Manual For The 62204 240 Volt Inverter Plasma Cutter With Digital Display
User Manual: Manual for the 62204 240 Volt Inverter Plasma Cutter with Digital Display 240 Volt Inverter Plasma Cutter with Digital Display
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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� Visit our website at: http://www.harborfreight.com email our technical support at: productsupport@harborfreight.com When unpacking, make sure that the product is intact and undamaged� If any parts are missing or broken, please call 1-888-866-5797 as soon as possible� Copyright© 2014 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 described herein� Tools required for assembly and service may not be included� read this material before using this product. Failure to do so can result in serious injury. SaVe tHiS ManuaL. 17f table of contents SaFety Safety ��������������������������������������������������������� 2 Specifications ��������������������������������������������� 5 Setup ���������������������������������������������������������� 6 Operation ���������������������������������������������������� 8 Maintenance ���������������������������������������������� 12 Troubleshooting ����������������������������������������� 13 Circuit Diagram ������������������������������������������ 17 Parts List and Diagram ������������������������������ 22 Warranty ���������������������������������������������������� 24 WarninG SyMBOLS anD DeFinitiOnS This is the safety alert symbol� It is used to alert you to potential personal injury hazards� Obey all safety messages that follow this symbol to avoid possible injury or death� Indicates a hazardous situation which, if not avoided, will result in death or serious injury� Indicates a hazardous situation which, if not avoided, could result in death or serious injury� Setup Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury� Addresses practices not related to personal injury� iMpOrtant SaFety inStructiOnS OperatiOn read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. 1� 2� Maintenance 3� DanGer! people with pacemakers should not use this plasma cutter or be nearby during use. plasma cutters, such as this one, produce strong, fluctuating electromagnetic fields that can cause pacemaker interference or pacemaker failure. people with pacemakers should consult their physician(s) for advice. Maintain a safe working environment. Keep the work area well lit� Make sure there is adequate surrounding workspace� Keep the work area free of obstructions, grease, oil, trash, and other debris� Do not use in areas near flammable chemicals, dusts, and vapors� Do not use in a damp or wet location� never leave the plasma cutter unattended when it is plugged into an electrical outlet. Turn off the Plasma Cutter, and unplug it from its electrical outlet before leaving� unplug the plasma cutter from its electrical outlet before performing any inspection, maintenance, or cleaning procedures, including changing accessories. Page 2 4� avoid unintentional starting. Make sure switch is in off position before plugging in� Make sure you are prepared to begin work before turning on the Plasma Cutter� 5� prevent eye injury and burns. Wearing personal protective equipment reduces the risk of injury� • Wear an ANSI-approved welding helmet featuring at least a number 10 shade lens rating� • Leather leggings, fire resistant shoes or boots should be worn when using this product� Do not wear pants with cuffs, shirts with open pockets, or any clothing that can catch and hold molten metal or sparks� • Keep clothing free of grease, oil, solvents, or any flammable substances� Wear dry, insulating gloves and protective clothing� • 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� • When welding/cutting overhead or in confined spaces, wear fi resistant ear plugs or ear muffs to keep sparks out of ears� For technical questions, please call 1-888-866-5797. ITEM 62204 • 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�, from sparks and heat with fire resistant material� 9� avoid overexposure to fumes and gases. 