Chicago Electric 08881 Assembly And Operating Instructions Manual

Brand: Chicago Electric

Model: 08881

Category: Welding System

Type: Assembly And Operating Instructions Manual

35 AMP Plasma Cutter

Model 08881

ASSEMBLY AND

OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www.harborfreight.com

2003 by Harbor Freight Tools

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.

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

REV 02/05

Page 1

Introduction

35 AMP Plasma Cutter is an inverter-based power source designed for the plasma cutting of metals, especially in

medium and light steel structural works. It is equipped with a arc restart device which allows the continuous cutting of

punched plates and grids. Its special design, totally based on electronic controls, offers the following advantages:

• cutting current stability in spite of mains fluctuations

• cutting current stability in spite of cutting arc length

• compact design if compared to a traditional machine

Prevention against electric shocks

Before connecting the power source to the mains, always check that:

• the voltage received falls within ±10% allowance of the nominal value displayed on the machine plate;

• the mains input is properly grounded (as provided in the relevant legislation) and the yellow/green wire of the

welding machine is connected to the ground;

• the mains supply is equipped with a grounded neutral conductor;

• the power source is in a dry and ventilated place.

When using the machine, make sure that the following precautionary measures are taken in the workplace:

• ensure that no metallic body may accidentally get into contact with the power cables;

• do not carry out any welding operation in damp or wet areas;

• ground any metallic parts falling within the operator’s reach;

• keep all flammable materials away from the working· area;

• connect the work return lead of the cutting circuit to a place as close as possible to the cutting area in order to

minimise the current path and the relevant risks;

• make sure that cutting torches and cables are in perfect condition.

WARNING! Since the operating voltage in a plasma cutting circuit may range between 100V and 500V (vs.

10÷100V in a welding circuit) special attention should be paid to the maintenance and wear condition of

cables and torches. Non-insulated parts of the torch should never be touched as they represent a serious

danger of electrocution.

Furthermore, the operator should stick to the following behavioural rules:

• do not connect plasma cutting machines in series or parallel;

• in the case two or more cutters should operate on electrically connected parts, it is suggested that they work at a

suitable distance from each other and that none of them touches two torches at the same time;

• do not place the torch on metallic surfaces: this might be a condition for the machine to be started accidentally;

• always wear insulating garments.

In the case the power source should be introduced into areas characterised by a high risk of electric shocks, it is

recommended that the connection to the mains be protected by a highly-sensitive differential circuit breaker (releasing

current: 30 mA, operating time: 30 ms).

Such areas are:

A) places offering limited freedom of movement and preventing the operator from standing while working;

B) places surrounded by conductive surfaces that may accidentally come into contact with the welding circuit;

C) wet, damp and hot places.

Prevention against UV rays, fumes and fires

Arc cutting is a cutting process by which UV rays are emitted. Operators should therefore protect their eyes and faces

with suitable face masks or helmets equipped with adequate filter lenses.

Recommended DIN protection grades for filter lenses are listed below for plasma cutting procedure in relation of

current used:

• grade 11 - up to 150 Amps

• grade 12 - from 150 to 250 Amps

• grade 13 - over 250 Amps

Page 2

Operators should wear gauntlets, insulating shoes and fireproof clothes to protect themselves from radiation, slags

and sparks.

Reflection and transmission of UV rays in workplaces should be reduced by using antiflash welding screens or panels.

In order to reduce the toxic action of cutting fumes, it is suggested to operate in ventilated areas. Use fume extractors

close to the cutting area, if ventilation is poor or lacking.

If the piece to be welded is covered by chemicals (solvents, paints, etc.), it should be carefully cleaned prior to welding

to prevent toxic gas emission.

It is strictly forbidden to plasma cut on fuel tanks, whether they are full or empty.

Maintenance

Any repair work or replacement of spares should be carried out by skilled personnel, qualified to operate on

electromechanical systems.

Welders are allowed to remove the side panels of the welding machine (after disconnecting it from the mains) only to

remove any dust or dirt that may have been taken in. Such operation, to be carried out by applying a compressed air

jet, is to be repeated at least every three months. This frequency should be increased if operating in very dusty places.

Electromagnetic compatibility (EMC)

Cutting machines are conceived for use in industrial applications only. If they are used differently (e.g. for domestic

use), they may cause compatibility problems, as they may interfere with other electrical appliances operating in the

vicinity (radios, phones, computers, etc.).

It’s the user’s responsibility to install the power source and use it in the proper places so that no EMC problems may

arise. When judging the suitability of a workplace, the presence of the following should be considered:

• telephone lines and sets

• receiving and transmitting radio/TV sets

• computers and control devices

• safety devices

• measuring instruments.

