Chicago Electric 91814 User manual

PLASMA AIR CUTTER

220 VOLT - 36 AMP

INVERTER TECHNOLOGY

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 MISSION OAKS BLVD., CAMARILLO, CA 93011

VISIT OUR WEB SITE AT HTTP://WWW.HARBORFREIGHT.COM

this manual or any artwork contained herein may be reproduced in any shape

or form without the express written consent of Harbor Freight Tools.

For technical questions and replacement parts, please call 1-800-444-

91814

MANUAL REVISED 02/05; 06/06

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

SKU 91814 PAGE 2

Contents

SPECIFICATIONS............................................................................3

GENERAL SAFETY RULES............................................................3

SPECIFIC SAFETY RULES.............................................................6

UNPACKING ...................................................................................10

ASSEMBLY INSTRUCTIONS .........................................................10

CONTROLS AND INDICATORS.....................................................11

OPERATING INSTRUCTIONS........................................................11

SETUP.....................................................................................................11

CUTTING TECHNIQUE ...........................................................................12

INSPECTION, MAINTENANCE, AND CLEANING.........................14

CIRCUIT DIAGRAM........................................................................15

PARTS LIST ....................................................................................16

TORCH DIAGRAM..........................................................................16

ASSEMBLY DIAGRAM ...................................................................17

TROUBLESHOOTING ....................................................................18

REV 07/05

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

SKU 91814 PAGE 3

SPECIFICATIONS

Cutting Depth 3/8 inch on steel

Cutting Current 5 to 36 Amps listed

Rated Load Voltage 100 VDC

No-load Voltage 200 VDC (maximum)

Power Consumption 220 VAC, 15 Amps, 50/60 Hz, single phase

Line Cord 6’ - 9” long (without 220 VAC twist plug); 14 AWG x 3-C

Arc Torch Cable 16’ - 3” long

Ground Cable 9’ long, 1 AWG x 6 mm2

Air Requirement 60-65 PSI, dry compressed air; 3.5 CFM @ 65 PSI

Arc Striking System Pilot arc feature with two second delay

Power Switch Rocker type, lighted

Overall Dimensions 16-3/4” (L) x 14-3/4” (H) x 8-1/8” (W)

Weight 26.5 lb.

Accessories Inlet air regulator (1/4” - 18 NPT), Shoulder strap, Electrode, Tip, Ceramic Ring

Rated Duty Cycle 40% at 36 amps, 60% at 28 amps

DUTY CYCLE is a welding or cutting, equipment speciﬁcation, which deﬁnes the number of

minutes, within a 10-minute period, that a given piece of equipment can safely weld or cut

at its rated load without overheating.

For example, if a welder or cutting type piece of equipment is rated at a 40% duty cycle at

36 amps, that particular piece of equipment must be “rested” for at least 6 minutes after 4

minutes of continuous welding or cutting.

Failure to carefully observe duty cycle limitations can easily over stress the power generation systems

of a piece of equipment contributing to the premature failure of that piece of equipment and the

voiding of the warranty.

SAVE THIS MANUAL

You will need the manual for the safety warnings and precautions, assembly instructions,

operating and maintenance procedures, parts list and diagram. Keep your invoice with this

manual. Write the invoice number on the inside of the front cover. Keep the manual and in-

voice in a safe and dry place for future reference.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS.Failure to follow all instructions

listed below may result in electric shock, ﬁre, and/or serious injury.

SAVE THESE INSTRUCTIONS

WORK AREA

1. Keep your work area clean and well lit. Cluttered benches and dark areas invite

accidents.

2. Do not operate power tools in explosive atmospheres, such as in the presence

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

SKU 91814 PAGE 4

of ﬂammable liquids, gases, or dust. Power tools create sparks which may ignite the

dust or fumes.

3. Keep bystanders, children, and visitors away while operating a power tool.

Distractions can cause you to lose control. Protect others in the work area from debris

such as chips and sparks. Provide barriers or shields as needed.

ELECTRICAL SAFETY

4. Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and

refrigerators. There is an increased risk of electric shock if your body is grounded.

5. Do not expose power tools to rain or wet conditions. Water entering a power tool

will increase the risk of electric shock.

6. Grounded tools must be plugged into an outlet properly installed and grounded in

accordance with all codes and ordinances. Never remove the grounding prong or

modify the plug in any way. Do not use any adapter plugs. Check with a qualiﬁed

electrician if you are in doubt as to whether the outlet is properly grounded. If the

tools should electrically malfunction or break down, grounding provides a low resistance

path to carry electricity away from the user.

