Operating Manual for 160PI/200PI/250PI AC/DC Series IGBT MultiPurpose Machines
160PI/200PI/250PI AC/DC Series IGBT Machines Table of Contents Table of Content Pg. 1 Thank you From LONGEVITY Pg. 2 Warranty/Shipping Damage/Order Information Pg. 2-4 Safety Information Pg. 5-6 General Description Pg. 7 Specifications and Ratings Pg. 8-9 Included Accessories Pg. 10-13 Wiring and Setup Instructions Pg. 14-15 Main Unit Diagram/ Water Separator Diagram Pg. 16-18 Knob Functions – Detailed Description of each knob Pg. 19-20 Operation Chart Pg.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com THANK YOU! We, at LONGEVITY, want to thank you for purchasing our product. You are almost ready to experience Longevity Welding first hand. Longevity definitely appreciates your business and understand that this equipment may be overwhelming to setup and operate so we have prepared a manual that will assist you in understand your new plasma cutter/welder.
160PI/200PI/250PI AC/DC Series IGBT Machines Warranty LONGEVITY Plasma Cutters, Welders, and Multi-Purpose Welders are covered for specific Parts and Labor warranty at our facility. For detailed information regarding yours pecific LONGEVITY welder or cutter, please view our Terms and Policies page on our website at the following website link: http://www.longevity-inc.com/terms/ Shipping Damage Your machine is insured against damage during shipping.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com In Warranty Service Customers, who own machines that are in warranty and require service, should contact our Warranty Department by email at help@longevity-inc.com to obtain a return authorization code. In addition to the warranty we offer, we would like for you to register your product on our website at www.longevityinc.com/resources. Remember, warranty starts from the date of purchase.
160PI/200PI/250PI AC/DC Series IGBT Machines Warnings and Safety Welding and plasma cutting may be dangerous to the operator and to bystanders, if the equipment is not operated properly. Welding or cutting must be performed in accordance with all relevant safety regulations. Carefully read and understand this instruction manual before installing and operating this equipment. Changing function modes during welding may damage equipment.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Safety Tips Consider the following tips to ensure safe operation of your welding/cutting equipment: Ensure that this welding equipment is installed in an area free of corrosive chemical gases, flammable gases or materials, and explosive chemicals. The area should contain little dust, and have a humidity of no more than 80%. Operate the welding equipment in an area sheltered from direct sunlight and precipitation.
160PI/200PI/250PI AC/DC Series IGBT Machines General Description The LONGEVITY WeldAll series multi-purpose units offer a variety of multiple welding aspects. You will be able to cut and weld all types of metals including aluminum. This LONGEVITY multi-process welder can AC/DC plasma cut, AC/DC TIG Weld and AC/DC ARC weld all in one machine with a flip of a switch. Weighing in at 69lbs, the unit is portable and reliable featuring a duty cycle of 60% in each function! www.longevity-inc.com www.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Technical Specifications and Ratings Type MODE Parameter WeldAll® 160PI WeldAll® 200PI Power Voltage AC TIG (GTAW) Input Frequency 50/60 Hz 50/60 Hz 50/60 Hz Rated Input Current 20A 25A 30A Power Capacity 4.8KVA 5.0KVA 4.8KVA 60 – 80V Working Voltage 26.4V 28.1V 29.0V Efficiency% >80% >80% >80% Power Factor 0.93 0.93 0.93 Insulation Class F F F Protection Class IP21S IP21S IP21S Weight 27kg 27kg 27kg Size 18.
160PI/200PI/250PI AC/DC Series IGBT Machines DC TIG (GTAW) AC/DC ARC/STICK Current Down-Slope Time 0-10 Seconds Pulse Width Ratio 0.1 – 0.9 Pulse Frequency 0.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.
160PI/200PI/250PI AC/DC Series IGBT Machines Included Accessories Continued.... Argon Regulator www.longevity-inc.
160/200/250PI AC/DC Series IGBT Machine Included Accessories Continued…. www.LWELD.
