Chicago Electric 92652 User manual

PLASMA AIR CUTTERPLASMA AIR CUTTER
PLASMA AIR CUTTERPLASMA AIR CUTTER
PLASMA AIR CUTTER
230 VOL230 VOL
230 VOL230 VOL
230 VOLTT
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T, INVER, INVER
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TECHNOLOGYTECHNOLOGY
TECHNOLOGYTECHNOLOGY
TECHNOLOGY
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 MISSION OAKS BLVD., CAMARILLO, CA 93011
VISIT OUR WEB SITE AT HTTP://WWW.HARBORFREIGHT.COM
Copyright©2005 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.
For technical questions and replacement parts, please call 1-800-444-3353
92652
®

Page 2SKU 92652 For technical questions, please call 1-800-444-3353
SPECIFICATIONS
Power Consumption 230 VAC, 50/60 Hz, single phase,
40 amp dedicated circuit required for
maximum output
Cutting Capacity Plate Steel 5/64” to 1/2"
Cutting Current 15 to 40 Amps
Rated Duty Cycle 35% at 40 Amps
Line Cord 7’ 5” (L) (without 220 VAC twist plug);
12 AWG x 3-C
Arc Torch Cable 16’ (L)
Ground Cable 9’ 7-3/4” (L) with clamp
Air Requirement 60 to 100 PSI, (maximum), dry compressed
air, 3.5 CFM
Arc Striking System Pilot arc
Power Switch Rocker type, lighted
Fuse Internal: 0.5A
Overall Dimensions 16-3/4” (L) x 14-3/4” (H) x 8-1/8” (W)
Weight 36.6 lb.
Accessories - Inlet air regulator
- Shoulder strap
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
invoice 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
REV 08/05; 10/06

Page 3SKU 92652 For technical questions, please call 1-800-444-3353
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
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. 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.
8. 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
9. 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.
10. 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.
11. 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.

Page 4SKU 92652 For technical questions, please call 1-800-444-3353
12. 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.
13. 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.
14. Use safety equipment. Always wear eye protection. Dust mask, non-skid safety
shoes, hard hat, or hearing protection must be used for appropriate conditions.
Tool Use and Care
15. 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.
16. 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.
17. 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.
18. 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.
19. Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.
20. 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.
21. 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.
22. 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
23. Tool service must be performed only by qualified repair personnel. Service or
maintenance performed by unqualified personnel could result in a risk of injury.
24. 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.

Page 5SKU 92652 For technical questions, please call 1-800-444-3353
SPECIFIC SAFETY RULES FOR THIS PRODUCT
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 Welder/Cutter.
4. Unplug before performing maintenance. Always unplug the Plasma Welder/Cutter
from its electrical outlet before performing and inspection, maintenance, or cleaning
procedures.
5. Never leave the Plasma Welder/Cutter unattended while energized.Turn power off
if you have to leave the Air Plasma Cutter.
6. 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.
7. 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 welding/cutting overhead or in confined spaces, wear flame resistant ear
plugs or ear muffs to keep sparks out of ears.
8. 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 door-
ways, windows, cracks, and other openings.

Page 6SKU 92652 For technical questions, please call 1-800-444-3353
•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
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 cut-
ting is completed.
•Do not weld or cut on materials having a combustible coating or combustible inter-
nal 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 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. 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 to operate the Plasma Welder/Cutter. Never use other
compressed gases. Don’t exceed maximum PSI for this product as stated on the
specification table on page 2.
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.

Page 7SKU 92652 For technical questions, please call 1-800-444-3353
•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 respi-
rator.
•Work in a confined area only if it is well ventilated, or while wearing an air-supplied
respirator.
•Follow OSHA guidelines for Permissible Exposure Limits (PEL’s) for various fumes
and gases.
•Follow the American Conference of Governmental Industrial Hygienists recommen-
dations 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.
10. Always keep hoses away from welding/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.
11. Read and understand all instructions and safety precautions as outlined in the
manufacturer’s manual for the material you will weld or cut.
12. 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.”
13. Never use oil or grease on any inlet connector, outlet connector, or cylinder
valves.
14. Use only supplied Torch on this Air Plasma Welder/Cutter. Using components from
other systems may cause personal injury and damage components within.
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 de-
fects (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.
GROUNDING
This Air Plasma Cutter requires a 3-prong, 230 VAC, polarized, twist-lock plug (not sup-
plied).This plug must be installed by a qualified electrician.

Page 8SKU 92652 For technical questions, please call 1-800-444-3353
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 230 VAC,
single phase at 40 amps (minimum), and have a twist-lock plug.
1. Grounded, 230 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 10 gauge cord can carry a higher current than a 12 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.

