Longevity 200 EX User Manual

TigWeld 200EX 200amp AC/DC TIG Welder

Operating Manual

For

TigWeld 200EX

200 AMP AC/DC Pulse TIG Welder and

AC/DC Stick Welder

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TigWeld 200EX 200amp AC/DC TIG Welder

Table of Contents:

PG. 3: Thank you From LONGEVITY

PG. 4-6: Warranty/Shipping Damage/Order Information

PG. 7-9: Warning and Safety Information

PG. 10: Specifications and Ratings

PG. 11: Specifications and Ratings

PG. 12: Connecting your Welder

PG. 13-16: Front Panel Overview

PG. 17: Enjoy your new welding machine from LONGEVITY!

PG. 18: Electronic Schematics

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TigWeld 200EX 200amp AC/DC TIG Welder

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. If you have any questions during or after reading this manual,
please feel to 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!

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TigWeld 200EX 200amp AC/DC TIG Welder

Longevity Global, Inc.
23591 Foley St
Hayward, CA 94545

Toll-Free Customer Support: 1-877-LONG-INC / 1-877-566-4462
Website: www.longevity-inc.com
Sales: [email protected]
Customer Service: [email protected]
Dealers: [email protected]
Complaints: [email protected]

Please join our welding forums to share welding tips and tricks, to receive useful
information from customers who also use our products, and to be a part of the

Longevity™ welding community at www.freeweldingforum.com

Check out LONGEVITY Racing at www.longevity-racing.com

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TigWeld 200EX 200amp AC/DC TIG Welder

W

arranty

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. We will initiate a claim with the
shipping company to cover damage or loss. If there is shipping damage upon opening
your package, our customer service team will work with you to get the matter
resolved.

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TigWeld 200EX 200amp AC/DC TIG Welder

In Warranty Service

Customers, who own machines that are in warranty and require service, should
contact our Warranty Department by email at [email protected] 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.longevity-inc.com/resources.
Remember, warranty starts from the date of purchase. For your convenience, write
your order information below so you can track your order in case you need warranty
work.

Order No.: _________________________________

Date of Purchase: _____________________________

Warranty Period: ______________________________

Out-of-Warranty Service

Customers, who own machines that are out of warranty and require service, should
contact us for an estimate. Longevity offers an exchange program on out of warranty
units. We also help non LONGEVITY customers with repairs, replacement, and
service.

If your unit is not manufactured by Longevity and you cannot receive service from
your manufacturer or seller, Longevity will lend out hand. Our warranty policy is also
available for all plasma cutters and welders. For more information, please email us at

[email protected]

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TigWeld 200EX 200amp AC/DC TIG Welder

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.

Before welding, disconnect the electrode-holder cable from the

equipment.

A circuit breaker is required to prevent electrical overload of the

equipment.

Only high quality welding tools should be used.

Electric Shock can be fatal.

Ensure that ground cable is connected in accordance with

applicable safety codes.

Never touch 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 working area is well ventilated.

Avoid breathing smoke and gas generated during the welding

process. Cutting and welding can cause cancer because of the

smoke that comes from the welds and cuts.

Arc-light emission can be harmful to eyes and skin.

Always wear a welding helmet, anti-radiation glass, and work

clothes while welding.

Warnings and Safety

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TigWeld 200EX 200amp AC/DC TIG Welder

Ensure that people in or near the working area are protected.

Welding splash is a fire hazard.

Keep flammable material away from the work place.

Keep a fire extinguisher nearby, and have all personnel trained in

its use.

Surface noise generated while welding or cutting can be harmful

to hearing.

In the event of a machine fault.

Refer to this instruction manual.

If the fault cannot be determined, contact your local dealer or

supplier for assistance.

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TigWeld 200EX 200amp AC/DC TIG Welder

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. Work area temperature should be maintained at - to

 If, because of an overload, the machine suddenly stops, and it is necessary to

restart it, leave the internal fan operating to lower the inside temperature.