160PI/200PI/250PI AC/DC Series IGBT Machines Installation and Setup Instructions: The item numbers referenced in the following paragraphs, refer to the numbered parts display in the diagrams shown below. Longevity has an instructional setup installation video on our website at www.longevity-inc.com, which we ask that you view prior installing the unit. The video shows the complete assembly of the machine.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Identifying the Ground wire Caution: The machine may appear to operate with an incorrectly connected ground wire, but it will not operate properly. Selecting the correct ground wire is important for proper machine operation and personnel safety. Ground wires on Longevity™ machines are usually one of the following colors: The ground wire is a dark green with a yellow stripe. The wire may also be just SOLID GREEN.
0PI/200PI/250PI AC/DC Series IGBT Machines Basic Diagram Pictured Model WeldAll™ 200PI (Note: All IGBT WeldAll series machines have same function adjustment knobs and settings at different amperage ratings.) www.longevity-inc.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.
160PI/200PI/250PI AC/DC Series IGBT Machines Water Separator Diagram and Assembly to Unit: LONGEVITY® includes an external water separator with your machine. You must attach the bracket to the holes dedicated on the back of the machine and fasten the water separator to the bracket so that it mounts face out as pictured. 1. Locate the ENTRANCE and OUTLET on the water separator labeled on the diagram pictured above and attach the hose coming from the Air Compressor to the ENTRANCE side on Water Separator.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Knob Functions: POWER SWITCH: Dual throw switch is located on the back of the unit. (NOTE: When finished welding or cutting, always let the machine's fan run for a minute or two to cool the machine before turning the power switch off.) POWER LAMP: This light illuminates while the unit is powered on.
160PI/200PI/250PI AC/DC Series IGBT Machines PULSE CURRENT. (Pulse Current 5-### amps): Only active in pulse mode. This Set’s the pulse peak (high) amperage of the pulse cycle. Select the peak amperage with this control to achieve the maximum amperage requirements for the high pulse cycle. The amperage change will be reflected on the digital display. PULSE FREQUENCY. (Pulse Frequency 0.5-25 cycles per second): Only active in pulse mode.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Push the knob in to lock it after regulator is set. Adjust the Argon regulator on the gas bottle to control gas flow for TIG welding. The air regulator, once set can be left for all plasma cutting and TIG welding projects. Further adjustment should not be required. Connectors: GROUND CLAMP DIN (+): The ground clamp is normally connected to this terminal. You can use reverse polarity in stick mode by switching the ground clamp and stick holder.
160PI/200PI/250PI AC/DC Series IGBT Machines Welding Method AC Stick (SMAW) DC Proces s Process used for Steel, Aluminum Gas used N/A Torch used Electrode Clamp Switch Settings tungsten N/A AC TIG (GTAW) DC Steels N/A Aluminum Argon Electrode Clamp TIG Ceriated (grey) tungesten, Steel, Stainless Steel Argon TIG Plasma Cutting Notes Cutting any contuctive AC TIG preferred for Aluminum, DC TIG/Stick preferred for Steels material Compressed Air purge hose with Argon using trigger on gun before
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Plasma Cutter: Plasma Cutter Torch Assembly The plasma cutter torch handle is made of fire and heat resistant materials. Avoid dropping the 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 copper tip on the ring, ensuring that is seated flat. 4. Place the shield cup over the tip and secure.
160PI/200PI/250PI AC/DC Series IGBT Machines Plasma Cutter Operating Tips from www.plasma-cutters.com Tips For Longevity Plasma Cutting Using a Longevity Plasma Cutter with either High Frequency or Pilot Arc technology is very easy to use, and since each Longevity unit is quality tested at our in house testing facility before it is shipped , most of our customers take right out of the box, plug it in and get to work.
