Vulcan 63621 Owner's manual

!"#"$%&'(%)*+#"$*%,$-%.$$/-00)))1.,(+&(2(*"3.$14&5

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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. 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

®

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 an d se rv ic e may n ot b e in cl uded.

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

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

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

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

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

Controls .............................................................. 8

MIG / Flux-Cored Wire Welding .......................... 10

TIG / Stick Welding ............................................. 24

Welding Tips ......................................................34

Maintenance ......................................................41

Parts List and Diagram ......................................46

Warranty ............................................................48

P@;ECER%?ODWVG?%@EQ%Q6<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.

CDSV;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%#.&4XI%2"(*%,890&(%#*("&'#%"8='(>1%%%

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

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

S;VA6TA%>&'(#*72%,89%&$.*(#1%%;*,9%,89%'89*(#$,89%$."#%"82&(5,$"&81

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

manufacturer′s instructions,

Material Safety Data Sheets (MSDS′s),

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

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

Keep children and bystanders away while operating.

3. S7,4*%$.*%)*79*(%&8%,%#$,+7*%7&4,$"&8%+*2&(*%'#*1%%%

If it falls while plugged in, severe injury,

electric shock, or fire may result.

4. Q&%8&$%&Y*((*,4.1%%%

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

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

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

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

prepared to begin work before turning on the Welder.

7. E*Y*(%7*,Y*%$.*%P*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&Y*(%,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 63621

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<'5*%,89%R,#%?,2*$>

INHALATION HAZARD:%

P*79"83%,89%S7,#5,%T'$$"83%/(&9'4*%$&["4%2'5*#1

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

2'5*#%4,8%"84(*,#*%$.*%("#X%&2%9*Y*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. Q&%8&$%'#*%8*,(%9*3(*,#"83%&(%

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

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

Do not breathe exhaust fumes.

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

+&$.I%$&%X**/%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. P&(X%"8%,%4&82"8*9%,(*,%&87>%"2%"$%

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

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

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

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

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

,89%5,X*%(*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*$>

@;T%;@O?%4,8%"8='(*%*>*#%,89%+'(8%#X"81

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

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

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

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

Wear dry, insulating gloves and protective clothing.

4. P*,(%,8%,//(&Y*9%.*,9%4&Y*("83%$&%/(&$*4$%

$.*%.*,9%,89%8*4X1%Use aprons, cape, sleeves,

shoulder covers, and bibs designed and

approved for welding and cutting procedures.

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

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

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

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

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

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

9"#4.,(3*%*7*4$(&9*%$&%3(&'89%+*2&(*%#*$$"83%

9&)8%$&(4.0*7*4$(&9*%.&79*(%,89%+*2&(*%#*(Y"4*1

2. Q&%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. T&88*4$%$&%3(&'89*9I%R<TCK/(&$*4$*9%

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

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

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

physician(s) before use. Electromagnetic fields

in close proximity to heart pacemaker could cause

pacemaker interference or pacemaker failure.

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

Water entering a welder will increase

the risk of electric shock.

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

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

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

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

cords increase the risk of electric shock.

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

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

10. ABC?%P6GQCER%D@TBCE6%DF?A%W6%

TVEE6TA6Q%AV%SVP6;%?VF;T6%CE%

@TTV;Q@ET6%PCAB%@SSGCT@WG6%

6G6TA;CT@G%TVQ6?1

<"(*%?,2*$>

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

1. T7*,(%,),>%&(%/(&$*4$%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. U**/%@WTK$>/*%2"(*%*[$"83'"#.*(%8*,(%

)&(X%,(*,%,89%X8&)%.&)%$&%'#*%"$1

3. D,"8$,"8%,%#,2*%)&(X"83%*8Y"(&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. Q&%8&$%&/*(,$*%)*79*(#%"8%,$5&#/.*(*#%

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

27,55,+7*%7"H'"9#I%3,#*#I%Y,/&(#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%)&(X"83%&8%,%5*$,7%),77I%4*"7"83I%*$41I%

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

&$.*(%#"9*%+>%5&Y"83%$.*%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. Q&%8&$%)*79%&(%4'$%&8%5,$*(",7#%.,Y"83%

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

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

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

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

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

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

2&(%*Y"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. Q&%8&$%,//7>%.*,$%$&%,%4&8$,"8*(%$.,$%.,#%.*79%

,8%'8X8&)8%#'+#$,84*%&(%,%4&5+'#$"+7*%

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

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

Clean and purge containers before applying heat.

Vent closed containers, including castings,

before preheating, welding, or cutting.

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

#&'(4*%+*2&(*%5,X"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. S(*Y*8$%'8"8$*8$"&8,7%#$,($"831%

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

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

#&'(4*%&(%5&Y"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%$,X"83%

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

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

for operations different from those intended

could result in a hazardous situation.