7. Double insulated tools are equipped with a polarized plug (one blade is wider than

the other). This plug will ﬁt in a polarized outlet only one way. If the plug does

not ﬁt fully in the outlet, reverse the plug. If it still does not ﬁt, contact a qualiﬁed

electrician to install a polarized outlet. Do not change the plug in any way. Double

insulation eliminates the need for the three wire grounded power cord and grounded

power supply system.

8. Do not abuse the Power Cord. Never use the Power Cord to carry the tools or pull

the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp edges, or

moving parts. Replace damaged Power Cords immediately. Damaged Power Cords

increase the risk of electric shock.

9. When operating a power tool outside, use an outdoor extension cord marked“W-A”

or “W”. These extension cords are rated for outdoor use, and reduce the risk of electric

shock.

PERSONAL SAFETY

10. Stay alert. Watch what you are doing, and use common sense when operating a

power tool. Do not use a power tool while tired or under the inﬂuence of drugs,

alcohol, or medication. A moment of inattention while operating power tools may result

in serious personal injury.

11. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep

your hair, clothing, and gloves away from arc. Loose clothes, jewelry, or long hair

can catch ﬁre.

12. Avoid accidental starting. Be sure the Power Switch is off before plugging in.

Carrying power tools with your ﬁnger on the Power Switch, or plugging in power tools

with the Power Switch on, invites accidents.

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

SKU 91814 PAGE 5

13. Remove adjusting keys or wrenches before turning the power tool on. A wrench

or a key that is left attached to a rotating part of the power tool may result in personal

injury.

14. Do not overreach. Keep proper footing and balance at all times. Proper footing and

balance enables better control of the power tool in unexpected situations.

15. Use safety equipment. Always wear eye protection. Dust mask, nonskid safety shoes,

hard hat, or hearing protection must be used for appropriate conditions.

TOOL USE AND CARE

16. Use clamps (not included) or other practical ways to secure and support the

workpiece to a stable platform. Holding the work by hand or against your body is

unstable and may lead to loss of control.

17. Do not force the tool. Use the correct tool for your application. The correct tool will

do the job better and safer at the rate for which it is designed.

18. Do not use the power tool if the Power Switch does not turn it on or off. Any tool

that cannot be controlled with the Power Switch is dangerous and must be replaced.

19. Disconnect the Power Cord Plug from the power source before making any

adjustments, changing accessories, or storing the tool. Such preventive safety

measures reduce the risk of starting the tool accidentally.

20. Store idle tools out of reach of children and other untrained persons. Tools are

dangerous in the hands of untrained users.

21. Maintain tools with care. Keep tools in good repair. Properly maintained tools will

get the job done better. Do not use a damaged tool. Tag damaged tools “Do not use”

until repaired.

22. Check for breakage of parts, and any other condition that may affect the tool’s

operation. If damaged, have the tool serviced before using. Many accidents are

caused by poorly maintained tools.

23. Use only accessories that are recommended by the manufacturer for your model.

Accessories that may be suitable for one tool may become hazardous when used on

another tool.

SERVICE

24. Tool service must be performed only by qualiﬁed repair personnel. Service or

maintenance performed by unqualiﬁed personnel could result in a risk of injury.

25. When servicing a tool, use only identical replacement parts. Follow instructions

in the “Inspection, Maintenance, And Cleaning” section of this manual. Use of

unauthorized parts or failure to follow maintenance instructions may create a risk of

electric shock or injury.

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

SKU 91814 PAGE 6

SPECIFIC SAFETY RULES

1. Maintain labels and nameplates on the Air Plasma Cutter. These carry important

information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

2. Maintain a safe working environment. Keep the work area well lit. Make sure there

is adequate surrounding workspace. Always keep the work area free of obstructions,

grease, oil, trash, and other debris. Do not use a power tool in areas near ﬂammable

chemicals, dusts, and vapors. Do not use this product in a damp or wet location.

3. Avoid unintentional starting. Make sure you are prepared to begin work before turning

on the Air Plasma Cutter.

4. Unplug before performing maintenance. Always unplug the Plasma Cutter from

its electrical outlet before performing and inspection, maintenance, or cleaning

procedures.

5. Never leave the Plasma Cutter unattended while energized. Turn power off if you

have to leave the Air Plasma Cutter.

6. Prevent eye injury and burns. Wearing and using ANSI-approved personal safety

clothing and safety devices reduce the risk for injury.

• Wear ANSI-approved safety impact eye goggles with a 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 cutting overhead or in conﬁned spaces, wear ﬂame resistant ear plugs or ear

muffs to keep sparks out of ears.

