Page 1
Operating Manual
for
160PI/200PI/250PI
AC/DC Series IGBT Multi-
Purpose Machines
Page 2
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. 21
Plasma Cutter Section: Torch Assembly Pg. 22
Plasma Cutter Operation Tips and Advice and Regulator Pg. 23-29
TIG Section: Torch Assembly Pg. 30
Selecting the Right Tungsten Pg. 31-32
Selecting the Right Filler Rod Pg. 33
Basic Installation for TIG Welding Pg. 34
Argon Regulator Installation Pg. 35
Basic TIG Operation Pg. 36-39
Basic Stick/Arc Welding Operation Pg. 40-44
Routine Maintenance Pg. 45
Troubleshooting Pg. 46-47
Enjoy your new welding machine from LONGEVITY
Pg. 48
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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. 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!
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
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160PI/200PI/250PI AC/DC Series IGBT Machines
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 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. 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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160/200/250PI AC/DC Series IGBT Machine
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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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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.
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.
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 it’s 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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160/200/250PI AC/DC Series IGBT Machine
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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 -10C to +40C;
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.
Use a screen or curtain designed to keep passers by from viewing the arc.
The arc spray and metal spray from machine use may cause nearby fires. Use caution.
Ensure proper ventilation through the machine’s louvers. Maintain a distance of at
between this cutting equipment and any other objects in the work area.
If, after reviewing this manual, you have any problems in setting up or operating your machine, contact us at
[email protected].
least 12 inches
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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!
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160/200/250PI AC/DC Series IGBT Machine
Technical Specifications and Ratings
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MODE
160/200/250PI
Units
Type
Parameter
Power Voltage AC220-240V
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
No load Voltage 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
WeldAll® 160PI WeldAll® 200PI
18.9 X 9.4 X 13.0
in.
19.4 X 13.0 X
12.6 in.
WeldAll®
250PI
22.0 X 14.4 X
14.0 in.
AC TIG (GTAW)
DC TIG (GTAW)
Welding Thickness (Steel) .31 in. .39 in. .5 in.
Cutting Thickness (Steel) .63 in. .79 in. .79 in.
Base Current Output Tig
(amps)
AC Balance 30 – 70%
AC Square Wave Frequency 20 – 100 Hz
Rated Duty Cycle at Max
Amps
Arc Starting Mode High Frequency (No Contact Required)
Remote Control/Pedal Yes
Base Current Adjusting Range 5 – 160A 5 - 200A 10 - 250A
Pulse Current Adjusting
Range
Rated Duty Cycle at Max
Amps
20-160A 20-200A 20-250A
60% 35%
5 – 160A 5 - 200A 10 - 250A
60% 35%
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160PI/200PI/250PI AC/DC Series IGBT Machines
DC TIG (GTAW)
AC/DC
ARC/STICK
AC/DC PLASMA
CUTTER
Current Down-Slope Time 0-10 Seconds
Pulse Width Ratio 0.1 – 0.9
Pulse Frequency 0.5-25Hz
Post Flow Time 1 – 25 Seconds
Remote Control/Pedal Yes
Arc Starting Mode High Frequency (No Contact Required)
No Load Voltage 60 – 80V
Base Current Adjusting Range
(Amps)
Rated Output Current (Amps) 160A 160A 200A
Rated Duty Cycle at Max
Amps
Base Current Range (Amps) 20 – 40A 20 – 50A 20 – 50A
Rated Duty Cycle at Max
Amps
5 – 160A 5 – 160A 10 – 200A
60%
60%
Arc Starting Method Pilot Arc (Continuous Arc)
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160/200/250PI AC/DC Series IGBT Machine
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Included Accessories:
S45 Plasma Torch TIG Torch (Compatible with leading brands!)
400AMP Stick Holder Durable Ground Clamp
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160PI/200PI/250PI AC/DC Series IGBT Machines
Included Accessories Continued....
Argon Regulator Foot Pedal With Adjustable Amperage Settings
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160/200/250PI AC/DC Series IGBT Machine
Included Accessories Continued….