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� • Do not weld or cut on materials having a combustible coating or combustible internal structure, as in walls or ceilings, without an approved method for eliminating the hazard� • 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 an approved respirator� • Do not dispose of hot slag in containers holding combustible materials� Keep a fire extinguisher nearby and know how to use it� • Work in a confined area only if it is well ventilated, or while wearing an air-supplied respirator� • After welding or cutting, make a thorough examination for evidence of fire� Be aware that easily visible smoke or flame may not be present for some time after the fire has started� Do not weld or cut in atmospheres containing dangerously reactive or flammable gases, vapors, liquids, and dust� • Follow OSHA guidelines for Permissible Exposure Limits (PELs) for various fumes and gases� • Provide adequate ventilation in work areas to prevent accumulation of flammable gases, vapors, and dust� Do not apply heat to a container that has held an unknown substance or a combustible material whose contents, when heated, can produce flammable or explosive vapors� Clean and purge containers before applying heat� Vent closed containers, including castings, before preheating, welding, or cutting� • Only use compressed air or nitrogen to operate the Plasma Cutter� Never use other compressed gases� Don’t exceed maximum PSI for this product as stated on the specification table on page page 5� ITEM 62204 • Follow the American Conference of Governmental Industrial Hygienists recommendations for Threshold Limit Values (TLVs) for fumes and gases� • Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding or cutting situation� 10� Keep hoses away from welding/cutting area. Examine all hoses and cables for cuts, burns, or worn areas before each use� If any damaged areas are found, replace the hoses or cables immediately� For technical questions, please call 1-888-866-5797. SaFety Exposure to welding or cutting exhaust fumes can increase the risk of developing certain cancers, such as cancer of the larynx and lung cancer� Also, some diseases that may be linked to exposure to welding or cutting exhaust fumes are: • Early onset of Parkinson’s Disease • Heart disease • Ulcers • Damage to the reproductive organs • Inflammation of the small intestine or stomach • Kidney damage • Respiratory diseases such as emphysema, bronchitis, or pneumonia Use natural or forced air ventilation and wear a respirator approved by NIOSH to protect against the fumes produced to reduce the risk of developing the above illnesses� prevent accidental fires. Remove any combustible material from the work area� • If working on a metal wall, ceiling, etc�, prevent ignition of combustibles on the other side by moving the combustibles to a safe location� If relocation of combustibles is not possible, designate someone to serve as a fire watch, equipped with a fire extinguisher, during the cutting process and for at least one half hour after the cutting is completed� inHaLatiOn HaZarD: Welding and cutting produce tOXic FuMeS. Setup 8� OperatiOn 7� Maintain labels and nameplates on the plasma cutter. These carry important information� If unreadable or missing, contact Harbor Freight Tools for a replacement� Page 3 Maintenance 6� 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� use only supplied torch on this plasma cutter. Using components from other systems may cause personal injury and damage components within� 14� Setup uSe prOper eXtenSiOn cOrD. Make sure your extension cord is in good condition� When using an extension cord, be sure to use one heavy enough to carry the current your product will draw� An undersized cord will cause a drop in line voltage resulting in loss of power and overheating� A 50 foot extension cord must be at least 12 gauge in diameter, and an 100 foot extension cord must be at least 10 gauge in diameter� If in doubt, use the next heavier gauge� The smaller the gauge number, the heavier the cord� 15� KEEP CHILDREN AWAY� All visitors should be kept safe distance from work area� 16� MAKE WORKSHOP KID PROOF with padlocks, master switches, or by removing starter keys� 17� USE RIGHT Plasma Cutter� Don’t force Plasma Cutter or attachment to do a job for which it was not designed� 18� SECURE WORK� Use clamps or a vise to hold work� It’s safer than using your hand and it frees both hands to operate Plasma Cutter� 19� MAINTAIN PLASMA CUTTER WITH CARE� Keep Plasma Cutter clean for best and safest performance� Follow instructions for changing accessories� 20� Inspect before every use; do not use if parts loose or damaged� Symbology Canadian Standards Association Underwriters Laboratories, Inc� OperatiOn Vac a Volts Alternating Current Amperes Maintenance Page 4 For technical questions, please call 1-888-866-5797. ITEM 