Vulcan-Hart PROTIG 165 Owner'S Manual Download

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Page 7

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

Item 63618

AFET

AINTENAN

ASI

c W

g T

SETUP

AFET

AINTENAN

ASI

c W

g T

SETUP

Symbology

Wire Feed (Speed)

Workpiece Ground Cable

Torch Cable

Overheat Shutdown Indicator

Cooling Fan

VAc

Volts Alternating Current

Amperes

OcV

Open Circuit Voltage

KVA

Kilovolt Amperes
(Volts / 1000 * Amperes)

IpM

Inches Per Minute

AWg

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.

Specifications

TIG

Stick

Power Input

120VAC / 60Hz 240VAC / 60Hz 120VAC / 60Hz 240VAC / 60Hz

Current Input at Output

21.4A at 130A

14.7A at 165A

21.4A at 90A

22.4A at 165A

Welding Current Range

10A - 130A

10A - 165A

10A - 90A

10A - 165A

Rated Duty Cycles

25% @ 130A
100% @ 65A

30% @ 165A
100% @ 90A

25% @ 90A

100% @ 55A

30% @ 165A
100% @ 90A

Maximum OCV

103VDC

82VDC

Weldable Materials

Mild Steel, Stainless Steel,

Chrome Moly

Mild Steel, Stainless Steel

Summary of Contents for PROTIG 165

Page 1: ...erence 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 m...

Page 2: ...ach 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 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 influe...

Page 3: ...le use an approved respirator 5 Work in a confined area only if it is well ventilated or while wearing an air supplied respirator 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 Gov...

Page 4: ... 35 feet 10 meters around the work area Use a fire resistant material to cover or block all open doorways windows cracks and other openings 2 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 debri...

Page 5: ...e 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 ...

Page 6: ...ified to do so 3 To ground the work bench connect a 12 AWG grounding wire not included from the work bench to a grounding rod not included The grounding rod must be an earth driven copper or brass rod electrode which can adequately ground the work bench 4 Refer to local regulations for ground source information High Frequency Radiation 1 The operator of welding equipment that causes harmful interf...

Page 7: ... 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 Specifications TIG Stick Power Input 120VAC 60Hz 240VAC 60Hz 120VAC 60Hz 240VAC 60Hz Curre...

Page 8: ... near the work area Leave space around the Welder for proper air flow TIg Setup connect cables TIg Torch ground clamp Negative Socket Foot pedal Socket positive Socket Foot pedal 1 Plug Ground Clamp cable into Positive Socket Twist clockwise all the way to lock in place 2 Plug TIG Torch cable into Negative Socket Twist clockwise all the way to lock in place 3 Plug Foot Pedal cable into Foot Pedal ...

Page 9: ...and dirt from the valve opening Close the cylinder valve 3 Close the Regulator s valve by backing off knob until it is loose then thread Regulator onto cylinder and wrench tighten connection 4 Attach the Gas Hose included to the Regulator s Outlet and the Welder s Gas Inlet Wrench tighten both connections 4 3 Briefly open valve to clean then close valve 2 1 Power Input Gas Inlet connect power cord...

Page 10: ...ace of the grinding wheel at an angle Rotate Electrode tip until a blunt point is formed Note Grinding direction must be parallel to length of Electrode 5 The conical portion of the ideal tip will be 2 1 2 times as long as the Electrode diameter 6 Re insert Electrode into Collet with tip protruding 1 8 1 4 beyond the Ceramic Nozzle then re tighten the Back Cap Assemble TIg Torch 1 Consult Settings...

Page 11: ...d 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 connect power cord Plug either 120VAC or 240VAC cord into Power Input Socket Note Plug will only fit one way WARNINg TO pREVENT SERIOUS INJURy FROM AccIdENTAL OpERATION Do not plug cord into wall outlet at this time Power In...

Page 12: ...c fumes DC TIG Welding is used to weld mild steel and stainless steel using a TIG Rod and shielding gas To weld aluminum an AC TIG Welder must be used Stick Welding is used to weld mild steel and stainless steel using a Stick Electrode without shielding gas Good welding takes a degree of skill and experience Practice a few sample welds on scrap before welding your first project Additional practice...

Page 13: ...or power Indicator process Select Button power Switch Amperage Knob Settings chart on top of Welder power Indicator Lights when power is on Voltage Input Thermal Overload Indicator Lights when input voltage is outside the Welder s specifications or duty cycle has been exceeded Amperage Knob Controls output amperage process Select Button Push to cycle through processes ...

Page 14: ...oncentrate 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 f...

Page 15: ... automatically shuts down and the Overload Indicator lights The welder automatically returns to service after cooling off Rest the Tig Torch or Electrode Holder on an electrically non conductive heat proof surface such as a concrete slab well clear of the ground clamp Allow the Welder to cool with the power Switch on so that the internal Fan will help cool the welder When the Overload Indicator is...