7. Prevent accidental ﬁres. Remove any combustible material from the work area.

• 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 covers.

• 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

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

SKU 91814 PAGE 7

not possible, designate someone to serve as a ﬁre watch, equipped with a ﬁre extin-

guisher, during the cutting process and for at least one half hour after the cutting is

completed.

• Do not cut on materials having a combustible coating or combustible internal structure,

as in walls or ceilings, without an approved method for eliminating the hazard.

• Do not dispose of hot slag in containers holding combustible materials. Keep a ﬁre

extinguisher nearby and know how to use it.

• After 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. Provide adequate ventilation in work areas to prevent ac-

cumulation 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 to operate the Plasma Cutter. Never use other compressed

gases.

Inhalation Hazard

Welding Produces TOXIC FUMES and GASSES.

Exposure to welding gasses 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 gasses

or fumes are:

• Early onset of Parkinson’s Disease • Heart Disease

• Damage to the reproductive organs • Ulcers

• Inﬂammation of the small intestine or stomach • Kidney damage

• Respiratory diseases such as emphysema, bronchitis or pneumonia

Safety precautions, such as using natural or forced air ventilation and

wearing an ANSI-approved respirator, are ESSENTIAL to reduce the risk

of developing the above illnesses.

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.

• 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.

• Work in a conﬁned area only if it is well ventilated, or while wearing an air-supplied

respirator.

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

SKU 91814 PAGE 8

• Follow OSHA guidelines for Permissible Exposure Limits (PEL’s) for various fumes

and gases.

• Follow the American Conference of Governmental Industrial Hygienists recommenda-

tions for Threshold Limit Values (TLV’s) 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.

9. Always keep hoses away from cutting spot. 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.

10. Read and understand all instructions and safety precautions as outlined in the

manufacturer’s manual for the material you will weld or cut.

11. 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.

WARNING! This product, when used for welding and similar applications, contains

or produces a chemical known to the State of California to cause cancer and birth defects

(or other reproductive harm). (California Health & Safety Code § 25249.5, et seq.)

WARNING! People with pacemakers should consult their physician(s) before us-

ing this product. Electromagnetic ﬁelds in close proximity to a heart pacemaker could

cause interference to, or failure of the pacemaker.

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

SKU 91814 PAGE 9

GROUNDING

This Air Plasma Cutter requires a 3-prong, 220 VAC, polarized, twistlock plug (not sup-

plied). This plug must be installed by a qualiﬁed electrician.

WARNING!

Improperly connecting the grounding wire can result in the risk of electric

shock. Check with a qualiﬁed electrician if you are in doubt as to whether the

outlet is properly grounded. Do not modify the power cord provided with the

tool or product. Never remove the grounding prong from the plug. Do not use

the tool if the power cord or plug is damaged. If damaged, have it repaired by

a service facility before use. If the plug will not ﬁt the outlet, have a proper

outlet installed by a qualiﬁed electrician.

EXTENSION CORDS

If an extension cord is to be used with this product, it must be rated to handle 220 VAC,

single phase at 20 amps (minimum), and have a twistlock plug.

1. Grounded, 220 VAC tools require a three wire extension cord.

2. As the distance from the supply outlet increases, you must use a heavier gauge extension

cord. Using extension cords with inadequately sized wire causes a serious drop in voltage,

resulting in loss of power and possible tool damage.

3. The smaller the gauge number of the wire, the greater the capacity of the cord. For

example, a 14 gauge cord can carry a higher current than a 16 gauge cord.

4. When using more than one extension cord to make up the total length, make sure each

cord contains at least the minimum wire size required.

5. If you are using one extension cord for more than one tool, add the nameplate amperes

and use the sum to determine the required minimum cord size.

6. If you are using an extension cord outdoors, make sure it is marked with the sufﬁx “W-A”

(“W” in Canada) to indicate it is acceptable for outdoor use.

7. Make sure your extension cord is properly wired and in good electrical condition. Always

replace a damaged extension cord or have it repaired by a qualiﬁed electrician before

using it.

8. Protect your extension cords from sharp objects, excessive heat, and damp or wet

areas.

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

SKU 91814 PAGE 10

SYMBOLOGY

Table B

UNPACKING

When unpacking, check to make sure that all the parts are included. Refer to the Assembly

section, and the Assembly Diagrams and Parts List on pages 15 & 16.

If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover

of this manual as soon as possible.

Air Plasma Cutter

Grounding Clamp/Cable (54)

220 VAC

Line Cord

Cutting Torch with Cable (53)

Carrying Strap

Air Inlet (8)

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