62204 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�5 second pilot arc Gas Supply Clean, dry, oil-free air, or nitrogen gas Air Outlet Pressure - Compressor 90 - 120 PSI Working Pressure - Plasma Cutter 60 - 80 PSI 4�5 CFM @ 80 PSI 1/4″ - 18 NPT Maintenance OperatiOn Air Inlet 3�6 CFM @ 60 PSI Setup Air Consumption SaFety Specifications ITEM 62204 For technical questions, please call 1-888-866-5797. Page 5 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. SaFety note: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual� note: This Plasma Cutter may be shipped with a protective plug covering the Air Inlet� Remove this plug before set up� power plug Setup 1� A 6-50P plug is wired into this item, rated to 250VAC and 50A� 2� if the receptacle does not match the plug, make sure that it is a 230-250Vac receptacle rated to at least 30 amps. If the receptacle is rated properly, a qualified electrician can cut the plug off of this machine and install a different appropriate 250Vac plug� Functions power cord Storage Hook air inlet (on back) air pressure regulator OperatiOn power cord Storage Hook power cord (on back) air pressure Gauge air Switch power Switch Maintenance torch Ground clamp Figure a Page 6 For technical questions, please call 1-888-866-5797. ITEM 62204 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� an in-line shutoff ball valve is an important safety device because it controls the air supply even if the air hose is ruptured. the shutoff valve should be a ball valve because it can be closed quickly. note: in humid locations, multiple dryers may need to be incorporated to keep the air dry. MOiSture in air SuppLy May cauSe SHOrteneD cOMpOnent LiFe anD pOOr cut QuaLity. note: Do not use an oiler system with this plasma cutter. the oil will mix with the air being propelled, causing poor results. 3� Attach an air hose to the compressor’s air outlet� Connect the air hose to the Air Inlet on the back of the Plasma Cutter� Other components, such as a coupler plug and quick coupler, will make operation more efficient, but are not required� note: Air flow, and therefore Plasma Cutter performance, can be hindered by undersized air supply components� The air hose must be long enough to reach the work area with enough extra length to allow free movement while working� Setup 1� SaFety air Supply 1� Set the Plasma Cutter’s power Switch to the OFF position� 2� Turn on the air compressor according to the manufacturer’s directions and allow it to build up pressure until it cycles off� 3� Set the air compressor’s output air pressure regulator between 90 - 120 pSi� Adjust the pressure gradually, while observing the air pressure gauge� 4� Inspect the air connections for leaks� Repair any leaks found� OperatiOn Setting compressor's air pressure Setting plasma cutter's air pressure 2� 3� Plug in the Plasm Cutter, set the power Switch to the On position and set the air Switch to Set air� There will be constant air flow� MAX Pull up on the air pressure regulator and set between 60 - 80 pSi, as observed on the air pressure Gauge. Ball MIN teSt air FLOW: WarninG! Make sure torch and cutting tip are completely cool. a� Hold Air Flowmeter firmly against end of Cutting Tip, pointing Torch and Air Flowmeter straight up� See Figure B. b� The ball should float in the marked area on the meter� If not, adjust air pressure, as needed, while observing the Air Pressure Gauge� 4� air Flowmeter torch Maintenance 1� Figure B iMpOrtant! After testing, set air Switch to cut to allow normal operation� ITEM 62204 For technical questions, please call 1-888-866-5797. Page 7 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 CURRENT 60 2 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� air pressure Gauge 3� Digital amp Meter Shows actual cutting current, which will vary during operation� 4� power On Light Green light will be on when power is on� 5� thermal Overload Light Yellow light will be on if the Plasma Cutter shuts down due to overload� Stop using the Plasma Cutter while leaving the Power Switch ON to allow the cooling fan to operate� The light will turn off automatically when the Plasma Cutter cools down. Continue use while paying attention to Duty Cycle discussed on page 10. 6� cutting Light Red light will be on during cutting operation� 7� air Switch cut: For cutting operation. Set air: Produces constant air flow for SettinG air preSSure OnLy� not for cutting operation. 