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

Brand: Harbor Freight Tools

Model: VULCAN PROTIG 200

Category: Welding System

Type: Owner's Manual & Safety Instructions

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Owner’s Manual & Safety Instructions

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.

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-<?>-1-888-380-0318 as soon as possible.

2017 by Harbor Freight Tools

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 may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein.

Tools required for assembly and s er vi ce m ay n ot be i nc lu de d.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

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?@!6%ABC?%D@EF@G1

Owner’s Manual & Safety Instructions

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.

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.

2017 by Harbor Freight Tools

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 may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein.

Too ls r eq ui re d fo r ass em bl y an d se rv ic e m ay n ot b e in cl ud ed.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

?@!6%ABC?%D@EF@G1

Owner’s Manual & Safety Instructions

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.

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.

2017 by Harbor Freight Tools

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 may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein.

Too ls r eq ui re d fo r ass em bl y an d se rv ic e m ay n ot b e in cl ud ed.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

?@!6%ABC?%D@EF@G1

Owner’s Manual & Safety Instructions

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.

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.

2017 by Harbor Freight Tools

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 may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein.

Too ls r eq ui re d fo r ass em bl y an d se rv ic e m ay n ot b e in cl ud ed.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

?@!6%ABC?%D@EF@G1

Owner’s Manual & Safety Instructions

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. 17k

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.

2017 by Harbor Freight Tools

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 may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein.

Too ls r eq ui re d fo r ass em bl y an d se rv ic e m ay n ot b e in cl ud ed.

;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%

<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%

?@!6%ABC?%D@EF@G1

Page 2 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

A,+7*%&2%P&8$*8$#

Safety ...................................................................... 2

Specifications .......................................................... 7

Setup ....................................................................... 8

Basic Welding ......................................................... 12

Welding Tips ........................................................... 20

Maintenance and Service ....................................... 24

Parts List and Diagrams ......................................... 25

Warranty ................................................................. 28

R@;ECET%?ODQVG?%@ES%S6<CECACVE?

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.

Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

Addresses practices not related to personal injury.

CDUV;A@EA%?@<6AO%CE<V;D@ACVE

;*,9%,77%?,2*$>%),(8"83#%,89%"8#$('4$"&8#1%%

<,"7'(*%$&%2&77&)%$.*%),(8"83#%,89%"8#$('4$"&8#%5,>%(*#'7$%"8%*7*4$("4%#.&4WI%2"(*%,890&(%#*("&'#%"8='(>1%%%

?,X*%,77%),(8"83#%,89%"8#$('4$"&8#%2&(%2'$'(*%(*2*(*84*1

T*8*(,7%?,2*$>

U;VA6PA%>&'(#*72%,89%&$.*(#1%%;*,9%,89%'89*(#$,89%$."#%"82&(5,$"&81

1. Q*2&(*%'#*I%(*,9%,89%'89*(#$,89%

manufacturer′s instructions,

Material Safety Data Sheets (MSDS′s),

employer′s Safety practices, and ANSI Z49.1.

2. Y**/%&'$%&2%(*,4.%&2%4."79(*81%%%

Keep children and bystanders away while operating.

3. U7,4*%$.*%)*79*(%&8%,%#$,+7*%7&4,$"&8%+*2&(*%'#*1%%%

If it falls while plugged in, severe injury,

electric shock, or fire may result.

4. S&%8&$%&X*((*,4.1%%%

Y**/%/(&/*(%2&&$"83%,89%+,7,84*%,$%,77%$"5*#1

5. ?$,>%,7*($I%),$4.%).,$%>&'%,(*%9&"83%,89%'#*%

4&55&8%#*8#*%).*8%&/*(,$"83%,%)*79*(1%%

S&%8&$%'#*%,%)*79*(%)."7*%>&'%,(*%$"(*9%&(%'89*(%

$.*%"827'*84*%&2%9('3#I%,74&.&7%&(%5*9"4,$"&81

A moment of inattention while operating welders

may result in serious personal injury.

6. @X&"9%'8"8$*8$"&8,7%#$,($"831%%Make sure you are

prepared to begin work before turning on the Welder.

7. E*X*(%7*,X*%$.*%R*79*(%'8,$$*89*9%)."7*%

*8*(3"Z*91%Turn power off if you have to leave.

8. A.*%),(8"83#I%/(*4,'$"&8#I%,89%"8#$('4$"&8#%

9"#4'##*9%"8%$."#%"8#$('4$"&8%5,8',7%4,88&$%

4&X*(%,77%/&##"+7*%4&89"$"&8#%,89%#"$',$"&8#%

$.,$%5,>%&44'(1%%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 3<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63619

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

<'5*%,89%T,#%?,2*$>

INHALATION HAZARD:%

R*79"83%,89%U7,#5,%P'$$"83%/(&9'4*%$&["4%2'5*#1

1. 6[/&#'(*%$&%)*79"83%&(%4'$$"83%*[.,'#$%

2'5*#%4,8%"84(*,#*%$.*%("#W%&2%9*X*7&/"83%

4*($,"8%4,84*(#I%#'4.%,#%4,84*(%&2%$.*%

7,(>8[%,89%7'83%4,84*(1 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

• Inflammation 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.

2. S&%8&$%'#*%8*,(%9*3(*,#"83%&(%

/,"8$"83%&/*(,$"&8#1

3. Y**/%.*,9%&'$%&2%2'5*#1%%

Do not breathe exhaust fumes.

4. F#*%*8&'3.%X*8$"7,$"&8I%*[.,'#$%,$%,(4I%&(%

+&$.I%$&%W**/%2'5*#%,89%3,#*#%2(&5%+(*,$."83%

Z&8*%,89%3*8*(,7%,(*,1%%If engineering controls

are not feasible, use an approved respirator.

