Chicago Electric Power Systems 95596 Set Up And Operating Instructions Manual

Brand: Chicago Electric

Model: Power Systems 95596

Type: Set Up And Operating Instructions Manual

2000 WATT / 4000 WATT

INVERTER

95596

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.

2006 by Harbor Freight Tools

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. Tools required for

assembly and service may not be included.

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

Cover Revised 09d

SKU 95596 For technical questions, please call 1-800-444-3353 PAGE 2

SAVE THIS MANUAL

You will need this manual for the

safety warnings and precautions, assem-

bly, 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 reference.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL

INSTRUCTIONS

Failure to follow all instructions

listed below may result in electric

shock, re, and/or serious injury.

SAVE THESE INSTRUCTIONS

WORK AREA

1. Keep your work area clean and

well lit. Cluttered benches and

dark areas invite accidents.

2. Do not operate power equipment

in explosive atmospheres, such

as in the presence of ammable

liquids, gases, or dust. Power

equipment create sparks which may

ignite the dust or fumes.

ELECTRICAL SAFETY

Never remove the grounding 1.

prong of a power tool or appli-

ance or modify the plug in any

way. Do not use any adapter

plugs with this product. If the tool

or appliance should electrically mal-

function or break down, grounding

provides a low resistance path to

carry electricity away from the user.

Double insulated tools and appli-2.

ances are equipped with a polar-

ized plug (one blade is wider than

the other). This plug will t in

a polarized outlet only one way.

If the plug does not t fully in

the outlet, reverse the plug. Do

not change the plug in any way.

Double insulation eliminates the

need for the three wire grounded

power cord and grounded power

supply system.

Avoid body contact with ground-3.

ed surfaces such as pipes, radia-

tors, ranges, and refrigerators.

There is an increased risk of electric

shock if your body is grounded.

SPECIFICATIONS

Continuous Power 2000 Watt

Surge Power 4000 Watt

Input Voltage 11 - 15 VDC

Output Voltage 120 V~ / 60 Hz

AC Receptacles Two 3-Prong, Grounding Outlets

Fuse Type Eight x 40 A, Blade Type

Operating Temperature 50° F to 113° F

Thermal Shutdown 149° F

Features 





Connection Cables

(Not included)

#1 AWG or Thicker Battery Cables Recommended

#12 AWG or Thicker Grounding Strap to Chassis Recommended

Dimensions 

SKU 95596 For technical questions, please call 1-800-444-3353 PAGE 3

Do not expose power tools and 4.

appliances to rain or wet condi-

tions. Water entering a power tool

or appliance will increase the risk of

electric shock.

Stay alert. Watch what you are 5.

doing, and use common sense

when operating this product. Do

not use this product while tired

or under the inuence of drugs,

alcohol, or medication. A moment

of inattention while operating this

product may result in serious per-

sonal injury.

PERSONAL SAFETY

Use safety equipment. Always

wear ANSI-approved safety impact

goggles when setting up and using

this product.

TOOL USE AND CARE

Do not force this product. Use 1.

the correct product for your ap-

plication. Do not overload this

inverter.

Do not use the Inverter if the 2.

Power Switch does not turn it on

or off. Any product that cannot be

controlled with the Power Switch is

dangerous and must be replaced.

Disconnect the Power Cord 3. (not

included) from the Inverter before

making any adjustments, chang-

ing accessories, or storing a tool

or appliance. Such preventive

safety measures reduce the risk of

starting the tool or appliance acci-

dentally.

Store the Inverter out of reach of 4.

children and other untrained per-

sons. This product may be danger-

ous in the hands of untrained users.

Maintain this product with care. 5.

Keep the Inverter clean and dry.

Properly maintained power sup-

plies are less likely to fail. Do not

use this product if damaged. Tag

a damaged Inverter “Do not use”

until repaired.

Check for misalignment or bind-6.

ing of moving parts, breakage of

parts, and any other condition

that may affect this product’s

operation. If damaged, have the

Inverter serviced before using.