8� power Switch & circuit Breaker Up is ON, down is OFF� This switch also functions as a circuit breaker� It will trip (disconnect power) if overcurrent occurs� Turn OFF, then back to ON to reset it� 90 30 0 PSI 120 MIN MAX CUT POWER CUTTING 3 SET AIR OVER LOAD POWER 4 5 6 7 ON 8 OFF Setup ITEM 62204 Figure c OperatiOn Maintenance Page 8 For technical questions, please call 1-888-866-5797. ITEM 62204 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. 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�, from sparks and heat with fire resistant covers� 4� 5� Set up Air Supply according to page 7� 8� Verify that the Power Switch is in the OFF position, then plug the Plasma Cutter into an appropriate 240VAC outlet rated to at least 30 amps to limit nuisance circuit breaker tripping� 9� pLaSMa cuttinG tipS: Using a Plasma Cutter is a skill that requires time and effort to do well� The floor and surrounding area must not be flammable� A clean concrete floor is recommended� The cutting process will eject molten metal slag onto the floor, and it will scatter for 8-10 feet or more in all directions� Keep multiple aBc-type fire extinguishers near work area. a� Practice striking and maintaining an arc on scrap work pieces before beginning work� This will help determine the best settings for the Plasma Cutter for the material at hand. b� All metals that conduct electricity can be cut, see Maximum cutting thickness on page 5 for thickness capabilities� Very thin or very thick metals are more difficult to cut cleanly� c� Set the air pressure between 60 and 80 PSI� Increased air pressure will increase plasma speed and cutting pressure� Air pressure and amperage should be adjusted in tandem – air pressure needs to increase as amperage increases, however, low amperage cuts will require less air pressure for a more stable cut� d� Generally start with a mid-range amperage setting (32-33 amps) and adjust up or down from there� Increased amperage will increase cutting heat� This is needed with thicker and harder metals� However, increased amperage will reduce Duty Cycle time� (See page10.) e� Move the Torch more slowly for thicker and harder metals, and more quickly for thin or soft metals� Keep the Torch moving while cutting� thicker Material thinner Material Place the Plasma Cutter on a sturdy, level surface at least six feet from the work area� Allow at least 18" around all sides of the Plasma Cutter for air flow� ITEM 62204 Setup Keep clothing free of grease, oil, solvents, or any flammable substances� Wear dry, insulating gloves and protective clothing� 3� 7� Wear an ANSI-approved welding helmet featuring at least a number 10 shade lens rating� Leather leggings, fire resistant shoes or boots should be worn when using this product� Do not wear pants with cuffs, shirts with open pockets, or any clothing that can catch and hold molten metal or sparks� 2� Put the workpiece on a sturdy metal work table that is open below the cutting area� Molten slag will be blown through the workpiece, and must be able to fall away freely� Mount the workpiece to be cut to the work table so that the cutting debris falls to the concrete floor� OperatiOn 1� 6� For technical questions, please call 1-888-866-5797. High amps More air pressure Low amps Maintenance WarninG! prevent eye injury and burns. Wearing personal protective equipment reduces the risk of injury. SaFety preparation and Work area Less air pressure Page 9 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� • • • • • 2� BeFOre eacH uSe, inspect the general condition of the Plasma Cutter� Check for: loose hardware, damaged cord/electrical wiring, cooling fan operation, cracked or broken parts, and any other condition that may affect its safe operation� Have a qualified technician correct any problems before operation� Setup Maintain tOrcH cOMpOnentS BeFOre eVery uSe anD aFter eVery HOur OF OperatiOn. Make sure Torch is completely cool, then: a� Disassemble Torch� 3� Attach the Drag Cup (cutting guide) to the end of the Torch so that its guides are parallel to the cutting path� It drags on the workpiece to keep the distance from the Torch to the workpiece constant for longer Cutting Tip life� note: For clarity, the Drag Cup is not shown in the following illustrations� Duty cycle Duty Cycle is the equipment specification which defines the number of minutes within a 10 minute period that a piece of equipment can safely operate� This Plasma Cutter has a 60% duty cycle at 40 amps, which means that it may be used only 6 minutes at 40 amps out of any 10 