Chicago Electric 96531 User's Manual
Contents
1. Tools with Three Prong Plugs 7 Double Insulated Tools Tools with Two Prong Plugs 7 Extension COrdS see een ee ee 7 SYMDOIOGY ene ene ene eee erence meee eee 8 SPECIFICATIONS siiin iaaeaie raaa 9 UNPACKING 2 aeei aE aeae Aaaa 9 ASSEMBLY oiei EERE A ARAA AAEN 9 OPERATION ceini EEE EEEE EEA EER 10 MAINTENANCE AND 12 PARIS LISI EKAMAN nEn 14 ASSEMBLY 14 WARRANTY eranda naiean 15 SKU 96531 For technical questions please call 1 800 444 3353 Page 2 SAVE THIS MANUAL Keep this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference IMPORTANT SAFETY INFORMATION In this manual on the labeling and all other information provided with this product AWARNING ACAUTION NOTICE CAUTION This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates a hazard2. have the problem corrected before further use Cleaning maintenance and lubrication 1 BEFORE EACH USE inspect the general condition of the tool Check for dam aged Soldering Iron 15 tip loose screws cracked or broken parts damaged electrical wiring and any other condition that may affect its safe operation 2 AFTER USE clean external surfaces and Soldering Tip WARNING If the supply cord of this power tool is damaged it must be replaced only by a qualified service technician Replacing the Soldering Iron 1 If Soldering Tip cracks or becomes eroded it must be replaced The Soldering Tip cannot heat up properly when cracked or eroded Heating Contact 17 Tip Retainer 16 Soldering Iron 15 2 Turn Power Switch 4 to the OFF position and unplug the Soldering Station from the electrical outlet Allow adequate time for all surfaces to cool down Unscrew Tip Retainer 16 that holds the Soldering Iron 15 onto the Heating Contact 17 and remove the Soldering Iron It may be necessary to force the Soldering Iron 15 out of the Tip Retainer 16 To do this place the Soldering Iron on the side of the work bench hold the Tip Retainer and push on it towards the Soldering Tip forcing it out Be sure to wear ANSI approved safety goggles and heavy duty work gloves while doing this 4 Place new Solder Tip on Heating Contact replace Retainer and finger tighten Replacing the Fuse 1 Tur
3. DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that this prod uct 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 installation normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESS LY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY 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 merchandise If our inspection verifies the defect 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 replacement We will return repaired products at our expense but i
4. Insulated do not require grounding They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories Inc the Canadian Stan dard Association and the National Electrical Code See Outlets for 2 Prong Plug Double insulated tools may be used in either of the 120 volt outlets shown in the preceding illustration See Outlets for 2 Prong Plug Extension Cords Grounded tools require a three wire extension cord Double Insulated tools can use either a two or three wire extension cord SKU 96531 For technical questions please call 1 800 444 3353 Page 7 2 As the distance from the supply outlet increases you must use a heavier gauge extension cord Using extension cords with inadequately sized wire causes a serious drop in voltage resulting in loss of power and possible tool damage See Table A The smaller the gauge number of the wire the greater the capacity of the cord For example a 14 gauge cord can carry a higher current than a 16 gauge cord See Table A 4 When using more than one extension cord to make up the total length make sure each cord contains at least the minimum wire size required See Table A 5 If you are using one extension cord for than one tool add the nameplate amperes and use the sum to determine the required minimum cord size See Table A 6 If you are using an extension cord outdoors make
5. up to 896 F Test a scrap piece or inconspicuous area of your work piece with the soldering tip before proceeding Be sure the surfaces being soldered are clean before beginning If necessary use a soldering flux not included for cleaning Apply the flux to the parts being joined and heat the parts until the flux burns away Heat the parts being joined with the soldering tool not the solder Once the parts being joined are sufficiently heated touch the solder to the work pieces The solder will melt and adhere to the work pieces Remove the soldering tip from the work pieces and hold the pieces together until they have cooled enough for the solder to solidify Solder will follow the heat Once a workpiece is sufficiently hot to melt the sol der the solder can be dragged along the workpiece by moving the soldering tip The solder will follow the heat This technique is helpful when soldering joints such as a tube in a coupling By applying solder to the edge of the coupling and then moving the soldering tip away from the edge solder can be dragged into a concealed joint as it follows the heat WARNING Some solders contain lead and some do not Be extremely careful not to 6 7 breathe vapors from any solder especially ones containing lead Lead is a heavy metal which can accumulate in the body and cause serious health problems Remember to use in a well ventilated work area and wear ANSI approved safety goggles heavy du
