Chicago Electric 91110 User manual

INVERTER ARC WELDER -

80 AMP

Model

91110

SET UP AND OPERATING INSTRUCTIONS

Distributed exclusively by Harbor Freight Tools®.

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our website at: http://www.harborfreight.com

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

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.

For technical questions or replacement parts, please call 1-800-444-3353.

Revised 08b

Page 2SKU 91110 For technical questions, please call 1-800-444-3353.

GENERAL SAFETY RULES

WARNING Read all safety

warnings and instructions.

Failure to follow the warnings and

instructions may result in electric

shock, re and/or serious injury.

WORK AREA

Keep your work area clean and1.

well lit. Cluttered benches and dark

areas invite accidents.

Do not operate power tools in2.

explosive atmospheres, such as in

the presence of ammable liquids,

gases, or dust. Power tools create

sparks which may ignite the dust or

fumes.

Keep bystanders, children, and3.

visitors away while operating a

power tool. Distractions can cause

you to lose control. Protect others

in the work area from debris such as

chips and sparks. Provide barriers or

shields as needed.

SPECIFICATIONS

Electrical Input 120 V~ / 60 Hz / 20 A

Power Cord: 12 Gauge With 3-Prong Plug

Thermal Overload Protection

Electrode Sizes 1/16” - 3/32” (1.6mm) - (2.5mm)

Duty Cycles 35% @ 80 A

60% @ 65 A

100% @ 50 A

Electrode Cable 6 Gauge x 6’ Long

Ground Clamp Cable 6 Gauge x 5’6” Long

Overall Dimensions 9-1/2” x 5-5/8” x 3-3/4”

Additional Features Amber Temperature Warning Light

Welding Capacity 6 Gauge Steel

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly,

operating, inspection, maintenance and cleaning procedures, parts list and assembly

diagram. Keep your invoice with this manual. Write the invoice number on the inside

of the front cover. Keep this manual and invoice in a safe and dry place for future refer-

ence.

UNPACKING

When unpacking, check to make sure all the parts shown on the Parts List are

included. If any parts are missing or broken, please call Harbor Freight Tools at the

number shown on the cover of this manual as soon as possible.

Page 3SKU 91110 For technical questions, please call 1-800-444-3353.

ELECTRICAL SAFETY

Grounded tools must be plugged1.

into an outlet properly installed

and grounded in accordance with

all codes and ordinances. Never

remove the grounding prong or

modify the plug in any way. Do

not use any adapter plugs. Check

with a qualied electrician if you

are in doubt as to whether the

outlet is properly grounded. If the

tools should electrically malfunction

or break down, grounding provides a

low resistance path to carry electricity

away from the user.

Double insulated tools are2.

equipped with a polarized plug

(one blade is wider than the other).

This plug will t in a polarized out-

let only one way. If the plug does

not t fully in the outlet, reverse

the plug. If it still does not t, con-

tact a qualied electrician to install

a polarized outlet. Do not change

the plug in any way. Double insula-

tion eliminates the need for the

three wire grounded power cord and

grounded power supply system.

Avoid body contact with grounded3.

surfaces such as pipes, radiators,

ranges, and refrigerators. There is

an increased risk of electric shock if

your body is grounded.

Do not expose power tools to rain4.

or wet conditions. Water entering

a power tool will increase the risk of

electric shock.

Do not abuse the Power Cord.5.

Never use the Power Cord to carry

the tools or pull the Plug from an

outlet. Keep the Power Cord away

from heat, oil, sharp edges, or

moving parts. Replace damaged

Power Cords immediately. Dam-

aged Power Cords increase the risk

of electric shock.

When operating a power tool out-6.

side, use an outdoor extension

cord marked “W-A” or “W”. These

extension cords are rated for outdoor

use, and reduce the risk of electric

shock.

PERSONAL SAFETY

Stay alert. Watch what you are do-1.

ing, and use common sense when

operating a power tool. Do not use

a power tool while tired or under

the inuence of drugs, alcohol, or

medication. A moment of inatten-

tion while operating power tools may

result in serious personal injury.