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

D,"8$*8,84*

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

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

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

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

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

are caused by poorly maintained welders.

2. B,Y*%>&'(%)*79*(%#*(Y"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%$.*%P*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.

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

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

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

2. Q&%8&$%,77&)%,8%*7*4$(&9*%.&79*(I%

*7*4$(&9*I%)*79"83%$&(4.I%&(%)*79"83%

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

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

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

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

*[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. S(&$*4$%3,#%4>7"89*(#%2(&5%.*,$I%+*"83%#$('4XI%

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

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

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

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Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

Overheat Shutdown Indicator

Cooling Fan

Housing Ground Point

!@T

Volts Alternating Current

@

Amperes

VT!

Open Circuit Voltage

U!@

Kilovolt Amperes

(Volts / 1000 * Amperes)

CSD

Inches Per Minute

@PR

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.

R(&'89"83

AV%S;6!6EA%6G6TA;CT%?BVTU%@EQ%Q6@AB%%

<;VD%CETV;;6TA%R;VFEQCER%PC;6%TVEE6TACVE-%

T.*4X%)"$.%,%H',7"2"*9%*7*4$("4",8%"2%>&'%,(*%"8%9&'+$%,#%$&%).*$.*(%$.*%&'$7*$%"#%

/(&/*(7>%3(&'89*91%%Q&%8&$%'#*%$.*%)*79*(%"2%$.*%/&)*(%4&(9%&(%/7'3%"#%9,5,3*91%%C2%9,5,3*9I%

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

"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 either 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.

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

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

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

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

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

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

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

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

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

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

(*#'7$"83%"8%*7*4$("4%#.&4X1

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DCR

Power Input 120 VAC%0%60 Hz 240 VAC / 60 Hz

Current Input at Output 20.8 A at 100 A 25.5 A at 200 A

Welding Current Range 30 –140 A 30 –220 A

Rated Duty Cycles

40% @ 100 A

100% @ 75 A

25% @ 200 A

100% @ 115 A

Maximum OCV 78 VDC

Weldable Materials

Mild Steel, Stainless Steel

Aluminum (with optional Spool Gun)

Welding Wire 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

ACR

Power Input 120 VAC / 60 Hz 240 VAC / 60 Hz

Current Input at Output 20.6 A at 125 A 15.6 A at 175 A

Welding Current Range 10 A –125 A 10 A –175 A

Rated Duty Cycles

40% @ 125 A

100% @ 90 A

30% @ 175 A

100% @ 105 A

Maximum OCV 78 VDC

Weldable Materials Mild Steel, Stainless Steel, Chrome Moly

?$"4X

Power Input 120 VAC / 60 Hz 240 VAC / 60 Hz

Current Input at Output 19.5 A at 80 A 23.7 A at 175 A

Welding Current Range 10 A – 80 A 10 A –175 A

Rated Duty Cycles

40% @ 80 A

100% @ 60 A

25% @ 175 A

100% @ 100 A

Maximum OCV 78 VDC

Weldable Materials Mild Steel, Stainless Steel

Page 8 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63621

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E&$*- When using an optional Spool Gun (sold separately), connect the

Spool Gun gas hose to the Spool Gun Gas Outlet.

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1. A'(8%$.*%S&)*(%?)"$4.%V<<%,89%'8/7'3%

$.*%P*79*(%+*2&(*%/(&4**9"831

2. Pull up on the Door Latch,

then open the Door.

3. JK]%S&'89%P"(*%?/&&7%C8#$,77,$"&8-

Remove the Wingnut and Spacer. If

replacing a Spool, remove the old Spool

and all remaining wire from the liners.

4. Place the new Wire Spool over the Spool Spindle

and against the Spool Brake Pad as illustrated.

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?/&&7%#&%$.,$%"$%)"77%'8)"89%47&4X)"#*1

5. Replace the Spacer over the

Spool Spindle and secure Spool

in place with the Wingnut.

E&$"4*- 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.

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E&$*-%Remove the protective foam and cardboard from the Welder before setup.

Wire Spool Installation / Wire Setup

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6. JNKJ]%S&'89%P"(*%?/&&7%C8#$,77,$"&8-%

Remove the Wingnut and Spacer. If

replacing a Spool, remove the old Spool

and all remaining wire from the liners.

7. Place the Spool Adapter over the Spool Spindle

and against the Spool Brake Pad as illustrated.

8. Place the new Wire Spool over the Adapter and

line up pin on Adapter with hole in Spool.

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?/&&7%#&%$.,$%"$%)"77%'8)"89%47&4X)"#*1

9. Replace the Spacer over the Spool Spindle

and secure Spool in place with the Wingnut.