Many accidents are caused by

poorly maintained power equip-

ment.

Use only accessories that are 

recommended by the manufac-

turer for your model. Accessories

that may be suitable for one Inverter

may become hazardous when used

on another Inverter.

SERVICE

Product service must be per-1.

formed only by qualied repair

personnel. Service or mainte-



personnel could result in a risk of

injury.

Aside from the fuses this Inverter 2.

does not contain any replaceable

parts. It the unit needs service,



service technician.

Maintain labels and nameplates 3.

on the Inverter. These carry im-

portant information. If unreadable

SKU 95596 For technical questions, please call 1-800-444-3353 PAGE 4

or missing, contact Harbor Freight

Tools for a replacement.

SPECIFIC SAFETY RULES

Do not plug in a battery charger 1.

if the charger has a warning that

dangerous voltages are present

at the battery terminals.

Keep the Inverter away from any 2.

direct heat source or combus-

tible material.

Avoid potential electrical shock. 3.

Do not attempt to open the metal

housing of the Inverter.

Always disconnect power from 4.

the Inverter when not in use.

Avoid unintentional starting. 5.

Make sure the Power Switch of the

Inverter is in the “OFF” position

when not in use and before plug-

ging in any tool or appliance.

Keep the Inverter well ventilated. 6.

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



hazard and/or damage to the In-

verter.

Make sure to read and under-

stand all warnings and safety

precautions as outlined in the

manufacturer’s manual for the

device that this Inverter is used

to power.

Performance of this unit may 8.

vary depending on the battery

power or tool/appliance wattage.

The Inverter housing will become 9.

hot when in use. Avoid touching

materials (clothes, sleeping bags,

carpet, etc.) to the Inverter that can

not withstand such high tempera-

tures. Avoid touching a hot Inverter



This Inverter must only be con-10.

nected to batteries with a nomi-

nal output voltage of 12 VDC.



Inverter properly, and more voltage

could damage the unit.

Do not use this Inverter with pos-11.

itive ground electrical systems.

Some rechargeable tools and ap-12.

pliances may damage the Invert-

er or the tool/appliance. When





ten minutes. If it becomes abnor-

mally hot, do not use the device

with the Inverter.

It is recommended that the ve-13.

hicle be started every hour to

recharge its battery system. Do-

ing so will help prevent any unex-

pected shutdown of the equipment.

This will also ensure there will be

enough battery power to start the

vehicle.

Risk of re! 14. The positive (+) bat-

tery terminal on the Inverter must

be the LAST connection to be

made and must be done with the

Inverter’s Power Switch off.

Do not attempt to power a device 15.

(or devices when combined) over

2,000 watts. Doing so will damage

the Inverter.

SKU 95596 For technical questions, please call 1-800-444-3353 PAGE 5

NOTE:16. When using cables to power

the inverter, keep the cable length

to a minimum. The shorter the cable



voltage to the inverter will sound an

alarm and shut off the inverter.

People with pacemakers should 

consult their physician(s) before

using this product. Electromagnetic



pacemaker could cause interfer-

ence to or failure of the pacemaker.

The warnings and cautions dis-18.

cussed in this manual cannot cover

all possible conditions and situa-

tions 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.

SAVE THESE INSTRUCTIONS

GROUNDING

WARNING!

Improperly connecting the grounding

wire can result in the risk of electric

shock. Check with a qualied electri-

cian 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

Tools and appliances marked with 1.

“Grounding Required” have a three

wire cord and three prong ground-

ing plug. The plug must be con-

nected properly to the grounded

outlet of the Inverter. If the tool or

appliance should electrically mal-

function or break down, grounding

provides a low resistance path to

carry electricity away from the user,

reducing the risk of electric shock.

The grounding prong in the plug 2.

is connected through the green

wire inside the cord to the ground-

ing system in the tool or appliance.

The green wire in the cord must be

the only wire connected to the tool

or appliance grounding system and

must never be attached to an elec-

trically “live” terminal.

