Operating Manual for Multi-Process IGBT 180 Amp Welding Machine And 40 Amp Plasma Cutter
WELDMAX 185 Table of Contents Table of Content Pg. 1 Thank you From LONGEVITY Pg. 2 Warranty/Shipping Damage/Order Information Pg. 3 Safety Information Pg. 4-5 Specifications and Ratings Pg. 6 What’s Included? Pg. 7 Main Unit Knob/Button/Function Diagram Pg. 8-9 Plasma Cutter Section: Torch Assembly Pg. 10 TIG Section: Torch Assembly Pg. 11 Selecting the Right Tungsten Pg. 12-14 Selecting the Right Filler Rods Pg. 15-16 Argon Regulator Installation Pg. 16 Basic TIG Operation Pg.
WELDMAX 185 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.
WELDMAX 185 Warranty LONGEVITY Plasma Cutters, Welders, and Multi-Purpose Welders are covered for specific Parts and Labor warranty at our facility. For detailed information regarding your specific 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. Keep all packing materials and containers in case machine must be returned.
WELDMAX 185 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.
WELDMAX 185 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.
WELDMAX 185 Techinical Specifications and Ratings TYPE Parameter MODE WELDMAX 185 DC TIG/STICK PLASMA CUTTING WELDMAX 185 Power Voltage 1~220±10% Input Frequency 50/60 Hz No load Voltage 67V/210V Efficiency% 85% Power Factor 0.75 Insulation Class H Protection Class IP23S Weight 30.8 lb (unit) 59.4 (boxed) Size L: 19in x H:15.5in x W:18.5 unit only Cutting Thickness (Steel) ¾ in.
WELDMAX 185 What’s Included? WP-26 FLEX HEAD TIG TORCH AG-60 BLOW BACK PLASMA CUTTING TORCH STICK ELECTRODE HOLDER GROUND CLAMP ARGON REGULATOR ARGON HOSE TIG TORCH PIECES .040 in (1.0 mm), 3/32 in (2.4 mm), 1/8 in (3.2 mm) and 1/16 in (1.6 mm) COLLET BODY .040 in (1.0 mm), 3/32 in (2.4 mm), 1/8 in (3.2 mm) and 1/16 in (1.
WELDMAX 185 Main Unit Pictured: WELDMAX 185 Multi Process 2 1 10 14 11 3 12 9 4 5 13 6 8 7 Main Unit Knob/Button/Function: 1. O.C. Over Current Light: Illuminates when the duty cycle has been exceeded or the machine has overheated due to improper ventilation. Discontinue use until lamp goes out. Allow the fan to continue to run. Once lamp goes out, you may resume using the unit. 2. Power Indicator : Shows unit is powered on. 3.
WELDMAX 185 10. Post Flow: Adjust the amount of post flow from 0-10 seconds. 11. ON/OFF Switch 12. Power Cord 13. Thermal Protection Fan: Cools your unit during operation. Fan should be operating once the power is turned on and the unit power indicator is lit. 14. Air Inlet: Attach air compressor hose to the air inlet here. www.longevity-inc.
WELDMAX 185 Assembly of Consumables for the 60AMP Torch Head 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 ceramic cup clockwise until it is snug. Do not over tighten. The torch consumables are now successfully assembled. www.longevity-inc.
WELDMAX 185 TIG Section: Setting Up The TIG Torch www.longevity-inc.
WELDMAX 185 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.
WELDMAX 185 Tungsten Chart Guide Tungsten Type Diameter 040"(1.0mm) 1/16"(1.6mm) 3/32"(2.4mm) 1/8"(3.2mm) Pure Tungsten TP-7040 TP-7116 TP-7332 TP-718 2% Thoriated TT2-7040 TT2-7116 TT2-7332 TT2-718 2% Ceriated TC2-7040 TC2-7116 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 important for a nice fine arc strike.
WELDMAX 185 www.longevity-inc.
WELDMAX 185 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.
WELDMAX 185 5. ER80S-D2 is for welding 4130 chrome moly tubing if a higher strength weld is required. 6. 1/16” diameter filler should be used when material is 1/8” and less thick. 3/32” diameter filler rod can be used for 1/8” and thicker material. For more info on Filler Rods, go to www.freeweldingforum.com Setting Up the Argon Regulator: The argon regulator (pictured below) is included with your unit. Setting it up to your argon bottle is easy.
WELDMAX 185 Basic TIG Operation (Tungsten Inert Gas - Gas Tungsten Arc Welding - GTAW) TIG Operation and Principles: Shielding Gas: 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. Tungsten Electrode: We recommend 2% Thoriated tungsten (red) for TIG welding with our DC TIG welders.
WELDMAX 185 Starting a TIG Weld: Filler rod selection is critical to a TIG welds density, strength and purity. Check out our filler rod selection chart on our website for optimum filler rod to properly complete a weld. In certain applications, TIG welding can be performed without the use of a filler rod. One of the biggest issues for beginning welders is holding and maintaining an arc. Starting an arc with your High Frequency welder is quite simple.
WELDMAX 185 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. When an arc is too short, it fails to generate enough heat to melt the base metal properly, causes the electrode Fig. 3 Setting the length of an arc to stick frequently to the base metal, and produces uneven deposits with irregular ripples.
WELDMAX 185 Sample of a quality stainless steel weld: TALLATION www.longevity-inc.
WELDMAX 185 STICK/ARC Welding Stick Welding (Also known as MMA-Manual Metal Arc or Shielded Metal Arc WeldingSMAW) 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 1. Insert electrode into electrode holder.
WELDMAX 185 Experimentation will be required to find the optimal setting desired. It is an excellent tool for out of position welding. 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).
WELDMAX 185 electrode holder cable. Many electrodes run with in reverse polarity, (DCEP) setting. A few run with a straight polarity (DCEN). Some will run either way. For reverse polarity (DCEP) stick welding, swap the electrode holder and ground cable connections. Proper weld identification. Overlap and undercutting are two main causes of weld failure. Proper washing of the weld bead into the sides or “toes” of the weld is important.
WELDMAX 185 www.longevity-inc.
WELDMAX 185 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). 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 protective clothing.
WELDMAX 185 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. Do not walk on or store items on the cables or cords.
WELDMAX 185 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 Causes/ Solutions Problems Machine will not turn on. The machine runs, but nothing is happening Arc will not start Consumables (tips) are being consumed Heavy Underside Slag (Cutting) Poor Cut Quality Inconsistent Arc O.C.