5. R&(W%"8%,%4&82"8*9%,(*,%&87>%"2%"$%

"#%)*77KX*8$"7,$*9I%&(%)."7*%)*,("83%

,8%,"(K#'//7"*9%(*#/"(,$&(1

6. B,X*%,%(*4&38"Z*9%#/*4",7"#$%"8%

C89'#$(",7%B>3"*8*%&(%68X"(&85*8$,7%?*(X"4*#%

4.*4W%$.*%&/*(,$"&8%,89%,"(%H',7"$>%

,89%5,W*%(*4&55*89,$"&8#%

2&(%$.*%#/*4"2"4%)*79"83%#"$',$"&81%%

Follow OSHA guidelines for

Permissible Exposure Limits (PEL’s) and

the American Conference of Governmental

Industrial Hygienists recommendations for

Threshold Limit Values (TLV’s) for fumes and gases.

@(4%;,>%?,2*$>

@;P%;@O?%4,8%"8='(*%*>*#%,89%+'(8%#W"81

1. R*,(%@E?CK,//(&X*9%)*79"83%*>*%/(&$*4$"&8%

2*,$'("83%,$%7*,#$%,%8'5+*(%JN%#.,9*%7*8#%(,$"831

2. R*,(%7*,$.*(%7*33"83#I%2"(*%(*#"#$,8$%#.&*#%

&(%+&&$#%9'("83%'#*1%%Do not wear pants with

cuffs, shirts with open pockets, or any clothing

that can catch and hold molten metal or sparks.

3. Y**/%47&$."83%2(**%&2%3(*,#*I%&"7I%

#&7X*8$#I%&(%,8>%27,55,+7*%#'+#$,84*#1%%

Wear dry, insulating gloves and protective clothing.

4. R*,(%,8%,//(&X*9%.*,9%4&X*("83%$&%/(&$*4$%

$.*%.*,9%,89%8*4W1%Use aprons, cape, sleeves,

shoulder covers, and bibs designed and

approved for welding and cutting procedures.

5. R*,(%,8%,//(&X*9%)*79"83%=,4W*$%&(%7&83%#7**X*#%

$&%/(&$*4$%2&(*,(5#%2(&5%(,9",$"&8%+'(8#1%

6. R.*8%)*79"8304'$$"83%&X*(.*,9%&(%"8%4&82"8*9%

#/,4*#I%)*,(%27,5*%(*#"#$,8$%*,(%/7'3#%&(%

*,(%5'22#%$&%W**/%#/,(W#%&'$%&2%*,(#1

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SETUP

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

67*4$("4,7%?,2*$>

6G6PA;CP%?BVPY%4,8%YCGG1

1. A'(8%&22I%9"#4&88*4$%/&)*(I%,89%

9"#4.,(3*%67*4$(&9*%$&%3(&'89%+*2&(*%#*$$"83%

9&)8%$&(4.067*4$(&9*%.&79*(%,89%+*2&(*%#*(X"4*1

2. S&%8&$%$&'4.%*8*(3"Z*9%*7*4$("4,7%/,($#1%%

Wear dry, insulating gloves. Do not touch Electrode

holder, Electrode, welding torch, or welding wire with

bare hand. Do not wear wet or damaged gloves.

3. P&88*4$%$&%3(&'89*9I%T<PCK/(&$*4$*9%

/&)*(%#'//7>%&87>1

4. S&%8&$%'#*%8*,(%),$*(%&(%9,5/%&+=*4$#1

5. U*&/7*%)"$.%/,4*5,W*(#%#.&'79%4&8#'7$%$.*"(%

physician(s) before use. Electromagnetic fields

in close proximity to heart pacemaker could cause

pacemaker interference or pacemaker failure.

6. S&%8&$%*[/&#*%)*79*(#%$&%(,"8%&(%)*$%4&89"$"&8#1%%%

Water entering a welder will increase

the risk of electric shock.

7. S&%8&$%,+'#*%$.*%4&(91%%E*X*(%'#*%$.*%4&(9%

2&(%4,((>"83I%/'77"83%&(%'8/7'33"83%$.*%)*79*(1%%

Y**/%4&(9%,),>%2(&5%.*,$I%&"7I%#.,(/%*93*#%

&(%5&X"83%/,($#1%%Damaged or entangled

cords increase the risk of electric shock.

8. S&%8&$%'#*%&'$9&&(#1

9. C8#'7,$*%>&'(#*72%2(&5%$.*%)&(W/"*4*%,89%

3(&'891%Use nonflammable, dry insulating

material if possible, or use dry rubber mats,

dry wood or plywood, or other dry insulating

material large enough to cover your full

area of contact with the work or ground.

<"(*%?,2*$>

@;P%@ES%?G@T%4,8%4,'#*%2"(*1

1. P7*,(%,),>%&(%/(&$*4$%27,55,+7*%&+=*4$#1%%%

Remove or make safe all combustible 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. Y**/%@QPK$>/*%2"(*%*[$"83'"#.*(%8*,(%

)&(W%,(*,%,89%W8&)%.&)%$&%'#*%"$1

3. D,"8$,"8%,%#,2*%)&(W"83%*8X"(&85*8$1%%%

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 debris.

4. S&%8&$%&/*(,$*%)*79*(#%"8%,$5&#/.*(*#%

4&8$,"8"83%9,83*(&'#7>%(*,4$"X*%&(%

27,55,+7*%7"H'"9#I%3,#*#I%X,/&(#I%&(%9'#$1%%

Provide adequate ventilation in work areas

to prevent accumulation of such substances.

Welders create sparks which may ignite flammable

substances or make reactive fumes toxic.

