background image

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

 

 

 

 

 

 

 

 

 

 

        

www.longevity-inc.com

 

 

 

 

Stick (SMAW )

 

TIG (GTAW )

 

Plasma

 

 

 

 

 

Welding Method

AC

 

DC

 

AC

 

DC

 

Cutting

 

 

Notes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cutting any

 

 

 

 

 

Process used for Steel, Aluminum

 

Steels

 

Aluminum

 

Steel, Stainless 

Steel

 

contuctive 

material

 

AC TIG preferred for Aluminum, DC TIG/Stick preferred for Steels

 

 

 

 

 

 

 

 

 

 

 

 

Gas used

N/A

 

N/A

 

Argon

 

Argon

 

Compressed Air

 

purge hose with Argon using trigger on gun before beginning TIG welding

 

 

P

ro

ce

s

s

 

 

 

 

 

 

 

 

 

Torch used Electrode Clamp

 

Electrode Clamp

 

TIG

 

TIG

 

Plasma

 

Ground cable and clamp used for all.  Plasma and Tig Torch share connections welding unit.

 

 

 

 

 

Ceriated (grey) 

tungesten,

 

 

 

Grey is typically for aluminum.  Red usually indicates 2% thoriated for steel and stainless steel.

 

 

tungsten

N/A

 

N/A

 

ball/flat end

 

Ceriated/thoriate

d, (red or grey) 

sharp tip

 

N/A

 

Sharpen to point grinding axially with taper with length of taper = 2.5 x Diameter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10-25 cu-ft/hr 

start

 

10-25 cu-ft/hr 

start

 

40-70 PSI

 

 

 

 

 

Gas pressure/flow

N/A

 

N/A

 

at 20

 

at 20

 

start at 65 psi

 

Start with Argon at 18 CFM  for TIG.  Start with compressed air at 60-75 psi for Plasma

 

 

 

 

 

 

 

 

 

 

 

 

S

e

tt

in

g

s

 

ARC/TIG/Plasma

ARC

 

ARC

 

TIG

 

TIG

 

Plasma

 

select welding type 
desired

 

 

 

AC/DC

AC

 

DC

 

AC

 

DC

 

DC

 

select DC or AC welding current

 

 

 

 

 

 

 

 

Normally set to 2T where trigger pulled = on, released = off.  Setting to 4T causes the trigger switch 
to latch on until

 

 

4T/2T

N/A

 

N/A

 

2T see note

 

2T see note

 

2T see note

 

triggered a second 
time

 

 

 

S

w

it

ch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

select as

 

 

While in DC/TIG mode this switch will provide pulsed DC or constant DC. It switches between the 
peak current and

 

 

DC/Pulse

N/A

 

N/A

 

N/A

 

appropriate

 

N/A

 

base current at the selected frequency.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Recommended to pre purge weld area for before current starts when TIG welding to help 
prevent oxidation, set

 

 

 

Gas Preflow

N/A

 

N/A

 

Set 0-1 sec

 

Set 0-1 sec

 

N/A set to 0

 

between 0 and 1 seconds.  Purge with Argon before starting first TIG weld.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0-200 Amps as

 

 

 

0-50 Amps as

 

 

 

 

 

 

0-200 Amps as

 

appropriate for

 

0-200 Amps as

 

0-200 Amps as

 

appropriate for

 

 

 

 

 

 

appropriate for

 

workpiece/

 

appropriate zero

 

appropriate zero 

for

 

workpiece/

 

 

 

 

 

Current (Amps)

workpiece/ 

electrode

 

electrode

 

for foot switch

 

foot switch

 

electrode

 

Set current as recommended for material and thickness. If using foot pedal  set to zero -- foot pedal 
adjusts current

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Only active when set to "Pulse"  in DC/TIG mode. Sets lower (trough/valley) current (percentage 
of the "current"

 

 

 

Base Current

N/A

 

N/A

 

N/A

 

set 20-90%

 

N/A

 

above) that is seen during each DC pulse cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Rate at which current is dropped after you release the weld trigger.  Adjusts time from 0 to 10 
seconds.  If using

 

 

 

Slope Down Control

N/A

 

N/A

 

set 0-10 sec

 

set 0-10 sec

 

N/A

 

foot pedal, set to zero as foot pedal is used to reduce current.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Designed for use when Stick welding, but influences maximum current of all modes.  Also called 
Dig or Arc Force

 

 

 

 

 

 

 

 

 

Control. Gives a welder variable additional amperage during low voltage (short arc length) 
conditions while welding.

 

 

S

e

tt

in

g

s

 

 

 

 

 

 

 

Helps avoid "sticking" stick electrodes when a short arc length is used and gives stick operator 
some heat control.

