Harbor Freight Tools Welding System 93096 User Manual

POWER INVERTER AND CHARGER  
500 WATT / 800 WATT PEAK  
93096  
ASSEMBLY AND OPERATING INSTRUCTIONS  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
TO PREVENT SERIOUS INJURY,  
READ AND UNDERSTAND ALL WARNINGS  
AND INSTRUCTIONS BEFORE USE.  
©
®
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 FreightTools.  
For technical questions and replacement parts, please call 1-800-444-3353  
 
5. Keep children away. Children must never be allowed in the work area. Do not  
let them handle machines, equipment, or extension cords.  
6. Use the right inverter for the job. Do not attempt to force a small inverter or  
attachment to do the work of a larger industrial inverter.There are certain appli-  
cations for which this Inverter was designed. It will do the job better and more  
safely at the rate for which it was intended. Do not modify this Inverter and do  
not use this Inverter for a purpose for which it was not intended.  
7. Dress properly. Do not wear loose clothing or jewelry as they can be caught in  
moving parts. Protective, electrically nonconductive clothes and nonskid foot-  
wear are recommended when working. Wear restrictive hair covering to contain  
long hair.  
8. Always wear eye protection. When working around lead acid batteries, always  
wear ANSI approved safety impact eye goggles, full face shield and work gloves.  
When working under the vehicle’s hood, always be careful of hot engine parts.  
9. Do not overreach. Keep proper footing and balance at all times. Do not reach  
over or across running machines.  
10. Maintain inverters with care. Keep inverters clean for better and safer perfor-  
mance. Follow instructions for changing accessories. Inspect inverter cords  
periodically and, if damaged, have them repaired by an authorized technician.  
11. Disconnect power.Unplug inverter when not in use.  
12. Avoid unintentional starting. Be sure the switch is in the Off position when  
not in use and before plugging in any appliance.  
13. Stay alert. Watch what you are doing, use common sense. Do not operate any  
inverter when you are tired.  
14. Check for damaged parts. Before using any inverter, any part that appears  
damaged should be carefully checked to determine that it will operate properly  
and perform its intended function. Check for alignment and binding of moving  
parts; any broken parts or mounting fixtures; and any other condition that may  
affect proper operation.Any part that is damaged should be properly repaired or  
replaced by a qualified technician.Do not use the inverter if any switch does not  
turn On and Off properly.  
15. Servicing. This device should be serviced only by a qualified technician. Aside  
from the fuse, this item does not have any user-replaceable parts.  
16. Do not operate inverter if under the influence of alcohol or drugs. Read  
warning labels on prescriptions to determine if your judgment or reflexes are  
impaired while taking drugs. If there is any doubt, do not operate the inverter.  
17. Read and adhere to all warnings and safety precautions in the owner’s  
manual for the device or battery that this inverter is used to power.  
SKU 93096 For technical questions, please call 1-800-444-3353.  
Page 3  
 
18.  
Guard against electric shock.  
Prevent body contact with grounded surfaces such as pipes, radia-  
tors, ranges, and refrigerator enclosures during installation.  
Connect all wires securely.  
Store metal objects away from the inverter.  
19. People with pacemakers should consult their physician(s) before using  
this product. Electromagnetic fields in close proximity to a heart pacemaker  
could cause interference to or failure of the pacemaker.  
20. Keep the Inverter well-ventilated. Do not place any objects on top of or next to  
the Inverter or allow anything to cover the cooling fans; doing so can cause the  
Inverter to overheat, causing a potential fire hazard and/or damage to the In-  
verter. Leave adequate ventilation space underneath the Inverter as well; thick  
carpets or rugs can obstruct air flow, causing the Inverter to overheat.  
21. A vehicle’s engine must never be used in any sealed structure. Carbon  
monoxide is produced during operation and is DEADLY in a closed envi-  
ronment. Early signs of carbon monoxide poisoning resemble the flu, with  
headaches, dizziness, or nausea. If you have any of these signs, get fresh air  
immediately.  
22.  
Risk of explosion! Hydrogen gas is explosive. NEVER smoke when  
working with batteries. Lead acid batteries generate hydrogen during nor-  
mal operation, and more is generated while the battery is charging.  
23. Proper Battery Care: Battery leakage may occur under extreme usage or tem-  
perature conditions. If Battery fluid comes in contact with skin, wash with soap  
and water and rinse with lemon juice and vinegar. If the fluid comes into contact  
with the eyes, flush with water for several minutes and contact a doctor immedi-  
ately. Never burn the Battery, as it can explode in a fire. Do not use the Battery  
Charger on a vehicle with a leaking Battery. Contact local solid waste authori-  
ties for instructions on correct disposal or recycling of the Battery.  
Note:Performance of this unit may vary depending on the available battery power or  
appliance wattage.  
Warning:The warnings, cautions, and instructions discussed in this instruction  
manual cannot cover all possible conditions and situations that may occur. It  
must be understood by the operator that common sense and caution are fac-  
tors which cannot be built into this product,but must be supplied by the operator.  
Unpacking  
When unpacking, check to make sure that the Inverter is in good condition  
and the AC Power Cord is included. 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.  
SKU 93096 For technical questions, please call 1-800-444-3353.  
Page 4  
 