DOUBLE INSULATED TOOLS:

TOOLS WITH TWO PRONG

PLUGS

Tools marked “Double Insulated” do

not require grounding. They have

a special double insulation system



and complies with the applicable

-

tories, Inc., the Canadian Standard

Association, and the National Elec-

trical Code.

REV 08g, 09d

SKU 95596 For technical questions, please call 1-800-444-3353 PAGE 6

REV 08g, 09d

UNPACKING

When unpacking, check to make

sure that the item is intact and undam-

aged. If any parts are missing or broken,

please call Harbor Freight Tools at

1-800-444-3353 as soon as possible.

INSTALLATION

1. CAUTION! This Inverter must

only be connected to a battery with

a nominal output voltage of 12 volts

DC. The battery should be checked

before each use and changed when



operate the Inverter properly, and

more voltage could damage the In-

verter or the device being powered.

Do not use this Inverter with posi-

tive ground electrical systems.

Note:2. When using cables to power

the inverter, keep the cable length

to a minimum. The shorter the cable



voltage to the inverter will sound an

alarm and shut off the inverter.

3.

level surface capable of supporting

the weight of the unit. Make sure

the Inverter has adequate ventila-

tion and is not in direct sunlight.

Connect one end of a ground wire 4.

(not included, #12 AWG or thicker

cable recommended) to the wing

nut located on the back of the In-

verter. Then connect the other end

of the ground wire to a paint/rust

free grounded metal surface, such

as a water pipe. (See Figure C.)

Battery Type Selection:5.

Use only deep cycle lead-acid bat-

teries with this inverter, such as 12

volt marine/RV deep-cycle batter-

ies. Do not use automotive, engine



wet cell batteries with this inverter;

they are designed for repeated,

shallow discharge and will wear out

quickly.

Gel and AGM (Absorbed Glass 

Mat) batteries can be used with this

inverter, but they require special

charging procedures. Refer to bat-

tery supplier’s instructions.

Battery capacity selection:6.

Inverter

Output

about 1 hour

discharge time

(Minimum battery

capacity)

about 4 hour

discharge time

(Optimal battery

capacity)

500W 80 Ah 200 Ah

1000W 150 Ah 400 Ah

1500W 240 Ah 

2000W 300 Ah 1000 Ah

Consult the chart above for approxi-

mate run time at different battery

capacities. If the battery does not

BACK

CONNECT

GROUND WIRE

WING NUT

FIGURE C

BLACK

(–)

RED

(+)

WARNING!

RISK OF FIRE!

THE POSITIVE

BATTERY TERMINAL

CONNECTIONS

MUST BE THE LAST

CONNECTIONS AND

MUST BE DONE WITH

THE INVERTER’S

POWER SWITCH OFF.

SKU 95596 For technical questions, please call 1-800-444-3353 

have a capacity this large indi-

vidually, use a bank of batteries as

explained below.

Battery Bank assembly instructions:

Read the following safety a.

rules before assembling the

battery bank:

Connect batteries in parallel •

(negative terminals together to

one cable; positive terminals

together to the other cable) as

shown in Battery Bank Example

illustration ONLY.

Do not connect 12V batteries •

in series (from negative of one

battery to the positive of the

next). This connection can result

in voltage high enough to cause

ELECTROCUTION.

Wear splash-resistant ANSI-•

approved safety goggles and

electrically insulated gloves

while assembling battery bank.

Only connect similar batteries 

together in a battery bank. Do

not connect old and new batteries

together, wet and gel cells together,

or batteries of different capacities

together.

Connect all batteries in the battery 

bank together using #00 AWG or

thicker cables. Since amp draw on

this low-voltage circuit will be very

high, thinner cables would present





ventilated area, away from ignition



Batteries release explosive hydro-

gen gas while charging.

Charge, store, and maintain batter-

ies according to supplier’s instruc-

tions.