5. C2%)&(W"83%&8%,%5*$,7%),77I%4*"7"83I%*$41I%

/(*X*8$%"38"$"&8%&2%4&5+'#$"+7*#%&8%$.*%

&$.*(%#"9*%+>%5&X"83%$.*%4&5+'#$"+7*#%$&%,%

#,2*%7&4,$"&81 If relocation of combustibles is

not possible, designate someone to serve as

a fire watch, equipped with a fire extinguisher,

during the cutting process and for at least one

half hour after the cutting is completed.

6. S&%8&$%)*79%&(%4'$%&8%5,$*(",7#%.,X"83%

,%4&5+'#$"+7*%4&,$"83%&(%4&5+'#$"+7*%

"8$*(8,7%#$('4$'(*I%,#%"8%),77#%&(%4*"7"83#I%)"$.&'$%

,8%,//(&X*9%5*$.&9%2&(%*7"5"8,$"83%$.*%.,Z,(91

7. S&%8&$%9"#/&#*%&2%.&$%#7,3%"8%4&8$,"8*(#%

.&79"83%4&5+'#$"+7*%5,$*(",7#1

8. @2$*(%)*79"83I%5,W*%,%$.&(&'3.%*[,5"8,$"&8%

2&(%*X"9*84*%&2%2"(*1%%Be aware that easily

visible smoke or flame may not be present

for some time after the fire has started.

9. S&%8&$%,//7>%.*,$%$&%,%4&8$,"8*(%$.,$%.,#%.*79%

,8%'8W8&)8%#'+#$,84*%&(%,%4&5+'#$"+7*%

5,$*(",7%).&#*%4&8$*8$#I%).*8%.*,$*9I%

4,8%/(&9'4*%27,55,+7*%&(%*[/7&#"X*%X,/&(#1%%

Clean and purge containers before applying heat.

Vent closed containers, including castings,

before preheating, welding, or cutting.

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SETUP

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

R*79*(%F#*%,89%P,(*

1. S&%8&$%'#*%$.*%)*79*(%"2%$.*%#)"$4.%9&*#%8&$%$'(8%

"$%&8%,89%&221%%Any welder that cannot be controlled

with the switch is dangerous and must be repaired.

2. S"#4&88*4$%$.*%/7'3%2(&5%$.*%/&)*(%

#&'(4*%+*2&(*%5,W"83%,8>%,9='#$5*8$#I%

4.,83"83%,44*##&("*#I%&(%#$&("83%)*79*(#1%%

Such preventive Safety measures reduce the

risk of starting the welder accidentally.

3. U(*X*8$%'8"8$*8$"&8,7%#$,($"831%

68#'(*%$.*%#)"$4.%"#%"8%$.*%&22K

/&#"$"&8%+*2&(*%4&88*4$"83%$&%/&)*(%

#&'(4*%&(%5&X"83%$.*%)*79*(1 Carrying

or energizing welders that have the

switch on invites accidents.

4. ?$&(*%"97*%)*79*(#%&'$%&2%$.*%(*,4.%&2%

4."79(*8%,89%9&%8&$%,77&)%/*(#&8#%'82,5"7",(%

)"$.%$.*%)*79*(%&(%$.*#*%"8#$('4$"&8#%$&%

&/*(,$*%$.*%)*79*(1%%Welders are dangerous

in the hands of untrained users.

5. F#*%$.*%)*79*(%,89%,44*##&("*#%"8%

,44&(9,84*%)"$.%$.*#*%"8#$('4$"&8#I%$,W"83%

"8$&%,44&'8$%$.*%)&(W"83%4&89"$"&8#%,89%

$.*%)&(W%$&%+*%/*(2&(5*91 Use of the welder

for operations different from those intended

could result in a hazardous situation.

6. S&%8&$%'#*%$.*%)*79*(%2&(%/"/*%$.,)"831

D,"8$*8,84*

1. D,"8$,"8%)*79*(#1%%P.*4W%2&(%5"#,7"385*8$%&(%

+"89"83%&2%5&X"83%/,($#I%+(*,W,3*%&2%/,($#%

,89%,8>%&$.*(%4&89"$"&8%$.,$%5,>%,22*4$%$.*%

)*79*(\#%&/*(,$"&81%%C2%9,5,3*9I%.,X*%$.*%

)*79*(%(*/,"(*9%+*2&(*%'#*1 Many accidents

are caused by poorly maintained welders.

2. B,X*%>&'(%)*79*(%#*(X"4*9%+>%,%H',7"2"*9%

(*/,"(%/*(#&8%'#"83%&87>%"9*8$"4,7%

(*/7,4*5*8$%/,($#1%%This will ensure that

the Safety of the welder is maintained.

3. D,"8$,"8%7,+*7#%,89%8,5*/7,$*#%&8%$.*%R*79*(1%%%

These carry important information.

If unreadable or missing, contact

Harbor Freight Tools for a replacement.

4. F8/7'3%+*2&(*%5,"8$*8,84*1%Unplug the Welder

from its electrical outlet before any inspection,

maintenance, or cleaning procedures.

T,#%?."*79*9%R*79"83%K%P>7"89*(%?,2*$>

P>7"89*(#%4,8%*[/7&9*%).*8%9,5,3*91

1. S&%8&$%)*79%&8%,%/(*##'("Z*9%&(%47&#*9%4>7"89*(1

2. S&%8&$%,77&)%,8%67*4$(&9*%.&79*(I%

67*4$(&9*I%)*79"83%$&(4.I%&(%)*79"83%

)"(*%$&%$&'4.%$.*%4>7"89*(1

3. Y**/%4>7"89*(#%,),>%2(&5%,8>%*7*4$("4,7%4"(4'"$#I%

"847'9"83%)*79"83%4"(4'"$#1

4. Y**/%/(&$*4$"X*%4,/%"8%/7,4*%&X*(%$.*%X,7X*%

*[4*/$%).*8%$.*%4>7"89*(%"#%"8%'#*1

5. F#*%&87>%4&((*4$%3,#%#."*79"83%*H'"/5*8$%

9*#"38*9%#/*4"2"4,77>%2&(%$.*%$>/*%&2%)*79"83%

>&'%)"77%9&1%%Maintain this equipment properly.