E&$"4*- 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

loosen it enough to pull it down to remove tension.

The spring-loaded Idler Arm will move up as shown.

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12. <**9%;&77*(%C8#$('4$"&8#-%

Check that the Feed Roller is correct for the

type of wire being used (solid core or flux-

cored) and that it is turned to properly match

the wire size marked on the Wire 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

$.*%8'5+*(%#.&)"83%"#%$.*%#,5*%,#%

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d. Screw the Feed Roller Knob back into

place to secure the Feed Roller.

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13. Loosen the Knob on the Wire Feed

mechanism, then insert the Gun Cable

Connector through the hole on the Welder

front and into the socket on the Wire Feed.

14. Ensure that the Gun Cable Connector

is fully inserted into the socket on

the Wire Feed mechanism as shown,

then tighten the Knob securely.

If Connector is not fully inserted, the gas

connection will leak, preventing shielding

gas from reaching the welding arc.

EVACT6- To prevent damage, do

not overtighten 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. QT6E%Q"(*4$%T'((*8$%67*4$(&9*%

E*3,$"Y*%P"(*%?*$'/%2&(%<7'[KT&(*9%

(gasless) welding:

Plug Ground Clamp Cable into Positive (`)

Socket. Plug Wire Feed Power Cable

into Negative (

a

) Socket. Twist cables

clockwise all the way to lock in place.

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Page 14 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63621

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17. QT6S%Q"(*4$%T'((*8$%67*4$(&9*%S&#"$"Y*%P"(*%

Setup for Solid Core (gas shielded) welding:

a. Plug Ground Clamp Cable into Negative (

a

)

Socket. Plug Wire Feed Power Cable

into Positive (`) Socket. Twist cables

clockwise all the way to lock in place.

b. Determine which type of shielding

gas would be appropriate for

the welding you will do. Refer

to the Settings Chart on the

inside of the Welder door.

c. With assistance, set the 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.

d. 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.

e. Locate the Regulator (included) and close its

valve until it is loose, then thread Regulator

onto cylinder and wrench-tighten connection.

E&$*- When 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.

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Solid Core (Gas Shielded)

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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%

U

0

 78V

I

2

200A 130A 115A

U

2

24V 20.5V 19.75V

1~50/60Hz

U

1

= 240V

I

1max

= 25.5A

23.7A

15.6A

I

1eff

 12.8A

11.9A

8.5A

10A/20.4V to 175A/27V

X 25% 60% 100%

U

0

 78V

I

2

175A 115A 100A

U

2

27V 24.6V 24V

10A/10.4V to 175A/17V

X 30% 60% 100%

U

0

 15V

I

2

175A 125A 105A

U

2

17V 15V 14.2V

30A/15.5V to 140A/21V

X 40% 60% 100%

U

0

 78V

I

2

100A 85A 75A

U

2

19V 18.25V 17.75V

1~50/60Hz

U

1

= 120V

I

1max

= 20.8A

19.5A

20.6A

I

1eff

= 13.1A

12.3A

13A

10A/20.4V to 80A/23.2V

X 40% 60% 100%

U

0

 78V

I

2

80A 70A 60A

U

2

23.2V 22.8V 22.4V

10A/10.4V to 125A/15V

X 40% 60% 100%

U

0

 15V

I

2

125A 105A 90A

U

2

15V 14.2V 13.6V

2

*

4

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Page 15<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63621

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18. Cut off all bent and crimped wire.

The cut end must have no burrs or

sharp edges; cut again if needed.

19. Keep tension on the wire and guide at

least 12 inches of wire into the Wire

Inlet Liner and Feed Guide.

20. Make sure the welding wire is resting in the groove

of the Feed Roller, then push the wire Idler Arm

down, and swing 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.

E&$*- 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 line

so that the welding wire moves through it

easily. Leave the cover open, so that the

feed mechanism can be observed.

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Page 16 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63621

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%

1.

2. %

3.

24. Plug either 120 VAC or 240 VAC Power

Cord into Power Input Socket.

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

25. Do not touch the Gun’s Trigger. Plug the Power

Cord into a properly grounded, GFCI protected

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

matches the plug and turn the Power Switch ON.

The circuit must be equipped with delayed

action-type circuit breaker or fuses.

26. Point the Gun away from

all objects. Press and

hold the Cold Wire Feed

Switch until the wire feeds

through two inches.