minute period, and must be rested the remaining 4 minutes� nOtice: Failure to follow the duty cycle limitations of this Plasma Cutter can easily damage this equipment, and will void the warranty� electrode Swirl ring OperatiOn cutting tip retaining cup 4� Securely attach the Ground Clamp to a part of the workpiece or metal work table that is clean, dry, and free from paint, oil, or dirt. Clamp as close as possible to the planned cut without exposing the Clamp to damage� 5� When everything is in place for cutting, set the Power Switch to the On position� The green Power Light will illuminate, but the Torch is not yet energized� 6� Orient yourself to one side of the cutting area, and move the Welding Helmet (sold separately) over your eyes� Drag cup b� Inspect the cutting tip. replace if interior is damaged, or if opening is enlarged or gouged. Clean inside as needed with steel wool, (remove any pieces of steel wool afterwards)� c� Inspect the electrode. replace if pitted 1/16" or more or if misshapen. iMMeDiateLy repLace WOrn cOMpOnentS. Maintenance d� Make sure all other internal torch components are undamaged, clean, and free of debris� e� nOtice: assemble electrode just snug using the included wrench, but do not overtighten. f� Insert the Swirl Ring and Cutting Tip into the torch� g� Assemble the Retaining Cup tightly� DO nOt uSe WitH WOrn cOMpOnentS. uSinG WOrn cOMpOnentS WiLL VOiD tHe Warranty anD DaMaGe tHe pLaSMa cutter. Page 10 keep 1/16" distance from workpiece 7� 90º Position Torch near workpiece at start of cut� Keep Cutting Tip at a 90º angle to workpiece, and at 1/16" distance from workpiece� For technical questions, please call 1-888-866-5797. ITEM 62204 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 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� 9� Setup 8� e� thermal Overload tripping. (See number 5 on page 8.) SaFety c� dirty/painted workpiece, 12� Pause briefly at end of cut� 13� Release the Trigger� The air will continue to come out of the Torch for a few seconds once the Trigger is released to cool off the Torch components� 14� When finished cutting: Slowly move the Torch along the cutting line with the Cutting Tip trailing� if sparks do not pass through workpiece 10� If sparks start shooting up from the workpiece instead of passing through, the Torch is being moved too quickly so the cut is not being made completely� Move the Torch along the workpiece more slowly to cut completely� a� Lift the Torch from the workpiece and set down on a cool part of the metal work table, b� Wait 10 minutes for the Plasma Cutter to cool down with the Power Switch On so the fan continues to operate, c� Press the Power Switch to the OFF position, SpeeD up if sparks pass straight down through bottom of workpiece 11� d� Turn the air supply off and disconnect air lines, e� Unplug the Power Cord from the electrical outlet� If sparks pass straight down through bottom of workpiece instead of at a slight angle, the Torch is being moved too slowly� This could cause the arc to extinguish� Move the Torch a little faster� ITEM 62204 For technical questions, please call 1-888-866-5797. Page 11 Maintenance SLOW DOWn OperatiOn note: Keep the Torch Cutting Tip pointed straight (90º) into the workpiece 1/16" from the surface� Consistent workpiece distance and cutting speed are critical� Sparks should pass through the workpiece at a slight angle. 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. if abnormal noise, vibration, or leaking air occurs, have the problem corrected before further use. cleaning and Maintenance note: These procedures are in addition to the regular checks and maintenance explained as part of the regular operation of the air-operated tool� Setup OperatiOn 1� BeFOre eacH uSe, disassemble torch, inspect and replace worn components, then reassemble torch tightly according to number 2 on page 10� 4� If the unit repeatedly shuts down from thermal overload, stop all use� Have the Plasma Cutter inspected and repaired by a qualified service technician� 2� Daily - air Supply Maintenance: Every day, maintain the air supply according to the component manufacturers' instructions� Drain the dryer regularly. Performing routine air supply maintenance will allow the tool to operate more safely and will also reduce wear on the tool� 5� Opening the plasma cutter will void the warranty, and may result in damage to equipment or possible personal injury. DO nOt Open tHe HOuSinG. Any repairs must be completed by a qualified