Dress properly. Do not wear loose2.

clothing or jewelry. Contain long

hair. Keep your hair, clothing, and

gloves away from moving parts.

Loose clothes, jewelry, or long hair

can be caught in moving parts.

Avoid accidental starting.3. Be sure

the Power Switch is off before

plugging in. Carrying power tools

with your nger on the Power Switch,

or plugging in power tools with the

Power Switch on, invites accidents.

Remove adjusting keys or wrench-4.

es before turning the power tool

on. A wrench or a key that is left at-

tached to a rotating part of the power

tool may result in personal injury.

Do not overreach. Keep proper5.

footing and balance at all times.

Proper footing and balance enables

Page 4SKU 91110 For technical questions, please call 1-800-444-3353.

better control of the power tool in

unexpected situations.

Use safety equipment. Always6.

wear eye protection. Always wear

ANSI-approved safety glasses under

a properly shaded welding helmet.

Respirator, leather work shoes with

rubber soles, hard hat or hearing pro-

tection must be used for appropriate

conditions.

TOOL USE AND CARE

Use clamps (not included) or other1.

practical ways to secure and sup-

port the work piece to a stable

platform. Holding the work by hand

or against your body is unstable and

may lead to loss of control.

Do not force the tool. Use the cor-2.

rect tool for your application. The

correct tool will do the job better and

safer at the rate for which it is de-

signed.

Do not use the power tool if the3.

Power Switch does not turn it on

or off. Any tool that cannot be con-

trolled with the Power Switch is dan-

gerous and must be replaced.

Disconnect the Power Cord Plug4.

from the power source before

making any adjustments, changing

accessories, or storing the tool.

Such preventive safety measures

reduce the risk of starting the tool ac-

cidentally.

Store idle tools out of reach of chil-5.

dren and other untrained persons.

Tools are dangerous in the hands of

untrained users.

Maintain tools with care. Keep cut-6.

ting tools sharp and clean. Prop-

erly maintained tools with a sharp

cutting edge are less likely to bind

and are easier to control. Do not use

a damaged tool. Tag damaged tools

“Do not use” until repaired.

Check for misalignment or binding7.

of moving parts, breakage of parts,

and any other condition that may

affect the tool’s operation. If dam-

aged, have the tool serviced before

using. Many accidents are caused

by poorly maintained tools.

Use only accessories that are8.

recommended by the manufac-

turer for your model. Accessories

that may be suitable for one tool may

become hazardous when used on

another tool.

SERVICE

Tool service must be performed1.

only by qualied repair personnel.

Service or maintenance performed by

unqualied personnel could result in

a risk of injury.

When servicing a tool, use only2.

identical replacement parts. Fol-

low instructions in the “Inspec-

tion, Maintenance, And Cleaning”

section of this manual. Use of

unauthorized parts or failure to follow

maintenance instructions may create

a risk of electric shock or injury.

SPECIFIC SAFETY RULES

Maintain a safe working environ-1.

ment. Keep the work area well lit.

Make sure there is adequate sur-

rounding workspace. Always keep

Page 5SKU 91110 For technical questions, please call 1-800-444-3353.

the work area free of obstructions,

grease, oil, trash, and other debris.

Do not use the Inverter Arc Welder

in areas near ammable chemicals,

dusts, and vapors.

Maintain labels and nameplates2.

on the Inverter Arc Welder. These

carry important information. If un-

readable or missing, contact Harbor

Freight Tools for a replacement.

Never plug the Power Cord of this3.

product into an electrical outlet

while standing on a wet or damp

surface.

Do not unplug the Inverter Arc4.

Welder by pulling on the Power

Cord. Keep the Power Cord away

from heated surfaces.

Always turn off the Inverter Arc5.

Welder and unplug the unit from

its electrical outlet before perform-

ing any inspection, maintenance,

or cleaning procedures.

