Manual For The 63621 Omni Pro™ 220 Multiprocess Welder With 120/240 Volt Input

User Manual: Manual for the 63621 OmniPro™ 220 Multiprocess Welder with 120/240 Volt Input OmniPro™ 220 Multiprocess Welder with 120/240 Volt Input

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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.

18a

Visit our website at: http://www.harborfreight.com
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 1-888-380-0318 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 service may not be included.

Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

Table of contents
SAFETy

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

WARNINg SyMBOLS ANd dEFINITIONS

cONTROLS

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.

WIRE

Addresses practices not related to personal injury.

IMpORTANT SAFETy INFORMATION
TIg / STIck

Read all Safety warnings and instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.

general Safety
pROTEcT yourself and others. Read and understand this information.

WELdINg TIpS

1. Before use, read and understand
manufacturer′s instructions,
Material Safety Data Sheets (MSDS′s),
employer′s Safety practices, and ANSI Z49.1.
2. keep out of reach of children.
Keep children and bystanders away while operating.
3. place the welder on a stable location before use.
If it falls while plugged in, severe injury,
electric shock, or fire may result.
4. do not overreach.
keep proper footing and balance at all times.

MAINTENANcE
Page 2

5. Stay alert, watch what you are doing and use
common sense when operating a welder.
do not use a welder while you are tired or under
the influence of drugs, alcohol or medication.
A moment of inattention while operating welders
may result in serious personal injury.
6. Avoid unintentional starting. Make sure you are
prepared to begin work before turning on the Welder.
7. Never leave the Welder unattended while
energized. Turn power off if you have to leave.
8. The warnings, precautions, and instructions
discussed in this instruction manual cannot
cover all possible conditions and situations
that may occur. 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.

For technical questions, please call 1-888-380-0318.

Item 63621

Fume and gas Safety

6. Have a recognized specialist in
Industrial Hygiene or Environmental Services
check the operation and air quality
and make recommendations
for the specific welding situation.
Follow OSHA guidelines for
Permissible Exposure Limits (PEL’s) and
the American Conference of Governmental
Industrial Hygienists recommendations for
Threshold Limit Values (TLV’s) for fumes and gases.

Arc Ray Safety
ARc RAyS can injure eyes and burn skin.
1. Wear ANSI-approved welding eye protection
featuring at least a number 10 shade lens rating.
2. Wear leather leggings, fire resistant shoes
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing
that can catch and hold molten metal or sparks.

4. Wear an approved head covering to protect
the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
approved for welding and cutting procedures.
5. Wear an approved welding jacket or long sleeves
to protect forearms from radiation burns.
6. When welding/cutting overhead or in confined
spaces, wear flame resistant ear plugs or
ear muffs to keep sparks out of ears.

MAINTENANcE

3. keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.

cONTROLS

5. Work in a confined area only if it
is well-ventilated, or while wearing
an air-supplied respirator.

WIRE

4. Use enough ventilation, exhaust at arc, or
both, to keep fumes and gases from breathing
zone and general area. If engineering controls
are not feasible, use an approved respirator.

TIg / STIck

2. do not use near degreasing or
painting operations.

3. keep head out of fumes.
Do not breathe exhaust fumes.

WELdINg TIpS

1. Exposure to welding or cutting exhaust
fumes can increase the risk of developing
certain cancers, such as cancer of the
larynx and lung cancer. 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.

SAFETy

INHALATION HAZARD:
Welding and plasma cutting produce toxic fumes.

Item 63621

For technical questions, please call 1-888-380-0318.

Page 3

Electrical Safety
SAFETy

ELEcTRIc SHOck can kILL.
1. Turn off, disconnect power, and
discharge electrode to ground before setting
down torch/electrode holder and before service.

cONTROLS

2. do not touch energized electrical parts.
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. connect to grounded, gFcI-protected
power supply only.
4. do not use near water or damp objects.
5. people with pacemakers should consult their
physician(s) before use. Electromagnetic fields
in close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.

WIRE

6. do not expose welders to rain or wet conditions.
Water entering a welder will increase
the risk of electric shock.

7. do not abuse the cord. Never use the cord
for carrying, pulling or unplugging the welder.
keep cord away from heat, oil, sharp edges
or moving parts. Damaged or entangled
cords increase the risk of electric shock.
8. do not use outdoors.
9. Insulate yourself from the workpiece and
ground. 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. THIS WELdINg MAcHINE MUST BE
cONNEcTEd TO pOWER SOURcE IN
AccORdANcE WITH AppLIcABLE
ELEcTRIcAL cOdES.

Fire Safety
TIg / STIck

ARc ANd SLAg can cause fire.
1. clear away or protect flammable objects.
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.

WELdINg TIpS

2. keep ABc-type fire extinguisher near
work area and know how to use it.
3. Maintain a safe working environment.
Keep the work area well lit.
Make sure there is adequate
surrounding workspace. Keep the work area free
of obstructions, grease, oil, trash, and other debris.

MAINTENANcE

4. do not operate welders in atmospheres
containing dangerously reactive or
flammable liquids, gases, vapors, or dust.
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.

Page 4

5. If working on a metal wall, ceiling, etc.,
prevent ignition of combustibles on the
other side by moving the combustibles to a
safe location. 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. do not weld or cut on materials having
a combustible coating or combustible
internal structure, as in walls or ceilings, without
an approved method for eliminating the hazard.
7. do not dispose of hot slag in containers
holding combustible materials.
8. After welding, make a thorough examination
for evidence of fire. Be aware that easily
visible smoke or flame may not be present
for some time after the fire has started.
9. do not apply heat to a container that has held
an unknown substance or a combustible
material whose contents, when heated,
can produce flammable or explosive vapors.
Clean and purge containers before applying heat.
Vent closed containers, including castings,
before preheating, welding, or cutting.

For technical questions, please call 1-888-380-0318.

Item 63621

6. do not use the welder for pipe thawing.

Maintenance
1. Maintain welders. check for misalignment or
binding of moving parts, breakage of parts
and any other condition that may affect the
welder’s operation. If damaged, have the
welder repaired before use. Many accidents
are caused by poorly maintained welders.
2. Have your welder serviced by a qualified
repair person using only identical
replacement parts. This will ensure that
the Safety of the welder is maintained.

3. Maintain labels and nameplates on the Welder.
These carry important information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
4. Unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
maintenance, or cleaning procedures.

cONTROLS

3. prevent unintentional starting.
Ensure the switch is in the offposition before connecting to power
source or moving the welder. Carrying
or energizing welders that have the
switch on invites accidents.

5. Use the welder and accessories in
accordance with these instructions, taking
into account the working conditions and
the work to be performed. Use of the welder
for operations different from those intended
could result in a hazardous situation.

WIRE

2. disconnect the plug from the power
source before making any adjustments,
changing accessories, or storing welders.
Such preventive Safety measures reduce the
risk of starting the welder accidentally.

4. Store idle welders out of the reach of
children and do not allow persons unfamiliar
with the welder or these instructions to
operate the welder. Welders are dangerous
in the hands of untrained users.

TIg / STIck

1. do not use the welder if the switch does not turn
it on and off. Any welder that cannot be controlled
with the switch is dangerous and must be repaired.

SAFETy

Welder Use and care

cylinders can explode when damaged.
1. do not weld on a pressurized or closed cylinder.
2. do not allow an electrode holder,
electrode, welding torch, or welding
wire to touch the cylinder.
3. keep cylinders away from any electrical circuits,
including welding circuits.

5. Use only correct gas shielding equipment
designed specifically for the type of welding
you will do. Maintain this equipment properly.
6. protect gas cylinders from heat, being struck,
physical damage, slag, flames, sparks, and arcs.
7. Use proper procedures to move cylinders.

MAINTENANcE

4. keep protective cap in place over the valve
except when the cylinder is in use.

SAVE THESE INSTRUcTIONS.
Item 63621

WELdINg TIpS

gas Shielded Welding - cylinder Safety

For technical questions, please call 1-888-380-0318.

Page 5

grounding
SAFETy

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. If the plug will not fit the outlet, have a proper outlet
installed by a qualified electrician, do not use adapter plugs.

cONTROLS

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.

Extension cords
do not use an extension cord on this welder.

WIRE

Replacement cords
1. Use only one of the supplied power cords for
this welder or an identical replacement cord.
2. do not install a thinner or longer
cord on this welder.

3. do not patch cords of any length
together for this item, patches may allow
moisture to penetrate the insulation,
resulting in electric shock.

TIg / STIck

Symbology
Wire Feed (Speed)

Workpiece Ground Cable

IpM
AWg

Torch Cable

WELdINg TIpS

Overheat Shutdown Indicator
Cooling Fan
Housing Ground Point

MAINTENANcE

VAc
A
OcV
kVA
Page 6

Volts Alternating Current
Amperes
Open Circuit Voltage
Kilovolt Amperes
(Volts / 1000 * Amperes)

For technical questions, please call 1-888-380-0318.

