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

Harbor Freight Tools
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.
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 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$1%
<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%
?@!6%ABC?%D@EF@G1
Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-380-0318 as soon as possible.
Copyright
©
2017 by Harbor Freight Tools
®
. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Too ls r eq ui re d fo r ass em bl y an d se rv ic e m ay n ot b e in cl ud ed.
;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%
<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%
?@!6%ABC?%D@EF@G1
Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-380-0318 as soon as possible.
Copyright
©
2017 by Harbor Freight Tools
®
. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Too ls r eq ui re d fo r ass em bl y an d se rv ic e m ay n ot b e in cl ud ed.
;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%
<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%
?@!6%ABC?%D@EF@G1
Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-380-0318 as soon as possible.
Copyright
©
2017 by Harbor Freight Tools
®
. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Too ls r eq ui re d fo r ass em bl y an d se rv ic e m ay n ot b e in cl ud ed.
;*,9%$."#%5,$*(",7%+*2&(*%'#"83%$."#%/(&9'4$1%
<,"7'(*%$&%9&%#&%4,8%(*#'7$%"8%#*("&'#%"8='(>1%
?@!6%ABC?%D@EF@G1
Owner’s Manual & Safety Instructions
Save This Manual%Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference. 17k
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-380-0318 as soon as possible.
Copyright
©
2017 by Harbor Freight Tools
®
. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Too ls r eq ui re d fo r ass em bl y an d se rv ic e m ay n ot b e in cl ud ed.
;*,9%$."#%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'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63619
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SETUP
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SETUP
A,+7*%&2%P&8$*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
Page 4 <&(%$*4.8"4,7%H'*#$"&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
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.
Page 5<&(%$*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
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
4
M
Q("*27>%&/*8%X,7X*%
$&%47*,8I%%
$.*8%47&#*%%
X,7X*1
^
J
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&)*(%
V8
a
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'$*#%
R*79"83
L
D"8'$*#%
;*#$"83
J^N!@P
20% Use at 80 A
<&(%JN%P&8$"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*%
&2%)*79"83%+*,9#I%?AVU%,89%
*[,5"8*%>&'(%)*79%'#"83%
$.*%2&77&)"83%3'"9*7"8*#1
?$("W*%A*#$
@%$*#$%)*79%&8%,%UC6P6%V<%?P;@U%4,8%+*%
$*#$*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*(
!"#*
?P;@U%
R&(W/"*4*
UVV;%R6GS%%
?8,/#%&(%P(,4W#
S*,9KQ7&)%B,55*(
P7*,8"83%?$"4W%R*79
AV%U;6!6EA%?6;CVF?%CE]F;O-%
R*,(%@E?CK,//(&X*9%#,2*$>%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

Harbor Freight Tools
Brand
Harbor Freight Tools
Model
VULCAN PROTIG 200
Category
Welding System
Type
Owner's Manual & Safety Instructions
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