Vulcan-Hart OMNIPRO 220, Owner'S Manual & Safety Instructions

Page 1: ...rence 17i 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 manua...

Page 2: ... 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 in severe i...

Page 3: ...rator 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 Governmental Industrial Hyg...

Page 4: ...ble materials for a radius of 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 gre...

Page 5: ...awing 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 ensure that the Safety o...

Page 6: ...he power cord or plug is damaged If damaged have it repaired by a service facility before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician do not use adapter plugs 1 The green wire inside the cord is connected to the grounding system in the Welder The green wire in the cord must be the only wire connected to the Welder s grounding system and must ne...

Page 7: ... Capacity Solid Core 0 025 0 030 0 035 Flux Cored 0 030 0 035 0 045 Wire Speed 50 500 IPM Wire Spool Capacity Up to 12 lb spool TIg Power Input 120VAC 60Hz 240VAC 60Hz Current Input at Output 20 6A at 125A 15 6A at 175A Welding Current Range 10A 125A 10A 175A Rated Duty Cycles 40 125A 100 90A 30 175A 100 105A Maximum OCV 78VDC Weldable Materials Mild Steel Stainless Steel Chrome Moly Stick Power I...

Page 8: ...nt panel controls Wire Feed power cable power Switch Lcd display Right knob Left knob control knob Home Button Back Button Spool gun gas Outlet MIG Gun Spool gun cable Socket Negative Socket positive Socket Storage compartment Note When using an optional Spool Gun sold separately connect the Spool Gun gas hose to the Spool Gun Gas Outlet ...

Page 9: ...0318 Item 63621 SAFETy WELdINg TIpS MAINTENANcE TIg STIck cONTROLS WIRE Interior controls cold Wire Feed Switch Idler Arm Wire Feed Mechanism Wire Spool Spool knob Feed Tensioner Wire Inlet Liner Feed Roller knob Wire Feed control Socket Foot pedal Socket ...

Page 10: ... Spacer over the Spool Spindle and secure Spool in place with the Wingnut Notice If Wire Spool can spin freely Wingnut is too loose This will cause the welding wire to unravel and unspool which can cause tangling and feeding problems power Switch door Latch door Welder Wall Wingnut 1 2 lb Wire Spool Spool Brake pad Spacer Spool Spindle 1 2 lb Spool Loading MIG Flux Cored Wire Welding Read the ENTI...

Page 11: ...ms set the Spool so that it will unwind clockwise 9 Replace the Spacer over the Spool Spindle and secure Spool in place with the Wingnut Notice If Wire Spool can spin freely Wingnut is too loose This will cause the welding wire to unravel and unspool which can cause tangling and feeding problems 10 Screw the Spool Knob into the Spool Adapter 11 Turn the Feed Tensioner knob counterclockwise to loos...

Page 12: ...e Spool a Unscrew the Feed Roller Knob counterclockwise b Remove the Feed Roller Knob to expose the Feed Roller c Flip or replace the Feed Roller as needed and confirm that it is the correct Roller for the type of wire being used and that the number showing is the same as the wire diameter on the Spool d Screw the Feed Roller Knob back into place to secure the Feed Roller Feed Roller knob Feed Rol...

Page 13: ...rtighten the Knob 15 Insert the Wire Feed Control Cable through the hole on the Welder front and connect it to the Wire Feed Control Socket inside the machine then tighten the lock ring on the Cable plug Note that the plug on the Cable fits into the Socket in one specific orientation only 16 dcEN direct current Electrode Negative Wire Setup for Flux cored gasless welding Plug Ground Clamp Cable in...

Page 14: ...hen using C100 shielding gas connect the enclosed CGA 580 320 adapter to the inlet connection of the Regulator and wrench tighten Thread the adapter onto the gas cylinder and wrench tighten f Attach the Gas Hose included to the Regulator s outlet and the Welder s gas inlet Wrench tighten both connections ground clamp cable in Negative Socket dcEp Solid Core Gas Shielded polarity Setup Wire Feed po...