–

OUTPUT

(To Positive

Inverter Terminal)

To Increase

Capacity, Connect

Additional

12 V / 200* Ah

Lead-Acid

Batteries Here

(To Negative

Inverter Terminal)

OUTPUT

12 V /

200* Ah

Lead- Acid

Battery

12 V /

200* Ah

Lead- Acid

Battery

12 V / 400^ Ah Battery Bank Example

* 200 Ah batteries shown for illustration.

^ Bank Capacity = (single battery capacity) x (# of batteries)

400 Ah capacity is for two, 200 Ah batteries.

b. Connect the batteries in parallel

as shown above. Connect all

of the positive terminals to one

another.

Then connect all the negative c.

terminals to one another.

Connect the negative and posi-d.

tive output cables to opposite

ends of the bank. Do not allow

the output cables to touch

one another.

Test the voltages at the output e.

cables to help ensure that the

battery bank is properly wired.

If the voltage is higher than 13

volts, then part of the battery

REV 09d

SKU 95596 For technical questions, please call 1-800-444-3353 PAGE 8

bank is likely connected in se-

ries (a negative terminal of one

battery attached to a positive

terminal of another) instead of in

parallel. Carefully examine the

diagram and correct the wiring

before attaching to the inverter.

Turn the Power Switch on the front 8.

of the inverter off.

Connect the output cables from the 9.

battery bank to the inverter.

OPERATION

FRONT

POWER SWITCH

OFF

OVER

LOAD

TEMP

OVER

VOLTAGE

AMPS OUT 1

OUT 2

FIGURE D

1. Plug the 120 V~ device(s) you wish to power into the 3-prong AC Receptacles.

The tools/appliances must not use more than 2,000 (total) Watts during continu-

ous operation, otherwise it may overload the Inverter. (See Figure D.)

Turn the Power Switch to the 2. “ON” position. (See Figure D.)

Turn on the tool/appliance. If an alarm sound is heard, turn off the tool/appliance. 3.

Unplug the tool/appliance from the Inverter and discontinue using the tool/appli-

ance with the Inverter.

NOTE: 4. Some rechargeable tools/appliances may damage the Inverter or the





device with the Inverter.

REV 07c, 08c , 09d

SKU 95596 For technical questions, please call 1-800-444-3353 PAGE 9

INSPECTION, MAINTENANCE,

AND CLEANING

1. WARNING! Always make sure

the Power Switch of the Inverter

is in the “OFF” position and the

unit is disconnected from its

power source before perform-

ing inspection, maintenance, or

cleaning procedures.

Before each use,2. inspect the

general condition of the Inverter.

Check for misalignment or binding

of moving parts, cracked or broken

parts, damaged electrical wiring,

and any other condition that may

affect its safe operation. If abnor-

mal heat, noise, or vibration occurs,

have the problem corrected before

further use.

Do not use damaged equipment.

To clean the exterior parts of the 3.

Inverter, use only a clean, dry

cloth. Do not clean the unit with

water or harsh cleaners.

This Inverter does not contain 4.

any replaceable parts. It the unit

needs service, make sure to take it



Make sure to store the Inverter in a 5.

clean, dry, safe location out of reach

of children and other unauthorized

people.

6. CAUTION! All maintenance,

service, or repairs not mentioned

in this manual must only be

performed by a qualied service

technician.

TROUBLESHOOTING

If the low battery alarm sounds, 1.

this means the input voltage is

below the necessary 10.6 volts

DC. The battery needs recharging.

You should stop using the tool/ap-

pliance and then recharge the bat-

tery. If this is not done, the Inverter

will shut off automatically at around

10.0 volts DC.

If you are unsure if the Inverter 2.

will have the proper amount of

current to run a tool/appliance,

use this rough guideline: Take

the power consumption of the load

in amps and multiply it by 120

(output voltage). The result will be

the approximate number of watts

needed to power the tool/appliance.

Example: 

amps. 26 amps x 120 volts = 3120

watts needed. You can not use this

device with the Inverter.

If your television will not turn on, 3.

it is important to keep in mind

some appliances (including many

televisions) may require two to

six times their wattage to turn on.