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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.
The video is located in the Resources section of the website under manuals and installation/set-up videos.
Connecting the electrical plug to the unit
Connecting the power plug to 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
machine to an electrical power source. Longevity units should be wired by a certified electrician to insure your
safety and a proper 220v plug match at your operating facility. 220v plugs come with 3 or 4 prongs on them.
Have the electrician check your existing receptacle.
Note: The power cord on single-phase machines has one ground wire and two hot wires when connecting to
220vac. Connecting these wires properly is extremely important. Improperly connected wires will void the
warranty, affect personnel safety, and possibly damage your machine and electrical power outlet.
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160/200/250PI AC/DC Series IGBT Machine
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Identifying
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.
Clean the ends of the wires to more easily distinguish the colors. The best and safest way to determine which
wire is ground is to measure the resistance between the machine chassis and the selected 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 wire will cause the meter to
illuminate. If, for any reason, you cannot visually detect the ground wire or do not feel comfortable with your
selection, ask an electrician for help.
Identifying
For 220vac service, both the brown and blue wire are positive wires. As you may know, 220vac features
two hot wires. If you are wiring to 220vac, your blue and brown wires are both hot. The green with yellow
or SOLID GREEN is the ground. Remember, any hot wire can be attached to either hot leg on the plug.
Note: Hot Wires May also be WHITE and BLACK if a GREEN WIRE is one of the three wires. Therefore,
GREEN is ALWAYS GROUND.
the Ground wire
the hot wire
Finished Plug:
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160PI/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.)
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160/200/250PI AC/DC Series IGBT Machine
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Basic Diagram Pictured Model WeldAll™ 200PI (Rear)
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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. Attach
the smaller clear plastic hose provided to the EXIT side of the water separator, leading into the back of
the machine. Secure both lines with quick connects given for assembly with water separator (Standard
quick connect used on inlet side). Set compressor above 75 PSI and set your Air regulator on the
front of the machine to 75 PSI exactly. Proper air pressure is key to cut quality and consumable
life.
2. Periodically, after long periods of use, you must remove water from the water separator by pushing the
bleeder valve inward to release water from the water separator section of the regulator.
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160/200/250PI AC/DC Series IGBT Machine
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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.
OVER CURRENT/OVER HEAT WARNING LAMP: (lightning bolt) 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.
DIGITAL DISPLAY: The display shows the approximate welding amps controlled by base current.
FUNCTION POSITION SWITCH: Selects Stick welding, plasma Cutting, or TIG welding.
AC/DC SWITCH: Use AC for Aluminum and Magnesium, DC for all other metals. Plasma cutting must be
performed in DC mode.
BASE CURRENT.: (Base Current 5-### amps welding, 20-### amps plasma cutting) This is the primary
amperage control for all functions. In TIG pulse mode, this knob sets the base current (low) amperage. For TIG
pulse adjustment, set the Pulse current knob full left, then set the desired base current (low amperage) using the
Base current knob. The digital display will show the amp setting. Next use the Pulse current control to set the
high amperage of the high pulse cycle. As you turn the Pulse current control to the right the digital 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 machine. When the Foot Control is depressed, the welding
current starts. Base Current will increase with pedal depression. In pulse mode, the Foot Control changes both
the base (low) amps and pulse (high) amps, just as turning the Base Current knob would. The Foot Control
Knob can be used to reduce the maximum current allowed by the Foot Control. Example for 200PI: Placing
the knob to the 5 position will limit the maximum amps to approximately 20 amps, the 6 position approximately
50 amps, 7 about 90 amps, 8 about 150, and the 9 position 200 amps. This allows the Foot Control to be less
sensitive.