BACK  
Negative Positive  
Charger  
AC Input  
Ground  
Terminal  
Charger  
Fuse Holder  
WARNING! Risk of Fire! The positive battery terminal connection must  
be the LAST connection and must be done with the inverter’s switch off.  
Connection  
For the power Inverter to work properly, your power source must provide 12 volts DC,  
and enough current (i.e., 32 amps to operate a load of 384 Watts or under).  
Warning:This Inverter must only be connected to batteries with a nominal out-  
put voltage of 12 volts. More voltage could damage the Inverter or the device  
being powered. If more than one 12 volt battery is to be used, the batteries must  
be connected in a parallel circuit; batteries connected in a series circuit will  
produce too much voltage.  
1. Place the Power Inverter on a flat surface. Make sure it has adequate ventila-  
tion and is not in direct sunlight. Fasten the Inverter securely to the surface,  
using screws or some other means. If holes are to be drilled, follow safe, proper  
installation techniques.  
3
2. Strip the insulation off of the last / ” of each Battery Cable (not included; #4-#0  
4
AWG cable recommended). Insert the Cables into the (Positive) red and (Nega-  
tive) black terminals on the back of the Inverter. Securely tighten the Screw on  
top of each connection. Connect the Ground Cable (not included; #6 AWG or  
larger cable recommended) lug to the Ground Terminal, see BACK above. Se-  
curely tighten.  
3. The Power Inverter can be used either while the engine is running or off. Con-  
nect the Battery Cables to the (Negative) black and (Positive) red terminals of  
the battery.  
4. Connect the Ground Cable to the appropriate location below:  
a. If this unit is mounted within a vehicle with a grounded metal chassis,  
attach the Ground Cable to a nearby location on the chassis.  
b. If this unit is mounted in a boat or vehicle with an ungrounded chassis,  
attach the Ground Cable to the vehicle’s grounding system.  
c. ONLY if this unit is being used outside a vehicle,  
attach the Ground Cable to the Negative Cable leading into the Inverter.  
SKU 93096 For technical questions, please call 1-800-444-3353.  
Page 5  
REV 06/06  
 
FRONT  
Indicators  
Power Switch  
Charge Current Switch  
Outlets  
Operation  
Powering AC Appliances  
1. Plug the 115VAC device(s) you wish to power into the 3-prong AC Receptacles.  
See FRONT above.The appliance(s) must not use more than 500 (total) watts  
during continuous operation, otherwise it may overload the Inverter.  
Warning:Some rechargeable appliances may damage the Power Inverter or the  
appliance. When first using a rechargeable device, check the Inverter’s tem-  
perature for the first 10 minutes. If it becomes abnormally hot, do not use this  
device with the Inverter.  
2. Flip the Power Switch to the ON position. Do not use the appliance until the  
Inverter LED indicator is on.  
3. Turn on appliance. If an alarm sound is heard or if either the Overload or the  
Overheat indicators light, turn off the appliance.  
Warning: It is recommended that the vehicle be started every hour to recharge  
the battery. Doing this will help prevent any unexpected shutdown of the equip-  
ment. This will also help ensure that there will be enough battery power to start  
the vehicle. Due to the risk of carbon monoxide inhalation (see Warning # 21 on  
page 4), do not run the vehicle’s engine within an enclosed area.  
4. After use, disconnect appliances and flip the Power Switch to the OFF position.  
Charging theVehicle’s Battery  
1. Make sure that no appliances are connected to the Inverter. Plug the AC Power  
Cord into the Charger AC Input (see BACK, page 5) and plug the other end into  
a fused, properly grounded, 3-prong 120VAC receptacle.  
2. Select the desired charge rate with the Charge Current Switch. Flip the Power  
Switch to ON. The Charger LED indicator should illuminate.  
3. Monitor the Inverter and turn the Power Switch to the OFF position once the Full  
LED indicator illuminates. Disconnect the AC Power Cord.  
SKU 93096 For technical questions, please call 1-800-444-3353.  
Page 6  
 