160/200/250PI AC/DC Series IGBT Machine Check List Suggestions Connect the air supply to your Longevity Plasma Cutter and consult your owner's manual to ensure the correct PSI. The PSI is about 65-75. Each Longevity Plasma Cutter, regardless if it uses Pilot Arc or High Frequency technology, comes with an air flow regulator and water catcher. Reference the owner's manual of your Longevity Plasma Cutter for specifications and care instructions of your air flow regulator and filter.
160PI/200PI/250PI AC/DC Series IGBT Machines The old adage says to measure twice and cut once, but we want to go ahead and suggest you make a sample cut (of the same caliber as the intended use) with your Longevity Plasma Cutter before you get started. Use this rehearsal just to be sure you have correctly calibrated all the settings to work as desired.
160/200/250PI AC/DC Series IGBT Machine material or stop and restart the Pilot Arc, the shorter the life span of your consumables will be. Using a torch guide or tip shield is a great way to protect the consumables of your Longevity Plasma Cutter. Remember to maintain a 1/16in. - 1/8in. distance from the material when cutting.
160PI/200PI/250PI AC/DC Series IGBT Machines Know Your Amperage, Know Your Metal At www.longevity-inc.com, you can see the cutting thickness capability. Understanding the amperage in relation to your cut speed is important. Some metals respond differently than others. For example the faster you move on a material such as aluminum, the cleaner your cut will be. Conversely, when using your Longevity Plasma Cutter to cut thicker material, set your unit to full output and vary your travel speed accordingly.
160/200/250PI AC/DC Series IGBT Machine For more information on plasma cutting from professionals go to www.freeweldingforum.com and www.plasma-cutters.com Sample Photo: www.LWELD.
160PI/200PI/250PI AC/DC Series IGBT Machines Sample Photo: www.longevity-inc.
160/200/250PI AC/DC Series IGBT Machine TIG Function: Setting Up The TIG Torch www.LWELD.
160PI/200PI/250PI AC/DC Series IGBT Machines Selecting the Right Tungsten Electrodes: Selecting the right tungsten is crucial to a successful TIG weld. You have to insure the correct tungsten is used for the type of metal you are welding, the type of technology used in your welder such as transformer or inverter, and the thickness of the metal you will need to weld.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Tungsten Chart Guide Tungsten Type Diameter 040"(1.0mm) 1/16"(1.6mm) 3/32"(2.4mm) 1/8"(3.
160PI/200PI/250PI AC/DC Series IGBT Machines Selecting the right FILLER RODS FOR TIG WELDING: Filler Rods are essential to TIG Welding because the filler rod is fed into the molten puddle by hand filling in the puddle to create a stronger metal bond or puddle to join two metal pieces. It is extremely important to have the right filler rod based on the metal you are welding. It is also necessary to have the right tungsten to insure you are properly setup to weld your metal.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Basic Installation for TIG Function: 1. Plug the argon regulator to the bottle. 2. Plug the torch into the unit on the right side of the unit (+) 3. Either plug the pedal or the remote 7 pin connector to the machine. You cannot plug both in. 4. Plug the ground clamp into the left side din Ground Clamp Din (+) is plugged on the right side (+) and attaches on the work piece. 5. Plug in the Power Cord to the wall.
160PI/200PI/250PI AC/DC Series IGBT Machines Setting Up the Argon Regulator: The argon regulator (pictured below) is included with your unit. Setting it up to your argon bottle is easy. Simply screw in the valve to the bottle and set the pressure to about. Use 100% Argon at 15-25 (cubic feet per hour). Set the gas flow using the regulator on the gas bottle. Use higher flow when extending the tungsten electrode to reach into corners or gaps. We recommend about 18 CFM.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Basic TIG Operation (Tungsten Inert Gas - Gas Tungsten Arc Welding - GTAW) Connect the TIG torch to the (-) terminal, Torch Control and Gas Outlet. Connect the ground clamp to the (+) terminal of the machine and clamp the other side to the metal that will be welded. AC TIG (Aluminum & Magnesium): Select TIG on the function switch. The AC function will be required for aluminum welding. Set desired amps using the Base current knob, AC freq.