6. U(&$*4$%3,#%4>7"89*(#%2(&5%.*,$I%+*"83%#$('4WI%

/.>#"4,7%9,5,3*I%#7,3I%27,5*#I%#/,(W#I%,89%,(4#1

7. F#*%/(&/*(%/(&4*9'(*#%$&%5&X*%4>7"89*(#1

%?@!6%AB6?6%CE?A;FPACVE?1

Page 6 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

T(&'89"83

AV%U;6!6EA%6G6PA;CP%?BVPY%@ES%S6@AB%%

<;VD%CEPV;;6PA%T;VFESCET%RC;6%PVEE6PACVE-%

P.*4W%)"$.%,%H',7"2"*9%*7*4$("4",8%"2%>&'%,(*%"8%9&'+$%,#%$&%).*$.*(%$.*%&'$7*$%"#%

/(&/*(7>%3(&'89*91%%%

S&%8&$%'#*%$.*%)*79*(%"2%$.*%/&)*(%4&(9%&(%/7'3%"#%9,5,3*91%%C2%9,5,3*9I%.,X*%"$%(*/,"(*9%+>%,%#*(X"4*%

2,4"7"$>%+*2&(*%'#*1%%C2%$.*%/7'3%)"77%8&$%2"$%$.*%&'$7*$I%.,X*%,%/(&/*(%&'$7*$%"8#$,77*9%+>%,%H',7"2"*9%*7*4$("4",8I%

9&%8&$%'#*%,9,/$*(%/7'3#1

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 never

be attached to an electrically “live” terminal.

Never leave the grounding wire disconnected

or modify the Power Cord Plug in any way.

2. Make sure the tool is connected to an outlet having

the same configuration as the plug. If the tool must

be reconnected for use on a different type of electric

circuit, the reconnection should be made by qualified

service personnel; and after reconnection, the tool

should comply with all local codes and ordinances.

B"3.%<(*H'*84>%T(&'89"83

1. The Welder has internal grounding, there

is no need to ground the Welder.

2. The metal work bench must be properly grounded

in accordance with all relevant electrical codes

and standards before operation. Have the work

bench grounded by a qualified electrician

if you are not qualified 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.

B"3.%<(*H'*84>%;,9",$"&8

1. The operator of welding equipment that causes

harmful interference to radio services shall promptly

take appropriate measures to correct the problem.

2. If the operator of welding equipment is notified

by the FCC that operation of such equipment is

endangering the functioning of a radio navigation

or safety service, the operator shall immediately

cease operating the equipment. Operation may

be resumed on a temporary basis only for the

purpose of eliminating the harmful interference.

Operation may be resumed on a regular basis

only after the harmful interference has been

eliminated and approval from the FCC obtained.

3. When notified by the FCC that a particular

installation is causing harmful interference, the

operator or manufacturer shall arrange for an

engineer skilled in techniques of interference

measurement and control to make an investigation

to ensure that the harmful interference has

been eliminated. The Regional Director may

require the engineer making the investigation

to furnish proof of his or her qualifications.

6[$*8#"&8%P&(9#

S&%8&$%'#*%,8%*[$*8#"&8%4&(9%&8%$."#%)*79*(1

;*/7,4*5*8$%P&(9#

1. F#*%&87>%&8*%&2%$.*%#'//7"*9%/&)*(%4&(9#%2&(%

$."#%)*79*(%&(%,8%"9*8$"4,7%(*/7,4*5*8$%4&(91

2. S&%8&$%"8#$,77%,%$."88*(%&(%7&83*(%

4&(9%&8%$."#%)*79*(1

3. S&%8&$%/,$4.%4&(9#%&2%,8>%7*83$.%

$&3*$.*(%2&(%$."#%"$*51%%U,$4.*#%5,>%,77&)%

5&"#$'(*%$&%/*8*$(,$*%$.*%"8#'7,$"&8I%

(*#'7$"83%"8%*7*4$("4%#.&4W1

Page 7<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63619

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

?>5+&7&3>

Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

Overheat Shutdown Indicator

Cooling Fan

!@P

Volts Alternating Current

Amperes

VP!

Open Circuit Voltage

Y!@

Kilovolt Amperes

(Volts / 1000 * Amperes)

CUD

Inches Per Minute

@RT

American Wire Gauge

Electric Shock Hazard.

Do not touch energized parts.

Inhalation Hazard.

Keep head out of fumes

and use proper ventilation.

Read manual 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.

?/*4"2"4,$"&8#

TIG Stick

120VAC / 60Hz 240VAC / 60Hz 120VAC / 60Hz 240VAC / 60Hz

Power Input at Output 21.4A at 115A 21A at 200A 21A at 80A 24A at 170A

Welding Current Range

15A: 10A - 115A

10A - 200A 10A - 80A 10A - 170A

20A: 10A - 130A

Rated Duty Cycles

15A:

35% @ 115A

100% @ 63A

25% @ 200A

100% @ 100A

20% @ 80A

100% @ 50A

20% @ 170A

100% @ 75A

20A:

25% @ 120A(AC)/130A(DC)

100% @ 63A

Maximum OCV 13.5VDC (with VRD) 13.5VDC (with VRD)

Weldable Materials Mild Steel, Stainless Steel, Aluminum, Chrome Moly Mild Steel, Stainless Steel

Page 8 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

?*$'/

% ;*,9%$.*%6EAC;6%CDUV;A@EA%?@<6AO%CE<V;D@ACVE%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%

5,8',7%"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1

AV%U;6!6EA%?6;CVF?%CE]F;O%<;VD%@PPCS6EA@G%VU6;@ACVE-%

A'(8%$.*%U&)*(%?)"$4.%&22%,89%'8/7'3%$.*%)*79*(%+*2&(*%#*$%'/1

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.