Special attention should be paid to people with pace-makers and similar bio-electronic devices since they may be

influenced by electromagnetic fields. These people are strongly suggested to keep away from any places in which

cutting is going on.

Plasma cutting: procedure and technical data

Plasma is the high temperature (around 10,000°C), ionized gas generated by the electric arc during any welding

process. In the plasma cutting process the ionized gas is constricted at high speed (over 1,000 m/s) through the torch

nozzle. The nozzle and electrode constrict and maintain the plasma jet. The cutting operation is therefore the result of

the following combined actions:

• the temperature of the plasma arc melts the metal, pierces through the workpiece and

• the high speed gas flow removes the molten material

The special shape of the torch nozzles attains maximum arc constriction so as to minimize cutting width and maximize

cutting depth.

The basic plasma cutting system consists of:

• a DC power source

• a compressed gas source

• a pressure reducer

• a plasma cutting torch

The arc is started with the help of a high frequency

generator. Energy transferred from the HF starter to the gas

causes the ionized gas to create a current path between the

electrode and the nozzle, and a resulting cutting arc is

formed.

Page 3

Plasma cutting process is used as an alternative to the oxyacetylene cutting process when cutting mild steel, whereas

it is essential for cutting stainless steel, aluminium and its alloys, as well as other non-ferrous metals.

Air is the most widely used plasma gas, probably due to the fact that compressed air is relatively cheap and readily

available at virtually any location. There are may different plasma and shield gas combinations (e.g. argon, nitrogen,

hydrogen and their mixtures) which can be used to enhance the cut performance on different materials and

applications, but they require the use of special water-cooled torches.

The table illustrate, as an indication, the relation existing among

current output, workpiece thickness (mild steel in this example)

and cutting speed. Purely as an indication, it can be stated that

aluminium workpieces that can be cut are roughly the same

thickness as mild steel, whereas in the case of stainless steel

thickness is reduced by about 30%.

Set up

The safety rules reported in the preceding sections should be carefully followed when setting up the machine.

Connect the power cable to a suitable power socket and insert a delayed-action fuse.

Make sure that the yellow-green wire, which is the earth wire, is properly connected to the ground (this will protect the

user).

To start up the machine follow these steps:

• Place the unit so that the vents are clear of any obstruction to ventilation air. Keep it in a dry place and at a distance

of at least 0.5 m from walls, shields or anything.

• Make sure the machine is off.

• Connect the compressed air hose to the regulating filter connection on

the rear panel of the machine. Adjust pressure by turning the regulating

filter knob and set it to 44-58 PSI. To do this, the filter knob should be

pulled until released and turned either clockwise or anticlockwise to

respectively decrease or increase pressure; after setting pressure, the

filter knob should be pushed until released.

• Connect the work return lead to a clean area of the workpiece.

• Screw out the torch outside nozzle, turn on the machine and make sure the pressure of the torch trigger does not

operate the power source: i.e. the solenoid valve is not opened and the high frequency generator is not started. This

confirms proper functioning of the torch safety. After this check, the torch outside nozzle can be screwed in again.

• Make sure the compressed air used for cutting is free from oil, moisture, dust or any other polluter. Compressed air

can be adequately cleaned if special filters are installed on the compressor outlet in addition to the one present in

the compressor. Dry and clean air ensures better cut quality.

Notice:

In order to prevent the torch or its parts from serious damage, always use original spares.

Current output 30A

Cutting Speed (INOH/MIN) Thickness (in.)

8" 0.35"

20" 0.28"

28" 0.22"

40" 0.18"

59" 0.14"

79" 0.10"

Page 4

Description of functions and controls

The controls of the machine are described here below with reference to the following figure.

The machine is set to work by turning the main switch placed on the rear panel to its ON position. The green LED ‘1’ will

show when the machine is on.

Yellow led ‘2’ shows when thermal circuit breakers have tripped: this will stop the machine for some minutes to allow it

to cool down.

Red led ‘3’ shows when output voltage is available while cutting is in progress. It blinks when gas circuit breakers have

tripped, i.e. gas pressure has dropped under the minimum level necessary for cutting: this will stop the torch trigger

until the problem has been solved.

Switch ‘4’ allows the cutting mode to be selected out of three:

• NORMAL for full plates: cutting arc is started by pressing the torch trigger and bringing the torch into contact with

the workpiece; cutting arc will go off as soon as the torch trigger is released and/or the torch is detached from the

workpiece.

• GRID for grids or punched plates: if the torch trigger is kept pressed, cutting arc will automatically be restarted on

detection of metal to be cut; it will go off as soon as the torch trigger is released.

• SMART for full plates with improved end-of-cutting control: cutting arc is started by pressing and releasing the torch

trigger and bringing the torch into contact with the workpiece; by the end of the cutting operation the torch trigger is

pressed again: this will bring current down to its minimum value allowing better control of the arc out of the

workpiece; cutting arc will go off as soon as the torch trigger is released again.

