Chicago Electric 97994 Installation manual

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.
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
FreightTools. 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.

Page 2SKU 97994 For technical questions, please call 1-800-444-3353.
CONTENTS
IMPORTANT SAFETY
INFORMATION............................3
GENERAL SAFETY RULES ..............3
SPECIFIC SAFETY RULES ...............5
SPECIFICATIONS.......................... 8
DUTY CYCLE .....................................8
UNPACKING..................................9
INITIAL SET UP INSTRUCTIONS. 9
ASSEMBLY.........................................9
CONTROLS & INDICATORS.....10
OPERATING INSTRUCTIONS ....10
WORK PIECE AND WORK AREA
SET UP ..........................................11
GENERAL OPERATING
INSTRUCTIONS ............................11
PLASMA CUTTING TECHNIQUE13
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
DIAGRAM..................................17
LIMITED 1 YEAR / 90 DAY
WARRANTY .............................. 18
PLEASE READ THE
FOLLOWING CAREFULLY.......18

Page 3SKU 97994 For technical questions, please call 1-800-444-3353.
SAVE THIS MANUAL
Keep this manual for the safety warn-
ings and precautions, assembly, operat-
ing, 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.
IMPORTANT SAFETY
INFORMATION
In this manual, on the labeling,
and all other information provid-
ed with this product:
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.
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
WARNING
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, used
with the 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
electric shock, re, and/or
serious injury.
Work area safety1.
Keep work area clean and well lit.a. Cluttered or dark areas invite acci-
dents.
Do not operate plasma cutters inb. explosive atmospheres, such as in
the presence of ammable liquids,
gases or dust. Plasma cutters cre-
ate sparks which may ignite the dust
or fumes.
Keep children and bystanders awayc. while operating a plasma cutter.
Distractions can cause you to lose
control.
Electrical safety2.
Avoid body contact with groundeda. surfaces such as pipes, radiators,
ranges and refrigerators. There is
an increased risk of electric shock if
your body is grounded.
Do not expose plasma cutters to rainb. or wet conditions. Water entering a
plasma cutter will increase the risk of
electric shock.

Page 4SKU 97994 For technical questions, please call 1-800-444-3353.
Do not abuse the Power Cord (32).c. Never use the Cord for pulling or
unplugging the plasma cutter. Keep
Cord away from heat, oil, sharp
edges or moving parts. Damaged or
entangled Cords increase the risk of
electric shock.
When operating a plasma cutter out-d. doors, use an extension cord suit-
able for outdoor use. Use of a cord
suitable for outdoor use reduces the
risk of electric shock.
Personal safety3.
Stay alert, watch what you are doinga. and use common sense when oper-
ating a plasma cutter. Do not use a
plasma cutter while you are tired or
under the inuence of drugs, alcohol
or medication. A moment of inatten-
tion while operating plasma cutters
may result in serious personal injury.
Use safety equipment. Always wear b. eye protection. Safety equipment
such as arc shaded, impact safety
full face shield, dust mask or respi-
rator, heavy-duty work gloves, non-
skid safety shoes, or hearing protec-
tion used for appropriate conditions
will reduce personal injuries.
Avoid accidental starting. Ensurec. the Power Switch (11) is in the off-
position before plugging in. Plug-
ging in plasma cutters that have the
Switch on invites accidents.
Do not overreach. Keep proper foot-d. ing and balance at all times. This
enables better control of the plasma
cutter in unexpected situations.
Plasma cutter use and care4.
Use the correct plasma cutter fora. 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 theb. 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 be repaired.
Disconnect the Power Cord (32)c. from the power source before mak-
ing any adjustments, changing ac-
cessories, or storing plasma cutters.
Such preventive safety measures
reduce the risk of starting the plasma
cutter accidentally.
Store idle plasma cutters out of thed. reach of children and do not allow
persons unfamiliar with the plasma
cutter or these instructions to oper-
ate the plasma cutter. Plasma cut-
ters are dangerous in the hands of
untrained users.
Maintain plasma cutters. Check fore. misalignment or binding of moving
parts, breakage of parts and any
other condition that may affect the
plasma cutter’s operation. If dam-
aged, have the plasma cutter re-
paired before use. Many accidents
are caused by poorly maintained
plasma cutters.
Use the plasma cutter and accesso-f. ries in accordance with these in-
structions and in the manner intend-
ed for the particular type of plasma
cutter, taking into account the work-
ing conditions and the work to be
performed. Use of the plasma cutter
for operations different from those
intended could result in a hazardous
situation.