technician� 6� 3� periODicaLLy, blow the dust from the cooling vents with compressed air� Store the Plasma Cutter and accessories in a clean and dry location out of reach of children� 7� WarninG! if the supply cord of this plasma cutter is damaged, it must be replaced only by a qualified service technician. Maintenance Page 12 For technical questions, please call 1-888-866-5797. ITEM 62204 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. Setup air preSSure tOO LOW a. Verify that the compressor is delivering 4.5 cFM @ 80 pSi. b. Set cutter's air pressure regulator between 60 - 80 pSi. Dirty Or cOateD MetaL MetaL iS cLean in BOtH areaS use a wire wheel brush or sander (not included) to thoroughly clean both the grounding point and the area that will be cut. if any cleaners are used, allow them to dry thoroughly before continuing. torch isn’t maintaining contact with the workpiece. a. Maintain a 1/16" distance from workpiece at all times. b. Disassemble torch, inspect and replace worn components, then reassemble torch tightly according to number 2 on page 10. c. torch is moving too slowly across the metal and cutting the material from underneath, breaking contact. Move torch more quickly. if the steps above do not solve the problem or if the repairs involved are too complex, contact a qualified technician. ITEM 62204 For technical questions, please call 1-888-866-5797. Page 13 OperatiOn air preSSure tOO HiGH Set compressor's air pressure regulator between 90 - 120 pSi. air SWitcH Set tO "cut" air pressure too high or too low. check the cutter's air pressure Gauge. Set between 60 - 80 pSi. Maintenance air SWitcH Set tO "Set air" Set air Switch to "cut". "Set air" is OnLy used to set air pressure. it does not allow normal operation. 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. 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. air preSSure tOO LOW a. Verify that the compressor is delivering 4.5 cFM @ 80 pSi. b. Set cutter's air pressure regulator between 60 - 80 pSi. c. Verify air flow by performing "test air Flow:" on page 7. Dirty Or cOateD MetaL MetaL iS cLean in BOtH areaS OperatiOn use a wire wheel brush or sander (not included) to thoroughly clean both the grounding point and the area that will be cut. if any cleaners are used, allow them to dry thoroughly before continuing. torch isn’t maintaining contact with the workpiece. a. Maintain a 1/16" distance from workpiece at all times. b. Disassemble torch, inspect and replace worn components, then reassemble torch tightly according to number 2 on page 10. c. torch is moving too slowly across the metal and cutting the material from underneath, breaking contact. Move torch more quickly. Maintenance if the steps above do not solve the problem or if the repairs involved are too complex, contact a qualified technician. Page 14 For technical questions, please call 1-888-866-5797. ITEM 62204 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 take note of the setting required for this metal thickness. prOBLeM perSiStS at MaXiMuM current SettinG air pressure too low. Set cutter's air pressure regulator between 60 - 80 pSi. air preSSure cOrrect air preSSure tOO LOW Disassemble torch, inspect and replace worn components, then reassemble torch tightly according to number 2 on page 10. a. Verify that the compressor is delivering 4.5 cFM @ 80 pSi. OperatiOn cut GOeS OnLy partiaLLy tHrOuGH tHe WOrKpiece Setup 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. tOrcH in GOOD cOnDitiOn DaMaGeD cOMpOnentS FOunD cut at a slower pace, the arc may not have enough time to cut through the workpiece. Maximum cutting speeds: Disassemble torch, inspect and replace worn components, then reassemble torch tightly according to number 2 on page 10. 3/8" Mild Steel @ 10 ipM (rated) 5/8" Mild Steel @ 5 ipM (Severence) if the steps above do not solve the problem or if the repairs involved are too complex, contact a qualified technician. ITEM 62204 For technical questions, please call 1-888-866-5797. Page 15 Maintenance b. Set cutter's air pressure regulator between 60 - 80 pSi 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. Setup current set too high; cut at lowest setting possible for the metal being cut. prOBLeMS reDuceD prOBLeMS perSiSt at LOWeSt practicaL SettinG take into account the thickness and type of metal to be cut before starting. thinner materials require lower amp settings. OperatiOn tOrcH in GOOD cOnDitiOn Disassemble and inspect torch according to number 2 on page 