 

 

 

 

 

 

 

 

This must be set to maximum to achieve maximum power for all modes, but variable voltage/arc-
length dependent

 

 

Arc Force

set 0-100%

 

set 0-100%

 

N/A set to max

 

N/A set to max

 

N/A  set to max

 

current is only active while stick welding.

 

 

D

ia

l

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Set from 0.3 to 

300

 

 

 

 

 

 

Pulse Frequency

N/A

 

N/A

 

N/A

 

pulses/sec

 

N/A

 

Adjusts pulse frequency from 0.5 to 300 Hz. Only active when set to "Pulse" in DC TIG mode.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Only active when set to "Pulse" in DC/TIG mode.  Sets width of DC Pulse from 10 to 90% of each 
DC pulse cycle.

 

 

 

Pulse Duty

N/A

 

N/A

 

N/A

 

set 10-90%

 

N/A

 

This is the duration as % of pulse width (one pulse cycle) of the  higher current  pulse

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Only active in AC welding.  Biases the AC  current by varying the percentage of current going in 
each direction.  This

 

 

 

 

 

 

 

 

 

balances the weld heat penetration (DCEN) and cleaning action (DCEP). This setting can help 
prevent overheating

 

 

 

 

 

 

 

 

 

and damaging the tungsten vs cleaning oxidation on the work pieces.  Middle setting is 50/50.  Low 
is 20% positive

 

 

 

 

Set 20-80%, 

neutral

 

 

 

 

 

on.  High is 80% positive on.  Large current small clear width and vice versa. This setting 
depends on weld

 

 

 

Clear Width

set to 50%

 

N/A

 

Set 20-80%

 

N/A

 

N/A

 

penetration needed (current), tungsten diameter, gas flow (tungsten cooling), and existing 
work oxidation.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Controls gas flow duration after trigger is released.  Higher time uses more gas but helps prevent 
oxidation of hot

 

 

 

 

 

 

 

 

 

TIG weld material. Also helps cool weld pool, tungsten electrode, and ceramic cups. Post flow can 
also cool freshly

 

 

 

Gas Post Flow

N/A

 

N/A

 

Set 1-10 sec

 

Set 1-10 sec

 

Set 1-10 sec

 

cut work pieces and plasma torch parts.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Strength

 

Electrode Chart Example: E 60 1 3

 

 

 

 

 

 

 

 

 

60--60,000 psi,

 

 

 

 

 

 

 

Distance between

 

 

70--70,000 psi

 

 

 

 

 

 

 

 

 

Weld Position

 

 

 

 

 

 

 

tungsten and

 

 

 

 

 

 

 

 

 

 

 

1--All positions: Flat, Vertical, Horizontal, & Overhead

 

 

 

 

 

 

workpiece should 

be

 

Distance between

 

 

 

 

Notes

 

 

 

2--Flat Position or Horizontal Fillets Only

 

 

 

 

 

2-4 mm, either set

 

tungsten and

 

lower current if 

cut is

 

 

 

 

requires slag 

removal

 

 

current or use 

foot

 

workpiece should 

be

 

too wide.  Air flow 

is

 

3--Flat Position Only

 

 

 

 

 

with chipping

 

 

pedal recommend

 

2-4 mm, either set

 

critical to prevent

 

Weld Characteristics

 

 

 

 

 

hammer, use AC for

 

requires slag 

removal

 

5356 filler rod,

 

current or use foot

 

damage to tip.  Tilt

 

0--Non-low hydrogen, DC Reverse polarity

 

 

 

 

less spatter 

(depends

 

with chipping

 

remember to 

allow

 

pedal  remember 

to

 

nozzle to start 

hole

 

1--Non-low hydrogen, AC or DC Reverse polarity

 

 

 

 

on electrode 

chosen)

 

hammer

 

post flow

 

allow post flow

 

in thicker 

materials.

 

2--Non-low hydrogen, AC or DC Straight polarity

 

 

 

 

 

 

 

 

 

3--Non-low hydrogen, AC or DC Either polarity

 

 

 

 

 

 

 

 

 

4--Non-low hydrogen, iron powder coating, AC or DC Reverse polarity

 

 

 

 

 

 

 

 

 

5--Low-hydrogen, DC Reverse polarity

 

 

 

 

 

 

 

 

 

6--Low-hydrogen, AC or DC Reverse polarity

 

 

 

 

 

 

 

 

 

7--Non-low hydrogen, iron powder coating, AC or DC Reverse polarity

 

 

 

 

 

 

 

 

 

8--Low hydrogen, iron powder coating, AC or DC Reverse polarity

 

 

 

 

 

 

 

 

 

Polarity Definition

 

 

 

 

 

 

 

 

 

 

electrode negative =straight polarity (typical stock machine setup)

 

 

Содержание WeldAll 160

Страница 1: ...Operating Manual for 160 200 160P 200P AC DC Series Machine...