Inches Per Minute
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.
Item 63621

SAFETy

Specifications
MIg
Power Input

120 VAC / 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

40% @ 100 A
100% @ 75 A

25% @ 200 A
100% @ 115 A

Maximum OCV
Weldable Materials
Welding Wire Capacity

78 VDC

cONTROLS

Rated Duty Cycles

Mild Steel, Stainless Steel
Aluminum (with optional Spool Gun)
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

Power Input

120 VAC / 60 Hz

240 VAC / 60 Hz

Current Input at Output
Welding Current Range

20.6 A at 125 A
10 A –125 A
40% @ 125 A
100% @ 90 A

15.6 A at 175 A
10 A –175 A
30% @ 175 A
100% @ 105 A

Maximum OCV
Weldable Materials

78 VDC
Mild Steel, Stainless Steel, Chrome Moly

TIg / STIck

Rated Duty Cycles

WIRE

TIg

Power Input
Current Input at Output
Welding Current Range
Rated Duty Cycles
Maximum OCV

240 VAC / 60 Hz

19.5 A at 80 A
10 A – 80 A
40% @ 80 A
100% @ 60 A

23.7 A at 175 A
10 A –175 A
25% @ 175 A
100% @ 100 A
78 VDC

Mild Steel, Stainless Steel

MAINTENANcE

Weldable Materials

120 VAC / 60 Hz

WELdINg TIpS

Stick

Item 63621

For technical questions, please call 1-888-380-0318.

Page 7

controls

SAFETy

Front panel controls

cONTROLS

Home
Button

Back
Button

control
knob

WIRE

Lcd
display

Left
knob

Right
knob

power
Switch

TIg / STIck

Storage
compartment

MIG Gun /
Spool gun
cable Socket

positive
Socket

Spool gun
gas Outlet

WELdINg TIpS
Negative
Socket

Wire Feed
power cable

MAINTENANcE

Note: When using an optional Spool Gun (sold separately), connect the
Spool Gun gas hose to the Spool Gun Gas Outlet.

Page 8

For technical questions, please call 1-888-380-0318.

Item 63621

SAFETy

Interior controls
cold Wire
Feed Switch

Idler
Arm

Wire Spool

Feed
Roller
knob

Spool knob
Wire Inlet
Liner

Wire Feed
control Socket

MAINTENANcE

WELdINg TIpS

TIg / STIck

Foot pedal
Socket

WIRE

Wire Feed
Mechanism

cONTROLS

Feed
Tensioner

Item 63621

For technical questions, please call 1-888-380-0318.

Page 9

MIG / Flux-Cored Wire Welding

SAFETy

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 setup.
Note: Remove the protective foam and cardboard from the Welder before setup.

cONTROLS

Wire Spool Installation / Wire Setup
power
Switch

1. Turn the power Switch OFF and unplug
the Welder before proceeding.

WIRE
TIg / STIck

2. Pull up on the Door Latch,
then open the Door.

door

door
Latch

WELdINg TIpS

3. 1-2 pound Wire Spool Installation:
Remove the Wingnut and Spacer. If
replacing a Spool, remove the old Spool
and all remaining wire from the liners.

Wingnut
1-2 lb
Wire Spool

Spacer
4. Place the new Wire Spool over the Spool Spindle
and against the Spool Brake Pad as illustrated.
To prevent wire feed problems, set the
Spool so that it will unwind clockwise.

MAINTENANcE

5. Replace the Spacer over the
Spool Spindle and secure Spool
in place with the Wingnut.

Spool
Spindle
Spool
Brake pad
Welder
Wall
1-2 lb Spool Loading

Notice: If Wire Spool can spin freely, Wingnut is too
loose. This will cause the welding wire to unravel and
unspool which can cause tangling and feeding problems.

Page 10

For technical questions, please call 1-888-380-0318.

Item 63621

Wingnut

SAFETy

Spool knob

6. 10-12 pound Wire Spool Installation:
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.

10-12 lb
Wire Spool
Spool Spindle
Spool
Brake pad
Welder
Wall

WIRE

8. Place the new Wire Spool over the Adapter and
line up pin on Adapter with hole in Spool.
To prevent wire feed problems, set the
Spool so that it will unwind clockwise.

10-12 lb
Spool
Adapter

cONTROLS

Spacer

10-12 lb Spool Loading
9. Replace the Spacer over the Spool Spindle
and secure Spool in place with the Wingnut.

Wire
must
unwind
in this
direction

WELdINg TIpS

10. Screw the Spool Knob into the Spool Adapter.

TIg / STIck

Notice: If Wire Spool can spin freely, Wingnut
is too loose. This will cause the welding
wire to unravel and unspool which can
cause tangling and feeding problems.

Feed Tensioner
Idler Arm

Item 63621

For technical questions, please call 1-888-380-0318.

MAINTENANcE

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.

Page 11

SAFETy

12. Feed Roller Instructions:
Check that the Feed Roller is correct for the
type of wire being used (solid core or fluxcored) and that it is turned to properly match
the wire size marked on the Wire Spool:

Feed Roller
knob

cONTROLS

0.025
groove
0.030 / 0.035
groove

WIRE

0.030 / 0.035
groove

Solid core
V-groove

0.045
groove

a. Unscrew the Feed Roller Knob
counterclockwise.

Feed
Roller

b. Remove the Feed Roller Knob
to expose the Feed Roller.

TIg / STIck

c. Flip or replace the Feed Roller as needed
and confirm that it is the correct Roller
for the type of wire being used and that
the number showing is the same as
the wire diameter on the Spool.

Flux-cored
knurled groove

WELdINg TIpS

d. Screw the Feed Roller Knob back into
place to secure the Feed Roller.

MAINTENANcE
Page 12

For technical questions, please call 1-888-380-0318.

Item 63621

gun cable
connector
knob

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.

Incorrect – Connector not fully inserted

cONTROLS

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.

SAFETy

Wire Feed
Mechanism

Wire
Feed
control
cable

TIg / STIck

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.

WIRE

NOTIcE: To prevent damage, do
not overtighten the Knob.

Correct – Connector fully inserted

dcEN

Wire Feed
power cable in
Negative Socket

MAINTENANcE

16. dcEN direct current Electrode
Negative Wire Setup for Flux-cored
(gasless) welding:
Plug Ground Clamp Cable into Positive (+)
Socket. Plug Wire Feed Power Cable
into Negative (–) Socket. Twist cables
clockwise all the way to lock in place.

WELdINg TIpS

Flux-Cored (Gasless)
polarity Setup

ground clamp cable
in positive Socket

Item 63621

For technical questions, please call 1-888-380-0318.

Page 13

dcEp

SAFETy

17. dcEp direct current Electrode positive Wire
Setup for Solid Core (gas shielded) welding:

Solid Core (Gas Shielded)
polarity Setup

ground clamp cable
in Negative Socket
a. Plug Ground Clamp Cable into Negative (–)
Socket. Plug Wire Feed Power Cable
into Positive (+) Socket. Twist cables
clockwise all the way to lock in place.

cONTROLS

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.

Wire Feed
power cable in
positive Socket

WIRE

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.

TIg / STIck

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.

Briefly open valve
to clean,
then close
valve.

e. Locate the Regulator (included) and close its
valve until it is loose, then thread Regulator
onto cylinder and wrench-tighten connection.

WELdINg TIpS

Note: 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. Wrenchtighten both connections.

Serial:

Vulcan OMNIPRO 220
Conforms to UL Std. 60974-1

63621

269317

17b

30A/15.5V to 220A/25V
X

U0 78V

Power Input

25%

I2
U2

60%

100%

200A

130A

115A

24V

20.5V

19.75V

10A/20.4V to 175A/27V
X

U0 78V

25%

I2
U2

60%

100%

175A

115A

27V

24.6V

100A
24V

10A/10.4V to 175A/17V
X

U0 15V
1~50/60Hz

30%

60%

175A

125A

17V

100%

15V

105A
14.2V

I1max = 25.5A
23.7A
15.6A

U1 = 240V

I1eff

12.8A
11.9A
8.5A

30A/15.5V to 140A/21V
X

40%

60%

100%

100A

85A

75A

19V

18.25V

17.75V

U0 78V

80A

70A

60A

23.2V

22.8V

22.4V

U0 15V

10A/20.4V to 80A/23.2V
X

40%

60%

100%

10A/10.4V to 125A/15V
X

Reset
Gas Inlet

1~50/60Hz

IP21S

U1 = 120V

40%

60%

100%

125A

105A

90A

15V

14.2V

13.6V

I1max = 20.8A
19.5A
20.6A
f1

I1eff = 13.1A
12.3A
13A

MAINTENANcE
Page 14

For technical questions, please call 1-888-380-0318.

Item 63621

If this is not done, the welding wire will unravel and unspool
which can cause tangling and feeding problems.

18. Cut off all bent and crimped wire.
The cut end must have no burrs or
sharp edges; cut again if needed.

Feed
guide

Welding
Wire

Wire
Spool

Wire Inlet
Liner

WIRE

19. Keep tension on the wire and guide at
least 12 inches of wire into the Wire
Inlet Liner and Feed Guide.

HOLd WIRE
SEcURELy

cONTROLS

SAFETy

IMpORTANT
Securely hold onto the end of the welding wire and keep
tension on it during the following steps.

Idler Arm

Feed Tensioner

TIg / STIck

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.
Note: The tension should be 3 – 5 for solid wire and
2 – 3 for flux-cored wire. Too much force on flux-cored
wire will crush it and may cause feeding issues.

MIg gun

22. Unscrew the Contact Tip
counterclockwise and remove.

Nozzle

WELdINg TIpS

21. Pull the Nozzle to remove it.

contact
Tip

MAINTENANcE

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.