10. DaMaGeD cOMpOnentS FOunD air supply pressure may be inadequate: a. Verify that the compressor is delivering 4.5 cFM @ 80 pSi. b. Set cutter's air pressure regulator between 60 - 80 pSi. replace worn components, then reassemble torch tightly according to number 2 on page 10. Maintenance additional factors: a. Maintain a 1/16" distance from workpiece at all times. b. Move torch at proper rate. Maximum cutting speeds: 3/8" Mild Steel @ 10 ipM (rated) 5/8" Mild Steel @ 5 ipM (Severence) c. compare workpiece thickness to Maximum cutting thickness on page 5. if the steps above do not solve the problem or if the repairs involved are too complex, contact a qualified technician. Page 16 For technical questions, please call 1-888-866-5797. ITEM 62204 1K 1K 1/4 1N4148 D3 D4 1N4148 1UF-275V C1 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 Maintenance 100PF-63V C8 1/4 R28 C7 1/4 R24 J8_3P(PWM) EARTH AC2 1/4 R9 180K R8 180K 5 6 7 8 4.7NF-250V V2- 5 6 7 8 V1- 4.7NF-250V AC1 100PF-63V R16 10R V1+ C5 C6 R40 10R V2+ R10 270K R2 200K 1/4 1/4 v 10R 1/4 R18 10R 1/4 R12 1/4 10R R11 RV1 MYG511KD14 3 J2 DZ2 C10V R26 1K Q1_1 FGH60N60SFD DZ8 18V DZ10 18V DZ3 18V DZ4 C18V R23 1K C23 100NF-63V DZ1 C10V C26 C29 47UF-50V 100NF-63V C28 47UF-50V R19 1K 10R 1/4 R17 C25 47UF-50V C24 47UF-50V R14 1K * Q2_1 FGH40N60SFD +HT 10NF-630V C36 ∼ R22 1K R15 1K * BR5006 J1 2 4 14 R27 R14W-10Ω-5% Q1_2 FGH60N60SFD D1 HER307 680UF-400V D2 HER307 C27 D20 C22 3.3NF-1600V C9 RHRP1560 R21 R14W-10Ω-5% Q2_2 FGH40N60SFD - + BR5006 ∼ 3 BGR 1 680UF-400V D14 RHRP1560 C3 680UF-400V * CBB21-1UF-630V C4 Setup C2 +HT T2 * T2 3 4 BK C43 R54 R45 D36_1 Mess_I 14 J R53 R52 D10 1N4007 VCC 3.3K R55 3.3K OUT- C51 4.7NF400V 4.7NF400V C50 SaFety * L2 K1A 12VDC30A R14W-22Ω-5% RHRG30120 CBB-2.2NF-1600V C53 12VDC16A K2A CBB-2.2NF-1600V 2 1 J CURRENT-SAMPLING * GAS D33 1N4007 VCC 5 Page 17 OperatiOn DZ7 18V DZ9 18V DZ5 18V DZ6 18V 4 12VDC16A 5 K2B 120R 1/2 R7 12 1/4 1/4 1/4 1/4 R12W-47Ω-5% 1/4 1/4 1 2 R14W-22Ω-5% R14W-22Ω-5% 12VDC30A 4 D37_1 D38_2 RHRG30120 R1 D38_1 K1B 3.3NF-1600V 14 14 1/2 1/2 For technical questions, please call 1-888-866-5797. 14 1 2 1 2 RHRG30120 1 2 RHRG30120 ITEM 62204 5 3 * * -OUT +OUT circuit Diagram V1- C11 100N V3- 9 8 7 6 11 10 5 2 D30 ER2D R48 V3+ 100k 1/4 47UF-50V C35 100N C31 ER2D D6 12 C13 47UF-50V R018 3Ω R013 3Ω D012 18V R04 1/2 1/2W-100R Q02 STP6N95K5 4.7NF-630V C014 R03 3 3W-10K R012 10K V2- Vref 5 6 7 8 C015 100NF-275V 100NF-100V C018 C016 100NF-100V BYV26E D010 C14 100N R011 1/4 47R EC2834-88:13:23:23:11-Φ0.25-L D8 ER2D R021 3Ω 1/4 C10 47UF-50V T1 1/4 1 1/4 Maintenance V1+ CS VF UC3842BN GND RT/CT OUT VCC 4 3 2 1 1N4148 Vref COMP U1 Vf D011 R016 1/4 Vref 43K C022 1NF-50V R014 150K 1/4 100UF-35V C017 R07 1/2 56K ER2D D9 ER2D D32 C013 22UF-50V C021 C39 100N R034 1K 47NF-50V C020 C019 470PF-50V R08 1/2 56K Vf 470PF-50V OperatiOn For technical questions, please call 1-888-866-5797. 1/4 1/2 R09 56K ER2D D013 R033 4.3K R015 22K Vf 3 IN Q03 LM317 +HT 2 RJ2W-1Ω-5% R010 C42 220UF-63V 1/4 1/4 Adj 1 * FAN R25 1/4 2.2K R29 1/4 240R OUT ER2D D014 2 1 2 Setup V2+ 1/4 SaFety Page 18 ITEM 62204 C38 100UF-35V VCC ISO1_3 OUT+ V3- V3+ J11 ISO1_3 J14 J13 V3- C58 OUT- C79 100n 0 1/4 R59 1/4 J11 C52 470UF-35V BAT42W D59 R47 5.6k 1/4 12 R43 R12W-0.47Ω-5% 12 R12W-0.47Ω-5% R44 R57 5.6k D55 1N4148 C33 100n C34 100n R60 5.6k D22 C4V7 C32 100n Maintenance OUT+ 120 R49 THERMAL SENSOR ST4 1/4 560 R46 X1Y1-3.3NF-250V 390 1/4 R31 J11 D57 1N4148 D56 1N4148 C44 100n D54 1N4148 +HT 8 7 6 5 4 3 2 1 K A K A K A K A E C E C E C E C 1/2 2 9 10 11 12 13 14 15 16 1/2 300k 1/2 270k R3 1/4 C75 J8_2P(LV) 100n J8_14P R56 1k GUN J8-18 J8_1P(OV) C40 1UF-100V J8_9P J8_17P 390 R64 OperatiOn 150 1/4 R38 1/2 270k R6 0 1/4 R51 OVER_HOT R4 RJ2W-47Ω-5% R37 270k R5 IN4007 D40 TLP621-4 ISO1 1/4 1/4 1 2 1 2 2 1 2 1 R36 0 R32 33k 1/4 1 Ig C71 100n VCC 120k 1/4 R39 C46 100n J8_10P THERMAL SENSOR ST1 2 1 THERMAL SENSOR 2 1 3 C48 100UF-35V 1/4 GND 2 ST +5V +5V 2 R33 330k 3 C41 * C_PWM VR1 50K C63 100n 1/4 20k R35 6 5 C37 10nF 7 C47 100n CON7 7 6 5 4 3 2 1 J1 1/4 100k R75 1/4 10k R67 VCC VR2 50k GUN J8-18 C55 100n +5V D015 1N4148 PWM J8_2P J8_1P GAS Mess_I J8 D26 D35 D2 HOT OVER? POWER R8 1.8K 1/4 R36 1/4 1.8k R50 1.8k 1/4 FRONT PCB SaFety CZ-21 R42 10K HOT_POWER VCC J8_16P J8_9P CON7 7 6 5 4 3 2 1 J_3_2 VR3 100k J3 1 2 3 4 2.54*4 OVER_HOT J8_10P Ig HOT_POWER C_PWM J8_14P VCC J8_16P J8_17P R71 100k 1/4 HOT_POWER VCC J8_16P J8_10P（5V） C67 100n J2 2 2*2.54 1 R63 4.7k R13 15k LM358 U3B LM358 100n U3A C63 Setup Q1 BC817-25 3 2 VCC 8 4 U2 L7805 1/4 IN 1/4 V3+ 1/4 1 1/4 VCC 20 19 18 17 16 15 14 12 13 11 10 9 8 7 6 5 4 3 2 1 For technical questions, please call 1-888-866-5797. 