Page 5SKU 97994 For technical questions, please call 1-800-444-3353.
Service5.
Have your plasma cutter serviced bya.
a qualied repair person using only
identical replacement parts. This will
ensure that the safety of the plasma
cutter is maintained.
Specic Safety Rules
Maintain labels and nameplates on1. the Inverter Plasma Cutter. These
carry important safety information. If
unreadable or missing, contact Har-
bor Freight Tools for a replacement.
Avoid electric shock. Do not per-2. mit electrically live parts, cables, or
electrodes to contact skin, clothing, or
gloves. Wear ANSI-approved protec-
tive clothing. This unit draws enough
current to cause serious injury or
death. Do not use the Plasma Cut-
ter unless you are insulated from the
ground and the work piece.
Avoid eye and body damage. Arc3. rays and infrared radiation can injure
eyes and burn skin. Wear ANSI-ap-
proved eye and body protection. Do
not allow viewing by visitors without
proper eye and body protection. Use
a Face Shield with arc shaded lter
plate.
This Plasma cutter requires a dedi-4. cated 20 A circuit and NEMA type
5-20R receptacle.
Move ammable and explosive mate-5. rial at least 35 feet from the cutting
arc to prevent sparks or molten metal
from starting a re. Keep a type ABC
re extinguisher within easy reach.
Thoroughly clean the object being cut
of any paint, grease, or other foreign
material.
Avoid unintentional starting. Prepare6. 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
outlet before leaving.
Use clamps (not included) or other8. practical ways to secure and support
the work piece to a stable platform.
Holding the work by hand or against
your body is unstable and may lead
to loss of control.
This product is not a toy. Keep it out9. of reach of children.
Industrial applications must follow10. OSHA guidelines.
People with pacemakers should11. consult their physician(s) before use.
Electromagnetic elds in close prox-
imity to heart pacemaker could cause
pacemaker interference or pacemak-
er failure. In addition, people with
pacemakers should:
• Avoid operating alone.
• Do not use with Power Switch
locked on.
• Properly maintain and inspect to
avoid electrical shock.
• Any Power Cord must be prop-
erly grounded. Ground Fault Circuit
Interrupter (GFCI) should also be
implemented – it prevents sustained
electrical shock.
This product, when used for welding,12. plasma cutting, soldering, or similar
applications, produces chemicals
known to the State of California to
cause cancer and birth defects (or
other reproductive harm).

Page 6SKU 97994 For technical questions, please call 1-800-444-3353.
(California Health & Safety Code §
25249.5, et seq.)
13. 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 underneath welding
eye protection featuring at least a
Number 10 shade lens rating.
Leather leggings, re 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 ammable sub-
stances. 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 conned spaces, wear ame
resistant ear plugs or ear muffs to
keep sparks out of ears.
14. Prevent accidental res.
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 pos-
sible, protect the combustibles with
a cover made of re 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 re resistant material to cover
or block all open doorways, win-
dows, cracks, and other openings.
Enclose the work area with por-•
table re resistant screens. Protect
combustible walls, ceilings, oors,
etc., from sparks and heat with re
resistant covers.
If working on a metal wall, ceiling,• etc., prevent ignition of combus-
tibles on the other side by moving
the combustibles to a safe loca-
tion. If relocation of combustibles
is not possible, designate someone
to serve as a re watch, equipped
with a re extinguisher, during the
cutting process and for at least one
half hour after the cutting is com-
pleted.
Do not weld or cut on materials• having a combustible coating or
combustible internal structure, as
in walls or ceilings, without an ap-
proved method for eliminating the
hazard.
Do not dispose of hot slag in con-• tainers holding combustible materi-
als. Keep a re extinguisher nearby
and know how to use it.
After cutting, make a thorough•
examination for evidence of re. Be
aware that easily-visible smoke or
ame may not be present for some
time after the re has started. Do
not weld or cut in atmospheres
containing dangerously reactive or
ammable gases, vapors, liquids,
and dust. Provide adequate ven-
tilation in work areas to prevent
accumulation of ammable gases,

Page 7SKU 97994 For technical questions, please call 1-800-444-3353.
vapors, and dust. Do not apply
heat to a container that has held an
unknown substance or a combus-
tible material whose contents, when
heated, can produce ammable or
explosive vapors. Clean and purge
containers before applying heat.
Vent closed containers, including
castings, before preheating, weld-
ing, or cutting.
Do not touch live electrical parts.14. Wear dry, insulating gloves. Do not
touch electrode or conductor tong
with bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric shock.15. Do not use outdoors. Insulate your-
self from the work piece and ground.
Use nonammable, dry insulating
material if possible, or use dry rubber
mats, dry wood or plywood, or other
dry insulating material big enough to
cover your full area of contact with
the work or ground.
Ensure that the unit is placed on a16. stable location before use. If this unit
falls while plugged in, severe injury,
electric shock, or re may result.
Never remove the grounding prong17. or modify the Power Cord Plug in any
way. Do not use adapter plugs with
this product.
Avoid overexposure to fumes and18. 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 qualied 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.
WARNING
INHALATION HAZARD:
Welding and Plasma Cutting Produce
TOXIC FUMES.
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 plasma cutting
exhaust fumes are:
• Early onset of Parkinson’s Disease
• Heart disease • Ulcers
• Damage to the reproductive organs
• Inammation 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.
Follow OSHA guidelines for Permis-• sible Exposure Limits (PEL’s) for
various fumes and gases.
Follow the American Conference• of Governmental Industrial Hygien-
ists recommendations for Threshold
Limit Values (TLV’s) for fumes and
gases.

