Vulcan-Hart OMNIPRO 220 Owner's Manual & Safety Instructions
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Vulcan-Hart OMNIPRO 220 Owner's Manual & Safety Instructions

Multiprocess welding system
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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 1-888-380-0318 as soon as possible.
©
Copyright
2017 by Harbor Freight Tools
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Tools required for assembly and service may not be included.
Keep this manual for the safety warnings and precautions, assembly,
Visit our website at: http://www.harborfreight.com
®
. All rights reserved.
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 Vulcan-Hart OMNIPRO 220

  • Page 1 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.

  • Page 2: Table Of Contents

    Table of contents Safety ..............2 Welding Tips ............34 Specifications ............. 7 Maintenance ............41 Controls .............. 8 Parts List and Diagram ........46 MIG  /   F lux-Cored Wire Welding ......10 Warranty ............48 TIG  /   S tick Welding ..........24 WARNINg SyMBOLS ANd dEFINITIONS This is the Safety alert symbol.

  • 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 7. do not abuse the cord. Never use the cord discharge electrode to ground before setting for carrying, pulling or unplugging the welder. down torch/electrode holder and before service. keep cord away from heat, oil, sharp edges or moving parts.
  • Page 5 Welder Use and care 1. do not use the welder if the switch does not turn 4. Store idle welders out of the reach of it on and off. Any welder that cannot be controlled children and do not allow persons unfamiliar with the switch is dangerous and must be repaired.

  • 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

    Specifications Power Input 120  V AC / 60  H z 240  V AC / 60  H z 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 ...

  • Page 8: Controls

    controls Front panel controls Home Back Button Button control knob display Left knob Right power knob Switch Storage MIG Gun  / compartment Spool gun cable Socket positive Socket Spool gun gas Outlet Negative Wire Feed Socket power cable Note: When using an optional Spool Gun (sold separately), connect the Spool Gun gas hose to the Spool Gun Gas Outlet.
  • Page 9 Interior controls cold Wire Feed Switch Feed Tensioner Wire Feed Mechanism Idler Wire Spool Feed Spool knob Roller knob Wire Inlet Liner Foot pedal Wire Feed Socket control Socket Item 63621 For technical questions, please call 1-888-380-0318. Page 9...

  • Page 10: Mig / F Lux-Cored Wire Welding

    MIG  /   F lux-Cored Wire 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 FROM AccIdENTAL OpERATION: Turn the power Switch off and unplug the Welder before setup.
  • Page 11 Spool knob 6. 10-12 pound Wire Spool Installation: Remove the Wingnut and Spacer. If replacing a Spool, remove the old Spool Wingnut and all remaining wire from the liners. Spacer 7. Place the Spool Adapter over the Spool Spindle and against the Spool Brake Pad as illustrated. 10-12 lb Wire Spool Spool Spindle...
  • Page 12 Feed Roller knob 12. Feed Roller Instructions: Check that the Feed Roller is correct for the type of wire being used (solid core or flux- cored) and that it is turned to properly match the wire size marked on the Wire Spool: a.
  • Page 13 Wire Feed Mechanism 13. Loosen the Knob on the Wire Feed mechanism, then insert the Gun Cable gun cable Connector through the hole on the Welder connector front and into the socket on the Wire Feed. knob 14. Ensure that the Gun Cable Connector is fully inserted into the socket on the Wire Feed mechanism as shown, Incorrect ...
  • Page 14 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 Serial: Vulcan OMNIPRO 220 Conforms to UL Std. 60974-1 63621 269317 30A/15.5V to 220A/25V 100% 0 ...
  • Page 15 IMpORTANT Securely hold onto the end of the welding wire and keep tension on it during the following steps. If this is not done, the welding wire will unravel and unspool which can cause tangling and feeding problems. HOLd WIRE Feed SEcURELy guide...
  • Page 16 Serial: Vulcan OMNIPRO 220 Conforms to UL Std. 60974-1 63621 269317 30A/15.5V to 220A/25V Input 100% 200A 130A 115A   7 8V 24. Plug either 120  V AC or 240  V AC Power 0  20.5V 19.75V Power Input 10A/20.4V to 175A/27V 100%  ...
  • Page 17 27. To check the wire’s drive tension, feed the wire against a piece of wood from 2 to 3 inches away. If the wire stops instead of bending, unplug the Welder, slightly tighten the Feed Tensioner clockwise, and try again. If the wire bends from the feed pressure, then the Incrementally tension is set properly.
  • Page 18 Basic Wire Welding Read the ENTIRE IMpORTANT SAFETy INFORMATION section at the beginning of this manual including all text under subheadings therein before welding. 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 19 Duty Cycle (Duration of Use) 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 40% Use at 100 ...
  • Page 20 4. Turn the Power Switch to the OFF position, then plug the Power Cord into a properly grounded, GFCI protected 120  V AC (20 amp power rated) or 240  V AC receptacle that matches Switch the plug. The circuit must be equipped with delayed action-type circuit breaker or fuses.
  • Page 21 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. • Turn Main Control Knob to adjust setting. Available Optional Settings: •...
  • Page 22 Basic Wire Welding Technique 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.
  • Page 23 Note: If Welder is used too long, a warning screen appears in the LCD Warning display Display window and the unit automatically Screen 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.

