Chicago Electric 93096 User manual

POWER INVERTER AND CHARGER
500 WATT / 800 WATT PEAK
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
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.
93096

SKU 93096 Page 2For technical questions, please call 1-800-444-3353.
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.
Safety Warnings and Precautions
WARNING: When using this device, basic safety precautions should always be
followed to reduce the risk of personal injury and damage to equipment.
Read all instructions before using this product!
1. Do not plug a battery charger into the Inverter if the charger has a warning
that dangerous voltages are present at the battery terminals.
2. Keep work area clean. Cluttered areas invite injuries.
3. Keep Inverter away from any direct heat source or combustible material.
4. Observe work area conditions. Do not use machines or powered products in
damp or wet locations. Don’t expose to rain. Keep work area well lit. Do not use
electrically powered products in the presence of flammable gases or liquids.
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Specifications

SKU 93096 Page 3For technical questions, 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 Page 4For technical questions, please call 1-800-444-3353.
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 Page 5For technical questions, please call 1-800-444-3353.
BACK
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.
2. Strip the insulation off of the last 3/4” of each Battery Cable (not included; #4-#0
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.
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.
REV 06/06

SKU 93096 Page 6For technical questions, please call 1-800-444-3353.
Operation
Powering AC Appliances
1. Plug the 115 VAC 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.
FRONT
Outlets
Indicators
Power Switch Charge Current Switch

SKU 93096 Page 7For technical questions, please call 1-800-444-3353.
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 INSPECTING THE FUSES, MAKE SURE THAT THE UNIT HAS
HAD AMPLETIMETO COOL WITH 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 Line Terminal.
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.
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,
and reconnect the Inverter. Check
for proper operation.
Fuse
Holder
Internal
Fuses

SKU 93096 Page 8For technical questions, please call 1-800-444-3353.
Troubleshooting Tips
1. If the low battery alarm sounds, this means that the input voltage is below the
necessary 11 V. 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.