ACT%?*$'/

P&88*4$%P,+7*#

ACT%

A&(4.

T(&'89%

P7,5/

E*3,$"X*%

?&4W*$

<&&$%U*9,7%

?&4W*$

U&#"$"X*%

?&4W*$

<&&$%

U*9,7

1. Plug Ground Clamp cable into Positive Socket.

Twist clockwise all the way to lock in place.

2. Plug TIG Torch cable into Negative Socket.

Twist clockwise all the way to lock in place.

3. Plug Foot Pedal cable into Foot Pedal Socket.

Secure by turning collar clockwise until tight.

Page 9<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63619

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

P&88*4$%?."*79"83%T,#

1. With assistance, place an 100% Argon cylinder

(not included) onto a cabinet or cart near the

Welder and secure the cylinder in place with

two straps (not included) to prevent tipping.

2. Remove the cylinder’s cap. Stand to the

side of the valve opening, then open the

valve briefly to blow dust and dirt 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

Q("*27>%&/*8%X,7X*%

$&%47*,8I%%

$.*8%47&#*%%

X,7X*1

P&88*4$%U&)*(%P&(9

Plug either 120VAC or 240VAC cord

into Power Input Socket.

E&$*- Plug will only fit one way.

R@;ECET_ AV%U;6!6EA%?6;CVF?%CE]F;O%

<;VD%@PPCS6EA@G%VU6;@ACVE-%Do not

plug cord into wall outlet at this time.

Reset

Power Input

Gas Inlet

U&)*(%

C8/'$

Page 10 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

?.,(/*8%A'83#$*8%67*4$(&9*

To avoid Electrode contamination, dedicate a fine grit grinding wheel exclusively to Electrode grinding.

R@;ECET_ Some Electrodes may have

materials added to them that are hazardous to

breathe. Wear a respirator and ANSI-approved

Safety goggles when grinding an Electrode.

1. Shut off the welder and wait until Electrode

and Torch have cooled enough to handle.

2. Remove Back Cap. Pull Electrode from front

of Torch. (Pulling it from rear will damage

Collet and create burrs on Electrode).

3. If Electrode has dulled or been otherwise

contaminated, use pliers or a suitable tool to

grip the Electrode above the contaminated

section and snap off the end of the Electrode.

4. Lightly press Electrode tip

against the surface of

the grinding wheel at an angle.

Rotate Electrode tip until a

blunt point is formed.

E&$*- 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.

@##*5+7*%ACT%A&(4.

1. Consult Settings Chart, on top of Welder, to

determine proper Tungsten Electrode size to be

used with thickness of material to be welded.

2. Match Collet and Collet Body sizes

to Tungsten Electrode size.

3. Thread Collet Body into the front of the Torch.

4. Make sure Ceramic Nozzle size is

appropriate for application.

5. Thread Ceramic Nozzle onto Collet Body.

6. Insert Collet into back of Torch and into Collet Body.

7. Insert tungsten Electrode into

Collet on front of Torch.

8. Lock Electrode in place with Back Cap.

Electrode should protrude 1/8″ to 1/4″

beyond the Ceramic Nozzle.

P&77*$%

Q&9>

P*(,5"4%

E&ZZ7*

P&77*$

Q,4W%P,/

C8#*($%$'83#$*8%

67*4$(&9*%.*(*1

T("89"83%

R.**7

67*4$(&9*

Page 11<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63619

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

?$"4W%?*$'/

P&88*4$%P,+7*#

67*4$(&9*%

B&79*(

T(&'89%

P7,5/

U&#"$"X*%

?&4W*$

E*3,$"X*%

?&4W*$

1. Plug Ground Clamp 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.

P&88*4$%U&)*(%P&(9

Plug either 120VAC or 240VAC cord

into Power Input Socket.

E&$*- Plug will only fit one way.

R@;ECET_ AV%U;6!6EA%?6;CVF?%CE]F;O%

<;VD%@PPCS6EA@G%VU6;@ACVE-%Do not

plug cord into wall outlet at this time.

U&)*(%

C8/'$

Reset

Power Input

Gas Inlet

Page 12 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

Q,#"4%R*79"83

% ;*,9%$.*%6EAC;6%CDUV;A@EA%?@<6AO%CE<V;D@ACVE%#*4$"&8%,$%$.*%+*3"88"83%&2%$."#%

5,8',7%"847'9"83%,77%$*[$%'89*(%#'+.*,9"83#%$.*(*"8%+*2&(*%#*$%'/%&(%'#*%&2%$."#%/(&9'4$1

AV%U;6!6EA%?6;CVF?%CE]F;O-%

U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%R*79*(`%5"8"5'5%#.,9*%8'5+*(%JN%2'77%2,4*%#."*79%

(or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire

(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%#.&'79%+*%)&(8%).*8%)*79"831%%%

G"3.$%2(&5%$.*%,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%,89%#W"81%%

S&%8&$%+(*,$.*%,(4%2'5*#1

• 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 project. Additional practice

periods are recommended whenever you weld:

• a different thickness of material

• a different type of material

• a different type of connection

• using a different process

D,W*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%$&%/(,4$"4*%

$*4.8"H'*%+*2&(*%)*79"83%,8>$."83%&2%X,7'*1

AV%U;6!6EA%?6;CVF?%CE]F;OI%%

<C;6%@ES%QF;E?-%

Y**/%)*79"83%$"/%47*,(%&2%3(&'89*9%

&+=*4$#%).*8*X*(%'8"$%"#%/7'33*9%

"8%,89%$'(8*9%&81

U&)*(%

U(,4$"4*%>&'(%)*79"83%

$*4.8"H'*%&8%#4(,/%

/"*4*#%+*2&(*%)*79"83%

,8>$."83%&2%X,7'*1

Page 13<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63619

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

P&8$(&7#

!&7$,3*%

C8/'$0

A.*(5,7%

VX*(7&,9%

C89"4,$&(

U&)*(%

C89"4,$&(

!&7$,3*%%

;*9'4$"&8%

C89"4,$&(

?*$$"83#%

Y8&+

S"#/7,>

U(&4*##%

?*7*4$%

Y8&+

U&)*(%

?)"$4.