PULSE ON/OFF SWITCH: Enables pulsed AC and DC TIG welding. Pulse welding is an advanced welding
technique that allows fine control over the welding process. Pulse Mode gives the same effect as quickly
moving the Base current knob back and forth between a low and high amp setting, at a rate that would be
impossible to do by hand. To set the high and low pulse currents, first set the Pulse current knob full left, then
set the desired base current (low amperage) using the Base current knob. The digital display will show the amp
setting. Next use the Pulse current control to set the high amperage of the high pulse cycle. As you turn the
Pulse current control to the right, the amperage on the digital display will increase, showing your pulse peak
amps.
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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. The TIG
pulse frequency controls the number of pulse cycles per second (Hz). Changing the frequency sets the duration
of each pulse cycle, so the lower the frequency the longer the pulse. A higher pulse frequency will give a shorter
pulse cycle. This allows for fine control of heat input into the base metal.
PULSE WIDTH (0.1 to 0.9 or 10-90%): Only active in pulse mode. This TIG pulse control adjusts the relative
amount of time the pulse spends in the peak (high) current stage during a pulse cycle. For example, a control
knob setting of 90% or .9 will give you 90% of the time in the peak (high) current stage and 10% in the base
(low) current stage of the pulse cycle. Note: The Pulse width does not control the overall length of the pulse.
The Pulse frequency sets the cycle length, thereby setting the overall length of each leg of the cycle.
DOWN SLOPE (0-10 seconds): The Down slope time controls the end cycle of the weld by slowly bringing
down the welding current. The down slope helps prevent weld cracking and hole formation in the crater, as the
end of the weld is reached and the torch trigger is released.
AC FREQUENCY. (Alternating Current Frequency 20-100 cycles per second): Only active in AC mode. This
AC TIG & Stick control adjusts the arc frequency. Setting high frequency narrows the welding arc making it
more directional and increasing penetration. Lower frequency widens the arc and shallows the welding puddle.
AC BALANCE (30-70%): Only active in AC mode. 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, particularly in aluminum. More DCEN is preferred for better
penetration and faster travel speed. A 50% setting equalizes the time spent in both. 30% setting is a good
starting point. A higher AC balance setting will clean the weld more but put more heat into the electrode,
reduce this setting if you melt the electrode. For higher AC balance settings use a thicker electrode to keep it
from melting.
POST FLOW (1-25 seconds): This timer controls the flow of shielding gas after the TIG weld arc is
terminated. Not enough post flow can cause weld contamination or torch overheating. During plasma cutting,
Post Flow allows for cooling air to flow after terminating the arc. Keep the TIG torch in position over the weld
until the post flow ends. Five seconds for plasma cutting and 5 to 10 seconds for TIG welding is a
recommended starting point.
4T/2T SWITCH: This switch select is for the control of the TIG weld cycle via the TIG torch trigger. In the 2T
mode, simply touch and hold the trigger to start the arc and continue holding while welding. Release the trigger
to finish. In the 4T mode each push of the trigger toggles between on and off (push and release trigger once to
start, push and release once to stop welding).
PRESSURE REGULATOR: To adjust the pressure regulator, pull the knob out to unlock. Turn the knob left
to decrease the Argon/air flow, or right to increase flow. Both pressurized air for plasma cutting and Argon gas
for welding are affected by this knob. Set regulator to approximately 75 psi. air pressure for plasma cutting.
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160/200/250PI AC/DC Series IGBT Machine
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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.
TORCH CONNECTOR DIN (-): (TIG, Stick or Plasma Cutter) is normally connected to this terminal, 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 receptacle.
PLASMA TORCH PILOT ARC CONNECTOR: The plasma torch's pilot arc wire connects here.
GAS OUTLET: The TIG and plasma torch's gas/air line connect to this receptacle.
GAS INLET: (back of unit) Compressed air for the plasma torch and Argon gas for TIG welding are fed into
the machine using this barbed hose receptacle.