Never leave the Inverter Arc Weld-6.

er unattended when it is plugged

into an electrical outlet. Make sure

to unplug it from its electrical outlet

before leaving the area.

Do not allow children to handle or7.

play with this product.

Store idle equipment.8. When not in

use, tools and equipment should be

stored in a dry location to inhibit rust.

Always lock up tools and equipment,

and keep out of reach of children.

Do not use this product if under9.

the inuence of alcohol or drugs.

Read warning labels on prescrip-

tions to determine if your judgement

or reexes are impaired while taking

drugs. If there is any doubt, do not

attempt to use this product.

WARNING

INHALATION HAZARD:

Welding and Plasma 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 plasma cutting

exhaust fumes are:

• Early onset of Parkinson’s Disease

• Heart disease • Ulcers

• Damage to the reproductive organs

• Inammation 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.

Use eye, skin, and breathing pro-11.

tection. Always wear ANSI approved

safety glasses with side shields under

an ANSI approved welding helmet.

Wear re resistant work gloves, a

heavy, long-sleeved shirt, trousers

without cuffs, high top leather work

boots to protect skin from arc rays

and metal sparks. Also wear an ANSI

approved air respirator.

REV 04e

Page 6SKU 91110 For technical questions, please call 1-800-444-3353.

Industrial applications must follow12.

OSHA requirements.

Maintain this product with care.13.

Keep this product clean and dry for

better and safer performance.

Maintenance:14. For your safety,

service and maintenance should be

performed regularly by a qualied

technician.

Check for damaged parts.15. Before

using this product, carefully check

that it will operate properly and per-

form its intended function. Check for

damaged parts and any other condi-

tion that may affect the operation of

this product. Replace or repair dam-

aged or worn parts immediately.

Connect the earth ground as near16.

as possible to the operating area.

Earth connections to structural

parts of the building or other plac-

es distant to the operating area

will reduce their effectiveness and

increase the danger of electric

shock.

Do not pass equipment cables17.

through or near lifting chains,

crane cables, or any electrical

lines.

In addition to grounding the work18.

piece with the Inverter Arc Welder

Grounding Cable, an earth ground-

ing of the work piece is recom-

mended. Ground it directly to an

earth pipe or grounding rod with a

separate cable of appropriate size.

IMPORTANT: Only a qualied, certi-

ed electrician should perform this

procedure.

Do not touch the electrode if you19.

are in contact with the work piece,

ground, or another electrode from

a different machine.

Never use the Inverter Arc Welder20.

near water. Ensure that the sur-

rounding area and cutting objects

are dry. Do not spray water or other

liquids on or near the Inverter Arc

Welder.

Avoid all direct contact between21.

the skin and wet garments and

metal parts under electrical power.

Check that gloves and protective

clothing are dry.

Always wear welding gloves and22.

rubber soled leather work boots

when working in damp areas or

standing on metal objects.

Always turn off the Inverter Arc23.

Welder in the event of a power

failure.

Do not allow the Electrode Holder24.

to touch earth ground. Accidental

earth discharges may cause over-

heating and re hazards.

Signicant DC voltage exists af-25.

ter turning off and unplugging the

Inverter Arc Welder. Discharge the

electrode to ground before handling.

Position a re-resistant screen 26. (not

included) around the welding area

to protect people in the vicinity

from arc rays, sparks, and slag.

Clear away or protect ammable 27.

objects. Protect objects such as

wood, sawdust, clothing, paints,

solvents, petroleum products, natural

gas, acetylene, propane, and other

substances with reproof material

(not included).

Page 7SKU 91110 For technical questions, please call 1-800-444-3353.

Keep an ABC type re extinguisher 28.

near the work area.

Never perform welding or cutting29.

operations on closed pipes or

containers, as the possible internal

fumes may cause an explosion.

Never perform welding or cutting30.

operations on open pipes or con-

tainers that may have come in con-

tact with moisture, chemicals, or

ammable materials. Always clean

and dry the areas rst.