IMpORTANT

Stainless steel wire is less flexible than
other welding wire. Therefore, it is more
difficult to feed through the liner and gun.
It is especially important to keep the gun cable
straight while feeding stainless steel wire.

Item 63621

For technical questions, please call 1-888-380-0318.

Page 15

dANgER
SAFETy

pARTS MAy BE AT WELdINg VOLTAgE
TO pREVENT ELEcTRIc SHOck ANd dEATH:
1. keep hands away from Wire Feed mechanism.
2. close door before plugging in, unless using cold
Wire Feed to feed wire through to gun.
3. do not touch Trigger while feeding wire through to gun.

cONTROLS
24. Plug either 120 VAC or 240 VAC Power
Cord into Power Input Socket.

power
Input

Serial:

Vulcan OMNIPRO 220
Conforms to UL Std. 60974-1

63621

269317

17b

30A/15.5V to 220A/25V
X

25%

U0 78V

Power Input

60%

100%

200A

130A

115A

24V

20.5V

19.75V

10A/20.4V to 175A/27V
X

25%

60%

100%

175A

115A

27V

24.6V

100A
24V

10A/10.4V to 175A/17V

U0 15V
1~50/60Hz

30%

60%

175A

125A

17V

15V

100%
105A
14.2V

I1max = 25.5A
23.7A
15.6A

U1 = 240V

I1eff

12.8A
11.9A
8.5A

30A/15.5V to 140A/21V

U0 78V

40%

60%

100A

85A

75A

19V

18.25V

17.75V

100%

10A/20.4V to 80A/23.2V
X

40%

80A

60%

100%

70A

60A

22.8V

22.4V

U0 78V

U2
X

40%

U0 15V

125A

105A

90A

15V

14.2V

13.6V

23.2V

10A/10.4V to 125A/15V

Reset
Gas Inlet

Note: Plug will only fit one way.

1~50/60Hz

IP21S

U1 = 120V

I1max = 20.8A
19.5A
20.6A

60%

100%

I1eff = 13.1A
12.3A
13A

WIRE
TIg / STIck

power
Switch

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.

WELdINg TIpS

26. Point the Gun away from
all objects. Press and
hold the Cold Wire Feed
Switch until the wire feeds
through two inches.

MAINTENANcE

The wire liner may come
out with the welding
wire. This is normal,
just push the wire liner
back into the gun.
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.

Page 16

cold Wire
Feed Switch
2"

MIg gun

Welding
Wire

For technical questions, please call 1-888-380-0318.

Item 63621

Note: After pressing Trigger, wire will stop
feeding after 3 seconds if there is no arc.
check tension for less than 3 seconds.

SAFETy

27. To check the wire’s drive tension, press and hold
Trigger to feed the wire against a piece of wood
from 2 to 3 inches away.

Incrementally
increase tension
until
wire bends.

2–3"

cONTROLS

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. Close the Door. Make sure
Door is securely latched.

MIg gun
Nozzle

contact
Tip

WIRE

30. 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.
31. Replace the Nozzle and cut the wire
off at 1/2" from tip (1/2" stickout).

Optional Spool gun Setup

Spool gun

Wire Feed
control
cable

NOTIcE: 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.

Spool gun
gas Outlet

gas Hose

ground
clamp cable
in Negative
Socket

Wire Feed
power cable in
positive Socket

6. Refer to Spool Gun manual for
operational information.

Item 63621

For technical questions, please call 1-888-380-0318.

Page 17

WELdINg TIpS

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.

Spool gun
cable connector

MAINTENANcE

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.

TIg / STIck

1. To set up optional Spool Gun (sold separately), plug Ground Clamp Cable into Negative (–) Socket. Plug
Wire Feed Power Cable into Positive (+) Socket. Twist cables clockwise all the way to lock in place.

Basic Wire Welding
SAFETy

Read the ENTIRE IMpORTANT SAFETy INFORMATION section at the beginning of this manual
including all text under subheadings therein before welding.

cONTROLS

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.
Light from the arc can cause permanent damage to the eyes and skin.
do not breathe arc fumes.
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.

WIRE

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:

TIg / STIck

•
•
•
•

a different thickness of material
a different type of material
a different type of connection
using a different process

Make practice welds on pieces of scrap to practice
technique before welding anything of value.

power
Switch

WELdINg TIpS

TO pREVENT SERIOUS INJURy,
FIRE ANd BURNS:
keep welding tip clear of grounded
objects whenever unit is plugged
in and turned on.

MAINTENANcE

practice your welding
technique on scrap
pieces before welding
anything of value.

Page 18

For technical questions, please call 1-888-380-0318.

Item 63621

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.
Allow the Welder to cool with the power Switch on,
so that the internal Fan will help cool the Welder.
When normal operation resumes, use shorter welding
periods and longer rest periods to prevent needless wear.

4
Minutes
Welding

6
Minutes
Resting

cONTROLS

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.

40% Use at 100 A
For 10 continuous Minutes

100% continuous Use at 75 A

25% Use at 200 A
For 10 continuous Minutes
2-1/2
Minutes
Welding

7-1/2
Minutes
Resting

WIRE

Avoid damage to the Welder by not welding for more
than the prescribed duty cycle time. The Duty Cycle
defines the number of minutes, within a 10 minute
period, during which a given welder can produce a
particular welding current without overheating.

SAFETy

Duty Cycle (Duration of Use)

100% continuous Use at 115 A

clean surfaces
to bare metal.
chamfer thick workpieces.

1. Make practice welds on pieces of scrap the
same thickness as your intended workpiece
to practice technique before welding anything
of value. 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.

WELdINg TIpS

clamps
workpieces

TIg / STIck

Setting Up The Weld

3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.

ground
clamp

clean
surface to
bare metal.

ground connection depends
on desired welding polarity

Item 63621

For technical questions, please call 1-888-380-0318.

Page 19

MAINTENANcE

Workpiece

SAFETy

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.

power
Switch

5. Set MIG Gun down on nonconductive, nonflammable
surface away from any grounded objects.

cONTROLS

6. Turn the Power Switch ON.

Settings
b. Set Wire Diameter and Material Thickness:
• Turn Left Knob to set wire diameter.
• Turn Right Knob to set material thickness.

WIRE

.025"
Left
knob

TIg / STIck

Main
control
knob

Right
knob

1. Press Home Button on Control Panel.
2. Turn Main Control Knob until desired
process appears on LCD display screen.

c. Auto Weld Settings:
• Turn Left Knob to adjust Wire
Feed Speed (Amperage).
• Turn Right Knob to adjust Voltage.

3. Press Main Control Knob to select process.
Note: Press Main Control Knob to go to next screen.
Press Back Button to return to the previous screen.

121

13.8

0.0

WELdINg TIpS

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.

24Ga

Wire
diameter

.030"

process

24Ga

gas Type
25

Run-In WFS

Inductance

0.0

Material
Thickness

Spot Timer

Note: 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.

MAINTENANcE
Page 20

For technical questions, please call 1-888-380-0318.

Item 63621

SAFETy

d. Optional Settings:
• Press Main Control Knob to
enter Optional Settings.
• Turn Main Control Knob until desired
setting appears on screen.
• Press Main Control Knob to
select desired setting.

cONTROLS

• Turn Main Control Knob to adjust setting.
Available Optional Settings:
• Run-In WFS – Adjust wire speed before it
contacts workpiece. This setting represents
a % of the pre-set wire feed speed (WFS).
• Inductance – Adjust length of arc.
Increase for more fluid puddle and flatter
bead. Decrease for colder puddle.

WIRE

• Spot Timer – Set timer for spot welding.
• Recall Setting – Retrieve saved settings.

TIg / STIck

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

gas Shielded, Solid-core Wire Only

MAINTENANcE

WELdINg TIpS

dANgER! TO pREVENT dEATH
FROM ASpHyXIATION:
do not open gas without proper ventilation. Fix gas
leaks immediately.
Shielding gas can displace air and cause rapid loss of
consciousness and death.
Shielding gas without carbon dioxide can be
even more hazardous because asphyxiation
can start without feeling shortness of breath.

1. Open gas cylinder valve all the way.
2. Set Flow Gauge to SCFH value
indicated on Settings Chart.

Item 63621

For technical questions, please call 1-888-380-0318.

Page 21

Basic Wire Welding Technique
SAFETy

1. Press (and hold) Trigger and contact the area
to be welded with electrode wire to ignite arc.

stringer bead

weave bead

2. For a narrow weld, you can usually draw the wire
in a steady straight line.
This is called a stringer bead.

cONTROLS

For a wider weld, draw the wire back and forth
across the joint.
This is called a weave bead and takes
practice to perform properly.

Weld MIg gun angles,
viewed from front of weld joint.

WIRE

3. Direct the welding wire straight into the joint.
This gives an angle of 90° (straight up and
down) for butt (end to end) welds, and an
angle of 45° for fillet (T-shaped) welds.
90°

45°
fillet weld joint

TIg / STIck
WELdINg TIpS

4. For MIG welding using solid wire and
shielding gas, the end of the MIG Gun should
be tilted so that wire is angled anywhere
in-between straight on and 15° away
from the direction you are welding. The
amount of tilt is called the push angle.

butt weld joint

push Angle

drag Angle

0-15°

Weld
direction

Solid Wire with Shielding gas

Weld
direction

Flux-cored Wire without gas

5. When using flux-cored wire without
shielding gas, the end of the MIG Gun
should be tilted so that wire is angled
anywhere in-between straight on and
15° in the direction you are welding. The
amount of tilt is called the drag angle.