 Always wear protective clothing and a welding mask to protect your skin.
 Wear safety goggles designed to darken the arc generated by your machine.
 Wear suitable noise protection 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 while it’s in use. Doing so will damage the internal

circuitry.

 Ensure that your circuit breaker is rated to handle the current requirements of your

machine.

 Use a UL approved receptacles and plugs with your machine. Never hard wire the

machine to main power.

 Work in a well-ventilated area to avoid smoke. Keep your head out of the smoke.

Ensure that air is flowing away from you to avoid inhaling smoke.



Ensure proper ventilation through the machine’s louvers. Maintain a distance

least 12 inches between this cutting equipment and any other objects in the

of at
work area.

 Use a screen or curtain designed to keep passer byes from viewing the arc.
 The arc spray and metal spray from machine use may cause nearby fires. Use

caution.

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TigWeld 200EX 200amp AC/DC TIG Welder



If, after reviewing this manual, you have any problems in setting up or operating

your machine, contact us at [email protected].

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TigWeld 200EX 200amp AC/DC TIG Welder

Models

Parameters

TigWeld 200EX

Input power

1~220±10%，50Hz

Rated input current（A）

35.4（TIG）

39.5（STICK）

Rated input power（KW）

5.2（TIG）

6.4（STICK）

Power factor

0.68

Max no-load voltage(V)

66

Adjustment range of start
current（A）

TIG

STICK

AC

DC

AC

DC

10～welding

current

5～welding current

——

——

Adjustment range of
welding current（A）

10～200

5～200

10～170

5～170

Adjustment range of

downslope time（S）

0～10

Pre-gas time（S）

0.1~1

Adjustment range of
post-gas time（S）

0.1～10

Clearance effect（%）

15～50

Efficiency

Duty cycle（40℃，10
minutes）

AC

DC

25% 200A

25% 200A

60% 90A

60% 110A

100% 70A

100% 90A

Protection class

IP23S

Insulation class

F

Dimensions of Machine
（L×W×H）（mm）

470×250×400

Weight(Kg)

20

Specifications

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TigWeld 200EX 200amp AC/DC TIG Welder

Operation

Layout for the panel

1 Positive Welding Terminal: Positive polarity output. It is important that the plug be inserted and

secured.

2 8 pin Control Socket: Is used to connect either to the trigger switch on the TIG torch, or to the

foot pedal

3 Negative Welding Terminal: Negative polarity output. It is important that the plug be inserted

and secured.

4 Shielding gas connector: Is connected to the gas input pipe of torch.
5 Power source switch: Switch to “ON”, the welder is turned on, while switch to “OFF”, the

welder is turned off.

6 Power source input: To connect to a 220v power source.
7 Shield gas input joint: Gas inlet for shielding gas
8 Fan: Is used for cooling the components and parts inside the welder.

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TigWeld 200EX 200amp AC/DC TIG Welder

Overview

.(1) AC/DC Selection Button

AC welding

DC welding

(2) 2T/4T Selection Button

2T Mode

4T Mode

(3) Gas-test Button

Lights up when Gas-test key is selected, after that gas will flow out for 15 seconds. Press the
button again to stop the gas flow before the 15 seconds are up.

(4) HF (high-frequency) ignition Button

Lights up when High frequency key is pressed, HF (high-frequency) ignition has been selected.

(5) Pulse Button
Lights up when Pulse key is pressed, Pulse has been selected.
(6) and (7) Parameter selection keys

If “2T/4T mode” has been selected, it is possible to change welding parameters by means of the
parameter selection keys (6) and (7) while the welding operation is in progress.

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TigWeld 200EX 200amp AC/DC TIG Welder

PF

SA

UPS

WC

AC

PF

DS

PF

PW

BC

WC

(8) Adjusting dial

If the parameter indicator lights up, then the selected parameter can be altered on adjusting dial.

