Longevity WeldMax 416D Operating Manual Download Page 43

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160/200/160P/200P AC/DC Series Machine

www.longevity-inc.com

Problems, Causes, and Solutions

Problems

Causes/

Solutions

STICK Welder
Having a Hard
Time Striking an
Arc

Check the ground. Check the workpiece and clean it. Increase

the Arc Force on the unit.

STICK Welder
Producing Poor
Quality Welds

Use the proper rod and polarity.

Summary of Contents for WeldMax 416D

Page 1: ...Operating Manual for 416D 518D 520D Multi Purpose Welding Machines...

Page 2: ......

Page 3: ...Installation Wiring and Setup Instructions Pg 11 14 Main Unit Knob Button Function Diagram Pg 15 Plasma Cutter Section Torch Assembly Pg 16 17 Air Regulator Assembly Pg 18 Plasma Cutter Operation Tip...

Page 4: ...o contact us Please take a moment to register your product on our website at www longevity inc com or www lweld com Once again thank you for choosing Longevity as your main welding supplier Longevity...

Page 5: ...cipients own cost The product must be returned in its original packaging with all accompanying components Repair or replacement of the defective product will be at our option The repaired replaced pro...

Page 6: ...your order in case you need warranty work Order No _________________________________ Date of Purchase _____________________________ Warranty Period ______________________________ Out of Warranty Servi...

Page 7: ...h electrodes wires or circuit components with bare hands Wear dry welding gloves when welding The operator must be insulated from the work piece Smoke and gas can be harmful to health Ensure that the...

Page 8: ...otection to protect your hearing Ensure that machine is grounded through the power cord or on the machine case Never operate the machine in bare feet or on a wet floor Never switch the machine off whi...

Page 9: ...system This machine provides stable output and reliable completely portable efficient and low noise generation while welding or cutting The WeldMax series has three different functions TIG Arc and pla...

Page 10: ...Insulation Class F F F Protection Class IP21S IP21S IP21S Weight 38lbs 38lbs 39lbs Size 18 9 X 9 4 X 13 0 in 19 4 X 13 0 X 12 6 in 22 0 X 14 4 X 14 0 in Welding Thickness Steel 31 in 39 in 5 in Cutti...

Page 11: ...160 200 160P 200P AC DC Series Machine www longevity inc com 9 Amps PLASMA CUTTER Base Current Range Amps 20 40A 20 50A 20 50A Rated Duty Cycle at Max Amps 60 Arc Starting Method High Frequency...

Page 12: ...160 200 160P 200P AC DC Series Machine www longevity inc com What s Included...

Page 13: ...connect your machine to an electrical power source LONGEVITY units should be wired by a certified electrician to insure your safety and a proper 110 220v plug match at your operating facility Remember...

Page 14: ...he ground wire or do not feel comfortable with your selection ask an electrician for help Identifying the hot wire For 220vac service both the brown and blue wire are positive wires As you may know 22...

Page 15: ...wire using an ohmmeter Another method is to check the continuity between the chassis and the wire using a continuity meter If the selected wire is ground the connection between the chassis and the wi...

Page 16: ...160 200 160P 200P AC DC Series Machine www longevity inc com Main Unit Pictured WeldMax 416D Multi Purpose Unit...

Page 17: ...reverse polarity by switching the ground clamp 9 Torch Remote Connector 2 or 7 pin torch connector plugs here to activate the torch relay once the trigger is pressed on the torch 10 Torch Connector C...

Page 18: ...switch can be positioned on the top the side or the bottom of the torch body Assembly of Consumables for the 40 50AMP Torch Heads Assemble the consumables as pictured above and described below 1 Inser...

Page 19: ...Assemble the consumables as pictured above and described below 1 Insert the electrode 2 Place the copper tip on the ring ensuring that is seated flat 3 Secure all parts into place by turning the pink...

Page 20: ...h the Air Compressor to the inlet and the OUTLET to the INLET on Unit with the provided hose to back of the machine where shown and secure it with a hose tie 2 Set the air compressor to about 60 75 PS...

Page 21: ...an give it a once through and keep it near by in case you someone you know or someone you work with has a question about the use or specifications of your Longevity Plasma Cutter At this point let us...