Страница 2: ......

Страница 3: ...Unit Knob Button Function Diagram Pg 13 Knob Functions Detailed Description of each knob Pg 14 16 Operation Chart Pg 17 Plasma Cutter Section Torch Assembly Pg 18 Plasma Cutter Operation Tips and Adv...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 9: ...ltiple welding aspects You will be able to cut and weld all types of metals including aluminum This LONGEVITY multiprocess welder can plasma cut AC DC TIG Weld and ARC weld all in one machine with a f...

Страница 10: ...V 62V Working Voltage 26 4V 29 0V 28 0V 32 0V Pre flows 0 2 0 2 0 2 0 2 Output Frequency 60Hz 60Hz 60Hz 60Hz Clean Width 20 80 20 80 20 80 20 80 Slope down Times 2 10 0 5 0 5 0 5 Post flow Times 2 10...

Страница 11: ...160 200 160P 200P AC DC Series Machine www longevity inc com 9 What s Included...

Страница 12: ...o the unit is important Please view the proper connection instructions below Wiring Introduction Danger Read this manual completely before having your electrician attempt to wire up or connect your ma...

Страница 13: ...lected 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...

Страница 14: ...160 200 160P 200P AC DC Series Machine www longevity inc com Main Unit Pictured WeldAll 160P Multi Purpose Unit...

Страница 15: ...ital display will increase showing your pulse peak amps FOOT CONTROL The Foot Control overrides the Base Current knob The Base Current knob does not function when the Foot Control is plugged into the...

Страница 16: ...de This AC TIG Stick control determines the amount of time the AC cycle spends in DCEN Direct Current Electrode Negative or DCEP DC Electrode Positive More DCEP is preferred for cleaning oxidation par...

Страница 17: ...erminal but the and connectors can be reversed for DCEP Direct Current Electrode Positive stick welding TORCH CONTROL PEDAL CONNECTOR The Torch connector and the Foot pedal connector both attach to re...

Страница 18: ...c length conditions while welding Settings Helps avoid sticking stick electrodes when a short arc length is used and gives stick operator some heat control This must be set to maximum to achieve maxim...

Страница 19: ...he torch or striking anything with it Assemble the consumables as pictured above and described below 1 Insert the electrode Tighten it with pliers 2 Seat the swirl ring on the electrode 3 Place the co...

Страница 20: ...utlet to the GAS in on your unit The water separator can release water once you press the valve inside Any compressor from 3 gallons and up is suitable as long as it has 4 0 CFM and puts out 90PSI The...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 28: ...less steel and basically all metals except 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 alumi...

Страница 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...

Страница 30: ...Steel Wire E1 16 X 36 Longevity offers 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...

Страница 31: ...Plug the argon regulator to the bottle 2 Plug the torch into the unit on the left side as pictured Either plug the pedal or the remote 7 pin connector to the machine You cannot plug both 3 The ground...

Страница 32: ...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 tungst...

Страница 33: ...erage using the Base cur knob then adjust the high amperage using the Pulse cur knob Post flow 5 10 seconds Set pulse controls as desired Pulse frequency Pulse width TIG Operation and Principles Shiel...

Страница 34: ...rtable to you Place the torch so that the tungsten is no more than 1 8 inch from the weld surface Depending upon the setup either press the foot pedal down or press 2T setting the trigger to initiate...

Страница 35: ...his produces a wide spattered and irregular deposit with insufficient fusion between the base metal and the weld When an arc is too short it fails to generate enough heat to melt the base metal proper...

Страница 36: ...arc is necessary than for larger electrodes Remember the length of the arc should be about equal to the diameter of the bare electrode except when welding in the vertical or over head position In eit...

Страница 37: ...become entrapped in the metal The sound of a proper arc will be similar to a gentle frying sound A long arc will emit a humming sound An arc that is too short may be extinguished and the electrode may...

Страница 38: ...polarity 4 Non low hydrogen iron powder coating AC or DC Reverse polarity 5 Low hydrogen DC Reverse polarity 6 Low hydrogen AC or DC Reverse polarity 7 Non low hydrogen iron powder coating AC or DC R...

Страница 39: ...great 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 0...

Страница 40: ...160 200 160P 200P AC DC Series Machine www longevity inc com...

Страница 41: ...ve 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 an...

Страница 42: ...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 machi...

Страница 43: ...he consumables 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 Ch...

Страница 44: ...Causes and Solutions Problems Causes Solutions and filler rod 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 STIC...

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