  • Page 24: Tig / S Tick Welding

    TIG  /   S tick 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 FROM AccIdENTAL OpERATION: Turn the power Switch off and unplug the Welder before setup.
  • Page 25 Torch Cable Connector to the Regulator’s Outlet and wrench-tighten connection. connect power cord power Plug either 120  V AC or 240  V AC Power Serial: Vulcan OMNIPRO 220 Conforms to UL Std. 60974-1 63621 269317 30A/15.5V to 220A/25V 100% Input...
  • Page 26 Sharpen Tungsten Electrode (sold separately) 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 27 Twist clockwise all the way to lock in place. Twist clockwise all the way to lock in place. connect power cord power Plug either 120  V AC or 240  V AC Power Serial: Vulcan OMNIPRO 220 Conforms to UL Std. 60974-1 63621 269317 30A/15.5V to 220A/25V 100%...

  • Page 28: Important Safety Information

    Basic TIG  /   S tick 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 29 Duty Cycle (Duration of Use) Avoid damage to the Welder by not welding for more This Welder has an internal thermal protection system to than the prescribed duty cycle time. The Duty Cycle help prevent this sort of over-stress. When the Welder defines the number of minutes, within a 10 minute overheats, it automatically shuts down and a warning period, during which a given welder can produce a...

  • Page 30: 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 31 d. Optional Settings: 10. Hold TIG Torch in one gloved hand and the TIG Rod (sold separately) in other gloved hand. • Press Main Control Knob to enter Optional Settings. NOTE: Maintain a constant distance between the • Turn Main Control Knob until desired Tungsten Electrode and the workpiece: between setting appears on screen.

  • Page 32: 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, then b.
  • Page 33 e. Optional Settings:  WARNINg! TO pREVENT SERIOUS INJURy: protective gear must be worn when using the • Press Main Control Knob to Welder; minimum shade number 10 full face shield enter Optional Settings. (or welding mask), ear protection, welding gloves, •...

  • Page 34: 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. 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 35 Wire Weld Diagnosis  –   W orkpiece 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)
  • Page 36 Wire Weld Penetration (Workpiece Heat Control) EXcESS pENETRATION OR pROpER pENETRATION INAdEQUATE pENETRATION BURN-THROUgH Weld is visible underneath and Weld does not penetrate the Weld droops on top and bulges slightly on top. joint fully, just on the surface. underneath, or falls through entirely, making a hole.
  • Page 37 Wire Weld  –   P orosity Wire Weld  –   E xcessive Spatter Small cavities or holes in the bead. Fine spatter is normal. Spatter that is grainy and large is a problem. VIEW VIEW pOSSIBLE cAUSES ANd SOLUTIONS pOSSIBLE cAUSES ANd SOLUTIONS 1.
  • Page 38 Stick Weld Diagnosis  –   W orkpiece 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)
  • Page 39 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 40 Stick Weld  –   C oat 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 ...

  • Page 41: Maintenance

    Maintenance 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. 1. BEFORE EAcH USE, inspect the general 2. pERIOdIcALLy, have a qualified condition of the Welder.
  • Page 42 Troubleshooting  –   M IG  /   F lux-Cored Welding 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 Likely Solutions 1.
  • Page 43 problem possible causes Likely Solutions 1. Tripped thermal protection device. 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.
  • Page 44 Troubleshooting  –   T IG  /   S tick Welding 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 possible causes Likely Solutions Welder Does Not 1.

  • Page 45: Wiring Schematic

    Wiring Schematic Item 63621 For technical questions, please call 1-888-380-0318. Page 45...

  • Page 46: Parts List And Diagram

    parts List and diagram 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 47: Assembly Diagram

    Assembly diagram Item 63621 For technical questions, please call 1-888-380-0318. Page 47...

  • Page 48: 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.

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