Harbor Freight Tools VULCAN PROTIG 200, Owner'S Manual & Safety Instructions

Page 1: ...erence When unpacking make sure that the product is intact and undamaged If any parts are missing or broken please call 1 888 380 0318 as soon as possible Copyright 2017 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 Diagrams within this manual m...

Page 2: ...s for future reference general Safety pROTEcT yourself and others Read and understand this information 1 Before use read and understand manufacturer s instructions Material Safety Data Sheets MSDS s employer s Safety practices and ANSI Z49 1 2 Keep out of reach of children Keep children and bystanders away while operating 3 place the welder on a stable location before use If it falls while plugged...

Page 3: ...le use an approved respirator 5 Work in a confined area only if it is well ventilated or while wearing an air supplied respirator 6 Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding situation Follow OSHA guidelines for Permissible Exposure Limits PEL s and the American Conference of Gov...

Page 4: ... 35 feet 10 meters around the work area Use a fire resistant material to cover or block all open doorways windows cracks and other openings 2 Keep ABc type fire extinguisher near work area and know how to use it 3 Maintain a safe working environment Keep the work area well lit Make sure there is adequate surrounding workspace Keep the work area free of obstructions grease oil trash and other debri...

Page 5: ...e the welder for pipe thawing Maintenance 1 Maintain welders check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the welder s operation If damaged have the welder repaired before use Many accidents are caused by poorly maintained welders 2 Have your welder serviced by a qualified repair person using only identical replacement parts This will ...

Page 6: ...ified to do so 3 To ground the work bench connect a 12 AWG grounding wire not included from the work bench to a grounding rod not included The grounding rod must be an earth driven copper or brass rod electrode which can adequately ground the work bench 4 Refer to local regulations for ground source information High Frequency Radiation 1 The operator of welding equipment that causes harmful interf...

Page 7: ...nual before setup and or use Fire Hazard Keep flammable materials away during welding Spatter can cause accidental fires Arc Ray Hazard Wear welding helmet with properly rated filter lens Pacemaker Hazard Welding processes may interfere with pacemakers Consult doctor before use Specifications TIG Stick 120VAC 60Hz 240VAC 60Hz 120VAC 60Hz 240VAC 60Hz Power Input at Output 21 4A at 115A 21A at 200A ...

Page 8: ... Switch off and unplug the welder before set up Place the Welder on a level surface that can bear its weight near the work area Leave space around the Welder for proper air flow TIg Setup connect cables TIg Torch ground clamp Negative Socket Foot pedal Socket positive Socket Foot pedal 1 Plug Ground Clamp cable into Positive Socket Twist clockwise all the way to lock in place 2 Plug TIG Torch cabl...

Page 9: ...rt from the valve opening Close the cylinder valve 3 Close the Regulator s valve by backing off knob until it is loose then thread Regulator onto cylinder and wrench tighten connection 4 Attach the Gas Hose included to the Regulator s Outlet and the Welder s Gas Inlet Wrench tighten both connections Reset Power Input Gas Inlet 4 3 Briefly open valve to clean then close valve 2 1 connect power cord...

Page 10: ...ace of the grinding wheel at an angle Rotate Electrode tip until a blunt point is formed Note Grinding direction must be parallel to length of Electrode 5 The conical portion of the ideal tip will be 2 1 2 times as long as the Electrode diameter 6 Re insert Electrode into Collet with tip protruding 1 8 1 4 beyond the Ceramic Nozzle then re tighten the Back Cap Assemble TIg Torch 1 Consult Settings...

Page 11: ...lamp cable into Negative Socket Twist clockwise all the way to lock in place 2 Plug Electrode Holder cable into Positive Socket Twist clockwise al the way to lock in place connect power cord Plug either 120VAC or 240VAC cord into Power Input Socket Note Plug will only fit one way WARNINg TO pREVENT SERIOUS INJURy FROM AccIdENTAL OpERATION Do not plug cord into wall outlet at this time power Input ...

Page 12: ...G Welding is used to weld mild steel and stainless steel using a TIG Rod and shielding gas AC TIG Welding is used to weld aluminum using a TIG Rod and shielding gas Stick Welding is used to weld mild steel and stainless steel using a Stick Electrode without shielding gas Good welding takes a degree of skill and experience Practice a few sample welds on scrap before welding your first project Addit...

Page 13: ...cess Select Knob power Switch Storage compartment Voltage Reduction Indicator Lights when Voltage Reduction Device is operating power Indicator Lights when power is on Voltage Input Thermal Overload Indicator Lights when input voltage is outside the Welder s specifications or duty cycle has been exceeded process Select Knob Turn to select process functions Settings Knob Set process function parame...

Page 14: ... concentrate on proper welding technique The distance if any between the two workpieces must be controlled properly to allow the weld to hold both sides securely while allowing the weld to penetrate fully into the joint The edges of thicker workpieces may need to be chamfered or beveled to allow proper weld penetration NOTICE When welding equipment on a vehicle disconnect the vehicle battery power...