0 ITEM 62204 Page 19 HOT_POWER J8_16P VCC R62 10K J8_17P C27 100N 1/8 13 12 9 8 6 5 2 1 U4A C15 100N D8 1N4148 4093 U4D 4093 U4C 4093 U4B 4093 270K 4.7UF-100V C30 R40 330R 556_OUT1 VCC GUN 100N 1N4148 D6 1/8 R33 C32 3.3UF-100V C28 VCC 1/8 1K R47 82K R41 110K 11 10 4 3 R38 4.7K U4_11P 1/8 1K R39 1K 1/8 R45 D7 1N4148 1K 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 1/8 4.7K R34 R41 1/8 1/8 1K R32 4.7V D13 C31 1UF-50V 1/8 1/8 R42 1/8 VCC_R 18K 1/8 47R R22 10N Ig1 Q9 BAV70 40106 U3B 1/8 4 R21 4.7K 10 9 10N 1K MC33074D U1C 8 C8 1/8 J8_1P VCC R16 22K Trigger1 Reset1 100N Ig GND 1/8 C23 10nF 1/8 1K 12 13 10K 1/8 4.7V D10 4.7V D11 R15 1N C5 1/8 1K 14 C1 100N 1N4148 D3 10K 10N C7 1K C6 10N 1/8 1/8 R6 1K 1/8 R3 5 6 1/8 10K VCC 7 C10 1N R19 10K 100N R2 22K VCC D1 1N4148 R1 68K ERR_I OVER_HOT MC33074D U1B MC33074D 1 U1A 100N C21 VCC 556_OUT2 Rest2 47UF-35V 1/8 390K C29 R60 1N4148 VCC R18 Rest1 R17 10K 3 1/8 47K D9 R58 1K 1/8 2 10N C25 100R 1/8 1/8 R61 R59 R5 1K 1/8 R4 8 9 10 11 12 13 BC817-25 Q5 R10 7.15K Trigger Output Reset Control V R13 13K 1/8 C4 100N GND Trigger Output Reset Control V Threshold R11 100N C2 7 6 5 4 3 MC33074D U1D D2 1N4148 C3 100N P_Test J8_2P R7 556_OU1 Trigger1 R52 470R Q19 BC817-25 Q4 BC817-25 GAS 2.3nF Rest2 C22 D20 BAV99 C12 100N R9 4.7K Rest1 C24 1/8 R20 1K 1/8 R31 4.7K R48 4.7K R49 4.7K 1/8 R8 AIR-SET D17 BAV70 Reset2 U3_10P 1/8 C9 C16 10N 3 556_OUT2 1/8 1K R53 R23 6 12 1/8 D16 BC807-25 1/8 1/8 Threshold D charge 1/8 4 11 2 1/8 1/8 + C33 3.3uF 100V 1/8 1N C13 C_PWM BAV70 D18 1/8 Q17 R50 4.7K BC817-25 1K 1/8 R35 0R 1/8 R27 VCC J8_16P J8_17P 4.7K 1/8 R56 2N7002 Q13 HOT_POWER R51 4.7K BAV70 D14 BAV70 D15 Q17_2P Q11 BC817-25 ERR_I GUN VCC J8 CZ-21 U3_10P U4_11P Q17_2P R29 16k 20 100R 19 1/8 18 R55 17 VCC 820K J8_14P C_PWM Ig R57 4.7K R28 270K Ig1 VCC OUT C17 100P PWM GAS C20 D12 24V R24 1K Mess_I J8_9P J8_14P C19 100N VCC_R BAV99 D19 R30 100R R36 680R 100N VREF 0 AIR-SET J8_1P J8_2P PWM C14 R43 100R 470P 5 6 7 8 Q20 BC817-25 J8_16P C18 100P RT/CT GND CS VF COMP Vref 100R 1/8 R37 U2 UC3845BD1R2G Mess_I OVER_HOT J8_9P J8_10P HOT_POWER IF 4 3 2 1 1/8 1/8 16 VREF 15 C26 14 14 12 13 VCC 11 Maintenance 1/8 1/8 10 LM556 9 U5 8 Discharge 7 1 6 1/8 1/8 5 1/8 4 OperatiOn R54 3 1/8 1/8 1/8 2 Setup For technical questions, please call 1-888-866-5797. 1/8 1 SaFety Page 20 1/8 ITEM 62204 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� IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER� THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO� SaFety pLeaSe reaD tHe FOLLOWinG careFuLLy ITEM 62204 For technical questions, please call 1-888-866-5797. Page 21 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 part 1 1 1 2 3 1 1 1 1 1 1 1 1 1 1 1 3 1 2 1 1 1 1 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Description Air Pressure Gauge Digital Display Connector RHRG30120 Diode Radiator Rectifer Inductor Transformer Radiator Bridge Rectifier DC Cooling Fan IGBT Radiator Bracket IGBT Radiator IGBT FGH40N60SFD TO-247 Capacitor DC CoolingFan Fan Hood Power Cord Power Cord Clip PG13�5 Bottom Housing Connector Beam Air Inlet Wrench Air Flowmeter Qty 1 1 1 4 1 1 1 1 1 1 2 4 3 1 1 1 1 1 1 1 1 1 1 OperatiOn Maintenance record product’s Serial number Here: note: if product has no serial number, record month and year of purchase instead. note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts� Page 22 For technical questions, please call 1-888-866-5797. ITEM 62204 assembly Diagram 3 SaFety 4 2 1 5 6 7 8 34 20 9 21 22 33 32 10 11 12 13 14 19 31 30 23 24 29 Setup 36 38 40 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. OperatiOn 35 37 39 Page 23 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� This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance� We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product� Some states do not allow the exclusion or limitation of incidental or consequential damages, 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 merchandise� If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement� We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product� This warranty gives you specific legal rights and you may also have other rights which vary from state to state� 3491 Mission Oaks Blvd. • pO Box 6009 • camarillo, ca 93011 • 1-888-866-5797
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