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If the 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%

U

0

 78V

I

2

200A 130A 115A

U

2

24V 20.5V 19.75V

1~50/60Hz

U

1

= 240V

I

1max

= 25.5A

23.7A

15.6A

I

1eff

 12.8A

11.9A

8.5A

10A/20.4V to 175A/27V

X 25% 60% 100%

U

0

 78V

I

2

175A 115A 100A

U

2

27V 24.6V 24V

10A/10.4V to 175A/17V

X 30% 60% 100%

U

0

 15V

I

2

175A 125A 105A

U

2

17V 15V 14.2V

30A/15.5V to 140A/21V

X 40% 60% 100%

U

0

 78V

I

2

100A 85A 75A

U

2

19V 18.25V 17.75V

1~50/60Hz

U

1

= 120V

I

1max

= 20.8A

19.5A

20.6A

I

1eff

= 13.1A

12.3A

13A

10A/20.4V to 80A/23.2V

X 40% 60% 100%

U

0

 78V

I

2

80A 70A 60A

U

2

23.2V 22.8V 22.4V

10A/10.4V to 125A/15V

X 40% 60% 100%

U

0

 15V

I

2

125A 105A 90A

U

2

15V 14.2V 13.6V

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Page 17<&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1Item 63621

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27. To check the wire’s drive tension, feed the wire

against a piece of wood from 2 to 3 inches away.

If the wire stops instead of bending, unplug

the Welder, slightly tighten the Feed

Tensioner clockwise, and try again. If the

wire bends from the feed pressure, then the

tension is set properly. Before proceeding,

turn OFF the Power Switch and unplug the

Power Cord from its electrical outlet.

28. Turn OFF the Power Switch and unplug the

Power Cord from its electrical outlet.

29. Select a Contact Tip that is compatible with

the welding wire used. Slide the Contact

Tip over the wire and thread it clockwise into

the MIG Gun. Tighten the Contact Tip.

30. Replace the Nozzle and cut the wire

off at 1/2" from tip (1/2" stickout).

31. Close the Welder Door. Make sure

Door is securely latched.

C84(*5*8$,77>%%

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1. To s et u p op ti on al S po ol G un ( so ld s ep ar at el y) , pl ug G ro un d Cl am p Ca bl e in to N eg at iv e (

a

) 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

securely. If Connector is not fully

inserted, the gas connection will

leak, preventing shielding gas

from reaching the welding arc.

EVACT6- To prevent damage, do

not overtighten the Knob.

4. Insert the Wire Feed Control Cable

through hole on Welder front and

connect to the Wire Feed Control Socket

inside the machine, then tighten lock

ring on the Cable plug. Note that the

plug on the Cable fits into the Socket

in one specific orientation only.

5. Connect Gas Hose on Spool Gun Cable

Connector to Spool Gun Gas Outlet on front

of Welder. Refer to paragraph 17 on page 14

for further shielding gas setup information.

6. Refer to Spool Gun manual for

operational information.

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S&#"$"Y*%?&4X*$

Page 18 <&(%$*4.8"4,7%H'*#$"&8#I%/7*,#*%4,77%JKLLLKMLNKNMJL1 Item 63621

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

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Flux-cored wire welding is used to weld mild steel

and stainless steel 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 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

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1. D,X*%/(,4$"4*%)*79#%&8%/"*4*#%&2%#4(,/%$.*%

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&2%Y,7'*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.

E&$"4*- 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.

3. Clamp Ground Cable to bare metal on the

workpiece near the weld area, or to metal work

bench where the workpiece is clamped.

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Duty Cycle (Duration of Use)

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

defines the number of minutes, within a 10 minute

period, during which a given welder can produce a

particular welding current without overheating.

For example, a welder with a 40% duty cycle at

100 A welding current must be allowed to rest for at least

6 minutes after every 4 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 a

warning screen appears in the LCD Display window.

The Welder automatically returns to service after

cooling off. Should this occur, rest the MIG Gun on an

electrically non-conductive, heat-proof surface, such

as a concrete slab, well clear of the ground clamp.

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When normal operation resumes, use shorter welding

periods and longer rest periods to prevent needless wear.

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4. Turn the Power Switch to the OFF position,

then plug the Power Cord into a properly

grounded, GFCI protected 120 VAC (20 amp

rated) or 240 VAC receptacle that matches

the plug. The circuit must be equipped with

delayed action-type circuit breaker or fuses.

5. Set MIG Gun down on nonconductive, nonflammable

surface away from any grounded objects.

6. Turn the Power Switch ON.

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1. Press Home Button on Control Panel.

2. Turn Main Control Knob until desired

process appears on LCD display screen.

3. Press Main Control Knob to select process.

E&$*- 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.

• Turn Right Knob to set material thickness.

1N]_b 24Ga

c. Auto Weld Settings:

• Turn Left Knob to adjust Wire

Feed Speed (Amperage).

• Turn Right Knob to adjust Voltage.

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E&$*- If the Wire Feed Speed or Voltage settings are

adjusted manually, the white mark on the line shows

the recommended setting for your wire/electrode

diameter and workpiece thickness.

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