?$&(,3*%

P&5/,($5*8$

!&7$,3*%;*9'4$"&8%C89"4,$&(-%

Lights when Voltage Reduction Device is operating.

U&)*(%C89"4,$&(-

Lights when power is on.

!&7$,3*%C8/'$0A.*(5,7%VX*(7&,9%C89"4,$&(-

Lights when input voltage is outside the Welder’s

specifications or duty cycle has been exceeded.

U(&4*##%?*7*4$%Y8&+-%

Turn to select process functions.

?*$$"83#%Y8&+-%%%

Set process function parameters.

?$&(,3*%P&5/,($5*8$-%

Pull down to open.

Page 14 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

?*$$"83%'/%$.*%R*79

47,5/#

)&(W/"*4*#

P.,52*(%$."4W%)&(W/"*4*#1

P7*,8%#'(2,4*#%

$&%+,(*%5*$,71

EVA6- %D,W*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%

$.*%#,5*%$."4W8*##%,#%>&'(%"8$*89*9%)&(W/"*4*%$&%

/(,4$"4*%$*4.8"H'*%+*2&(*%)*79"83%,8>$."83%&2%X,7'*1

1. Clean the weld surfaces thoroughly with

a wire brush or angle grinder; there must

be no rust, paint, oil, or other materials on

the weld surfaces, only bare metal.

2. Use clamps (not included) to hold the workpieces

in position so that you can 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 from both the

positive connection and the ground before welding.

This prevents damage to some vehicle electrical

systems and electronics due to the high voltage

and high frequency bursts common in welding.

T(&'89%R&(W/"*4*

Attach Ground Clamp to bare metal on the

workpiece near the weld area, or to metal work

bench where the workpiece is clamped.

R&(W/"*4*

T(&'89%

P7,5/

P7*,8%

#'(2,4*%$&%

+,(*%5*$,71

Page 15<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63619

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU? ?6AFU

Duty Cycle (Duration of Use)

@X&"9%9,5,3*%$&%$.*%R*79*(%+>%8&$%)*79"83%2&(%

5&(*%$.,8%$.*%/(*#4("+*9%9'$>%4>47*%$"5*1 The Duty

Cycle defines the number of minutes, within a 10 minute

period, during which a given welding process can

produce a particular welding current without overheating.

For example, a 360% duty cycle at 165 A welding

current must be allowed to rest for at least 7 minutes

after every 3 minutes of continuous welding.

Failure to carefully observe duty cycle limitations

can easily over-stress a welder’s power generation

system contributing to premature welder failure.

This welder has an internal thermal protection

system to help prevent this sort of over-stress.

When the Welder overheats, it automatically 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.

@77&)%$.*%R*79*(%$&%4&&7%)"$.%$.*%U&)*(%?)"$4.%&8I%

#&%$.,$%$.*%"8$*(8,7%<,8%)"77%.*7/%4&&7%$.*%)*79*(1

When the Overload Indicator is no longer lit and the

Welder can be used again, use shorter welding periods

and longer rest periods to prevent needless wear.

240VAC

20% Use at 170 A

<&(%JN%P&8$"8'&'#%D"8'$*#

100% Continuous Use at 75 A

D"8'$*#%

R*79"83

D"8'$*#%

;*#$"83

J^N!@P

20% Use at 80 A

<&(%JN%P&8$"8'&'#%D"8'$*#

100% Continuous Use at 50 A

^KJ0^

D"8'$*#%

R*79"83

bKJ0^%

D"8'$*#%

;*#$"83

?$"4W%;,$*9%S'$>%P>47*#

240VAC

25% Use at 200 A

<&(%JN%P&8$"8'&'#%D"8'$*#

100% Continuous Use at 100 A

^KJ0^

D"8'$*#%

R*79"83

bKJ0^%

D"8'$*#%

;*#$"83

J^N!@P

35% Use at 115 A

<&(%JN%P&8$"8'&'#%D"8'$*#

100% Continuous Use at 63 A

MKJ0^

D"8'$*#%

R*79"83

cKJ0^%

D"8'$*#%

;*#$"83

ACT%;,$*9%S'$>%P>47*#

Page 16 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

ACT%R*79"83

AV%U;6!6EA%?6;CVF?%CE]F;O%@ES%S6@AB-%%%

S&%8&$%)*79%)"$.&'$%T(&'89"83%P7,5/1%%

R.*8%$.*%&/*(,$&(%"#%8&$%.&79"83%$.*%A&(4.I%"$%5'#$%+*%#"$$"83%&8%,%8&84&89'4$"X*I%8&827,55,+7*%#'(2,4*1%

V87>%.&79%ACT%;&9%)"$.%,8%*7*4$("4,77>%"8#'7,$*9%)*79"83%37&X*1

%%%

AV%U;6!6EA%S6@AB%<;VD%@?UBOdC@ACVE-%

S&%8&$%&/*8%3,#%)"$.&'$%/(&/*(%X*8$"7,$"&81%%<"[%3,#%7*,W#%"55*9",$*7>1 Shielding gas can displace

air and cause rapid loss of consciousness and death. ?."*79"83%3,#%)"$.&'$%4,(+&8%9"&["9*%4,8%+*%

*X*8%5&(*%.,Z,(9&'#%+*4,'#*%,#/.>[",$"&8%4,8%#$,($%)"$.&'$%2**7"83%#.&($8*##%&2%+(*,$.1

EVACP6-% TIG welding is a complicated process,

requiring experience and skill to achieve

successful results. Training beyond the scope of

this manual is required to TIG weld properly.

