Chicago Electric 2665 User manual

ARC WELDER - 160 AMP ACARC WELDER - 160 AMP AC

ARC WELDER - 160 AMP AC

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit ourWeb site at http://www.harborfreight.com

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

02665

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Specifications

ITEM DESCRIPTION

Arc Welding Current 80 and 160 amp

Power Requirement 220 VAC, 40 amps, single phase, 60 Hz

Open Voltage 22 VAC at 80 amps; 28 VAC at 160 amps

Duty Cycle 40% at 80 amps; 10% at 160 amps

Thermal Overload

Protection Automatic overload shutdown and reset

Dimensions 16 (L) x 6-7/8 (W) x 12-1/4 (H) inches

Ground Cable 4 AWG, single insulation, 6 foot

Torch Cable 4 AWG, single insulation, 6 foot

Power Cord 3-core, double insulated, 12 AWG, U.L. Approved

Features Power switch with green light indicator

Thermal overload protection with red light indicator

AC output

Weight 55.8 lbs

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 tool, basic safety precautions should always be followed to re-

duce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep work area clean. Cluttered areas invite injuries.

2. Observe work area conditions. Do not use machines or power tools in damp or wet

locations. Don’t expose to rain. Keep work area well lighted. Do not use electrically

powered tools in the presence of flammable gases or liquids.

3. Keep children away. Children must never be allowed in the work area. Do not let them

handle machines, tools, or extension cords.

4. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit

rust. Always lock up tools and keep out of reach of children.

5. Do not overreach. Keep proper footing and balance at all times. Do not reach over or

across running machines.

6. Use the right tool for the job.Do not attempttoforce asmalltoolorattachmenttodothe

workofalargerindustrialtool.Therearecertainapplicationsfor whichthistoolisdesigned.

It will do the job better and more safely at the rate for which it was intended. Do not

modify this tool and do not use this tool 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 non-conductive clothes and non-skid footwear are

recommended when working. Wear restrictive hair covering to contain long hair.

8. Use eye protection. Always wear ANSI approved impact safety glasses under an arc

shaded, welding helmet. Wear an ANSI approved dust mask or respirator when working

Page 3SKU 02665

aroundmetal,wood,andchemicaldustsandmists. AlwayswearANSIapprovedwelding

gear: leather gloves, leather apron and shoes.

9. Maintain tools with care. Keep tools clean for better and safer performance. Follow

instructionsforlubricating and changing accessories.Inspecttoolcordsperiodically and,

if damaged, have them repaired by an authorized technician.The handles must be kept

clean, dry, and free from oil and grease at all times.

10. Disconnect power.Unplug Arc Welder when not in use.

11. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are

removed from the tool or machine work surface before plugging it in.

12. Avoid unintentional starting. Be sure the switch is in the Off position when not in use

and before plugging in. Do not carry Arc Welder when it is plugged in.

13. Stay alert. Watchwhat youaredoing,usecommonsense.Do not operate anytoolwhen

you are tired.

14. Check for damaged parts. Beforeusinganytool, anypartthatappearsdamagedshould

be carefully checked to determine that it will operate properly and perform its intended

function.Check for alignment andbinding ofmovingparts;anybrokenparts ormounting

fixtures;and anyotherconditionthatmayaffectproperoperation.Anypartthatisdamaged

should be properly repaired or replaced by a qualified technician. Do not use the tool if

any switch does not turn On and Off properly.

15. Guard against electric shock. Prevent body contact with grounded surfaces such as

pipes, radiators, ranges, and refrigerator enclosures.

16. Replacement parts and accessories. When servicing, use only identical replacement

parts. Use of any other parts will void the warranty. Only use accessories intended for

use with this tool. Approved accessories are available from Harbor Freight Tools.

17. Do not operate tool if under the influence of alcohol or drugs. Read warning labels

if taking prescription medicine to determine if your judgment or reflexes are impaired

while taking drugs. If there is any doubt, do not operate the tool.

18. Pacemaker safety warning. People with pacemakers should consult with their

physician(s) before using this product; operation of equipment in close proximity to a

heart pacemaker could cause interference or failure of the pacemaker.

19. Use proper size and type extension cord.Ifanextensioncord is required, itmustbeof

the proper size and type to supply the correct current to the tool without heating up.

Otherwise, the extension cord could melt and catch fire, or cause electrical damage to

the tool.This tool requires use of an extension cord with up to 50 amps capability (up to

50 feet), with wire size rated at 8 AWG.Longer extension cords require larger size wire.

If you are using the tool outdoors, use an extension cord rated for outdoor use. (signified

by “WA” on the jacket).

20. Maintenance. For your safety, service and maintenance should be performed regularly

by a qualified technician.

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Additional Arc Welding Safety Warnings and Precautions

Warning:This product,when used for welding and similar applications,produces chemi-

cals known to the State of California to cause cancer and birth defects (or other repro-

ductive harm). California Health & Safety Code 25249.5, et seq.

1. Avoid electrical shock. Do not permit electrically live parts, cables, or electrodes to

contact skin, clothing, or gloves. Protective clothing should be hole-free, dry, and ANSI

approved.

