Chicago Electric 97994 Set Up And Operating Instructions Manual Download

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INVERTER PLASMA CUTTER

Model

97994

SET UP ANd OPERATINg INSTRUCTIONS

distributed exclusively by Harbor Freight Tools

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our website at: http://www.harborfreight.com

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

2008 by Harbor Freight Tools

contained herein may be reproduced in any shape or form without the express written consent of Harbor

Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements,

actual product may differ slightly from the product described herein.

For technical questions or replacement parts, please call 1-800-444-3353.

Summary of Contents for 97994

Page 1: ...in serious injury Save this manual Copyright 2008 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product descri...

Page 2: ...ns 10 Work Piece and Work Area Set Up 11 General Operating Instructions 11 PLASMA CUTTING TECHNIQUE 13 HOW PLASMA CUTTERS WORK 13 Maintenance And Servicing 14 Cleaning Maintenance and Lubrication 14 Nozzle Care 15 Troubleshooting 16 Cutting arc not stable 16 Plasma Cutter does not function when switched on 16 Weak Arc strength 16 Arc does not ignite 16 Gas does not flow 16 Parts list and assembly ...

Page 3: ...he safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE is used to address practices not related to personal injury CAUTION without the safety alert symbol is used to address practices not related to personal injury General Safety Rules WARNING Read all instructions Failure to follow all instructions listed below may result in ele...

Page 4: ...r control of the plasma cutter in unexpected situations Plasma cutter use and care 4 Use the correct plasma cutter for a your application The correct plasma cutter will do the job better and safer at the rate for which it was designed Do not use the plasma cutter if the b Power Switch 11 does not turn it on and off Any plasma cutter that can not be controlled with the Switch is dangerous and must ...

Page 5: ...ing a fire Keep a type ABC fire extinguisher within easy reach Thoroughly clean the object being cut of any paint grease or other foreign material Avoid unintentional starting Prepare 6 to begin work before turning on the Inverter Plasma Cutter Do not leave the Plasma Cutter unat 7 tended when it is plugged into an electrical outlet Turn off the plasma cutter and unplug it from its electrical outl...

Page 6: ... cover made of fire resistant mate rial Remove or make safe all combus tible 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 win dows cracks and other openings Enclose the work area with por table fire resistant screens Protect combustible walls ceilings floors etc from sparks and heat with fire resistant covers If ...

Page 7: ...ases Always keep your head out of the fumes Do not breathe the fumes Use enough ventilation or exhaust or both to keep fumes and gases from your breathing zone and general area Where ventilation is questionable have a qualified technician take an air sampling to determine the need for corrective measures Use mechanical ventilation to improve air quality If engineering controls are not feasible use...

Page 8: ... which cannot be built into this product but must be supplied by the operator Save these instructions Specifications Electrical Requirements 120 V 60 Hz 19 A Output 5 13 A Duty Cycle 40 13 A 60 10 A 100 8 A Control Mode IGBT Inverter Air Pressure 30 35 PSI Maximum Cutting Capacity 1 8 Clean Cut Steel 3 16 Sever Cut Steel 1 16 Stainless Steel Aluminum Copper or Brass Arc Striking System Pilot Start...

Page 9: ...ote For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near the end of this manual Assembly Remove the Regulator Nut from the 1 top of the Regulator Body Regulator Body Loop Regulator Nut 2 Slide the Regulator Body up through the Loop on the back of the Cutter and attach in place with the Regula tor Nut as shown in the illustration above The ...

Page 10: ...3 See Figure B CONTROLS INDICATORS FIGURE C POTENTIOMETER KNOB 10 POWER SWITCH 11 ON GREEN LED CUTTING YELLOW LED OVERHEATING RED LED 1 Power Switch 11 Up I is ON down O is OFF See Figure C Potentiometer Knob 10 Allows 2 you to adjust the current from 5 to 13 Amps See Figure C Green LED Light When illuminated 3 means the Plasma Cutter is on See Figure C Yellow LED Light When illuminated 4 means cu...

Page 11: ... the work area and limit the spray of sparks General Operating Instructions Protective gear must be worn when using the Plasma Cutter ANSI approved arc shaded eye protection a full face shield heavy duty work gloves a welding apron respirator and heavy duty work clothes without pockets should be worn when using this product Do not look at the ignited arc without eye protection Light from the arc c...

Page 12: ...he Cutting Torch 13 firmly 8 WARNING The Torch is live when its Trigger is pressed Keep the Torch away from people and flammables before touching Trigger When everything is in place for cut 9 ting press the Power Switch up to its ON position The GREEN Power On Light will illuminate See Figure C WARNING 10 To prevent seri ous injury point torch away from your body when squeez ing trigger Once the T...

Page 13: ...IQUE Using a Plasma Cutter is a skill that 1 requires time and effort to do well Practice striking and maintaining an arc on scrap workpieces before beginning work This will help you gauge the best settings for the Plas ma Cutter for the material at hand You can cut any metal that will con 2 duct electricity up to approximately 0 196 5mm thick mild steel or equivalent Very thin or very thick metal...

Page 14: ...ts safe operation After Use 2 clean external surfaces of the plasma cutter with clean cloth Periodically 3 using compressed air blow out all dust and debris from the interior WARNING If the Power Cord 32 of this Plasma Cutter is damaged it must be replaced only by a qualified service technician Nozzle Care FIGURE E 2A 1A 3A 4A 5A 6A 7A Part Description 1A Handle 2A Trigger 3A Body 4A Electrode 5A ...

Page 15: ...lown Have a quali fied technician check replace Weak Arc strength Possible Cause and Solution Incorrect line voltage Check the line voltage and if insuf ficient have a licensed electrician remedy the situation Arc does not ignite Possible Causes and Solutions Improper ground connection Make certain that the work piece is contacted properly by the Earth Clamp 14 and that the work piece is properly ...

Page 16: ...Knob 1 11 Power Switch 1 12 Cutting Holder Jacket 1 13 Cutting Torch 1 14 Earth Clamp 1 15 Earth Clamp Connector PG11 1 16 Tapping Screw 4 2x9 5 13 17 Steel Base 1 Part Description Qty 18 Inductance 1 19 Transformer 1 20 Radiator 3 21 LED 3 22 Potentiometer 1 23 Temperature Control 1 24 Electromagnetism Valve 1 25 PCB Support 1 26 PCB 1 27 Wind Pipe 1 28 Capacitor 4 29 Plastic Back Cover 1 30 Circ...

Page 17: ...ges so the above limitation of exclusion may not apply to you This warranty is expressly in lieu of all other warranties express or implied including the warranties of merchantability and fitness To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the complaint must accompany the mer chandise...

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