1. Open gas cylinder’s valve all the way.

2. Set Flow Gauge to SCFH value indicated

on Settings Chart on top of Welder.

3. Turn the Power Switch to the OFF position, then

plug the Welder into a properly grounded, GFCI

protected, 120 VAC (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 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.

EVA6- Settings are approximate. Adjust as necessary.

U(&4*##%

?*7*4$%Y8&+

?*$$"83#%

Y8&+

7. ?*7*4$%U(&4*##- Turn Process Select Knob

to desired process section.

@P%ACT%K%<&(%)*79"83%,7'5"8'5

a. @DU?%K%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.

b. UFG?6%K Set Pulses Per Second. Pulse

welding reduces heat input to minimize

distortion and allows for faster travel speeds.

c. AC BALANCE (%EN) - Controls the

amount of oxide cleaning. A higher number

reduces the amount of oxide cleaning.

d. AC FREQUENCY (Hz) - Controls the width of

the welding arc. For groove welds, use low

frequency. For narrow welds set to 120 or above.

%%SP%ACT%K%<&(%)*79"83%

5"79%,89%#$,"87*##%#$**7

e. @DU?%K%Set amperage according to

Settings Chart on top of Welder.

f. UFG?6%K Set Pulses Per Second. Pulse

welding reduces heat input to minimize

distortion and allows for faster travel speeds.

%%SP%?ACPY%K%T&%$&%?$"4W%

R*79"83%&8%/,3*%JL1

Page 17<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63619

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

R@;ECET_%%AV%U;6!6EA%?6;CVF?%CE]F;O-%%

U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%

R*79*(`%5"8"5'5%#.,9*%8'5+*(%JN%2'77%2,4*%#."*79%

(or welding mask), ear protection, welding gloves,

#7**X*#%,89%,/(&8I%ECV?BK,//(&X*9%(*#/"(,$&(I%

,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%

#.&'79%+*%)&(8%).*8%)*79"831%%G"3.$%2(&5%$.*%

,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%

,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1

After practice welding on scrap, stop,

and check your progress. Perform

Strike Test according to ?$("W*%A*#$%&8%

/,3*%^N1 After making any necessary

adjustments, continue to weld while

carefully following the DUTY CYCLE

guidelines as explained on page 14.

R@;ECET_ D*$,7%)&(W%+*84.%5'#$%+*%

3(&'89*9%).*8%ACT%)*79"83%e#**%B"3.%

Frequency Grounding on page 6).

8. Hold TIG Torch in one gloved hand and

the TIG Rod in other gloved hand.

9. Specific Welding Techniques:

B"3.%<(*H'*84>%?$,($%

• Hold Torch away from the workpiece

the same distance as 1 to 1.5 times the

diameter of the Tungsten Electrode.

• Press Foot Pedal down slowly until arc

ignites. Then, press Foot Pedal down all

the way to reach maximum amperage. Let

up on Foot Pedal to lower amperage.

U'7#*%R*79"83

• After arc is ignited, Welder will pulse between

Peak Amperage and Background Current.

• Peak Amperage Time is 50%.

Background Current is 25% of

Peak Amperage Current.

EVA6- 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. Add TIG Rod material as

needed to the front end of the weld puddle.

EVA6- When welding aluminum, if black spots

appear in the weld puddle, reduce AC Balance.

11. Alternate between pushing the torch/weld

puddle and adding the TIG Rod material.

EVA6- Back the TIG Rod off each time the Electrode

is advanced, but do not remove it from the gas shield.

This prevents oxidation from contaminating the weld.

12. When finished welding, release the Foot Pedal, but

keep Torch on weld puddle until gas flow ends.

13. Set TIG Torch down on nonconductive,

nonflammable surface away from

any grounded objects.

14. Turn the Current Output Knob to the lowest

setting, then turn the Power Switch off.

15. To prevent accidents, after use:

• Allow Welder to cool down.

• Unplug Welder’s power cord from outlet.

• Remove Ground Clamp from workpiece or table.

• Disconnect TIG Torch, Ground

and Food Pedal Cables.

• Close gas cylinder’s valve securely,

remove regulator and replace cap.

• Disconnect Gas Hose from Welder.

• Store and secure gas cylinder.

• Clean, then store Welder and its accessories

indoors out of children’s reach.

Page 18 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

?$"4W%R*79"83

AV%U;6!6EA%?6;CVF?%CE]F;O%@ES%S6@AB-%%%

S&%8&$%)*79%)"$.&'$%T(&'89"83%P7,5/1%%

R.*8%$.*%&/*(,$&(%"#%8&$%.&79"83%$.*%67*4$(&9*%B&79*(I%"$%5'#$%+*%

#"$$"83%&8%,%8&84&89'4$"X*I%8&827,55,+7*%#'(2,4*1%%

1. Turn the Power Switch to the OFF position,

then plug the Welder into a properly grounded

120 VAC (20 amp rated) or 240V receptacle that

matches the plug.

The circuit must be equipped with delayed

action-type circuit breaker or fuses.

2. Set Electrode Holder down on

nonconductive, nonflammable surface

away from any grounded objects.

3. Turn the Power Switch ON.

R@;ECET_ R.*8%?$"4W%"#%#*7*4$*9I%R*79*(%

"#%*8*(3"Z*9I%B&$%?$,($%"#%,4$"X,$*9%,89%

V/*8%P"(4'"$%!&7$,3*%"#%/(*#*8$1

4. ?*7*4$%U(&4*##- Turn Process Select Knob

to %%SP%?ACPY.