Page 15: ...the Feed Tensioner up to latch it across the tip of the arm After the wire is held by the Tensioner you may release it Note The tension should be 3 5 for solid wire and 2 3 for flux cored wire Too much force on flux cored wire will crush it and may cause feeding issues 21 Pull the Nozzle to remove it 22 Unscrew the Contact Tip counterclockwise and remove 23 Lay the MIG Gun Cable out in a straight ...

Page 16: ...e wire does not feed properly and the Spool is stationary turn OFF and unplug the Welder and slightly tighten the Feed Tensioner clockwise before retrying Reset Power Input Gas Inlet IP21S S 1 f1 f2 Serial 63621 17b Conforms to UL Std 60974 1 269317 Vulcan OMNIPRO 220 30A 15 5V to 220A 25V X 25 60 100 U0 78V I2 200A 130A 115A U2 24V 20 5V 19 75V 1 50 60Hz U1 240V I1max 25 5A 23 7A 15 6A I1eff 12 8...

Page 17: ...pool Gun sold separately plug Ground Clamp Cable into Negative Socket Plug Wire Feed Power Cable into Positive Socket Twist cables clockwise all the way to lock in place 2 Loosen the Knob on the Wire Feed mechanism then insert the Spool Gun Cable Connector through the hole on the Welder front and into the socket on the Wire Feed 3 Ensure Cable Connector is fully inserted and tighten the Knob secur...

Page 18: ... without shielding gas MIG welding uses solid wire and shielding gas and is used to weld mild steel and stainless steel MIG welding can also be used to weld thinner workpieces than flux cored welding can Aluminum welding can be performed with an optional Spool Gun sold separately using aluminum wire and shielding gas Good welding takes a degree of skill and experience Practice a few sample welds o...

Page 19: ...ped ground connection depends on desired welding polarity Workpiece ground clamp clean surface to bare metal Duty Cycle Duration of Use Avoid damage to the Welder by not welding for more than the prescribed duty cycle time The Duty Cycle defines the number of minutes within a 10 minute period during which a given welder can produce a particular welding current without overheating For example a wel...

Page 20: ...isplay screen 3 Press Main Control Knob to select process Note Press Main Control Knob to go to next screen Press Back Button to return to the previous screen 4 Adjust settings for the selected process a Polarity and Gas Settings Plug cables in according to screen Connect gas according to screen Set SCFH between 20 30 b Set Wire Diameter and Material Thickness Turn Left Knob to set wire diameter T...

Page 21: ...ettings Save Setting Program up to 5 different configurations Turn Main Control Knob to scroll between 5 available slots Press Main Control Knob to access OVERWRITE MEMORY SETTING screen and turn Main Control Knob to choose YES selection Press Main Control Knob to save current Welder settings Note The initial settings may need to be adjusted after stopping and carefully inspecting the weld Proper ...

Page 22: ... welds 4 For MIG welding using solid wire and shielding gas the end of the MIG Gun should be tilted so that wire is angled anywhere in between straight on and 15 away from the direction you are welding The amount of tilt is called the push angle 5 When using flux cored wire without shielding gas the end of the MIG Gun should be tilted so that wire is angled anywhere in between straight on and 15 i...

Page 23: ...UTION Weld will be hot do not touch 8 When welding is complete set the MIg gun down on a heat proof electrically non conductive surface Turn the Power Switch OFF 9 Allow Welder to cool down then unplug the Power Cord 10 Remove Ground Clamp from workpiece or table and disconnect MIG Gun 11 Respool wire by clipping wire removing gas nozzle contact tip on MIG gun releasing Idler Arm on Wire Feed mech...

Page 24: ...rk area Leave space around the Welder for proper air flow TIg Setup connect cables ground clamp cable in positive Socket ground clamp TIg Torch cable in Negative Socket TIg Torch sold separately Foot pedal Socket inside Welder Foot pedal sold separately Foot pedal cable Shielding gas Hose 1 Plug Ground Clamp Cable into Positive Socket Twist clockwise all the way to lock in place 2 Plug TIG Torch C...