MAINTENANcE

cTWd
(up to 1/2")

6. The Contact Tip should remain within 1/2″
of the work surface. This distance is called
CTWD - Contact Tip to Work Distance.

Page 22

For technical questions, please call 1-888-380-0318.

Item 63621

Lcd
display

Allow the Welder to cool with the
power Switch on, so that the internal
Fan will help cool the Welder.

After practice welding for a few seconds,
STOp and examine your weld using the
guidelines starting on the next page.

120 VAC
40% Use at 100 A

240 VAC
25% Use at 200 A

For 10 continuous Minutes

4
Minutes
Welding

6
Minutes
Resting

8. When welding is complete, set the MIg
gun down on a heat-proof, electrically
non-conductive surface.
Turn the Power Switch OFF.
9. Allow Welder to cool down, then
unplug the Power Cord.
10. Remove Ground Clamp from workpiece
or table and disconnect MIG Gun.

7-1/2
Minutes
Resting

100% Continuous Use at 115 A

TIg / STIck

100% Continuous Use at 75 A

2-1/2
Minutes
Welding

MIg gun

concrete slab
(or other heat-proof,
non-conductive surface)

power
Switch

MAINTENANcE

11. Respool wire by clipping wire, removing gas
nozzle/contact tip on MIG gun, releasing Idler
Arm on Wire Feed mechanism, and rotating
the Wire Spool counterclockwise. Be sure
to securely hold wire as it is being respooled
because the end of wire has a tendency to
quickly unravel once it clears the wire feeder.
12. MIg ONLy:
close shielding gas cylinder valve
securely. Remove Regulator and
replace cap. Disconnect Gas Hose from
Welder. Store and secure gas cylinder.

Item 63621

WIRE

FOLLOW dUTy cycLE!

WELdINg TIpS

cAUTION! Weld will be hot, do not touch.

SAFETy

power
Switch

When normal operation resumes, use
shorter welding periods and longer rest
periods to help prevent needless wear.

7. After welding the test weld on a piece
of scrap for a few seconds, stop, and
check your progress. Clean, then compare
your weld’s appearance with the diagrams
and descriptions in the Welding Tips 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 19.

Warning
Screen

cONTROLS

Note: If Welder is used too long, a
warning screen appears in the LCD
Display window and the unit automatically
shuts down. 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, away from the ground clamp.

For technical questions, please call 1-888-380-0318.

Page 23

TIG / Stick Welding

SAFETy

cONTROLS

TIg Setup
connect cables

WIRE

Foot pedal Socket
(inside Welder)
Foot pedal
(sold separately)
Foot pedal
cable

TIg / STIck

TIg Torch
cable in
Negative
Socket

Shielding
gas Hose

ground clamp cable
in positive Socket

WELdINg TIpS

TIg Torch
(sold separately)

ground
clamp

1. Plug Ground Clamp Cable into Positive Socket.
Twist clockwise all the way to lock in place.

MAINTENANcE

2. Plug TIG Torch Cable (TIG Torch sold
separately) into Negative Socket. Twist
clockwise all the way to lock in place.

3. Insert the Foot Pedal Cable (Foot Pedal
sold separately) through hole on Welder
front and connect to the Foot Pedal
Socket inside the machine. Secure by
turning collar clockwise until tight.
4. For connecting Shielding Gas Hose, refer to
Connect Shielding Gas section on next page.

Page 24

For technical questions, please call 1-888-380-0318.

Item 63621

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.

Briefly open valve
to clean,
then close
valve.

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.

cONTROLS

SAFETy

connect Shielding gas

TIg / STIck

4. Connect Shielding Gas Hose on TIG
Torch Cable Connector to the Regulator’s
Outlet and wrench-tighten connection.

WIRE

3. Locate the Regulator (included) and close its
valve until it is loose, then thread Regulator
onto cylinder and wrench-tighten connection.

Plug either 120 VAC or 240 VAC Power
Cord into Power Input Socket.

power
Input

Serial:

WELdINg TIpS

connect power cord

Vulcan OMNIPRO 220
Conforms to UL Std. 60974-1

63621

269317

17b

30A/15.5V to 220A/25V
X

U0 78V

Power Input

25%

I2
U2

60%

100%

200A

130A

115A

24V

20.5V

19.75V

10A/20.4V to 175A/27V

U0 78V

25%

60%

175A

115A

27V

24.6V

100%
100A
24V

10A/10.4V to 175A/17V

U0 15V
1~50/60Hz

30%

60%

175A

125A

105A

17V

15V

14.2V

I1max = 25.5A
23.7A
15.6A

U1 = 240V

100%

I1eff

12.8A
11.9A
8.5A

30A/15.5V to 140A/21V
X

Note: Plug will only fit one way.

U0 78V

I2
U2

60%

100%

100A

85A

75A

19V

18.25V

17.75V

10A/20.4V to 80A/23.2V
X

40%

80A

60%

100%

70A

60A

22.8V

22.4V

U0 78V

U2
X

40%

U0 15V

125A

105A

90A

15V

14.2V

13.6V

23.2V

10A/10.4V to 125A/15V

Gas Inlet

WARNINg! TO pREVENT SERIOUS INJURy
FROM AccIdENTAL OpERATION: Do not
plug cord into wall outlet at this time.

For technical questions, please call 1-888-380-0318.

1~50/60Hz

IP21S

U1 = 120V

I1max = 20.8A
19.5A
20.6A

60%

100%

I1eff = 13.1A
12.3A
13A

MAINTENANcE

Reset

Item 63621

40%

Page 25

Sharpen Tungsten Electrode (sold separately)

SAFETy

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

cONTROLS

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.

Electrode

Note: Grinding direction must be
parallel to length of Electrode.

grinding
Wheel

5. The conical portion of the ideal
tip will be 2-1/2 times as long
as the Electrode diameter.
6. Re-insert Electrode into Collet with tip
protruding 1/8"-1/4" beyond the Ceramic
Nozzle, then re-tighten the Back Cap.

Assemble TIG Torch (sold separately)

WIRE

1. Consult Settings Chart, on top of Welder, to
determine proper Tungsten Electrode size to be
used with thickness of material to be welded.

8. Lock Electrode in place with Back Cap.
Electrode should protrude 1/8" to 1/4"
beyond the Ceramic Nozzle.

2. Match Collet and Collet Body sizes
to Tungsten Electrode size.

Back cap

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

TIg / STIck

4. Make sure Ceramic Nozzle size is
appropriate for application.
5. Thread Ceramic Nozzle onto Collet Body.

Insert tungsten
Electrode here.

collet

6. Insert Collet into back of Torch and into Collet Body.
7. Insert Tungsten Electrode into
Collet on front of Torch.

collet
Body
ceramic
Nozzle

WELdINg TIpS
MAINTENANcE
Page 26

For technical questions, please call 1-888-380-0318.

Item 63621

SAFETy

Stick Setup

cONTROLS

connect cables

ground clamp cable
in Negative Socket

WIRE

ground
clamp

Electrode Holder
cable in positive Socket

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 all the way to lock in place.

TIg / STIck

Electrode
Holder

Plug either 120 VAC or 240 VAC Power
Cord into Power Input Socket.

power
Input

Serial:

WELdINg TIpS

connect power cord

Vulcan OMNIPRO 220
Conforms to UL Std. 60974-1

63621

269317

17b

30A/15.5V to 220A/25V
X

U0 78V

Power Input

25%

I2
U2

60%

100%

200A

130A

115A

24V

20.5V

19.75V

10A/20.4V to 175A/27V

U0 78V

25%

60%

175A

115A

27V

24.6V

100%
100A
24V

10A/10.4V to 175A/17V

U0 15V
1~50/60Hz

30%

60%

175A

125A

105A

17V

15V

14.2V

I1max = 25.5A
23.7A
15.6A

U1 = 240V

100%

I1eff

12.8A
11.9A
8.5A

30A/15.5V to 140A/21V
X

Note: Plug will only fit one way.

U0 78V

I2
U2

60%

100%

100A

85A

75A

19V

18.25V

17.75V

10A/20.4V to 80A/23.2V
X

40%

80A

60%

100%

70A

60A

22.8V

22.4V

U0 78V

U2
X

40%

U0 15V

125A

105A

90A

15V

14.2V

13.6V

23.2V

10A/10.4V to 125A/15V

Gas Inlet

WARNINg! TO pREVENT SERIOUS INJURy
FROM AccIdENTAL OpERATION: Do not
plug cord into wall outlet at this time.

For technical questions, please call 1-888-380-0318.

1~50/60Hz

IP21S

U1 = 120V

I1max = 20.8A
19.5A
20.6A

60%

100%

I1eff = 13.1A
12.3A
13A

MAINTENANcE

Reset

Item 63621

40%

Page 27

Basic TIG / Stick Welding
SAFETy

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.

cONTROLS

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.
Light from the arc can cause permanent damage to the eyes and skin.
do not breathe arc fumes.
• 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.

