 13.
Rated Input 240VAC / 50/60Hz / 30A Open Circuit Voltage (OCV) 360V Cutting Current 15 - 40A DC Rated Output Voltage 96VDC Rated Duty Cycle Maximum Cutting Thickness 60% @ 40A 100% @ 30A 3/8" Mild Steel @ 10 IPM (Rated) 5/8" Mild Steel @ 5 IPM (Severence) 1/4" Stainless Steel, Aluminum, Galvanized Steel 1/8" Brass, Copper Arc Striking System 2.
Setup read the entire iMpOrtant SaFety inFOrMatiOn section at the beginning of this manual including all text under subheadings therein before set up or use of this product.
TO PREVENT SERIOUS INJURY AND DEATH FROM EXPLOSION: Use only clean, dry, regulated, oil-free, compressed air or nitrogen gas with this Plasma Cutter. Do not use oxygen, acetylene, carbon dioxide, combustible gases, or any other bottled gas as a power source for this Plasma Cutter. Use a compressor that is capable of supplying 4.5 CFM @ 80 PSI. 2. Incorporate a filter, regulator with pressure gauge, dryer, in-line shutoff valve, and quick coupler for best service.
Operation Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Safety Controls and Indicators 1 2 CURRENT 60 1. Output Current Knob Turn the Output Current Knob to the desired current (15 to 40 amps). Lower currents reduce circuit breaker tripping. Adjust as needed after test cuts. Thicker material will use greater amperage. Thinner material will use lower amperage. 2.
Wear an approved head covering to protect the head and neck. Use aprons, cape, sleeves, shoulder covers, and bibs designed and approved for welding and cutting procedures. Wear fire resistant ear plugs or ear muffs to keep sparks out of ears. Do not breathe arc fumes. Use natural or forced air ventilation and wear a NIOSH-approved respirator. WARNING! Prevent accidental fires. Remove any combustible material from the work area.
Basic Operation Safety PLASMA ARC CAN CAUSE SERIOUS INJURY, INCLUDING SEVERE CUTS, BURNS, PERMANENT EYE DAMAGE AND BLINDNESS! Once the trigger is squeezed, the arc will ignite IMMEDIATELY. The Torch does not need to contact the workpiece before the pilot arc ignites. Do not look at the Plasma Arc without an ANSI‑approved welding helmet featuring at least a number 10 shade lens rating. 1. BEFORE EACH USE, inspect the general condition of the Plasma Cutter.
Note: If the Plasma Cutter suddenly shuts off, check: a. Torch distance from workpiece, b. poor workpiece grounding, d. Circuit Breaker & Power Switch tripping, or 8. Do not squeeze Trigger until Torch is in position to start cutting. Starting at the edge of the workpiece, squeeze and hold the Trigger to strike the pilot arc. When the arc ignites, start slowly moving the Torch along your cut line. Setup 7. e. Thermal Overload tripping. (See number 5 on page 8.) Safety c.
Maintenance Instructions Procedures not specifically explained in this manual must be performed only by a qualified technician. Safety TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION OR ELECTRIC SHOCK: Make sure the Power Switch of the Plasma Cutter is in its "OFF" position and that the Plasma Cutter is unplugged from the electrical outlet before performing any inspection, maintenance, or cleaning procedures. TO PREVENT SERIOUS INJURY FROM Plasma Cutter FAILURE: Do not use damaged equipment.
Troubleshooting IMPORTANT! Safety Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. FAN RUNS WHEN SWITCHED ON BUT ARC WILL NOT IGNITE Check Air Switch AIR PRESSURE CORRECT Check that the grounding point and the metal being cut are both clean, dry, and free from paint, oil, or dirt. These sections need to conduct electricity efficiently.
Troubleshooting (cont.) IMPORTANT! Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. Safety ARC IGNITES FOR SEVERAL SECONDS BUT THEN GOES OUT Air pressure too high or too low. Check the air pressure setting on both the Compressor and the Cutter. AIR PRESSURE TOO HIGH Setup Set Compressor's Air Pressure Regulator between 90 - 120 PSI.
Troubleshooting (cont.) IMPORTANT! Material being cut is too thick. See Maximum Cutting Thickness on page 5. WITHIN THICKNESS RANGE TOO THICK Turn up the Output Current Knob and try again at a slower Torch travel speed. Use a more powerful PlasmaCutter. PROBLEM CORRECTED PROBLEM PERSISTS AT MAXIMUM CURRENT SETTING Air pressure too low. Set Cutter's Air Pressure Regulator between 60 - 80 PSI. Take note of the setting required for this metal thickness.
Troubleshooting (cont.) IMPORTANT! Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. Safety FAST CUTTING TIP WEAR OR EXCESSIVE SLAG FORMATION These two problems have similar causes and will often appear simultaneously. The same diagnostic procedures and remedies apply to both.
1K 1K C1 1UF-275V 1N4148 D3 D4 1N4148 R9 180K R8 180K 4 3 2 1 1 4 3 2 ISO2 VO VCC VO A3120 NC VEE CATHODE VO ANODE VCC VEE A3120 NC U? NC CATHODE VO ANODE NC L1 T25*15*10-9.5-Φ1.4 5 6 7 8 4.7NF-250V V2- 5 6 7 8 V1- 4.
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ISO1_3 OUT+ V3- V3+ J11 ISO1_3 J14 J13 C58 OUT- C79 100n 0 1/4 R59 J11 C52 470UF-35V BAT42W D59 R47 5.6k 1/4 12 R12W-0.47Ω-5% 12 R12W-0.47Ω-5% R44 R43 R57 5.6k D55 1N4148 C33 100n C34 100n R60 5.6k D22 C4V7 C32 100n Maintenance OUT+ 120 1/4 R49 ST4 �保�开关 1/4 560 R46 X1Y1-3.
C27 R62 10K J8_17P 100N 1/8 13 12 9 8 6 5 2 1 4.7UF-100V C30 R40 330R 556_OUT1 VCC GUN 100N C32 3.3UF-100V C28 U4A C15 100N D8 1N4148 4093 U4D 4093 U4C 4093 U4B 4093 270K 1/8 R33 1N4148 R41 110K 11 10 4 3 R38 4.7K 1/8 U4_11P 1K R39 1K 1/8 R45 D7 1N4148 1K R41 1/8 1/8 1K R32 1 11 9 40106 U3C 40106 U3F 470 R46 40106 U3D 1/8 2 10 R25 14k 1N4148 D4 8 R14 43k VREF R26 47K D5 1N4148 40106 U3A 40106 U3E 5 13 Mess_I 2N7002 Q12 4.
Maintenance Operation Setup THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE CIRCUIT DIAGRAM, PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT.
Parts List and Diagram Parts List Safety Part Setup 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16a 16b 16c 16d 16e 17 18 19 Description Air Pressure Regulator Top Housing Handle Power Cord Storage Hook Connector Air Flow Control Valve Main Switch Bracket Main Switch Air Switch Potentiometer Cutting (Red) LED lamp Overheat (Yellow) LED lamp Output Current Knob Power (Green) LED lamp (not shown) Connector Torch Electrode Swirl Ring Cutting Tip Retaining Cup Ground Clamp Cable Clip PG11L Front Panel Qty 1 1 1
Assembly Diagram 3 Safety 4 2 1 5 6 7 8 34 20 9 21 22 33 32 Setup 36 38 40 10 11 12 13 14 19 31 30 23 24 29 28 27 26 25 16a 16b 16c 16d 16e Maintenance 41 17 42 15 18 ITEM 62204 For technical questions, please call 1-888-866-5797.
Limited 90 Day Warranty Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase.