Welding and cutting fumes and31.

gases may be hazardous if inhaled

for long periods of time.

Install a natural or forced-air ven-32.

tilation system in the work area. If

the ventilation system is inadequate,

use an air respirator.

Use a forced-air ventilation system33.

when welding or cutting lead, be-

ryllium, cadmium, zinc, zinc-coat-

ed or painted materials. Always

wear an air respirator.

When welding or cutting in small34.

areas, the operator should be

externally accompanied by an-

other person (standing near the

enclosed work area) to observe

accident prevention procedures.

Do not perform welding or cut-35.

ting operations near chlorinated

hydrocarbon vapors produced by

degreasing or painting. The heat

generated by arc rays can react to

form phosgene, a highly toxic gas.

Irritation of the eyes, nose, and36.

throat are symptoms of inadequate

ventilation. Take immediate steps to

improve ventilation. Do not continue

operations if symptoms persist.

Electric shock can be fatal.37. Never

touch exposed electrical parts.

Switch off and disconnect the38.

power source before installing the

Inverter Arc Welder.

Installation must be performed by39.

a qualied technician. Installation

procedures must comply with the

National Electric Code, and all other

relevant regulations.

When welding or cutting, be aware40.

that high frequency radiation may

be produced which can interfere

with radio navigation, safety de-

vices, computers, and communica-

tions equipment. Before operating,

have a qualied technician check out

that possibility.

Keep high frequency source doors41.

and panels tightly shut. Keep

spark gaps at the correct settings.

Use proper grounding and shielding

to minimize the possibility of interfer-

ence. Keep all cables close together

and close to the ground. Locate the

welding or cutting operation as far

as possible from sensitive electronic

equipment, or have the electronic

equipment shut down temporarily.

Performance of this Inverter Arc42.

Welder may vary depending on

variations in local line voltage.

Extension cord usage may also affect

tool performance.

Welding and cutting operations are43.

a source of radiation, noise, heat,

and noxious fumes. The protec-

tion of the operator and any specta-

tors must be guaranteed with suit-

Page 8SKU 91110 For technical questions, please call 1-800-444-3353.

able safety devices and precautions.

Never approach arc rays or hot metal

without protection. Failure to observe

these standards during operation

could lead to serious health risks.

Use the right tool or attachment44.

for the right job. Do not attempt to

force a small tool or attachment to do

the work of a larger industrial tool or

attachment. There are certain ap-

plications for which this product was

designed. It will do the job better

and more safely at the rate for which

it was intended. Do not modify this

product, and do not use this product

for a purpose for which it was not

intended.

Replacement parts and acces-45.

sories: When servicing, use only

identical replacement parts. Only use

accessories intended for use with this

product.

WARNING: The brass components46.

of this product contain lead, a chemi-

cal known to the State of California

to cause birth defects (or other repro-

ductive harm). (California Health &

Safety code § 25249.5, et seq.)

WARNING: This product, when used47.

for welding, plasma cutting, solder-

ing, 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.)

People with pacemakers should48.

consult their physician(s) before use.

Electromagnetic elds in close prox-

imity to heart pacemaker could cause

pacemaker interference or pacemak-

er failure. In addition, people with

pacemakers should:

Avoid operating alone.•

Don’t use with power switch locked•

on.

Properly maintain and inspect to•

avoid electrical shock.

Any power cord must be properly•

grounded. Ground Fault Circuit

Interrupter (GFCI) should also be

implemented – it prevents sustained

electrical shock.

The warnings, precautions, and in-49.

structions discussed in this instruction

manual cannot cover all possible con-

ditions and situations that may occur.

It must be understood by the operator

that common sense and caution are

factors which cannot be built into this

product, but must be supplied by the

operator.

Page 9SKU 91110 For technical questions, please call 1-800-444-3353.