WIRE

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

TIg / STIck

• using a different process
Make practice welds on pieces of scrap to practice
technique before welding anything of value.

power
On

WELdINg TIpS

TO pREVENT SERIOUS INJURy,
FIRE ANd BURNS:
keep welding tip clear of grounded
objects whenever unit is plugged
in and turned on.

MAINTENANcE

practice your welding
technique on scrap
pieces before welding
anything of value.

Page 28

For technical questions, please call 1-888-380-0318.

Item 63621

Failure to carefully observe duty cycle limitations
can easily over-stress a welder’s power generation
system contributing to premature welder failure.

Allow the Welder to cool with the power Switch on,
so that the internal Fan will help cool the Welder.
When normal operation resumes, use
shorter welding periods and longer rest
periods to prevent needless wear.

TIg Rated duty cycles

Stick Rated duty cycles

240 VAC
30% Use at 175 A

120 VAC
40% Use at 125 A

240 VAC
25% Use at 175 A

120 VAC
40% Use at 80 A

For 10 continuous Minutes

3
Minutes
Welding

7
Minutes
Resting

100% Continuous Use at 105 A

4
Minutes
Welding

6
Minutes
Resting

100% Continuous Use at 90 A

2-1/2
Minutes
Welding

7-1/2
Minutes
Resting

100% Continuous Use at 100 A

4
Minutes
Welding

6
Minutes
Resting

100% Continuous Use at 60 A

cONTROLS

For example, a welder with a 40% duty
cycle at 125 A welding current must be
allowed to rest for at least 6 minutes after
every 4 minutes of continuous welding.

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 Tig Torch or Electrode Holder on an
electrically non-conductive, heat-proof surface, such
as a concrete slab, well clear of the ground clamp.

WIRE

SAFETy

Duty Cycle (Duration of Use)

clean surfaces
to bare metal.
chamfer thick workpieces.

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.

WELdINg TIpS

clamps
workpieces

TIg / STIck

Setting up the Weld

3. Clamp Ground Cable to bare metal on the
workpiece near the weld area, or to metal work
bench where the workpiece is clamped.

ground
clamp

clean
surface to
bare metal.

ground connection depends
on desired welding polarity

Item 63621

For technical questions, please call 1-888-380-0318.

Page 29

MAINTENANcE

Workpiece

TIg Welding
SAFETy

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.

cONTROLS

TO pREVENT dEATH FROM ASpHyXIATION:
do not open gas without proper ventilation. Fix gas leaks immediately. Shielding gas can displace
air and cause rapid loss of consciousness and death. Shielding gas without carbon dioxide can be
even more hazardous because asphyxiation can start without feeling shortness of breath.
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.
1. Open gas cylinder’s valve all the way.

9. Adjust settings for the TIG process.
a. Polarity and Gas Settings:
• Plug cables in according to screen.
• Connect gas according to screen.
• Set SCFH between 10-25.

WIRE

2. Set Flow Gauge to SCFH value indicated on the
Settings Chart on the inside of the Welder door.
3. Turn the Power Switch to the OFF position, then
plug the Welder into a properly grounded, GFCI
protected, 120 VAC (20 amp rated) outlet or
240 V outlet. The circuit must be equipped with
delayed action-type circuit breaker or fuses.

TIg / STIck

4. Set TIG Torch down on nonconductive,
nonflammable surface away from
any grounded objects.
5. Turn the Power Switch ON.

b. Set Rod Diameter and Material Thickness:
• Turn Left Knob to set rod diameter.
• Turn Right Knob to set material thickness.

6. Press Home Button on Control Panel.
7. Turn Main Control Knob until TIG process
appears on LCD display screen.
8. Press Main Control Knob to select TIG process.

WELdINg TIpS

Note: Press Main Control Knob to go to next screen.
Press Back Button to return to the previous screen.

TIg

c. Auto Weld Settings:
• Turn Left Knob to adjust output amperage.
• Turn Right Knob to ON to energize TIG Torch.
WARNINg! Welder is now energized and
Open circuit Voltage is present.

MAINTENANcE

Left
knob

Main
control
knob

Right
knob
process
gas Type

Page 30

For technical questions, please call 1-888-380-0318.

Rod
diameter
Material
Thickness

Item 63621

• Turn Main Control Knob to adjust setting.
Available Optional Settings:
• Recall Setting – Retrieve saved settings.
• Save Setting – Program up to
5 different configurations.

NOTE: Maintain a constant distance between the
Tungsten Electrode and the workpiece: between
1 and 1.5 times the diameter of the Electrode.
11. Open valve on TIG Torch to start gas flow.

SAFETy

• Turn Main Control Knob until desired
setting appears on screen.
• Press Main Control Knob to
select desired setting.

10. Hold TIG Torch in one gloved hand and the TIG
Rod (sold separately) in other gloved hand.

12. To initiate welding arc, push Foot Pedal and touch
Electrode to work piece and lift. If not using Foot
Pedal, touch Electrode to work piece and lift.
13. 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.
14. Alternate between pushing the torch/weld
puddle and adding the TIG Rod material.

cONTROLS

d. Optional Settings:
• Press Main Control Knob to
enter Optional Settings.

15. When finished welding, release the Foot Pedal but
keep Torch on weld puddle until weld solidifies.
If not using Foot Pedal, pull Torch away from
work piece until welding arc is broken, then
return the gas coverage until weld solidifies.

WIRE

NOTE: Remove the TIG Rod each time the Electrode
is advanced, but do not remove it from the gas shield.
This prevents oxidation from contaminating the weld.

16. Close valve on TIG Torch and turn Right Knob
to OFF to turn off power to TIG Torch.

After practice welding on scrap, stop,
and check your progress. Perform
Strike Test according to Strike Test on
page 34. After making any necessary
adjustments, continue to weld while
carefully following the DUTY CYCLE
guidelines as explained on page 29.

TIg / STIck

19. To prevent accidents, after use:
• Allow Welder to cool down.
• Unplug Welder’s power cord from outlet.
• Remove Ground Clamp from workpiece or table.

WELdINg TIpS

WARNINg! 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. Light from the
arc can cause permanent damage to the eyes
and skin. do not breathe arc fumes.

18. Turn the Power Switch OFF.

• 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.

MAINTENANcE

Note: The initial settings may need to be
adjusted after stopping and carefully inspecting
the weld. Proper welding takes experience.

17. Set TIG Torch down on nonconductive,
nonflammable surface away from
any grounded objects.

WARNINg! Metal work bench must
be grounded when TIg welding.

Item 63621

For technical questions, please call 1-888-380-0318.

Page 31

Stick Welding
SAFETy

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.

cONTROLS

1. 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
240 V outlet. The circuit must be equipped with
delayed action-type circuit breaker or fuses.

b. Set Electrode type:
• Turn Main Control Knob to set electrode type.

2. Set Electrode Holder down on
nonconductive, nonflammable surface
away from any grounded objects.
3. Turn the Power Switch ON.
4. Press Home Button on Control Panel.

WIRE

5. Turn Main Control Knob until Stick process
appears on LCD display screen.
6. Press Main Control Knob to select STICK process.

c. Set Electrode Diameter and Material Thickness:
• Turn Left Knob to set electrode diameter.
• Turn Right Knob to set material thickness.

Note: Press Main Control Knob to go to next screen.
Press Back Button to return to the previous screen.

Stick

TIg / STIck

d. Auto Weld Settings:
• Turn Left Knob to adjust output amperage.

WELdINg TIpS

Left
knob

Main
control
knob

Right
knob

• Turn Right Knob to ON to
energize Electrode Holder.
WARNINg! Welder is now energized and
Open circuit Voltage is present.

7. Adjust settings for the STICK process.
a. Polarity Setting:
• Plug cables in according to screen.

process
Electrode
Type

MAINTENANcE

Hot Start

Page 32

For technical questions, please call 1-888-380-0318.

Electrode
diameter
Material
Thickness
Arc Force

Item 63621

• Turn Main Control Knob until desired
setting appears on screen.
• Press Main Control Knob to
select desired setting.
• Turn Main Control Knob to adjust setting.

SAFETy

e. Optional Settings:
• Press Main Control Knob to
enter Optional Settings.

• Hot Start – Adjust amperage at start of weld.
• Arc Force – Adjust weld penetration
and smoothness.
• Recall Setting – Retrieve saved settings.
• Save Setting – Program up to
5 different configurations.

cONTROLS

Available Optional Settings:

9. 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.

WIRE

8. Place the bare metal end of the Stick Electrode (sold
separately) inside the jaws of the Electrode Holder.

c. Strike the surface like a match with the Electrode.
10. After the arc ignites:

b. Tilt Electrode back 10 to 20 degrees.
c. Drag Electrode to the back end of the weld
puddle to deposit material as needed.
11. When finished welding; lift the Electrode from
the workpiece, then set Electrode Holder
down on nonconductive, nonflammable
surface away from any grounded objects.

TIg / STIck

a. Lift the Electrode off workpiece the same
distance as the diameter of the bare metal end.

13. 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.

WELdINg TIpS

12. Turn the Power Switch OFF.

MAINTENANcE

14. Clean, then store Welder and its accessories
indoors out of children’s reach.

Note: The initial settings may need to be
adjusted after stopping and carefully inspecting
the weld. Proper welding takes experience.

Item 63621

For technical questions, please call 1-888-380-0318.