Maintenance  
1. Keep this unit clean and dry. Unplug before cleaning. Clean only the outside of  
this unit with a soft, dry cloth; never clean this unit with water or cleaners.  
2. Aside from the fuse, this device does not contain any user replaceable parts. If  
it needs service, take it to a qualified technician.  
BEFORE INSPECTINGTHE FUSES, MAKE SURETHATTHE UNIT HAS  
HAD AMPLETIMETO COOLWITH NO LOAD.  
3.  
Charger Fuse Replacement  
a. If the Inverter stops functioning in Charger mode, the charging fuse may  
have blown.  
b. The Charger’s fuse is underneath the AC LineTerminal.  
c. Disconnect the Inverter from both the battery and the AC input.  
d. Remove the fuse holder and in-  
spect the fuse, see illustration. If  
the fuse is intact, check the inter-  
nal fuses as noted below. Other-  
wise, replace the fuse ONLY with  
another F10A250V (Fast-acting, 10  
Amp, 250 Volt) fuse of the same  
type.  
Fuse  
Holder  
e. Replace the fuse holder and recon-  
nect the Inverter. Check for proper  
operation.  
4.  
Internal Fuse Replacement  
a. If the Inverter stops functioning, one of the internal fuses may have blown.  
b. Disconnect the Inverter from the battery, AC input, and all devices. Then,  
remove the Inverter from the vehicle.  
c. Turn the Inverter upside down and remove the four black screws holding the  
cover on. Carefully set the back  
cover aside. DO NOT TOUCH  
INTERNAL PARTS.  
d. Remove the fuses and inspect  
them; see illustration. If both fuses  
are intact and the unit still does  
not function, have the unit serviced  
by a qualified technician. Other-  
wise, replace damaged fuse(s)  
ONLY with 30 Amp fuse(s) of the  
same type.  
e. Carefully reassemble, reinstall,  
Internal  
Fuses  
and reconnect the Inverter. Check  
for proper operation.  
SKU 93096 For technical questions, please call 1-800-444-3353.  
Page 7  
 
Troubleshooting Tips  
1. If the low battery alarm sounds, this means that the input voltage is below the  
necessary 11V. The battery needs recharging. You should stop using the appli-  
ance and then recharge the battery. If this is not done, the Inverter will shut off  
automatically at around 10 V.  
2. If you are unsure if the Inverter will have the proper amount of current to run the  
device, use this rough guideline: Take the power consumption of the load in  
watts and divide it by 12 (input voltage). The result will be the approximate  
number of amps needed to power your device.  
Example: Load is rated at 312 watts. 312 watts / 12 V = 26 amps needed. You  
could use this device with the Inverter.  
3. If your television will not start, it is important to keep in mind that some appli-  
ances (including many televisions) may require two to six times their wattage to  
start up.  
4. If your audio system buzzes while using this Inverter, it is because some sound  
systems can not filter out the modified sine wave produced by the Inverter. Use  
a sound system that incorporates a higher quality power supply.  
5. This Inverter is made to minimize the interference with TV signals. However,  
especially with weak TV signals, some interference may still be visible. To  
correct this, place the Inverter as far away as possible from the television an-  
tenna and it’s cables. Next, adjust the orientation of the Inverter to the antenna  
cables and TV power cord to minimize the interference. Also use a shielded  
antenna cable.  
6. If the low battery alarm is on all the time, try these corrective measures: Re-  
charge battery if in poor condition. Next, check the battery connection. You may  
need to clean the connectors.  
7. If you are getting a low output voltage, try reducing the load to minimize watts.  
You may have overloaded the Inverter. Reduce your load to 490 watts. Also,  
keep input voltage above 11 volts to maintain a constant flow of power.  
8. If you are not getting any power output, turn the power switch Off and On again,  
until the green power light comes on. Your devices may draw too much power to  
operate them. The Inverter may be in thermal shutdown. Let it cool down and  
make sure there is adequate ventilation around the unit.  
SKU 93096 For technical questions, please call 1-800-444-3353.  
Page 8  
 

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