Air test button ‘5’ is used to check that the torch is able to deliver the gas necessary for cutting.

Potentiometer ‘6’ is used to adjust current output.

NOTES ON THE USE OF THE TORCH

A plasma torch is held at right angle to the workpiece when a vertical cut is desired or at any other angle for sloping cuts

and bevels.

Cutting speed should allow the cutting arc to cut the material and protrude from the workpiece vertically or at a max.

angle of 5÷10° to the perpendicular.

When plasma is used to pierce a material, molten material ejection may deposit on the torch, thus causing abnormal

wear, especially with thickness over 10 mm. In these cases it is suggested to start piercing with the torch slightly

slanting so that the ejection of molten metal is directed outwards and the torch is preserved from damage and

overheating. The material deposited on the ceramic cap or on the nozzle should be removed immediately

paying attention to the high temperature of the workpiece and torch parts.

Circular cuts may be carried out by means of rotating head calipers sliding on rollers, with magnetic centering.

Page 5

The machine should not be switched off before the post-cut gas has flown completely, since this is necessary

to cool the torch.

In order to extend consumable life, both nozzle and electrode should be replaced when servicing a torch. The nozzle

should be replaced when the inner bore is irregular or greater than the nominal bore (this causes raking and poor

quality cuts); the electrode should be replaced before the tungsten core of the electrode tip is totally worn out. The use

of worn parts may damage the torch body.

Particular care should be taken in fitting the new parts into the torch so as not to irrevocably damage the torch body.

Troubleshooting

A list of the possible failures of a 35 AMP Plasma Cutter generator is reported here below with the indication of the

possible causes.

A) If when starting the machine the green LED on the front panel is on but the machine does not cut, check that:

• the mains voltage ranges between 200V˜ to 260V˜

B) If the machine stops and the yellow LED ‘2’, when welding, shows for over 4 minutes, check that:

• the air flow for the cooling of the components is not hindered by dust or foreign objects placed in the vicinity of the air

vents

• the fan is working properly; if its air flow rate is not enough, it should be replaced

C) If the gas flow suddenly stops, check that:

• the hoses and connectors are not clogged

• there is about 230Vac at the ends of the solenoid valve with the torch trigger pressed; if so, replace the solenoid

valve; if not, replace p.c. board 0050513

D) When the machine is switched on, the red LED ‘3’ blinks indicating insufficient air pressure:

• adjust air pressure until 44-58 PSI is shown on pressure gauge

• replace pressure switch.

Possible cutting faults

Fault Possible cause

Poor penetration Low current - Fast cutting speed - Excessively thick workpiece

Interruption of cutting arc

Worn electrode, nozzle and diffuser - Elevated air pressure - Insufficient air quantity

delivered - Faulty pressure switch - Low input voltage

Torch nozzle overheating Insufficient air quantity delivered - Worn electrode

Too much slag on the

workpiece

Inadequate air pressure - Worn nozzle - Slow cutting speed

Item Description Q.ty

Part

number

1 Clamp, TAU 1 1 0400010

2 ERGOCUT 50 plasma torch 1 0621000

3 Switch 1 0410170

4 Electrode, PR17 1 0621001

5 Air diffuser,PE07 1 0621003

6 Hood, PD88-11 1 0621002

7 Nozzle, PC03 1 0621004

Page 6

94 87

10 1215-16

191413

17-18-19-20

Spare parts for 35 AMP Plasma Cutter

Item Description Q.ty Part number (MP04)

1 Handle 1 0020245

2 Top cover 1 1550061

3 Lower panel 1 1550036

4 Front panel

Self-sticking serigraphy

1550011

0300405

5 Anti-slip foot 4 0040170

6 Cable clamp

Nut

Input cable, 3x14 AWG

0020236

0020237

0060501

7 Switch 1 0040133

8 35A board, complete 1 0050180

9 Front board 1 0050513

10 Knob, ø36 1 0040174

11 H.F. board 1 0050512

12 H.F. transformer 1 1800210

13 Fan 1 0070044

14 Air conveyor 1 0300378

15 Solenoid valve 1 0040291

16 Pressure switch 1 0020335

17 Pressure regulator filter 1 0020320

18 Pressure gauge 1 0020321

19 Regulator filter support 1 0020322

20 Connection, M5ø6

Connection, 1/4”-ø6 female

0020329

0020371

Chicago Electric 08881 Assembly And Operating Instructions Manual

Brand: Chicago Electric

Model: 08881

Category: Welding System

Type: Assembly And Operating Instructions Manual

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Chicago Electric 08881 Assembly And Operating Instructions Manual

Chicago Electric 08881 Assembly And Operating Instructions Manual

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