Page 33

Welding Tips

SAFETy

A good way to test welding technique is to examine a weld’s appearance after it has cooled and the slag has been
removed. 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.

cONTROLS

After practice welding a couple
of welding beads, STOp and
examine your weld using
the following guidelines.

Strike Test
A test weld on a pIEcE OF ScRAp can be
tested by using the following procedure.
WEAR ANSI-AppROVEd SAFETy gOggLES
dURINg THIS pROcEdURE.

clamp

dead-blow hammer

ScRAp
workpiece

WIRE

WARNINg! This test WILL damage the weld it is
performed on. This test is ONLy an indicator of weld
technique and is not intended to test working welds.
gOOd WELd
bends and is not brittle

1. After two scraps have been welded together and the
weld has cooled, clamp one scrap in a sturdy vise.
2. Stay clear from underneath while you strike
the opposite scrap with a heavy hammer,
preferably a dead-blow hammer.

dead-blow hammer

clamp
ScRAp
workpiece

TIg / STIck

3. A gOOd WELd will deform but not break, as shown
on top.
A pOOR WELd will be brittle and snap at the
weld, as shown on bottom.
pOOR WELd
snaps or cracks

cleaning the Weld
WELdINg TIpS

TO pREVENT SERIOUS INJURy:
continue to wear ANSI-approved
safety goggles and protective wear
when cleaning a weld.
Sparks or chips may fly when cleaning.

chipping
Hammer

MAINTENANcE

1. A weld from flux-cored wire welding or stick
welding will be covered by slag. Use a chipping
hammer to knock this off. Be careful not
to damage the weld or base material.

Wire Brush

2. Use a wire brush to further clean the weld
or use an angle grinder (sold separately) to
shape the weld.

Page 34

For technical questions, please call 1-888-380-0318.

Item 63621

pROpER pENETRATION

EXcESS pENETRATION OR
BURN-THROUgH

Not hot enough

Ideal heat

Too hot

How to increase workpiece heat
and increase penetration:

How to reduce workpiece heat
and limit penetration:

(to weld THIckER workpieces properly)

(to weld THINNER workpieces properly)

a. Increase weld current c. Use faster wire feed

e. decrease weld current g. Use slower wire feed

b. decrease travel speed d. Use shorter cTWd

f. Increase travel speed h. Use longer cTWd

Voltage
Too Low or
Wire Feed
Too Slow

Voltage
Too High or
Wire Feed
Too Fast

Travel Speed
Too Fast

Travel Speed
Too Slow

cTWd
Too Long
or
Wrong polarity

TO cORREcT:

Increase
Output Voltage

decrease
Output Voltage

Increase Wire
Feed Speed

decrease Wire
Feed Speed

travel
slower

travel
faster

check polarity
and
maintain
less
than 1/2"
cTWd

MAINTENANcE

good
Weld

WELdINg TIpS

TIg / STIck

WIRE

Example Wire Weld diagrams

cONTROLS

INAdEQUATE pENETRATION

SAFETy

Wire Weld Diagnosis – Workpiece Heat Control / Weld Penetration

Item 63621

For technical questions, please call 1-888-380-0318.

Page 35

Wire Weld Penetration (Workpiece Heat Control)
SAFETy

EXcESS pENETRATION OR
BURN-THROUgH
Weld droops on top and
underneath, or falls through
entirely, making a hole.

pROpER pENETRATION
Weld is visible underneath and
bulges slightly on top.

INAdEQUATE pENETRATION
Weld does not penetrate the
joint fully, just on the surface.

cONTROLS

PROFILE VIEWS

WIRE

pOSSIBLE cAUSES ANd SOLUTIONS
1. Workpiece overheating:
Reduce wire feed speed.
Decrease weld current.
2. Travel speed too slow:
Increase travel speed and ensure
that travel speed is kept steady.
3. Excessive material at weld:
Reduce wire feed speed.

Bend at Joint

TIg / STIck

PROFILE
VIEW

Weld Not Adhering properly

WELdINg TIpS

pOSSIBLE cAUSES ANd SOLUTIONS
1. Improper clamping:
Clamp workpieces securely.
Make tack welds to hold workpieces.
2. Excessive heat:
Weld a small portion and allow to cool before
proceeding.
Increase travel speed.
Reduce wire feed speed.

coat of Slag Over Weld

gaps present between weld and previous bead or
between weld and workpiece. See areas below.

PROFILE
VIEW

TOP
VIEW
2.
PARTIALLY CHIPPED AWAY TO SHOW WELD

MAINTENANcE

Slag is a necessary part of a flux-cored wire
weld. It shields the weld from impurities.
clean off the slag with a chipping Hammer
and Wire Brush after welding.

gas-shielded MIg welds are protected by the
shielding gas and do not need slag to protect them.

Page 36

pOSSIBLE cAUSES ANd SOLUTIONS
Incorrect welding technique:
Maintain 1/2" or less CTWD.
Keep arc on leading edge of weld puddle.
Hold MIG Gun at proper angles.
Insufficient weld heat:
Reduce travel speed.
Increase weld current.
Workpieces too thick/close:
Bevel thick workpieces, allow slight
gap, and weld in several passes.
Insufficient weld material:
Increase wire feed speed.

pOSSIBLE cAUSES ANd SOLUTIONS
Incorrect welding technique:
Place stringer bead at correct place in joint.
Adjust workpiece position or weld angle to permit
proper welding to bottom of piece.
Pause briefly at sides during weave bead.
Keep arc on leading edge of weld puddle.
Hold MIG Gun at proper angles.
Insufficient weld heat:
Increase current.
Increase wire feed speed.
dirty workpiece:
Clean workpiece down to bare metal.
Insufficient weld material:
Increase wire feed speed.
Workpiece gap too narrow:
Widen groove or increase bevel.

For technical questions, please call 1-888-380-0318.

Item 63621

TOP
VIEW

3.
4.

5.
6.

TOP
VIEW

pOSSIBLE cAUSES ANd SOLUTIONS
Incorrect polarity:
Check that polarity is set correctly
for type of welding.
Insufficient shielding gas (MIG only):
Increase flow of gas.
Clean nozzle.
Maintain proper CTWD.
Incorrect shielding gas (MIG only):
Use shielding gas recommended by wire supplier.
dirty workpiece or welding wire:
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
Inconsistent travel speed:
Maintain steady travel speed.
cTWd too long:
Reduce CTWD.

Wire Weld – Crooked/Wavy Bead

4.
5.

pOSSIBLE cAUSES ANd SOLUTIONS
dirty workpiece or welding wire:
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
Incorrect polarity:
Check that polarity is set correctly
for type of welding.
Insufficient shielding gas (MIG only):
Increase flow of gas.
Clean nozzle.
Maintain proper CTWD.
Wire feeding too fast:
Reduce wire feed speed.
cTWd too long:
Reduce CTWD.

TIg / STIck

Fine spatter is normal.
Spatter that is grainy and large is a problem.

cONTROLS

Small cavities or holes in the bead.

SAFETy

Wire Weld – Excessive Spatter

WIRE

Wire Weld – Porosity

Wire Weld – Burn-Through

TOP
VIEW

pOSSIBLE cAUSES ANd SOLUTIONS
1. Inaccurate welding:
Use two hands or rest hand on steady surface.
2. Inconsistent travel speed:
Maintain steady travel speed.
3. cTWd too long:
Reduce CTWD.

Item 63621

pOSSIBLE cAUSES ANd SOLUTIONS
1. Workpiece overheating:
Reduce current and/or wire feed speed.
2. Travel speed too slow:
Increase travel speed and ensure
that travel speed is kept steady.
3. Excessive material at weld:
Reduce wire feed speed.

For technical questions, please call 1-888-380-0318.

Page 37

MAINTENANcE

TOP
VIEW

WELdINg TIpS

Base material melts away,
leaving a hole in the weld.

Stick Weld Diagnosis – Workpiece Heat Control / Weld Penetration
SAFETy
cONTROLS

INAdEQUATE pENETRATION

pROpER pENETRATION

EXcESS pENETRATION OR
BURN-THROUgH

Not hot enough

Ideal heat

Too hot

How to increase workpiece heat
and increase penetration:

How to reduce workpiece heat
and limit penetration:

(to weld THIckER workpieces properly)

(to weld THINNER workpieces properly)

a. Increase current. b. Weld more slowly.

c. Decrease current. d. Weld more quickly.

Example Stick Weld diagrams
WIRE

cLEAN WELdS FIRST!
Stick welds will have a coat of slag over them until cleaned.

TIg / STIck
good
Weld

WELdINg TIpS

current
Too Low

current
Too High

Weld Speed
Too Fast

Weld Speed
Too Slow

Arc Length
Too Short

Arc Length
Too Long

TO cORREcT:
Increase the
current

TO cORREcT:
Decrease
the current

TO cORREcT:
Weld slower

TO cORREcT:
Weld faster

TO cORREcT:
Increase
distance

TO cORREcT:
Decrease
distance

MAINTENANcE
Page 38

For technical questions, please call 1-888-380-0318.

Item 63621

pROpER pENETRATION
Weld is visible underneath and
bulges slightly on top.

INAdEQUATE pENETRATION
Weld does not contact the joint
fully, just on the surface.