GROUNDING

TO PREVENT

ELECTRIC SHOCK

AND DEATH FROM

INCORRECT GROUNDING

WIRE CONNECTION:

Check with a qualied

electrician if you are in doubt

as to whether the outlet is

properly grounded. Do not

modify the power cord plug

provided with the tool. Never

remove the grounding prong

from the plug. Do not use the

tool if the power cord or plug

is damaged. If damaged, have

it repaired by a service facility

before use. If the plug will not

t the outlet, have a proper

outlet installed by a qualied

electrician.

Grounded Tools: Tools with Three

Prong Plugs

1. Tools marked with “Grounding Re-

quired” have a three wire cord and

three prong grounding plug. The

plug must be connected to a properly

grounded outlet. If the tool should

electrically malfunction or break

down, grounding provides a low

resistance path to carry electricity

away from the user, reducing the risk

of electric shock. (See 3-Prong Plug

and Outlet.)

The grounding prong in the plug is2.

connected through the green wire in-

side the cord to the grounding system

in the tool. The green wire in the cord

must be the only wire connected to

the tool’s grounding system and must

never be attached to an electrically

“live” terminal. (See 3-Prong Plug

and Outlet.)

The tool must be plugged into an3.

appropriate outlet, properly installed

and grounded in accordance with all

codes and ordinances. The plug and

outlet should look like those in the

preceding illustration. (See 3-Prong

Plug and Outlet.)

Double Insulated Tools: Tools

with Two Prong Plugs

1. Tools marked “Double Insulated” do

not require grounding. They have

a special double insulation system

which satises OSHA requirements

and complies with the applicable

standards of Underwriters Labora-

tories, Inc., the Canadian Standard

Association, and the National Electri-

cal Code. (See Outlets for 2-Prong

Plug.)

Page 10SKU 91110 For technical questions, please call 1-800-444-3353.

Double insulated tools may be used2.

in either of the 120 volt outlets shown

in the preceding illustration. (See

Outlets for 2-Prong Plug.)

Extension Cords

Grounded1. tools require a three wire

extension cord. Double Insulated

tools can use either a two or three

wire extension cord.

As the distance from the supply outlet2.

increases, you must use a heavier

gauge extension cord. Using exten-

sion cords with inadequately sized

wire causes a serious drop in voltage,

resulting in loss of power and pos-

sible tool damage.

(See Table A.) The smaller the

gauge number of the wire, the greater

the capacity of the cord. For ex-

ample, a 14 gauge cord can carry a

higher current than a 16 gauge cord.

(See Table A.)

When using more than one exten-3.

sion cord to make up the total length,

make sure each cord contains at

least the minimum wire size required.

(See Table A.)

If you are using one extension cord4.

for more than one tool, add the

nameplate amperes and use the sum

to determine the required minimum

cord size. (See Table A.)

If you are using an extension cord5.

outdoors, make sure it is marked with

the sufx “W-A” (“W” in Canada) to

indicate it is acceptable for outdoor

use.

Make sure the extension cord is prop-6.

erly wired and in good electrical con-

dition. Always replace a damaged

extension cord or have it repaired by

a qualied electrician before using it.

Protect the extension cords from7.

sharp objects, excessive heat, and

damp or wet areas.

RECOMMENDED MINIMUM WIRE

GAUGE FOR EXTENSION CORDS*

(120/240 VOLT)

NAMEPLATE

AMPERES

(at full load)

EXTENSION CORD

LENGTH

25’

50’

75’

100’

150’

0 – 2.0 18 18 18 18 16

2.1 – 3.4 18 18 18 16 14

3.5 – 5.0 18 18 16 14 12

5.1 – 7.0 18 16 14 12 12

7.1 – 12.0 18 14 12 10 -

12.1 – 16.0 14 12 10 - -

16.1 – 20.0 12 10 - - -

TABLE A

* Based on limiting the line

voltage drop to ve volts at

150% of the rated amperes.

Symbology

Double Insulated

Canadian Standards Association

Underwriters Laboratories, Inc.

V~ Volts Alternating Current

AAmperes

n0xxxx/min. No Load Revolutions per Minute

(RPM)

Table of contents

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