6. CHICAGO DIGITAL SOLDERING STATION SET UP AND OPERATING INSTRUCTIONS Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein 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 Copyright 2007 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 or replacement parts please call 1 800 444 3353 CONTENTS IMPORTANT SAFETY INFORMATION 3 GENERAL SAFETY RULES sc secisctecsssisscassicassssscscatasnresanasiass 3 Work Area 4 Electrical Safety 2 iiaeaa 4 Personal Safety nnnnnnsnennesensnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 4 Tool Use teenie 5 SOIC Eai aeaa aeaaea aen aeaa A eae E SNE ARARE aaa 6 SPECIFIC SAFETY RULES scsccibicmesstscesuseiid ioawcttuteoadeaddowesten 6 GROUNDING nssssnsnnsssssnnnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nenne 6 Grounded Tools
7. ain power tools Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the power tools operation If damaged have the power tool repaired before use Many ac cidents are caused by poorly maintained power tools f Use the power tool accessories and tool bits etc in accordance with these instructions and in the manner intended for the particular type of power tool taking into account the working conditions and the work to be performed Use of the power tool for operations different from those intended could result in a hazardous situation 5 Service a Have your power tool serviced by a qualified repair person using only identi cal replacement parts This will ensure that the safety of the power tool is maintained SKU 96531 For technical questions please call 1 800 444 3353 Page 5 SPECIFIC SAFETY RULES 1 Maintain labels and nameplates the tool These carry important safety infor mation If unreadable or missing contact Harbor Freight Tools for a replacement 2 Avoid unintentional starting Prepare to begin work before turning the tool Do not leave the tool unattended when it is plugged into an electrical outlet Turn off the tool and unplug it from its electrical outlet before leaving Make sure sol dering wire is not connected to tool that is plugged in 4 Use clamps not included or other practical ways to secure and support the workpiece to a stab
8. ep children and bystanders away while operating a power tool Dis tractions can cause you to lose control 2 Electrical safety a Power tool plugs must match the outlet Never modify the plug in any way Do not use any adapter plugs with earthed grounded power tools Unmodi fied plugs and matching outlets will reduce risk of electric shock b Avoid body contact with earthed or grounded surfaces such as pipes radia tors ranges and refrigerators There is an increased risk of electric shock if your body is earthed or grounded c Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock d Do not abuse the cord Never use the cord for carrying pulling or un plugging the power tool Keep cord away from heat oil sharp edges or moving parts Damaged or entangled cords increase the risk of electric shock e Never operate this power tool outdoors 3 Personal safety a Stay alert watch what you are doing and use common sense when operating a power tool Do not use a power tool while you are tired or under the influ ence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury SKU 96531 For technical questions please call 1 800 444 3353 Page 4 b Use safety equipment Always wear eye protection Safety equipment such as dust mask non skid safety shoes heavy duty work gloves hard hat or hea
9. f we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state 3491 Mission Oaks Blvd Box 6009 Camarillo 93011 800 444 3353 Record Product s Serial Number Here Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 96531 For technical questions please call 1 800 444 3353 Page 15
10. le platform Holding the work by hand or against your body is unstable and may lead to loss of control 5 Use in well ventilated area only and keep out of reach of children 6 People with pacemakers should consult their physician s before use Electro magnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure 7 WARNING This product when used for welding plasma cutting soldering or similar applications produces chemicals known to the State of California to cause cancer and birth defects or other reproductive harm California Health amp Safety Code 25249 5 et seq 8 Use caution when handling the Soldering Tip it comes to a sharp point and is especially dangerous when heated The soldering tip can generate temperatures up to 896 F always use caution when working with this tool and keep flammable items at a clear safe distance 9 The warnings precautions 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 factors which cannot be built into this product but must be supplied by the operator SAVE THESE INSTRUCTIONS GROUNDING Improperly connecting grounding wire can result in electric AWARNING shock Check with qualified electrician if you in doubt as to whether outlet is properly grounded Do not modify