PROFILE VIEWS

1. Workpiece overheating:
Reduce current.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.

pOSSIBLE cAUSES ANd SOLUTIONS FOR
INAdEQUATE pENETRATION
1. Incorrect welding technique:
Keep arc on leading edge of weld puddle.
Hold torch at proper angles.
2. Insufficient weld heat:
Slow down so fill material has time to melt
into the weld location. Increase current.

WIRE

pOSSIBLE cAUSES ANd SOLUTIONS FOR
EXcESS pENETRATION OR BURN-THROUgH

cONTROLS

EXcESS pENETRATION OR
BURN-THROUgH
Weld droops on top and
underneath or falls through
entirely, making a hole.

SAFETy

Stick Weld Penetration (Workpiece Heat Control)

3. Workpieces too thick/close:
Bevel thick workpieces, allow slight
gap, and weld in several passes.
4. Insufficient weld material:
Increase amount of fill material.

TIg / STIck

Stick Weld – Weld Not Adhering Properly
gaps present between weld and previous bead or between weld and workpiece. See areas below.
pOSSIBLE cAUSES ANd SOLUTIONS

2. Insufficient weld heat:
Increase current.
3. dirty workpiece:
Clean workpiece down to bare metal.

PROFILE
VIEW

1. Incorrect welding technique:
Place stringer bead at correct place in joint.
Adjust workpiece position or weld angle to permit
proper welding to bottom of piece.
Keep arc on leading edge of weld puddle.
Hold Electrode and fill material at proper angles.

WELdINg TIpS

4. Insufficient weld material:
Increase amount of fill material.
5. distance between workpieces to large:
Decrease distance and increase bevel.

pOSSIBLE cAUSES ANd SOLUTIONS

PROFILE
VIEW

Item 63621

1. Improper clamping:
Clamp workpieces securely.
Make tack welds to hold workpieces.
2. Excessive heat:
Weld a small portion and allow to cool before
proceeding.
Increase weld speed.

For technical questions, please call 1-888-380-0318.

Page 39

MAINTENANcE

Stick Weld – Bend at Joint

Stick Weld – Coat of Slag Over Weld
SAFETy

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.

TOP
VIEW
PARTIALLY CHIPPED AWAY TO SHOW WELD

cONTROLS

Stick Weld – Porosity — Small cavities or holes in the bead.
pOSSIBLE cAUSES ANd SOLUTIONS

TOP
VIEW

1. dirty workpiece or fill material:
Clean workpiece down to bare metal.
Make certain that fill material and Electrode are
clean and free from oil, coatings, and other residues.
2. Inconsistent welding speed:
Maintain steady weld speed.

Stick Weld – Crooked/Wavy Bead
WIRE

pOSSIBLE cAUSES ANd SOLUTIONS

1. Inaccurate welding:
Use two hands or rest hand on steady surface.
2. Inconsistent welding speed:
Maintain steady weld speed.

TOP
VIEW

TIg / STIck

Stick Weld – Excessive Spatter
pOSSIBLE cAUSES ANd SOLUTIONS

Fine spatter is normal. Spatter that is
grainy and large is a problem.
dirty workpiece or fill material:
Clean workpiece down to bare metal.
Make certain that fill material and Electrode are
clean and free from oil, coatings, and other residues.

TOP
VIEW

WELdINg TIpS

Stick Weld – Burn-Through — Base material melts away, leaving a hole in the weld.
pOSSIBLE cAUSES ANd SOLUTIONS

MAINTENANcE

TOP
VIEW

Page 40

1. Workpiece overheating:
Reduce current.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
3. Excessive material at weld:
Reduce amount of fill material.

For technical questions, please call 1-888-380-0318.

Item 63621

TO pREVENT SERIOUS INJURy, FIRE ANd BURNS:
Unplug the Welder, rest the tool on a heat-proof, electrically non-conductive surface, and allow
all parts of the Welder to cool thoroughly before service.

• loose hardware
• misalignment or binding of moving parts
• damaged cord / electrical wiring
• frayed or damaged cables

2. pERIOdIcALLy, have a qualified
technician remove the Rear Panel
and use compressed air to blow
out all dust from the interior.

cONTROLS

1. BEFORE EAcH USE, inspect the general
condition of the Welder. Check for:

SAFETy

Maintenance

3. AFTER EVERy USE, store in
a clean and dry location.

• any other condition that may
affect its safe operation.

MIg gun Nozzle and contact Tip Inspection and cleaning
1. Make sure that the entire MIg gun is completely
cool and that the power cord is unplugged
from the electrical outlet before proceeding.

7. Examine the shape of the hole at the end of
the Contact Tip. It should be an even circle; it
should not be oblong or have any bulges in it.

2. Pull the Nozzle to remove it.

8. If any problems are noted, replace the
Contact Tip. Select a new Tip of the
correct size for the welding wire used.

5. Unscrew the Contact Tip counterclockwise
and slide it off the welding wire to remove.

9. Reinstall the Tip and securely
reinstall the Nozzle as well.

Nozzle

6. Scrub the outside of the Tip clean with a wire brush.
Clean out the inside of the tip with a tip
cleaner (sold separately). Check that the Tip
is the proper type for the wire size used.

TIg / STIck

4. Examine the end of the Nozzle. The end should be
flat and even. If the end is uneven, chipped, melted,
cracked, or otherwise damaged, the Nozzle will
adversely effect the weld and should be replaced.

contact
Tip

WELdINg TIpS

3. Scrub the interior of the Nozzle
clean with a wire brush.

Replacing the Lcd Screen cover
1. Carefully pry frame off of Display (17)
by inserting flathead screwdriver (sold
separately) into one of the side slots.

2. Insert a new Screen Cover (18) into Screen
Frame (19) with the gap facing downward.
Screen
Frame

display

WIRE

4. For optimal MIG / Flux-Cored wire weld
quality, clean and inspect the MIg
gun contact Tip and Nozzle before
each use, as explained below.

• cracked or broken parts

MAINTENANcE

Screen
cover

3. Insert frame back into slot on Display with
the top end being placed in first.
Item 63621

For technical questions, please call 1-888-380-0318.

Page 41

Troubleshooting – MIG / Flux-Cored Welding
SAFETy

IMpORTANT!
Be cERTAIN to shut off the Welder, disconnect it from power, and discharge the MIg gun to
ground before adjusting, cleaning, or repairing the unit.
problem

possible causes
1. Insufficient wire feed pressure.

cONTROLS

2. Incorrect wire feed roller size.
Wire Feed Motor
Runs but Wire Does 3. Damaged MIG Gun, cable, or liner assembly.
Not Feed Properly
4. Feed Tensioner is too tight.

1. Excess wire feed pressure.
Wire Creates a
Bird’s Nest During
Operation

2. Incorrect Contact Tip size.
3. MIG Gun Cable Connector not fully
inserted into Wire Feed mechanism.
4. Damaged liner.

WIRE

1. Gun cable is severely bent and Wire
Feed mechanism cannot feed wire.
2. Gun liner is clogged or worn.
Wire Stops
During Welding

3. Gun liner is too small for
welding wire being used.
4. Wire is tangled on the spool.
5. Wire is not making contact with Feed Rollers.

TIg / STIck

6. Feed Roller is not making enough contact
with wire or is crushing flux-cored wire.
1. Wire not feeding properly.
2. Incorrect Contact Tip or liner
size or excessive wear.
3. Incorrect wire feed speed.

WELdINg TIpS

4. Loose MIG Gun cable or ground cable.
5. Damaged MIG Gun or loose
connection within Gun.
6. Incorrect polarity for process being run.

Welding Arc
Not Stable

7. Gas coverage may be insufficient or too high.

8. Poor connection with workpiece.

1. Incorrect line voltage.

MAINTENANcE

Weak Arc Strength

2. Improper gauge or length of cord.

3. Not enough current.

Likely Solutions
1. Increase wire feed pressure properly.
Follow step 27 on page 17.
2. Flip roll to correct size. Follow the Feed
Roller instructions on page 12.
3. Have a qualified technician inspect these
parts and replace as necessary.
4. Loosen Feed Tensioner so it applies only
enough pressure to prevent continued
spinning after the Gun Trigger is released.
1. Adjust wire feed pressure properly.
Follow step 27 on page 17.
2. Replace with the proper tip for wire used.
3. Insert Gun Cable Connector properly.
Follow steps 13 and 14 on page 13.
4. Have a qualified technician inspect
and repair/replace as necessary.
1. Straighten Gun cable.
2. Check gun liner for obstruction.
Replace if necessary.
3. Check that gun liner is correct size for wire.
4. Check wire for cross winding or tangled spool.
5. Check Feed Rollers and ensure correct
groove for wire diameter is being used.
6. Check Feed Tensioner and ensure it is set properly.
1. See first Troubleshooting section above.
2. Replace with the proper tip or
liner size for wire used.
3. Adjust wire feed speed to achieve
a more stable arc.
4. Check to ensure that all connections are tight.
5. Have a qualified technician inspect
and repair/replace as necessary.
6. Ensure polarity is correct for operation:
DCEP for MIG welding and DCEN for
Flux-Cored self-shielded welding.
7. Ensure gas flow rate is set according to
Settings Chart. Make sure MIG Gun Cable
Connector is fully inserted into Wire Feed
mechanism with no O-Rings exposed.
8. Check the ground clamp connection to
the workpiece and machine. Ensure
the MIG Gun is properly secured.
1. Check the line voltage and, if insufficient, have
a licensed electrician remedy the situation.
2. Do not use an extension cord on this Welder.
Use only one of the supplied power cords for
this Welder or an identical replacement cord.
3. Switch current to proper setting for metal thickness.