Page 8SKU 97994 For technical questions, please call 1-800-444-3353.
Have a recognized specialist in• Industrial Hygiene or Environmental
Services check the operation and
air quality and make recommenda-
tions for the specic welding or cut-
ting situation.
Live torch when Trigger is pressed.19. Keep Torch away from people and
ammables before touching Trigger.
Turn off, unplug, and discharge20. electrode to ground before perform-
ing any inspection, maintenance, or
cleaning.
Use only compressed air at between21. 30 and 35 PSI. Never use oxygen,
carbon dioxide, combustible gases
or any bottled gas as an air source
for the Plasma Cutter. Such gases
are capable of explosion and serious
injury to people.
The brass components of this product22. contain lead, a chemical known to
the State of California to cause birth
defects (or other reproductive harm).
(California Health & Safety code §
25249.5, et seq.)
The warnings, precautions, and in-23. structions discussed in this instruction
manual cannot cover all possible con-
ditions and situations that may occur.
It must be understood by the operator
that common sense and caution are
factors 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 (5 Second Intervals)
LED Indicators Power On: Green LED Light Cutting in Process: Yellow LED Light
Unit Overheating: Red LED Light
Note: This Plasma cutter requires a dedi-
cated 20 A circuit and NEMA type
5-20R receptacle.
Duty Cycle
Duty Cycle is the equipment speci-
cation which denes the number of min-
utes within a 10 minute period that a piece
of equipment can safely operate.
This Plasma Cutter has a 60% duty
cycle at 10 Amps, which means that it
may be used only 6 minutes at 10 Amps
out of any 10 minute period, and must be
rested the remaining 4 minutes.
CAUTION: Failure to observe the duty
cycle limitations of this Plasma Cutter
can easily damage the equipment,
and will void the warranty.
UNPACKING
When unpacking, check to make sure
that the item is intact and undamaged. If
any parts are missing or broken, please
call Harbor Freight Tools at the number
shown on the cover of this manual as soon
as possible.
REV 09a

Page 9SKU 97994 For technical questions, please call 1-800-444-3353.
INITIAL SET UP
INSTRUCTIONS
Read the ENTIRE IMPORTANT
SAFETY INFORMATION section
at the beginning of this manual
including all text under
subheadings therein before set
up or use of this product.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
Turn the Power Switch (11) of
the Plasma Cutter to its “OFF”
position and unplug the
plasma cutter from its
electrical outlet before
assembling or making any
adjustments to the plasma
cutter.
Note: 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 the1. 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 Loop is keyed so that the
Regulator should only align in one
position.
Regulator
Body
connector
Air Line
3. Attach the Air Line to the connector
on the side of the Regulator Body.
The connector is designed to secure-
ly hold the line after inserting. Gently
pull on the line to ensure it is rmly
held.
REV 09a

Page 10SKU 97994 For technical questions, please call 1-800-444-3353.
MALE
QUICK
RELEASE
ADAPTER
AIR PRESSURE
REGULATOR (33)
AIR
PRESSURE
GAUGE
FIGURE B
CIRCUIT
BREAKER (30)
4. A male Quick Release Adapter is
mounted on the Air Pressure Regu-
lator (33) at the rear of the Plasma
Cutter. Attach your compressor’s air
supply hose to the Quick Release
Adapter. Then, adjust your com-
pressor to deliver 30 to 35 PSI com-
pressed air. (See Figure B.)
During operation, you can regulate air5. pressure through the Plasma Cutter
by adjusting the Knob located on the
Air Pressure Regulator (33).
(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): Allows2. 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 cutting is in process.
(See Figure C.)
Red LED Light: When illuminated,5. means the Plasma Cutter has be-
come overheated and the unit will
automatically shut down. Stop using
the Plasma Cutter while leaving the
Power Switch (11) ON to allow the
cooling Fan to operate. The LED
Light will turn off automatically when
the unit cools down and then you
may resume cutting. (See Figure C.)