Page 15: ...omatically shuts down and the Overload Indicator lights The welder automatically returns to service after cooling off Rest the Tig Torch or Electrode Holder on an electrically non conductive heat proof surface such as a concrete slab well clear of the ground clamp Allow the Welder to cool with the power Switch on so that the internal Fan will help cool the welder When the Overload Indicator is no ...

Page 16: ... 240V outlet The circuit must be equipped with delayed action type circuit breaker or fuses 4 Set TIG Torch down on nonconductive nonflammable surface well away from any grounded objects 5 Turn the Power Switch ON 6 Set amperage according to Settings Chart on top of Welder Set to high end of amperage range For example Range is 80 100A set amperage to 100A NOTE Settings are approximate Adjust as ne...

Page 17: ... ignited Welder will pulse between Peak Amperage and Background Current Peak Amperage Time is 50 Background Current is 25 of Peak Amperage Current NOTE Maintain a constant distance between the Tungsten Electrode and the workpiece between 1 and 1 5 times the diameter of the Electrode 10 When welding puddle is hot enough tilt torch backward about 10 15 degrees from vertical and move it back slightly...

Page 18: ...onductive nonflammable surface away from any grounded objects 3 Turn the Power Switch ON WARNINg When Stick is selected Welder is energized Hot Start is activated and Open circuit Voltage is present 4 Select process Turn Process Select Knob to dc STIcK process Select Knob Settings Knob 5 Set Amperage according to Stick Settings Chart NOTE Settings are approximate Adjust as necessary Stick Settings...

Page 19: ...CLE guidelines as explained on page 14 6 Place the bare metal end of the Stick Electrode sold separately inside the jaws of the Electrode Holder 7 Stroke the workpiece lightly to ignite the arc Tips for igniting the arc a Tap the surface with the Electrode b Stroke the surface with the Electrode c Strike the surface like a match with the Electrode 8 After the arc ignites a Lift the Electrode off w...

Page 20: ...age the weld it is performed on This test is ONLy an indicator of weld technique and is not intended to test working welds 1 After two scraps have been welded together and the weld has cooled clamp one side in a sturdy vise 2 Stay clear from underneath while you strike the opposite side with a heavy hammer preferably a dead blow hammer 3 A gOOd WELd will deform but not break as shown on top A pOOR...

Page 21: ...ces properly a Increase current b Weld more slowly How to reduce workpiece heat and limit penetration to weld THINNER workpieces properly a Decrease current b Weld more quickly Stick Weld Example diagrams cLEAN WELdS FIRST Stick welds will have a coat of slag over them until cleaned good Weld current Too Low TO cORREcT Increase the current TO cORREcT Decrease the current current Too High TO cORREc...

Page 22: ...3 Workpieces too thick close Bevel thick workpieces allow slight gap and weld in several passes 4 Insufficient weld material Increase amount of fill material Stick Weld Weld Not Adhering properly gaps present between weld and previous bead or between weld and workpiece See areas below pOSSIBLE cAUSES ANd SOLUTIONS PROFILE VIEW 1 Incorrect welding technique Place stringer bead at correct place in j...

Page 23: ...ng speed Maintain steady weld speed Stick Weld crooked Wavy Bead pOSSIBLE cAUSES ANd SOLUTIONS TOP VIEW 1 Inaccurate welding Use two hands or rest hand on steady surface 2 Inconsistent welding speed Maintain steady weld speed Stick Weld Excessive Spatter pOSSIBLE cAUSES ANd SOLUTIONS TOP VIEW Fine spatter is normal Spatter that is grainy and large is a problem dirty workpiece or fill material Clea...

Page 24: ... Voltage Input Thermal Overload Indicator is illuminated check input voltage and ensure it falls within the specified range If input voltage is correct press Reset Button on back of machine 4 Connect shielding gas to Welder When Switched On Power Indicator Does Not Light 1 Unit is not connected to outlet properly 2 Outlet is unpowered 3 Circuit supplies insufficient input voltage or amperage 4 Cir...

Page 25: ... 1 23 Copper Cathode 1 24 Negative Socket 1 25 Gas Socket 1 26 Foot Pedal Socket 1 27 Positive Socket 1 28 Out PCB 1 29 Ground Clamp 1 30 Electrode Holder 1 31 Bottom Housing 1 32 IGBT 16 33 Inverter Radiator 1 34 Fast Recovery Diode 6 35 Fast Recovery Diode 4 36 Rectifier Radiator 2 part description Qty 37 Inductance 1 38 IGBT 8 39 IGBT Left Radiator 2 40 IGBT 2 41 Radiator 1 42 Fast Recovery Dio...

Page 26: ...itch 1 2 3 4 5 CN3 1 2 3 4 5 6 7 8 9 CN1 1 2 CN2 1 2 3 4 5 6 7 CN4 DC DC Q5 Q15 C24 C6 C7 D1 D7 D9 C1 5 R2 C2 5 R3 C3 5 R4 C4 5 R5 v RY2 B A 2 1 L2 2 1 L1 4 5 13 7 15 3 2 9 12 10 8 16 1 11 F 22 20 T1 D4 3 4 B t C L03 1 2 FAN 1 2 3 HF 1 2 CN1 1 2 3 4 5 KEY Foot Pedal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 CONT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 27: ...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 ...

Page 28: ...ow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY 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 a...