Page 25: ...ither 120VAC or 240VAC Power 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 4 3 1 Briefly open valve to clean then close valve 2 Reset Power Input Gas Inlet IP21S S 1 f1 f2 Serial 63621 17b Conforms to UL Std 60974 1 269317 Vulcan OMNIPRO 220 30A 15 5V to 220A 25V X 25 60 100 U0...

Page 26: ...rface 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 sold separately ...

Page 27: ...JURy FROM AccIdENTAL OpERATION Do not plug cord into wall outlet at this time Reset Power Input Gas Inlet IP21S S 1 f1 f2 Serial 63621 17b Conforms to UL Std 60974 1 269317 Vulcan OMNIPRO 220 30A 15 5V to 220A 25V X 25 60 100 U0 78V I2 200A 130A 115A U2 24V 20 5V 19 75V 1 50 60Hz U1 240V I1max 25 5A 23 7A 15 6A I1eff 12 8A 11 9A 8 5A 10A 20 4V to 175A 27V X 25 60 100 U0 78V I2 175A 115A 100A U2 27...

Page 28: ...s DC TIG 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 projec...

Page 29: ...C 40 Use at 80A For 10 continuous Minutes 100 Continuous Use at 60A 4 Minutes Welding 6 Minutes Resting Stick Rated duty cycles 240VAC 30 Use at 175A For 10 continuous Minutes 100 Continuous Use at 105A 3 Minutes Welding 7 Minutes Resting 120VAC 40 Use at 125A For 10 continuous Minutes 100 Continuous Use at 90A 4 Minutes Welding 6 Minutes Resting TIg Rated duty cycles Setting up the Weld clamps wo...

Page 30: ...on the inside of the Welder door 3 Turn the Power Switch to the OFF position then plug the Welder into a properly grounded GFCI protected 120VAC 20 amp rated outlet or 240V outlet The circuit must be equipped with delayed action type circuit breaker or fuses 4 Set TIG Torch down on nonconductive nonflammable surface away from any grounded objects 5 Turn the Power Switch ON 6 Press Home Button on C...

Page 31: ...lowing the DUTY CYCLE guidelines as explained on page 29 WARNINg Metal work bench must be grounded when TIg welding 10 Hold TIG Torch in one gloved hand and the TIG Rod sold separately in other gloved hand NOTE Maintain a constant distance between the Tungsten Electrode and the workpiece between 1 and 1 5 times the diameter of the Electrode 11 When welding puddle is hot enough tilt torch backward ...

Page 32: ...itch ON 4 Press Home Button on Control Panel 5 Turn Main Control Knob until Stick process appears on LCD display screen 6 Press Main Control Knob to select STICK process Note Press Main Control Knob to go to next screen Press Back Button to return to the previous screen Main control knob Left knob Right knob Stick 7 Adjust settings for the STICK process a Polarity Setting Plug cables in according ...

Page 33: ...o not breathe arc fumes After practice welding on scrap stop and check your progress Perform Strike Test according to Strike Test on page 34 After making any necessary adjustments continue to weld while carefully following the DUTY CYCLE guidelines as explained on page 29 8 Place the bare metal end of the Stick Electrode sold separately inside the jaws of the Electrode Holder 9 Stroke the workpiec...

Page 34: ...d 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 scrap in a sturdy vise 2 Stay clear from underneath while you strike the opposite scrap with a heavy hammer preferably a dead blow hammer 3 A gOOd WELd will deform but not break as shown on top A pOOR WELd will be brittle and...

Page 35: ...n to weld THINNER workpieces properly a Increase weld current b decrease travel speed c Use faster wire feed d Use shorter cTWd e decrease weld current f Increase travel speed g Use slower wire feed h Use longer cTWd Example Wire Weld diagrams good Weld Voltage Too Low or Wire Feed Too Slow Voltage Too High or Wire Feed Too Fast Travel Speed Too Fast Travel Speed Too Slow cTWd Too Long or Wrong po...

Page 36: ...ROFILE VIEWS Weld Not Adhering properly gaps present between weld and previous bead or between weld and workpiece See areas below pOSSIBLE cAUSES ANd SOLUTIONS 1 Incorrect welding technique Place stringer bead at correct place in joint Adjust workpiece position or weld angle to permit proper welding to bottom of piece Pause briefly at sides during weave bead Keep arc on leading edge of weld puddle...