This Inverter will not work with such

devices.

If your audio system buzzes 4.

while using this Inverter, it is be-

cause some sound systems can-

not lter out the modied sine

wave produced by the Inverter. A

possible solution is to use a sound

system that incorporates a higher

quality power supply.

This Inverter is designed to mini-5.

mize the interference with televi-

sion signals. However, especially

with weak television signals, some

SKU 95596 For technical questions, please call 1-800-444-3353 PAGE 10

interference may still be visible. To

correct this, place the Inverter as far

away as possible from the televi-

sion antenna and its cables. Next,

adjust the orientation of the Inverter

to the antenna cables and television

power cord to minimize the interfer-

ence. Also, use a shielded antenna

cable.

If the low battery alarm is on all 6.

the time, try these corrective

measures: Recharge the battery,

or use a different fully charged bat-

tery.

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 under 2,000 watts.

Also, keep input voltage above 10.6



of power.

If you are not getting any power 8.

output, turn the Power Switch off

and on again until the GREEN

LED light illuminates. Some

automotive systems require that the

ignition be turned on. Turn the igni-

tion to the accessory position. Your

devices may draw too much power

to operate them. The Inverter may



unit cool down, and make sure

there is adequate ventilation around

the unit.

If none of the preceding steps work,

fuse(s) may be blown. Only if you

are comfortable and experienced

doing such maintenance yourself,

follow the instructions that follow.

Otherwise, have the unit repaired



Disconnect and insulate both a.

positive and negative cables

from the back of the inverter.

Connect a lamp to one of the b.

outlets on the front, turn the

inverter on and switch the lamp

on. Wait until the lamp fades

completely. This step is im-

portant for safety, because it

helps to drain power that may

still be present in the inverter

out. Switch off lamp and invert-

er and unplug lamp.

c.

over. Remove four screws from

bottom cover.

Carefully open the bottom cover d.

and detach the connector that

powers the fans. Take note of

the bottom cover’s orientation.

Remove all fuses one-by-one e.



If any fuses are broken, replace

with identical type 40 A rated

fuses.

Reconnect fans and reinstall f.

cover. Reinstall and reconnect

inverter and check inverter and

cooling fans for proper opera-

tion.

SKU 95596 For technical questions, please call 1-800-444-3353 PAGE 11

LIMITED 90 DAY WARRANTY

Harbor Freight Tools Co. makes ev-

ery effort to assure that its products meet

high quality and durability standards, and

warrants to the original purchaser that this

product is free from defects in materials

and workmanship for the period of 90 days

from the date of purchase. This warranty

does not apply to damage due directly or

indirectly, to misuse, abuse, negligence or

accidents, repairs or alterations outside

our facilities, criminal activity, improper in-

stallation, normal wear and tear, or to lack

of maintenance. We shall in no event be

liable for death, injuries to persons or prop-

erty, or for incidental, contingent, special

or consequential damages arising from the

use of our product. Some states do not al-

low the exclusion or limitation of incidental

or consequential damages, so the above

limitation of exclusion may not apply to

you.

-





AND FITNESS.

To take advantage of this warranty,

the product or part must be returned to us

with transportation charges prepaid. Proof

of purchase date and an explanation of the

complaint must accompany the merchan-



we will either repair or replace the product

at our election or we may elect to refund

the purchase price if we cannot readily

and quickly provide you with a replace-

ment. We will return repaired products at

our expense, but if we determine there is

no defect, or that the defect resulted from

causes not within the scope of our warran-

ty, then you must bear the cost of returning

the product.



legal rights and you may also have other

rights which vary from state to state.

3491 Mission Oaks Blvd. • PO Box

6009 • Camarillo, CA 93011 • (800)

444-3353

REV 08g

Chicago Electric Power Systems 95596 Set Up And Operating Instructions Manual

Chicago Electric Power Systems 95596 Set Up And Operating Instructions Manual

Chicago Electric Power Systems 95596 Set Up And Operating Instructions Manual

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