Page 9SKU 92652 For technical questions, please call 1-800-444-3353
SYMBOLOGY
Table B
UNPACKING
When unpacking, check to make sure that all the parts are included. Refer to the Assembly
section, and the Assembly Drawing and Parts List at the end of this manual. 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.
ASSEMBLY INSTRUCTIONS
1. Connect a 3-prong, 230 VAC, polarized, twist-lock plug (not supplied) to the Line Cord.
This plug must be installed by a qualified electrician.
2. Insert the Air Regulator (43) into the Valve Body (4) (unit rear) using the snap-lock.
Air Plasma Cutter
Grounding Clamp/Cable (45)
230 VAC Line Cord (44)
without plug
Torch and Cable (47)
Carrying Strap (46)
Valve Body (4)
Air Regulator (43)

Page 10SKU 92652 For technical questions, please call 1-800-444-3353
OPERATING INSTRUCTIONS
Controls and Indicators
Air Plasma Cutting
Before beginning, please read and understand all the safety precautions starting on
page 2, and especially the section “Specific Safety Rules” starting on page 4.
1. Mount the metal to be cut to the metal welding-cutting table. It should be mounted so
that the cutting debris falls to the cement floor.
2. Place the Air Plasma Cutter unit no closer than six feet from the workpiece to be cut.
3. Connect an air hose and coupling (not supplied) from the air supply tank to the Air
Regulator (43) at the rear of the unit. See photo on page 9, bottom.
The Air Regulator (43) output must be regulated to between 60 and 100 PSI as read
on the Air Pressure Gauge (5). The air supply must be dry. It is recommended to install
a moisture filter (not included) on the compressor. Do not use an air oiler.
4. Connect the Torch Cable (47) plug into the twist-lock connector on the unit front.Twist
to lock. See photo on page 9, bottom.
5. Plug in the Grounding Cable (45) into the Ground Cable Quick Coupler. Twist to lock.
6. Securely place the clamping end of the Grounding Cable Clamp (45) to a part of the
workpiece or metal table that is clean of paint, oil, or dirt.
Clamp as close as possible to the workpiece without damaging the cable during
cutting.
7. Verify that the Power Switch (30) is in the Off (O) position, then plug the 220 VAC line
cord plug into a 230 VAC, 40 amp outlet.
8. Turn the Current Adjustment Knob (48) to the desired current (15 to 40 amps).
REAR VIEW
Grounding Cable (45)
Quick Coupler
Quick
Coupler (34)
Current
Adjustment
Knob (48)
FRONT VIEW
Power Switch
with Light (30)
Air Pressure Gauge (5)
Air
Regulator (43)
LED Indicators:
Grn.- Power On
Yel.- Energized Torch
Red - Thermal Fault
Yel.+Red - Air Pressure Fault
Line Cord (44)
Torch
Trigger
(2A)
Air Switch (49)
Valve
Body (4)

Page 11SKU 92652 For technical questions, please call 1-800-444-3353
Maximum current is required to cut 1/2 inch steel.
9. Press up on the Air Switch (49) to turn on air without activating the Torch Handle.
Adjust air pressure by turning the knob on the rear Air Regulator (43). Read pressure
on Pressure Gauge (5).
10. When everything is in place for cutting, press the Power Switch to the On (I) position.
The green Power Indicator lights, but the Torch (47) is not energized yet.
11. Orient yourself to one side of the area to be cut, and hold the Arc Shaded Face Shield
(not included) over your eyes.
12. Squeeze (and hold) the Torch Handle Trigger (2A) to energize the Torch Electrode
(4A). The air output is delayed a few seconds to enable a proper arc to begin.
Warning:The Torch handle is now energized. Be careful not to touch anything else with
the Torch Body (3A) except the workpiece to be cut.
Warning: Never look at the ignited arc without ANSI approved, arc shaded, eye protec-
tion in a full face shield. Permanent eye damage or blindness can occur. Skin burns can
occur. Never breath arc fumes.
13. Bring the Electrode (4A) of the Torch Body (3A) close enough to the starting point of
the cut to create an arc.The yellow Cutter Indicator lights.
14. Lightly tap the Torch Electrode (4A) into the cutting surface to ignite the arc, then pull
back slightly. If the arc is not started within two seconds, the unit goes into standby
mode. Release the Trigger once and squeeze to reset to arc mode.
15. Slowly move the Torch Handle (1A) at a slight angle along the cutting line with the
Torch tip trailing.
The air causes the molten metal to fall away from the workpiece being cut. If proper
cutting is not achieved, adjust the Current Adjustment Knob (48) to a higher level, and/
or increase air flow. To increase air flow, press the Power Switch (30) to the Off (O)
position, then adjust the air pressure at the Air Regulator (43). The air will continue to
come out of the Torch Handle (1A) for 30 seconds once the trigger is released.
Note: If too much current is drawn from the Plasma Cutter (i.e., short circuit), the Thermal
Switch, an overload protector, will activate and the red Overheat indicator will light.The Plasma
Cutter will turn off until it cools down. It will automatically reset. Press Trigger (2A) to begin
cutting again.
16. When finished cutting:
A. Release the Torch handle trigger and lift the Torch handle from the workpiece,
B. press the Power Switch (30) to the Off (O) position,
C. set the Torch handle down on the metal workbench,
D. turn the air supply off,
E. unplug the line cord from the electrical outlet.

