Harbor Freight Tools 62204 Product manual

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�

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14e

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�

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�

Email our technical support at: productsupport@harborfreight.com

Read this material before using this product. Failure to do so can result in serious injury. SAVE THIS MANUAL.

Table of Contents

Safety �� 2 Specifications �� 5 Setup �� 6

SAFETY OPERATION MAINTENANCESETUP

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�

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

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� 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.

2� 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�

3� 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.

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�

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6� Maintain labels and nameplates

on the Plasma Cutter. These carry important information� If unreadable or missing, contact Harbor Freight Tools for a replacement�

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 material�

• 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�

• 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�

• 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 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�

8� INHALATION HAZARD:

Welding and 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 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�

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�

• 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�

• Follow OSHA guidelines for

Permissible Exposure Limits (PELs) for various fumes and gases�

• 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�

SAFETYOPERATIONMAINTENANCE SETUP

Page 3For technical questions, please call 1-888-866-5797.ITEM 62204

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�

SAFETY OPERATION MAINTENANCESETUP

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� WARNING: This product, when used for welding,

plasma cutting, soldering, or similar applications, produces chemicals known to the State of California to cause cancer and birth defects or other reproductive harm� (California Health & Safety Code § 25249�5, et seq.)

15� 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�

16� KEEP CHILDREN AWAY� All visitors should

be kept safe distance from work area�

17� MAKE WORKSHOP KID PROOF with padlocks,

master switches, or by removing starter keys�

18� USE RIGHT Plasma Cutter� Don’t force

Plasma Cutter or attachment to do a job for which it was not designed�

19� 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�

20� MAINTAIN PLASMA CUTTER WITH CARE�

Keep Plasma Cutter clean for best and safest performance� Follow instructions for changing accessories�

21� Inspect before every use;

do not use if parts loose or damaged�

22� WARNING: The brass components of this product

contain lead, 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.)

23� WARNING: The cord of this product

contains lead, a chemical known to the State of California to cause cancer, and birth defects or other reproductive harm� Wash hands after handling� (California Health & Safety Code § 25249�5, et seq.)

Symbology

VAC

A

Canadian Standards Association

Underwriters Laboratories, Inc�

Volts Alternating Current

Amperes

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Specifications

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

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

Air Consumption

Air Inlet 1/4″ - 18 NPT

60%

100%@@

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

3�6 CFM @ 60 PSI

4�5 CFM @ 80 PSI

40A 30A

SAFETYOPERATIONMAINTENANCE SETUP

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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 OPERATION MAINTENANCESETUP

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

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

(on back)

Air Pressure

Gauge

Air Inlet

(on back)

Power Cord

Storage Hook

Air Pressure

Regulator

Power Cord

Storage Hook

Air

Switch

Power

Switch

Torch

Ground

Clamp

Figure A

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Air Supply

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.

1� 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.

Setting Compressor's Air Pressure

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�

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�

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�

SAFETYOPERATIONMAINTENANCE SETUP

Setting Plasma Cutter's Air Pressure

1� 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�

2� Pull up on the Air Pressure Regulator

and set between 60 - 80 PSI, as observed on the Air Pressure Gauge.

3� 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� IMPORTANT! After testing, set Air Switch

to CUT to allow normal operation�

Flowmeter

Torch

Air

Ball

Figure B

MAX

MIN

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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 OPERATION MAINTENANCESETUP

Controls and Indicators

1

2

60

30

0

3

90

120PSI

CURRENT

MIN MAX

CUT

SET AIR

POWER CUTTING

POWER

ON

OVER LOAD

4 5

6 7

8

OFF

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�

Figure C

ITEM 62204

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�

Page 8 For technical questions, please call 1-888-866-5797. ITEM 62204