Follow all safety precautions whenever diagnosing or servicing the equipment.

Page 42

For technical questions, please call 1-888-380-0318.

Item 63621

Wire Feeds, but Arc
Does Not Ignite

Porosity in the
Weld Metal

3. Ensure the gun connection is properly
seated on machine. Qualified technician
must check and secure/replace Trigger.

4. Machine is in low- or
over-voltage protection.

4. Check input voltage and ensure it falls within
the specified range. If input voltage is correct,
press Reset Button on back of machine.

5. Machine is in the incorrect mode.

5. Ensure the correct process has been selected.

1. Unit is not connected to outlet properly.

1. Verify the voltage at the outlet and
the connection to the outlet.

2. Outlet is unpowered.

2. Check circuit breaker/GFCI devices;
if any are tripped, determine and
remedy cause before resetting.

3. Plug does not have correct rating.

3. Make sure installed plug is correct rating.
See Specifications on page 7.

4. Circuit breaker has tripped due
to high input amperage.

4. Press Reset Button on back of
machine to reset circuit breaker.

5. Input Power Cord is not seated properly.

5. Ensure the twist lock input Power
Cord is fully secured.

1. Improper ground connection.

1. Make certain that the workpiece is contacted
properly by the Ground Clamp and that
the workpiece is properly cleaned near the
ground clamp and the welding location.

2. Improperly sized Contact Tip.

2. Verify that Contact Tip is the proper size
for welding wire. If needed, replace
Contact Tip with proper size and type.

3. Excessively worn Contact Tip.

3. Check that the hole in the tip is not
deformed or enlarged. If needed, replace
Contact Tip with proper size and type.

4. Dirty Contact Tip.

4. Properly clean Contact Tip.

1. Shielding gas bottle is empty.

1. Check gas bottle and replenish as necessary.

2. Not enough or too much shielding gas.

2. Check gas regulator to ensure proper flow.

3. Dirty workpiece.

3. Clean workpiece down to bare metal.

4. Gun is being used too far
away from workpiece.

4. Check CTWD (contact tip to work
distance) for the proper procedure.

5. Polarity is incorrect for the application.

5. Check the polarity and ensure it is DCEP
for MIG and DCEN for Flux-Cored.

6. Dirty welding wire is introducing
contamination into the weld.

6. Make certain that welding wire is clean
and free of rust and residues.

Follow all safety precautions whenever diagnosing or servicing the equipment.

Item 63621

For technical questions, please call 1-888-380-0318.

SAFETy

3. Faulty or improperly connected Trigger.

cONTROLS

2. Verify that the circuit is designed to supply the
required input voltage and amperage as detailed
on the Specifications table. If a warning screen
appears in the LCD Display window, check the
input voltage to ensure it is within specified range.

WIRE

2. Circuit supplies insufficient input voltage or
amperage.

TIg / STIck

LCD Display
Does Not Light
When Welder is
Switched On

Likely Solutions
1. If a warning screen appears in the LCD Display
window, Welder may have overheated and shut
down. Stop and wait with the Power Switch ON
for the Welder to cool. The Welder automatically
returns to service after cooling off. Reduce
duration or frequency of welding periods to
help reduce wear on the Welder. Refer to
Duty Cycle (Duration of Use) on page 19.

WELdINg TIpS

Welder Does Not
Function When
Switched On

possible causes
1. Tripped thermal protection device.

MAINTENANcE

problem

Page 43

Troubleshooting – TIG / Stick Welding
SAFETy

IMpORTANT!
Be cERTAIN to shut off the Welder, disconnect it from power, and discharge the
electrode to ground before adjusting, cleaning, or repairing the unit.

problem
Welder Does Not
Function When
Switched On

possible causes

cONTROLS

1. Reduce duration or frequency of welding periods
to help reduce wear on the welder. Refer to
Duty Cycle (Duration of Use) on page 29.

2. Faulty or improperly
connected Trigger.

2. Qualified technician must check and
secure/replace Trigger.

3. Ground Clamp not attached
to workpiece.

3. Attach Ground Clamp to workpiece.

4. Shielding Gas not connected.
LCD Display Does Not 1. Unit is not connected
Light When Welder
to outlet properly.
is Switched On
2. Outlet is unpowered.

Weak Arc Strength

1. Incorrect line voltage.

WIRE

2. Improper gauge or length of cord.

Welding Arc
Not Stable.

Likely Solutions

1. Tripped thermal protection device.

1. Loose electrode cable
or ground cable.

4. Connect shielding gas to Welder.
1. Verify the voltage at the outlet and
the connection to the outlet.
2. Check circuit breaker/GFCI devices; if any are tripped,
determine and remedy cause before resetting. Verify
that the circuit is designed to supply the required input
amperage as detailed in Specifications on page 7.
1. Check the line voltage and, if insufficient, have
a licensed electrician remedy the situation.
2. Do not use an extension cord on this Welder. Use
only one of the supplied power cords for this
Welder or an identical replacement cord.
1. Check to ensure that all connections are tight.

TIg / STIck

2. Damaged electrode holder or loose
connection within electrode holder.

2. Have a qualified technician inspect and
repair/replace as necessary.

3. Adjust current setting.

3. Make sure setting matches
recommended setting on chart.

4. Shielding gas getting low.

4. Replace shielding gas cylinder.

Follow all safety precautions whenever diagnosing or servicing the equipment.

WELdINg TIpS
MAINTENANcE
Page 44

For technical questions, please call 1-888-380-0318.

Item 63621

FAN1

FAN2

MAINTENANcE

Fuse

AC2

AC1

FAN2

15V

Page 45

FAN1

∼
∼

1
3
-

RECITIFIER

∼

PFC

VR2A

CN5

IGBT

Main Board

VR1A

8
7
6
5
4
3
2
1

VR3A

11
10
9
8
7
6
5
4
3
2
1

CN1

S1
CN1
1
2
3
4
5
6
7
8
9
10
11

M4
1
2
3
4
5
6
7
8

control panel

TIg / STIck

Operation panel

LCD screen

WELdINg TIpS

3
4

1
2

∼

2
1
3

Switch

1
2
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1
3

For technical questions, please call 1-888-380-0318.
1
3

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

2
1

4
1

5
6

CN8

7
8
9
10

1
2
3
4

12
11

20
19

CN3

CN1

WIRE

CN1

Drawing Wire Motor

CN7

Remote control plug

Gun switch

cONTROLS

6
5
CN2 4
3
2
1

CN4

5
4
3
2
1
CN3 2
1

Remote Control Board

CN6

4
3
2
1
1
2
3
4
5
6
7
7
6
5
4
3
2
1

Item 63621
4

-t

1
2
3
4

3
2
1

Feed Motor
Gas Valve 1 Gas ValveWire
2
Touch Switch
Gas valve 1
Gas valve 2

OUT-

OUT+

SAFETy

Hall Sensor

Wiring Schematic

parts List and diagram

SAFETy

pLEASE REAd THE FOLLOWINg cAREFULLy

cONTROLS

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. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

parts List
part

WIRE
TIg / STIck
WELdINg TIpS

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

description
Housing
Handle Base
Handle Cover
Hinge
Hinge Pin
Door
Latch
Panel
PFC Inductor
Spool
Remote Control PCB
Wire Feed Mechanism
Foot Pedal Connector
Air Connector
Cover
Display PCB
Display
Screen Cover
Screen Frame
MIG Welding Gun
Front Handle Cover
Front Panel
Control Panel
Side Knob
Knob
Storage Door
Switch
Air Connector
Air Fitting
Quick Connector
Ground Clamp
Electrode Holder

Qty

part

1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1

33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64

description
Wire Feed Connector
Air Connector
Output Inductor
Air Connector
Solenoid Valve
Base
Insulating Board
Main PCB
Control PCB
Fast Recovery Diode
Air Duct
Rectifier Radiator Bracket
Rectifier Radiator
Fan
Transformer
IGBT
Heatsink
Fast Recovery Diode
IGBT Radiator Bracket
IGBT Radiator
Bridge Rectifier
IGBT
IGBT Radiator
Fan
Threaded Y-connector
120 VAC Power Cord
Rear Panel
Rear Handle Cover
Power Connector
Overload Protector
Rear Panel
240 VAC Power Cord

Qty
1
1
1
3
2
1
1
1
1
6
1
1
1
1
1
2
1
2
1
1
2
4
2
1
1
1
1
1
1
1
1
1

MAINTENANcE

Record product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.
Page 46

For technical questions, please call 1-888-380-0318.

Item 63621

cONTROLS
15

WIRE

TIg / STIck

WELdINg TIpS

17
18
19
20
21

22
23
24
25
26

Page 47

For technical questions, please call 1-888-380-0318.

Item 63621

MAINTENANcE

SAFETy

Assembly diagram

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. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries
to persons or property, or for incidental, contingent, special or consequential damages arising from the use of
our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.
If our inspection verifies the defect, we will either repair or replace the product at our election or we may
elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will
return repaired products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-380-0318

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Modify Date                     : 2018:01:04 00:21:41Z

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Manual For The 63621 Omni Pro™ 220 Multiprocess Welder With 120/240 Volt Input

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