Page 12SKU 92652 For technical questions, please call 1-800-444-3353
INSPECTION, MAINTENANCE, AND CLEANING
WARNING! Make sure the Power Switch (30) of the Plasma Cutter is in its “OFF”
position and that the tool is unplugged from the electrical outlet before performing any
inspection, maintenance, or cleaning procedures.
1. Before each use, inspect the general condition of the Air Plasma Cutter. Check for
loose cable connections, misalignment or binding of the fan, cracked or broken parts,
damaged electrical wiring, and any other condition that may affect its safe operation. If
abnormal noise or vibration occurs, have the problem corrected before further use. Do
not use damaged equipment.
2. Periodically recheck all nuts, bolts, and screws for tightness.
3. Periodically blow the dust from the cooling vents with compressed air.
4. Verify that the cooling fan is operational before cutting.
5. If an odd smell comes from the unit during operation, stop all use. Have the Air Plasma
Cutter inspected and repaired by a qualified service technician.
6. Store the welder and accessories in a clean and dry location.
7. Periodically disassemble and clean the Torch Head components with steel wool.
Replace burnt, cracked, distorted, or coated components. Refer to the assembly
drawing on page 14.
8. To gain access to the internal components of the unit, remove six screws from each
Panel (35), and two side screws from the Cover (27). Any repairs should be completed
by a qualified technician.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KINDTO THE BUYER THAT HE OR SHE
IS QUALIFIEDTO MAKE ANY REPAIRS TO THE PRODUCT ORTHAT HE OR SHE IS QUALIFIED TO
REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR
EXPRESSLY STATESTHAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN
BY CERTIFIED AND LICENSEDTECHNICIANS AND NOT BY THE BUYER.THE BUYER ASSUMES
ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TOTHE ORIGINAL PRODUCT
OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF
REPLACEMENT PARTSTHERETO.

Page 13SKU 92652 For technical questions, please call 1-800-444-3353
MAIN UNIT PARTS LIST
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1emarfesab1235.9*9.3TSwercs04
2BCP133lenaptnorf1
3BCP143relpuockciuq1
4ydobevlav153lenap2
5eguagerusserpria1634rehsaw4
6lanimrethcro
tgnidlew1734rehsawgnirps4
7etalpdim1835rehsawkcol21
831*8.4TSwercs49331*9.3TSwercs21
91rotcelfeddim1044rehsawkcol63
015.9*8.4
TSwercs814BCPlortnocmargorp1
11gniriwretlif124gniriwgnilpuocycneuqerfhgih1
21troppus234rotalugerria1
31retrevid244drocrewo
p1
41BCPyradnoces154elbacdnapmalcgnidnuorg1
51)rewop(rotaidar164partsgniyrrac1
61remrofsnartretrevni174elbacdnahcrot1
71)r
etrevni(rotaidar184bonkgnitsujdatnerruc1
81eceipgnitcennoc294hctiwsria1
912rotcelfed1
02dutsreppoc4
12BCPyramirp1
224Mtun8
3
2BCPmargorp1
425.9*9.2TSwercs3
5257*4Mtlob4
62draobgninil2
72revoc1
82lenapraer1
92temmorgdrocrewop1
03hctiwsrewop1
13nafrewol
b1
REV 03/05; 11/06
MAIN UNIT EXTERNAL PARTS
DRAWING

Page 14SKU 92652 For technical questions, please call 1-800-444-3353
MAIN UNIT INTERNAL ASSEMBLY DRAWING
REV 03/05
NOTE: Some parts are listed and shown for illustration purposes only and are
not available individually as replacement parts.

Page 15SKU 92652 For technical questions, please call 1-800-444-3353
TORCH HANDLE PARTS LIST
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A2reggirT
A3ydoB
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A5resuffiDgnitalusnI
A6elzzoN
A7elzzoN,redloH
TORCH HANDLE ASSEMBLY DRAWING
REV 03/05

Page 16SKU 92652 For technical questions, please call 1-800-444-3353
CIRCUIT DIAGRAM