11. lux on wiring circuits Place tip of Soldering Iron 15 under the joint which you are soldering If uncertain on how to proceed it may be wise to practice on a scrap workpiece first General operating instructions When operating use only in designated soldering work area Apply solder to the joint wiring or metal to be soldered not to the Soldering Tip When the metal is hot enough it will melt the solder and allow it to flow around the wiring or metal being soldered Slowly move Soldering Tip around to coat the entire area being soldered When the entire wiring or metal surface is encased in solder remove the Solder ing Tip and place in the handle rest Allow the soldering to cool completely before pulling gently on the item to ensure a secure hold Blowing air on the soldered joint will help speed up the cooling When you are finished soldering wipe the Soldering Tip thoroughly on the Sponge and apply a small amount of rosin core solder to coat the Soldering Tip and keep it clean Soldering Tips The soldering process bonds two metal objects together using a metallic bond ing material solder which has a lower melting point than the items being joined Soldering is not appropriate for non metallic objects such as plastic or wood SKU 96531 For technical questions please call 1 800 444 3353 Page 11 Check to be sure the objects being joined will not be damaged by the heat of soldering This tool generates a temperature
12. n the Power Switch 4 to the OFF position unplug the Soldering Station from the outlet and allow time for all surfaces of the unit to cool down completely 2 Turn the Soldering Station over and use a screwdriver to remove the cover marked FUSE on the bottom Remove the old fuse and replace with new 6 3A 250V fuse of the same type Replace cover and screw back into place SKU 96531 For technical questions please call 1 800 444 3353 Page 13 PARTS LIST amp ASSEMBLY DIAGRAM Part Description aty e Cord Connection 1 Temperature bial 1 e eushion 1 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO SKU 96531 For technical questions please call 1 800 444 3353 Page 14 LIMITED 90
13. ore set up or use of this product Risk of accidental starting resulting in serious personal AWARNING injury Turn the Power Switch of the tool to its OFF position and unplug the tool from its electrical outlet before assembling or making any adjustments to the tool SKU 96531 For technical questions please call 1 800 444 3353 Page 9 Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near the end of this manual Assembly 1 Match up holes in Plug 27 to pins in Cord Connection 6 plug in and secure with Cord Retainer 26 2 Place Sponge in the bottom of the handle rest Handle Rest when cold unit Set up handle rest unit within easy reach 2 Solder of the Soldering Station 4 Plug Soldering Station into any standard Sponge 120V AC electrical outlet Handle Rest Functions when hot The Digital Soldering Station is designed to heat solder in order to secure wiring and metal surfaces together OPERATING INSTRUCTIONS A Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product Tool set up 1 Check for breakage worn parts damaged cords or any other condition that may effect the tool s operation If damaged have the tool serviced by a qualified tech nician before using 2 Tighten the Tip Retainer 16 on
14. ous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE is used to address practices not related to personal injury CAUTION without the safety alert symbol is used to address practices not related to personal injury SKU 96531 For technical questions please call 1 800 444 3353 Page 3 GENERAL SAFETY RULES WARNING Read all instructions Failure to follow all instructions listed below may result in electric shock fire and or serious injury The term power tool in all of the warnings listed below refers to your mains operated corded power tool or battery operated cordless power tool SAVE THESE INSTRUCTIONS 1 Work area safety a Keep work area clean and well lit C uttered or dark areas invite accidents b Do not operate power tools in explosive atmospheres such as in the pres ence of flammable liquids gases or dust The intense heat from the Solder ing Station may ignite the dust or fumes c Operate this power tool only in a well ventilated area Be extremely careful not to breathe vapors from any solder especially ones containing lead Lead is a heavy metal which can accumulate in the body and cause serious health problems d Ke
15. power cord plug provided with the tool Never remove grounding prong from the plug Do not use tool if power cord or plug is damaged If damaged have it repaired by a service facility SKU 96531 For technical questions please call 1 800 444 3353 Page 6 before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician Grounded Tools Tools with Three Prong Plugs Tools marked with Grounding Required 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 is connected through the green wire inside 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 an appropriate outlet properly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in the following illustration See 3 Prong Plug and Outlet 1 3 Prong Plug and Outlet Outlets for 2 Prong Plug Double Insulated Tools Tools with Two Prong Plugs Tools marked Double