U(&4*##%

?*7*4$%

Y8&+

?*$$"83#%

Y8&+

5. Set Amperage according to Stick Settings Chart.

EVA6- Settings are approximate. Adjust as necessary.

?$"4W%?*$$"83#%P.,($%

67*4$(&9*%

A>/*

67*4$(&9*%

S",5*$*(

@5/*(,3*%

;,83*

cNJN%SP

cNJJ%@P0SP

M0M^f 40-70

J0Lf bgKJMN

g0M^f 90-175

M0Jcf 140-225

b0M^f ^NNK^bg

cNJM%@P0SP

J0Jcf 25-40

M0M^f 40-90

J0Lf bgKJ^g

g0M^f JNgKJbg

M0Jcf JgNK^^g

7014 AC/DC

M0M^f bgKJJN

J0Lf JNgKJcN

g0M^f JgNK^NN

M0Jcf ^NNK^bg

bNJL%@P0SP

M0M^f bNKJJN

J0Lf 90-160

g0M^f JMNK^JN

M0Jcf ^NNK^bg

7024 AC/DC

M0M^f 100-145

J0Lf JJNKJbg

g0M^f JcNK^Jg

M0Jcf ^^NK^LN

Page 19<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63619

?@<6AOD@CEA6E@EP6 Q@?CP%R6GSCETR6GSCET%ACU?

SETUP

R@;ECET_%%AV%U;6!6EA%?6;CVF?%CE]F;O-%%

U(&$*4$"X*%3*,(%5'#$%+*%)&(8%).*8%'#"83%$.*%

R*79*(`%5"8"5'5%#.,9*%8'5+*(%JN%2'77%2,4*%#."*79%

(or welding mask), ear protection, welding gloves,

#7**X*#%,89%,/(&8I%ECV?BK,//(&X*9%(*#/"(,$&(I%

,89%2"(*%(*#"#$,8$%)&(W%47&$.*#%)"$.&'$%/&4W*$#%

#.&'79%+*%)&(8%).*8%)*79"831%%G"3.$%2(&5%$.*%

,(4%4,8%4,'#*%/*(5,8*8$%9,5,3*%$&%$.*%*>*#%

,89%#W"81%%S&%8&$%+(*,$.*%,(4%2'5*#1

After practice welding on scrap, stop,

and check your progress. Perform

Strike Test, then clean and compare your

weld’s appearance with the diagrams and

descriptions in the R*79"83%A"/# section

starting on the next page. After making any

necessary adjustments, continue to weld

while carefully following the DUTY CYCLE

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 workpiece the same

distance as the diameter of the bare metal end.

b. Tilt Electrode back 10 to 20 degrees.

c. Drag Electrode to the back end of the weld

puddle to deposit material as needed.

9. When finished welding; lift the Electrode from

the workpiece, then set Electrode Holder

down on nonconductive, nonflammable

surface away from any grounded objects.

10. Turn the Power Switch off.

11. To prevent accidents, after use:

• Allow Welder to cool down.

• Unplug Welder’s power cord from outlet.

• Remove Ground Clamp.

• Disconnect Electrode Holder

and Ground Cables.

• Clean, then store Welder and its accessories

indoors out of children’s reach.

Page 20 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619

?@<6AO D@CEA6E@EP6Q@?CP%R6GSCET R6GSCET%ACU?

SETUP

R*79"83%A"/#

A good way to test welding technique is to examine a weld’s appearance after it has

cooled and the slag has been removed (for Stick welds). Then, better welding can be

learned by adjusting your weld technique to remedy any problems found.

NOTICE: TIG welding is a complicated process, requiring experience and skill to achieve successful

results. Training beyond the scope of this manual is required to TIG weld properly.

@2$*(%/(,4$"4*%)*79"83%,%4&'/7*%

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?$("W*%A*#$

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$*#$*9%+>%'#"83%$.*%2&77&)"83%/(&4*9'(*1

R6@;%@E?CK@UU;V!6S%?@<6AO%TVTTG6?%

SF;CET%ABC?%U;VP6SF;61

R@;ECET_ A."#%$*#$%RCGG%9,5,3*%$.*%)*79%"$%"#%

/*(2&(5*9%&81%%A."#%$*#$%"#%VEGO%,8%"89"4,$&(%&2%)*79%

$*4.8"H'*%,89%"#%8&$%"8$*89*9%$&%$*#$%)&(W"83%)*79#1

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 TVVS%R6GS will deform but not break, as shown

on top.

A UVV;%R6GS will be brittle and snap

at the weld, as shown on bottom.

!"#*

?P;@U%

R&(W/"*4*

TVVS%R6GS%%

Q*89#%,89%"#%E&$%Q("$$7*

S*,9KQ7&)%B,55*(

!"#*

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R&(W/"*4*

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?8,/#%&(%P(,4W#

S*,9KQ7&)%B,55*(

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AV%U;6!6EA%?6;CVF?%CE]F;O-%

R*,(%@E?CK,//(&X*9%#,2*$>%3&337*#%

,89%/(&$*4$"X*%)*,(%).*8%47*,8"83%,%

)*791%%

?/,(W#%&(%4."/#%5,>%27>%).*8%47*,8"831

1. A weld from Stick welding will be covered

by slag. Use a chipping hammer to knock

this off. Q*%4,(*2'7%8&$%$&%9,5,3*%

$.*%)*79%&(%+,#*%5,$*(",71

2. Use a wire brush to further clean the weld

or use an angle grinder (sold separately) to

shape the weld.

P."//"83%

B,55*(

R"(*%Q('#.

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

Brand: Harbor Freight Tools

Model: VULCAN PROTIG 200

Category: Welding System

Type: Owner's Manual & Safety Instructions

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

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

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