This unit draws enough current to cause serious injury or death. Before turning the Arc

Welder on, check the electrode holder to be sure that there are no protruding screw

heads, and that all insulation is secure, covering all conductors. Do not weld unless you

are insulated from ground and the work piece.

2. Avoid breathing fumes or gases. They can cause serious health problems. Use an

active ventilation system directly above the welding area. Keep your head out of the

fumes.

3. Avoid eye and body damage. Arc rays and infrared radiation can injure eyes and burn

skin. Wear ANSI approved eye and body protection. Do not allow viewing by visitors

without proper eye and body protection. Use a Face Shield with an arc shaded filter

plate.

4. Know proper arc welding practices. Read and understand the manufacturer’s

instructions, and well as your employer’s safety practices for arc welding.

5. Connect only to a code approved power source. Connect only to a grounding power

source conforming to the National Electrical Code and Local Codes.

6. Avoid fire and explosion. Remove flammable and explosive material from at least 35

feet from the welding arc to prevent welding sparks or molten metal from starting a fire.

Keep a type ABC fire extinguisher within easy reach.Thoroughly clean the object being

welded of any paint, grease, or other foreign material.

Warning:The warnings, cautions,and instructions discussed in this instruction manual

cannot cover all possible conditions and situations that may occur. It must be under-

stood by the operator that common sense and caution are factors which cannot be

built into this product,but must be supplied by the operator.

REV 05/04

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Note: Performance of this tool may vary depending on variations in local line voltage.Exten-

sion cord usage may also affect tool performance.

Unpacking

When unpacking, check to make sure the following parts are included.

If any parts are missing or broken, please call Harbor FreightTools at the number on the

cover of this manual as soon as possible.

Assembly

1. Connect an appropriate 220 VAC electrical plug to the Line Cord. This should only be

done by a licensed electrician.

2. Connect a AWG # 6 solid wire from the ground screw terminal (screw not included) on

the back of the unit to earth ground before welding.This grounds the internal

transformer in case of short circuits.

Operation

Caution: Before arc welding, read and understand all safety precautions and warnings

listed on pages 2 through 5.

1. Secure the pieces of metal to be welded so they cannot move.

2. Connect theTorch Cable (1A) to the ArcWelder connector for either 80 amp or 160

amp operation. See photo at the top of the next page.

3. Securely clamp the Ground Cable Clamp (2A) as close as possible to the metal object

to be welded, or to the metal work bench where the object is mounted and electrically

connected.

GroundCable(2A)

Torch Cable(1A)

LineCord(3A)

ArcWelderUnit

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4. Place the desired welding electrode rod securely into the jaws of the Torch Cable

Clamp (1A).Generally, the higher the amperage, the thicker the welding rod.

5. Verify that the Power Switch is in the OFF position, then plug the ArcWelder 220VAC

plug into a dedicated, 50 amp line with delayed action type circuit breaker or fuses.

If an extension cord is used, it must have the following wire size: up to 30 feet, use 10

AWG size wire;30 to 50 feet, use 8 AWG wire; Over 50 feet, use 6 AWG wire.

6. While holding the Torch Cable Clamp with electrode clearly out of the way of any

grounded objects, turn the Power Switch to the ON position.

7. Orient yourself on the area to be welded, then lower the Face Shield over your eyes.

WARNING: NEVER LOOK AT THE IGNITED ARC WITHOUT ANSI APPROVED, ARC

SHADED, EYE PROTECTION IN A FULL FACE SHIELD. PERMANENT EYE DAMAGE

OR BLINDNESS CAN OCCUR. SKIN BURNS CAN OCCUR. NEVER BREATH ARC

FUMES.

8. Stroke the area to be welded with the electrode to ignite the arc.

Never tap the electrode into the welding surface to ignite the arc.This damages its

external coating on the electrode which prevents oxygen in the air from coming into

contact with the molten metal, causing it to oxidize.

9. Once the arc is ignited, tilt the electrode forward at an angle of approximately 30° and

hold it at a distance from the welding object equal to the diameter of the electrode.

Note: If too much current is drawn from the Arc Welder, the Thermal Overload protector will

activate, the red indicator will light, and the Arc Welder will turn off until it cools down. If this

happens, turn the Power Switch to the OFF position and wait about 20 minutes.

10. When the weld is complete, lift the electrode clearly away from any grounded object

and lift the Face Shield up.Turn toward the ArcWelder to turn the Power Switch to the

OFF position.

Switch(5)

PowerOn(green)Indicator ThermalOverload(red)Indicator

160AmpConnector

80AmpConnector

GroundCable(2A) TorchCable(1A)

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11. Remove the electrode from theTorch Cable Clamp after it cools.

12. Unplug the Torch Cable plug from the Arc Welding unit.

13. Turn the ArcWelder unit on to allow the fan to cool it down for 20 minutes.

14. Unplug the Arc Welder Power Cord from the electrical outlet.

Maintenance

Warning; Unplug the ArcWelder before performing any maintenance.

