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

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Owner's Manual & Safety Instructions

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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.

Email our technical support at: productsupport@harborfreight.com

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.

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.

Tools required for assembly and service may not be included.

Keep this manual for the safety warnings and precautions, assembly,

Visit our website at: http://www.harborfreight.com

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

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Summary of Contents for Harbor Freight Tools VULCAN PROTIG 200

Page 1 Failure to do so can result in serious injury. Failure to do so can result in serious injury. any shape or form without the express written consent of Harbor Freight Tools. any shape or form without the express written consent of Harbor Freight Tools.
Page 2: Table Of Contents
Table of contents Safety ..............2 Welding Tips ............20 Specifications ............7 Maintenance and Service ........24 Setup ............... 8 Parts List and Diagrams ......... 25 Basic Welding ............12 Warranty ..............28 WARNINg SyMBOLS ANd dEFINITIONS This is the Safety alert symbol. It is used to alert you to potential personal injury hazards.
Page 3: Safety
Fume and gas Safety INHALATION HAZARD: Welding and plasma cutting produce toxic fumes. 1. Exposure to welding or cutting exhaust 3. Keep head out of fumes. fumes can increase the risk of developing Do not breathe exhaust fumes. certain cancers, such as cancer of the 4.
Page 4: Electrical Safety
Electrical Safety ELEcTRIc SHOcK can KILL. 1. Turn off, disconnect power, and 6. do not expose welders to rain or wet conditions. discharge Electrode to ground before setting Water entering a welder will increase down torch/Electrode holder and before service. the risk of electric shock.
Page 5 If unreadable or missing, contact welder’s operation. If damaged, have the Harbor Freight Tools for a replacement. welder repaired before use. Many accidents 4. Unplug before maintenance. Unplug the Welder are caused by poorly maintained welders.
Page 6: Extension Cords
grounding TO pREVENT ELEcTRIc SHOcK ANd dEATH FROM INcORREcT gROUNdINg WIRE cONNEcTION: check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. do not use the welder if the power cord or plug is damaged. If damaged, have it repaired by a service facility before use.
Page 7: Specifications
Symbology Wire Feed (Speed) American Wire Gauge Electric Shock Hazard. Workpiece Ground Cable Do not touch energized parts. Torch Cable Inhalation Hazard. Keep head out of fumes and use proper ventilation. Overheat Shutdown Indicator Read manual before Cooling Fan setup and/or use. Fire Hazard.
Page 8: Setup
Setup Read the ENTIRE IMpORTANT SAFETy INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. TO pREVENT SERIOUS INJURy FROM AccIdENTAL OpERATION: Turn the power Switch off and unplug the welder before set up. Place the Welder on a level surface that can bear its weight near the work area.
Page 9 connect Shielding gas 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.
Page 10 Sharpen Tungsten Electrode To avoid Electrode contamination, dedicate a fine grit grinding wheel exclusively to Electrode grinding. WARNINg! Some Electrodes may have 4. Lightly press Electrode tip materials added to them that are hazardous to against the surface of Electrode breathe.
Page 11 Stick Setup connect cables Negative Socket ground clamp positive Socket Electrode Holder 1. Plug Ground Clamp cable into Negative Socket. 2. Plug Electrode Holder cable into Positive Socket. Twist clockwise all the way to lock in place. Twist clockwise al the way to lock in place. connect power cord Plug either 120VAC or 240VAC cord into Power Input Socket.
Page 12: Basic Welding
Basic Welding Read the ENTIRE IMpORTANT SAFETy INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. TO pREVENT SERIOUS INJURy: protective gear must be worn when using the Welder; minimum shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH-approved respirator, and fire resistant work clothes without pockets should be worn when welding.