Available parameters where 2T and 4T mode have been selected:

PF Gas pre-flow time

Unit Seconds
Setting range 0.1—1
Factory setting 0.3

SA Starting current (only with 4T)

Unit Amps
Setting range 5—100% of main current WC (DC)；10—100%of main current WC (A/C)
Factory setting 5

UPS Upslope time

Unit Seconds
Setting range 0—10
Factory setting 0

WC Welding current

Unit Amps

5—200 (TIG-DC)；10—200 (TIG-AC)； 5—170 (Stick-DC)；10—170 (Stick-AC)

BC Base current

Unit Amps
5—200 (DC)；10—200 (AC)

Important! Only selectable when “pulse key” has been pressed.

PW Pulse Width

Unit %
Setting range 5—100
Factory setting 5
Important! Only selectable when “pulse key” has been pressed.

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TigWeld 200EX 200amp AC/DC TIG Welder

PF Pulse frequency

Unit Hz
Setting range 0.5—200
Factory setting 0.5

Important! Only selectable when “pulse key” has been pressed.

DS Downslope time

Unit Seconds
Setting range 0—10
Factory setting 0

AC Arc current (only with 4T)

Unit Seconds
Setting range 5—100% of main current WC (DC)；10—100% of main current WC (AC)
Factory setting 5

PF Gas post-flow time

Unit Seconds
Setting range 0.1—10
Factory setting 3

AC frequency (only with TIG-AC)

Unit Hz
Setting range 50—250 (WC<50A)
50—200 (50A≤WC<100A)
50—150 (100A≤WC<150A)
50—100 (150A≤WC<200A)

Balance (only with TIG-AC)

Balance adjustment is mainly used to set the adjustment of eliminating metal-oxide (such as
Aluminium, Magnesium and its alloy) while in AC output mode.

Unit %
Setting range 15—50
Factory setting 15

(9) Rod electrode (Stick) welding key

Parameter Setting range
Arc force 0-10
Hot start 0-10
Arc length 0-10

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TigWeld 200EX 200amp AC/DC TIG Welder

(10) Power/Alarm indicator

Power Indicator Light

Indicates if the welder reaches its duty cycle, or if the machine senses
over-voltage or over-current. At the same time “Err 001.” will display on the LCD

Display

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TigWeld 200EX 200amp AC/DC TIG Welder

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 [email protected].

LONGEVITY® Global, Inc.

Toll-Free 1-877-LONG-INC / 1-877-566-4462

Website: www.longevity-inc.com

Sales: [email protected]

Customer Service: [email protected]

Dealers: [email protected]

Please join our welding forums to share welding tips and tricks, to receive useful

information from customers who also use our products, and to be a part of the

LONGEVITY® welding community at www.freeweldingforum.com

For the coolest LONGEVITY sponsored race teams plus a complete racing forum that

covers everything from Drag Racing to RC Car Racing, please check out

www.longevity-racing.com!

Enjoy your new welding machine from LONGEVITY! Thanks again!

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TigWeld 200EX 200amp AC/DC TIG Welder

1~220V

C1

C2

HF ABSORB

PCB9







CONTROL PCB4



AC DRIVE PCB6



DISPLAY PCB7



HIGH

FREQUENCY

PCB8



VOLTAGE TEST PCB5

POWER

SOU

ACOUT

WA

20-lead socket

VC

20-lead socket
GD1

GD2

SOU1

HF

ACOUT

VC

SOUIN

HFOUT

KG

AC

DRIVER

F1

P

N

DRIVE

RECTIFIER PCB1

INVERTER PCB2

MUR PCB3

F2

ST

SS

K

power

switch

T1

rectifier

ST

soft start

box

C1、 C2

electrolytical

capacitor

T2

IGBT

B1

main transformer

T3

fast recovery diode

T2

IGBT model

H

Hall

L

inductance

B2

high frequency transformer

P

positive output

N

negative output

F

fuse

B3

switch power supply transformer

F1、 F2

fan

T2

T3

H

L

B1

B2

B3

K

F

DC

DR

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