1. Periodically tighten all cable connection screws on the cable clamps and line cord plug.

2. Periodicallycleanbothcable clamps of all grease,dirt,weldingslag, andcarbondeposits.

3. Store the Arc Welder and cable clamps in a clean and dry location free from airborne

impurities and contaminants which can breakdown insulation.

4. Periodically blow out dust from within the unit.

5. If the Arc Welder fails to operate after troubleshooting it, do not attempt to open and

repair it yourself.Take it to a qualified technician.

Troubleshooting

Symptom Probable Cause Suggested Remedy

Welder does not

operate, or

continually blows

fuses

1. Improper fuse or circuit breaker

2. Fuse blown or circuit breaker tripped

3. Thermal overload protection activated

4. Using incorrect welding techniques

1. Replace fuse, reset breaker, or use

delayed action breaker

2. Replace fuse or reset breaker

3.Turn switch OFF and wait until the unit

cools down and try again.

4. Review recommended welding

techniques

Welding current

low or weak

1. Low line voltage

2. Welding current too low

3. Poor cable connections

1. Check power source for at least 220

VAC at 40 amps.

2.Use the 160 amp output connector.

3. Check and tighten all cable connections

Will not hold an

arc

1. Using a D.C. welding rod

2. Using a low hydrogen rod 1. Use a proper size, AC welding electrode

2. Use a rod of 0.078" (2 mm) diameter or

smaller on 60 amp.

PLEASE READTHE FOLLOWING CAREFULLY

THEMANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHEPARTSDIAGRAM INTHIS

MANUALAS AREFERENCETOOLONLY. NEITHERTHEMANUFACTURERNORDISTRIBUTOR

MAKES ANY REPRESENTATION OR WARRANTY OF ANY KINDTO THE BUYERTHAT HE OR

SHEISQUALIFIEDTOMAKEANYREPAIRSTOTHEPRODUCTORTHATHEORSHEISQUALI-

FIEDTO REPLACE ANY PARTS OFTHE PRODUCT. IN FACT,THE MANUFACTURER AND/OR

DISTRIBUTOREXPRESSLYSTATESTHATALLREPAIRSANDPARTSREPLACEMENTSSHOULD

BE UNDERTAKEN BY CERTIFIED AND LICENSEDTECHNICIANS AND NOT BYTHE BUYER.

THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO

THEORIGINALPRODUCTOR REPLACEMENTPARTSTHERETO,ORARISINGOUTOFHISOR

HERINSTALLATION OF REPLACEMENTPARTSTHERETO.

Page 8SKU 02665

NOTE:Some parts are listed and shown for illustration purposes only and are not available indi-

vidually as replacement parts.

Parts List

Item # Designation Description Qty

1 T1 Power Transformer 1

2 T2 Control Transformer 1

3 M Vane, 1,0 CB-1, 4-4-140 1

4 VS1 Triac TC242-80-5 1

5SA1Switch,T120-15A 1

6 XS1 Socket, CHTI58-16B-21-2-B 1

7 SP1 Plug, CHTI58-16P-20-0-B 1

Diodes

8VD1-VD4,VD7KA243 5

9VD5,VD6KA212A 2

10 VD8 LED, AJ1307 LM 1

11 VD9 LED, AJI307AM 1

Resistors

12 R1 MJIT-2-100 ohms 1

13 R2 MJIT-0, 25-2, 7K ohms 1

14 R3 MJIT-0, 25-100 ohms 1

15 R4, 12, 13 MJIT-0, 25-3, 6k ohms 3

16 R5, R16 MJIT-0, 25-10K ohms 2

17 R6 MJIT-0, 25-5, 6k ohms 1

18 R7, R9 MJIT-0, 25-2k ohms 2

19 R8, R10 MJIT-0, 25-20k ohms 2

20 R11 MJIT-0, 25-360k ohms 1

21 R14 MJIT-0, 25-6.8k ohms 1

22 R15 MJIT-0, 25-200k ohms 1

23 R17 Posistor, CT-14-2A-1150M 1

24 R18 MJIT-0, 5-22 ohms 1

25 R19 MJIT-2-2, 2 ohms 1

26 R20 MJIT-1-24k ohms 1

Capacitors

27 C1, C2, C11 K73-17-1uf-250V 3

28 C3 K50-25-470uf-40V 1

29 C4, C5, C10 K10-17-1B (2B, 3B)-4700pF 3

30 C6 K10-17-1E (2E, 3E)-0, 01uf 1

31 C7 K10-17-1E (2E, 3E)-0, 068uf 1

32 C8 K50-35-10uf-25V 1

33 C9 K50-35-22uf-63V 1

Transistors

34 VT1 KT 973A 1

35 VT2, VT7 KT 3102A 2

36 VT3, VT4 KT 815L 2

37 VT5, VT6 KT 3107A 2

Main Unit Components

38 1A Torch Cable with Clamp 1

39 2A Ground Cable with Clamp 1

40 3A Line Cord 1

Page 9SKU 02665

Schematic Drawing

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