Page 13 controls Voltage Input/ Voltage Thermal Reduction power Overload Indicator Indicator Indicator display process Select Knob Settings Knob Storage compartment power Switch Voltage Reduction Indicator: process Select Knob: Lights when Voltage Reduction Device is operating. Turn to select process functions. power Indicator: Settings Knob: Lights when power is on.
Page 14: Setting Up The Weld
Setting up the Weld 2. Use clamps (not included) to hold the workpieces clamps in position so that you can concentrate on workpieces proper welding technique. The distance (if any) between the two workpieces must be clean surfaces controlled properly to allow the weld to hold to bare metal.
Page 15 Duty Cycle (Duration of Use) Avoid damage to the Welder by not welding for This welder has an internal thermal protection more than the prescribed duty cycle time. The Duty system to help prevent this sort of over-stress. Cycle defines the number of minutes, within a 10 minute When the Welder overheats, it automatically shuts period, during which a given welding process can down and the Overload Indicator lights.
Page 16: Tig Welding
TIg Welding TO pREVENT SERIOUS INJURy ANd dEATH: do not weld without grounding clamp. When the operator is not holding the Torch, it must be sitting on a nonconductive, nonflammable surface. Only hold TIg Rod with an electrically insulated welding glove. TO pREVENT dEATH FROM ASpHyXIATION: do not open gas without proper ventilation.
Page 17 WARNINg! TO pREVENT SERIOUS INJURy: NOTE: Maintain a constant distance between the protective gear must be worn when using the Tungsten Electrode and the workpiece: between Welder; minimum shade number 10 full face shield 1 and 1.5 times the diameter of the Electrode. (or welding mask), ear protection, welding gloves, 10.
Page 18: Stick Welding
Stick Welding TO pREVENT SERIOUS INJURy ANd dEATH: do not weld without grounding clamp. When the operator is not holding the Electrode Holder, it must be sitting on a nonconductive, nonflammable surface. 1. Turn the Power Switch to the OFF position, 5.
Page 19 WARNINg! TO pREVENT SERIOUS INJURy: 8. After the arc ignites: protective gear must be worn when using the a. Lift the Electrode off workpiece the same Welder; minimum shade number 10 full face shield distance as the diameter of the bare metal end. (or welding mask), ear protection, welding gloves, b.
Page 20: Welding Tips
Welding Tips 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.
Page 21 Stick Weld diagnosis - Workpiece Heat control / Weld penetration EXcESS pENETRATION OR INAdEQUATE pENETRATION pROpER pENETRATION BURN-THROUgH Not hot enough Ideal heat Too hot How to increase workpiece heat How to reduce workpiece heat and increase penetration: and limit penetration: (to weld THIcKER workpieces properly) (to weld THINNER workpieces properly) a.
Page 22 Stick Weld Penetration (Workpiece Heat Control) EXcESS pENETRATION OR pROpER pENETRATION INAdEQUATE pENETRATION BURN-THROUgH Weld is visible underneath and Weld does not contact the joint Weld droops on top and bulges slightly on top. fully, just on the surface. underneath or falls through entirely, making a hole.
Page 23 Stick Weld - coat of Slag Over Weld Slag is a necessary part of a stick weld. It shields the weld from impurities. clean off the slag with the chipping Hammer and Wire Brush after welding. VIEW PARTIALLY CHIPPED AWAY TO SHOW WELD Stick Weld - porosity - Small cavities or holes in the bead.
Page 24: Maintenance And Service
Maintenance and Service TO pREVENT SERIOUS INJURy, FIRE ANd BURNS: Unplug the Welder, rest the TIg Torch on a heat-proof, electrically non-conductive surface, and allow all parts of the Welder to cool thoroughly before service. 1. BEFORE EAcH USE, inspect the general 2.
Page 25: Parts List And Diagrams
parts List and diagrams part description part description part description Top Housing Power Switch Inductance Handle Base Foot Pedal IGBT Top Handle Cover Copper Anode IGBT Left Radiator Bridge Rectifier Current Sensor IGBT Bridge Heat Sink Copper Cathode Radiator Beam Negative Socket Fast Recovery Diode Cassette Holder...
Page 26: Wiring Diagram
Wiring diagram Control Board Power Switch Page 26 For technical questions, please call 1-888-380-0318. Item 63619...
Page 27: Please Read The Following Carefully
pLEASE REAd THE FOLLOWINg cAREFULLy THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT.
Page 28: Warranty
Limited One year Warranty Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of one year from the date of purchase.

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

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