Page 16: ...onconductive nonflammable surface away from any grounded objects 5 Turn the Power Switch ON 6 Set amperage according to Settings Chart on top of Welder Set to high end of amperage range For example Range is 80 100A set amperage to 100A NOTE Settings are approximate Adjust as necessary IMpORTANT If Welder is plugged into 120V outlet set amperage according to settings on white band If Welder is plug...

Page 17: ... 5 times the diameter of the Electrode to initiate the arc Press Foot Pedal down all the way to reach maximum amperage Let up on Foot Pedal to lower amperage TIg pULSE Welding After arc is initiated Welder will pulse between Peak Amperage and Background Current at a rate of 2 PPS Peak Amperage Time is 50 Background Current is 30 of Peak Amperage Current NOTE Maintain a constant distance between th...

Page 18: ...WARNINg When Stick is selected Welder is energized Hot Start is activated and Open circuit Voltage is present 4 Select process Press Process Select Button until STIcK process lights up process Select Button 120V Amperage Settings white 240V Amperage Settings orange 5 Set Amperage according to Stick Settings Chart NOTE Settings are approximate Adjust as necessary IMpORTANT If Welder is plugged into...

Page 19: ...metal end of the Stick Electrode sold separately inside the jaws of the Electrode Holder 7 Stroke the workpiece lightly to initiate the arc Tips for igniting the arc a Tap the surface with the Electrode b Stroke the surface with the Electrode c Strike the surface like a match with the Electrode 8 After the arc initiates a Lift the Electrode off workpiece the same distance as the diameter of the ba...

Page 20: ...age the weld it is performed on This test is ONLy an indicator of weld technique and is not intended to test working welds 1 After two scraps have been welded together and the weld has cooled clamp one side in a sturdy vise 2 Stay clear from underneath while you strike the opposite side with a heavy hammer preferably a dead blow hammer 3 A gOOd WELd will deform but not break as shown on top A pOOR...

Page 21: ...ces properly a Increase current b Weld more slowly How to reduce workpiece heat and limit penetration to weld THINNER workpieces properly a Decrease current b Weld more quickly Stick Weld Example diagrams cLEAN WELdS FIRST Stick welds will have a coat of slag over them until cleaned good Weld current Too Low TO cORREcT Increase the current TO cORREcT Decrease the current current Too High TO cORREc...

Page 22: ...rease current 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 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 PROFILE VIEW 1 Incorrect welding technique Place stringer bead at corr...

Page 23: ...ng speed Maintain steady weld speed Stick Weld crooked Wavy Bead pOSSIBLE cAUSES ANd SOLUTIONS TOP VIEW 1 Inaccurate welding Use two hands or rest hand on steady surface 2 Inconsistent welding speed Maintain steady weld speed Stick Weld Excessive Spatter pOSSIBLE cAUSES ANd SOLUTIONS TOP VIEW Fine spatter is normal Spatter that is grainy and large is a problem dirty workpiece or fill material Clea...

Page 24: ... Voltage Input Thermal Overload Indicator is illuminated check input voltage and ensure it falls within the specified range If input voltage is correct press Reset Button on back of machine 4 Connect shielding gas to Welder When Switched On Power Indicator Does Not Light 1 Unit is not connected to outlet properly 2 Outlet is unpowered 3 Circuit supplies insufficient input voltage or amperage 4 Cir...

Page 25: ...in PCB 1 19 Beam 1 20 Top Handle Cover 1 21 Top Handle Base 1 22 Top Housing 1 23 Front Panel 1 24 Display PCB 1 25 Control Panel 1 26 Foot Pedal 1 27 Settings Knob 1 28 Positive Socket 1 29 Power Switch 1 30 Food Pedal Socket 1 31 Gas Socket 1 32 Copper Anode 1 part description Qty 33 Transformer 1 34 Bottom Housing 1 35 Electrode Holder 1 36 Ground Clamp 1 37 High Frequency Rectifier 5 38 TIG To...

Page 26: ... CN9 High Frequency And Remote Control Board 1 2 CN3 LED4 LED5 LED6 VR1 M3 LED3 LED2 LED1 1 2 3 4 5 6 7 8 9 10 CN3 1 1 2 3 4 5 6 7 8 9 10 CN1 1 2 3 4 5 6 CN3 2 1 2 3 4 5 6 CN3 TIG HF TIG PULSE TIG LIFT STICK 1 2 3 4 CN2 M4 1 2 3 4 5 6 7 8 CN7 1 2 3 4 5 6 7 8 CN1 1 2 HF2 1 2 HF1 1 2 3 4 5 6 7 CN3 M2 1 2 FAN 1 2 3 4 5 6 POWER 1 2 3 4 5 6 POWER 1 2 3 4 5 6 7 8 9 CN5 1 2 3 4 5 6 7 8 9 CN5 Power Board ...

Page 27: ...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 ...

Page 28: ...ow 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 a...

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