Page 22: ...ended psi Examples on how to achieve the desired results can be referenced in the owner s manual of your Longevity Plasma Cutter Now you are ready to use your Longevity Plasma Cutter safely and effici...

Page 23: ...a 80 amp torch tip at a 40 amp setting will not focus the energy of your torch accurately and thus lead to a wider kerf And the opposite scenario of using an 80 amp setting with a 40 amp tip will abu...

Page 24: ...he Longevity Facility Testing Team One of the reasons you purchase a Longevity Plasma Cutter is because of it s quality Therefore we think you should have a few quality reminders to think about when y...

Page 25: ...ave an unnecessary buildup of dross or slag Your arc should be exiting the material at a 15 20 degree angle but opposite the direction of your cut path Using A Cutting Guide First thing in using a tor...

Page 26: ...0 200 160P 200P AC DC Series Machine www longevity inc com specification Sample Photos For more information on plasma cutting from professionals go to www freeweldingforum com and www plasma cutters c...

Page 27: ...160 200 160P 200P AC DC Series Machine www longevity inc com 25 TIG Section Setting Up The TIG Torch...

Page 28: ...pt aluminum and offers excellent performance A drawback is that this tungsten has a low level radiation hazard and the fact that they no recommend to weld aluminum We recommend this tungsten with our...

Page 29: ...TC2 7332 TC2 718 2 Lanthanated TL2 7040 TL2 7116 TL2 7332 TL2 718 Amparage Ac 20 30 30 80 60 130 120 200 Amparge Dc 15 50 50 120 80 150 130 250 Sharpening a Tungsten Sharpening a tungsten is very imp...

Page 30: ...quality filler rods at affordable prices Please take a look at the selection of filler rods that we carry to decide what the best application of rod will be for your weld Your choice of filler rod is...

Page 31: ...w in the valve to the bottle and set the pressure to about Use 100 Argon at 15 25 CFH cubic feet per hour Set the gas flow using the regulator on the gas bottle Use higher flow when extending the tung...

Page 32: ...to control the weld puddle Carefully rotate the tungsten as it is being ground to prevent a flat spot or a hollow ground point Also note that tapering the tungsten to 2 5 times of its diameter is gen...

Page 33: ...ller rod into the key hole area underneath the arc Wait for a single molten drop to fall off the tip of the rod 4 When a molten drop falls from the rod quickly remove the rod keeping it inside the gas...

Page 34: ...ase metal and produces uneven deposits with irregular ripples The recommended length of the arc is equal to the diameter of the bare end of the electrode as shown in figure 3 The length of the arc dep...

Page 35: ...160 200 160P 200P AC DC Series Machine www longevity inc com 33 Sample of a quality stainless steel weld TALLATION...

Page 36: ...ctrode holder and break the electrode loose by hand If the flux breaks off simply trim off the excess rod until flux and bare metal meet A welding rod must have flux to shield the weld from the atmosp...

Page 37: ...Low hydrogen iron powder coating AC or DC Reverse polarity Polarity Definition electrode negative straight polarity typical stock machine setup electrode positive reverse polarity Be sure to observe...

Page 38: ...reat choice for welding on dirty rusty greasy or painted steel especially in vertical or overhead applications E6011 All AC DCEP All purpose stick electrode used for carbon and galvanized steel 60 000...

Page 39: ...160 200 160P 200P AC DC Series Machine www longevity inc com 37...

Page 40: ...e Penetration DCEN Less penetration AC Medium can be more spatter also DCEP Most penetration Catalog and Capabilities LONGEVITY has what you need for stick welding from welders to welding supplies and...

Page 41: ...ng machine should be cleaned once a month Keep the machine exterior clean with mild soap and water Do not walk on or store items on the cables or cords Do not jar drop or stack items on top of the mac...

Page 42: ...es to insure they are producing a stable arc Replace Consumables and insure you have the proper PSI at the regulator Inconsistent Arc Improper grounding or possible lack of air pressure Check and repl...

Page 43: ...Problems Causes and Solutions Problems Causes Solutions STICK Welder Having a Hard Time Striking an Arc Check the ground Check the workpiece and clean it Increase the Arc Force on the unit STICK Weld...

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