Page 37: ...ity is set correctly for type of welding 2 Insufficient shielding gas MIG only Increase flow of gas Clean nozzle Maintain proper CTWD 3 Incorrect shielding gas MIG only Use shielding gas recommended by wire supplier 4 dirty workpiece or welding wire Clean workpiece down to bare metal Make certain that wire is clean and free from oil coatings and other residues 5 Inconsistent travel speed Maintain ...

Page 38: ...ieces properly a Increase current b Weld more slowly How to reduce workpiece heat and limit penetration to weld THINNER workpieces properly c Decrease current d Weld more quickly Example Stick Weld 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 cORR...

Page 39: ...t 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...

Page 40: ...ding 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 Cl...

Page 41: ...lectrical outlet before proceeding 2 Pull the Nozzle to remove it 3 Scrub the interior of the Nozzle clean with a wire brush 4 Examine the end of the Nozzle The end should be flat and even If the end is uneven chipped melted cracked or otherwise damaged the Nozzle will adversely effect the weld and should be replaced 5 Unscrew the Contact Tip counterclockwise and slide it off the welding wire to r...

Page 42: ...enough contact with wire or is crushing flux cored wire 1 Straighten Gun cable 2 Check gun liner for obstruction Replace if necessary 3 Check that gun liner is correct size for wire 4 Check wire for cross winding or tangled spool 5 Check Feed Rollers and ensure correct groove for wire diameter is being used 6 Check Feed Tensioner and ensure it is set properly Welding Arc Not Stable 1 Wire not feed...

Page 43: ...ped due to high input amperage 5 Input Power Cord is not seated properly 1 Verify the voltage at the outlet and the connection to the outlet 2 Check circuit breaker GFCI devices if any are tripped determine and remedy cause before resetting 3 Make sure installed plug is correct rating See Specifications on page 7 4 Press Reset Button on back of machine to reset circuit breaker 5 Ensure the twist l...

Page 44: ...t properly 2 Outlet is unpowered 1 Verify the voltage at the outlet and the connection to the outlet 2 Check circuit breaker GFCI devices if any are tripped determine and remedy cause before resetting Verify that the circuit is designed to supply the required input amperage as detailed in Specifications on page 7 Weak Arc Strength 1 Incorrect line voltage 2 Improper gauge or length of cord 1 Check...

Page 45: ...31 32 33 34 CN5 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 Main Board control panel F Fuse 1 2 FAN2 1 2 3 4 CN3 Gas valve 1 1 2 3 CN7 M Drawing Wire Motor Wire Feed Motor Gas Valve 1 Gas Valve 2 1 2 CN6 3 4 Touch Switch 1 2 3 4 CN1 Hall Sensor 1 2 3 4 5 6 7 CN8 Remote Control Board 1 2 3 4 5 6 7 CN1 1 2 CN3 3 4 Gun switch 1 2 3 4 5 6 CN2 Remote con...

Page 46: ... 1 53 Bridge Rectifier 2 54 IGBT 4 55 IGBT Radiator 2 56 Fan 1 57 Threaded Y connector 1 58 120VAC Power Cord 1 59 Rear Panel 1 60 Rear Handle Cover 1 61 Power Connector 1 62 Overload Protector 1 63 Rear Panel 1 64 240VAC Power Cord 1 parts List and diagram pLEASE REAd THE FOLLOWINg cAREFULLy THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A R...

Page 47: ...m 63621 SAFETy WELdINg TIpS MAINTENANcE TIg STIck cONTROLS WIRE Assembly diagram 1 2 3 4 5 6 7 10 9 12 11 8 15 14 16 17 18 19 20 21 22 23 26 24 25 27 32 31 28 29 30 35 34 36 37 43 38 44 45 46 47 42 39 40 41 48 49 52 51 55 63 62 61 57 56 60 59 58 50 54 53 13 64 33 ...

Page 48: ...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...