160PI/200PI/250PI AC/DC Series IGBT Machines Pre-TIG Welding As you get to know the above information of basic TIG welding applications, there are a couple of basic steps that need to be taken. The tungsten must be sharpened and shaped before initiating an arc. With inverter TIG welding machines, tungsten sharpness is important. Your weld’s outcome will be partially determined by the shape of your tungsten.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com 7. When finished welding always let the welder's fan run for a minute or two to cool the machine before turning the power switch off. Fig.1 Figure 1: Comparison chart of welds Fig. 2 Length of Arc When an arc is too long, the metal melts off the electrode in large globules and the arc may break frequently. This produces a wide, spattered, and irregular deposit with insufficient fusion between the base metal and the weld.
160PI/200PI/250PI AC/DC Series IGBT Machines The length of the arc depends upon the type of electrode and the type of welding being done; therefore, for smaller diameter electrodes, a shorter 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.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Stick/ARC Welding Stick Welding (Also known as MMA-Manual Metal Arc or Shielded Metal Arc Welding-SMAW) Connect the Stick torch to the - terminal and Torch Control receptacles. Connect the ground clamp to the + terminal and clamp the metal to be welded. Reverse the torch and ground connections for DCEP (Direct Current Electrode Positive). DC Stick - Select Stick, DC, desired amps using Base cur knob, Pulse Mode off.
160PI/200PI/250PI AC/DC Series IGBT Machines 5. Electrode selection. Electrodes are usually given performance and characteristic ratings using a system of letters and numbers determined by the American Welding Society (AWS). The rating system includes the minimum tensile strength of the finished weld, the weld position (flat, vertical, horizontal, or overhead or a combination of two or more positions) and the flux type. Additional information may be given.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com weld bead into the sides or “toes” of the weld is important. Keep the welding electrode or the TIG tungsten and welding arc within the weld joint to prevent overlap. Pausing on the sides of the welds to wait for the sides to fill reduces the chance of undercutting, even if the current is a little too high.
160PI/200PI/250PI AC/DC Series IGBT Machines www.longevity-inc.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Helpful Hints Use a drag technique for most applications. Take precautions with flying materials when chipping slag. Keep electrodes clean and dry - follow manufacturers instructions. Common steel electrodes (refer to chart above).
160PI/200PI/250PI AC/DC Series IGBT Machines Routine Maintenance The life of your machine and the quality of the work performed using your machine, will be enhanced by practicing periodic routine maintenance. At regular intervals, clear dust that may accumulate in the machine using clean and dry compressed air. If the working condition has heavy smoke and pollution, the welding machine should be cleaned once a month. Keep the machine exterior clean with mild soap and water.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com Troubleshooting If your unit is not properly functioning, please call us immediately toll free at 1-877-566-4462 for support. We have included a small table here to diagnose most common problems. Problems, Causes, and Solutions Problems Machine will not turn on. The machine runs, but nothing is happening Pilot Arc will not start Consumables (tips) are being consumed Heavy Underside Slag (Cutting) Poor Cut Quality Inconsistent Arc O.C.
160PI/200PI/250PI AC/DC Series IGBT Machines Problems, Causes, and Solutions Problems STICK Welder Having a Hard Time Striking an Arc STICK Welder Producing Poor Quality Welds www.longevity-inc.com Causes/ Solutions Check the ground. Check the work piece and clean it. Decrease amps. Use the proper rod and polarity.
160/200/250PI AC/DC Series IGBT Machine www.LWELD.com LONGEVITY® Global, Inc. thanks you for your purchase and the opportunity to be able to serve you. If, after reviewing this manual, you have any problems in setting up or operating your machine, contact us at help@longevity-inc.com. LONGEVITY® Global, Inc. Toll-Free 1-877-LONG-INC / 1-877-566-4462 Website: www.longevity-inc.com Sales: sales@longevity-inc.com Customer Service: help@longevity-inc.com Dealers: dealers@longevity-inc.