16. ring protection used for appropriate conditions will re duce personal injuries c Avoid accidental starting Ensure the switch is in the off position before plug ging in Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents d Do not overreach Keep proper footing and balance at all times This en ables better control of the power tool in unexpected situations e Dress properly Do not wear loose clothing or jewelry Keep your hair cloth ing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts 4 Power tool use and care Do not force the power tool Use the correct power tool for your application The correct power tool will do the job better and safer at the rate for which it was designed b Do not use the power tool if the switch does not turn it on and off Any power tool that cannot be controlled with the switch is dangerous and must be re paired c Disconnect the plug from the power source and from the power tool before making any adjustments changing accessories or storing power tools Such preventive safety measures reduce the risk of starting the power tool accidentally d Store idle power tools out of the reach of children and do not allow per sons unfamiliar with the power tool or these instructions to operate the power tool Power tools are dangerous in the hands of untrained users e Maint
17. sure it is marked with the suf fix W A W in Canada to indicate it is acceptable for outdoor use 1 Make sure the extension cord is properly wired and in good electrical condition Always replace a damaged extension cord or have it repaired by a qualified elec trician before using it 8 Protect the extension cords from sharp objects excessive heat and damp or wet areas NAMEPLATE AMPERES eds eee ae 100 Feet EXTENSION CORD LENGTH 12 1 16 0 E 8 2 0 i id TABLE A Based on limiting the line voltage drop to five volts at 150 of the rated amperes SKU 96531 For technical questions please call 1 800 444 3353 Page 8 Symbology o Double Insulated Volts Alternating Current Underwriters Laboratories Inc ae Revolutions per Minute SPECIFICATIONS Power Consumption 60 Watt Temperature Range 150 450 C 300 840 F 18 AWG X 3C 6 3A 250V Weight 5 1 Pounds UNPACKING When unpacking check to make sure that the item is intact and undamaged 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 List of contents Soldering Station Soldering Handle Assembly 1 Soldering Iron Stand SET UP INSTRUCTIONS Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the A beginning of this manual including all text under subheadings therein bef
18. the Soldering Iron 15 3 Select the correct solder for the intended application Read the directions for the solder being used to determine what temperature level to set on the Soldering Station To minimize the risk of damage to surrounding components select the minimum heat required to melt the solder chosen for the application 4 Plug Soldering Station in and turn Power Switch 4 to the ON position Turn the Temperature Dial 8 and wait until the desired temperature is displayed on the LCD Display 5 or push one of the Preset Buttons e Preset Button 1 150 C 302 F e Preset Button 2 270 C 518 F e Preset Button 3 360 C 680 F SKU 96531 For technical questions please call 1 800 444 3353 Page 10 Place Handle in the Handle Rest black socket and wait 20 seconds until Solder ing Tip heats up Work piece set up If wires are to be soldered thoroughly clean and scrape the wires so that only the clean copper is showing Splice wires that are to be soldered together If other metals are to be soldered thoroughly clean and scrape the metal sur faces It may be necessary to apply acid flux not included to clean the metal surfaces before soldering If soldering on printed circuit boards too much heat can soften the plastic form or loosen the metal eyelet connections Use the lowest heat setting possible see the solder s directions to perform the soldering operation Never use acid core solder or acid f
19. ty work gloves and a dust mask respirator during use Solder is available in various types Some solders have a flux core and some do not Flux core solders contain flux and reduce the need to clean the work pieces before joining Solid core solders do not contain flux and require careful clean ing of the work material and application of flux for additional cleaning Solder is available in various melting points The heat range of solder may be expressed in temperature or may be expressed as easy medium or hard u Easy solder will melt before medium medium will melt before hard and hard will melt at only the highest temperatures When making several solder joints on a single workpiece you may use a mix of solder temperatures Note The Anti Static Ground on the unit is not utilized when the Soldering Station is equipped with a 3 prong plug MAINTENANCE AND SERVICING Risk of serious personal injury from accidental starting or AWARNING electric shock Turn the Power Switch of the tool to its OFF position as marked with an O below the Power Switch SKU 96531 For technical questions please call 1 800 444 3353 Page 12 4 and unplug the tool from its electrical outlet before performing inspection maintenance or cleaning procedures Damaged equipment can fail causing personal injury Do not use damaged equipment If abnormal noise or vibration occurs
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