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160PI/200PI/250PI AC/DC Series IGBT Machines
AC DC AC DC
Gas used
N/A N/A Argon Argon Compressed Air
purge hose with Argon using trigger on gun before beginning TIG welding
Gas pressure/flow
DC AC DC DC
Normally set to 2T where trigger pulled = on, released = off. Setting to 4T causes the trigger switch
Gas Preflow
appropriate zero
foot pedal
Base Current
Gas Post Flow
Strength
Electrode Chart Examp
le: E 60 1 3
Weld Position
workpiece should
2-4 mm, either set
tungsten and
lower current if
cut is
too wide. Air flow
Weld Characteristics
Polarity Definition
Stick (SMAW)
Process used for
Slope Down Control
Pulse Frequency
Pulse Duty
Welding Method
Steel, Aluminum Steels
Torch used
Proces
s
ARC/TIG/Plasma
Settings
Switch
Current (Amps)
Settings
Dial
Electrode Clamp Electrode Clamp
tungsten
AC/DC
4T/2T
Pulse
Arc Force
N/A
N/A
ARC
AC
N/A
N/A
N/A
0-200 Amps as appropriate for 0-200 Amps as 0-200 Amps as appropriate for
appropriate for workpiece/ appropriate zero
workpiece/
electrode
N/A
N/A
set 0-100%
N/A
N/A
Ceriated (grey)
N/A
N/A
ARC
N/A
N/A
N/A
0-200 Amps as
electrode for foot switch foot switch
N/A
N/A
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.
N/A
N/A
ball/flat end
10-25 cu-ft/hr
2T see note 2T see note 2T see note
appropriate appropriate
set 0-10 sec set 0-10 sec
60--60,000 psi,
3--Non-low hydrogen, AC or DC Either polarity
4--Non-low hydrogen, iron powder coating, AC or DC Reverse polarity
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5--Low-hydrogen, DC Reverse polarity
8--Low hydrogen, iron powder coating, AC or DC Reverse polarity
electrode negative =straight polarity (typical stock machine setup)
Clear Width
Set 20-80%,
neutral
set to 50%
Notes
requires slag
removal
with chipping
hammer, use AC for
less spatter
(depends
on electrode
chosen)
N/A
N/A
N/A
requires slag
removal 5356 filler rod, current or use foot damage to tip. Tilt 0--Non-low hydrogen, DC Reverse polarity
with chipping
hammer
Set 1-10 sec Set 1-10 sec Set 1-10 sec cut work pieces and plasma torch parts.
Distance between
tungsten and
current or use
pedal recommend 2-4 mm, either set critical to prevent
remember to
TIG (GTAW)
Aluminum
TIG
tungesten,
start
at 20
TIG
select as
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.
N/A
N/A
N/A
Set 20-80%
foot
allow
post flow allow post flow
Steel, Stainless
Steel
TIG
Ceriated/thoriate
d, (red or grey)
sharp tip
10-25 cu-ft/hr
start
at 20
TIG
select as
for
set 20-90%
Set from 0.3 to
200
pulses/sec
set 10-90%
N/A
70--70,000 psi
be Distance between
workpiece should
be
pedal remember
to
Plasma
Cutting
Cutting any
contuctive
material AC TIG preferred for Aluminum, DC TIG/Stick preferred for Steels
Plasma Ground cable and clamp used for all. Plasma and Tig Torch share connections welding unit.
40-70 PSI
start at 65 psi Start with Argon at 18 CFM for TIG. Start with compressed air at 60-75 psi for Plasma
Plasma
0-50 Amps as
workpiece/
electrode
nozzle to start
in thicker
materials.
Grey is typically for aluminum. Red usually indicates 2% thoriated for steel and stainless steel.
N/A Sharpen to point grinding axially with taper with length of taper = 2.5 x Diameter
select welding type
desired
select DC or AC welding current
to latch on until
triggered a second
time
While in DC/TIG mode this switch will provide pulsed DC or constant DC. It switches between the
peak current and
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
Set current as recommended for material and thickness. If using foot pedal set to zero -adjusts current
Only active when set to "Pulse" in DC/TIG mode. Sets lower (trough/valley) current (percentage
of the "current"
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
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.
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/arclength dependent
N/A Adjusts pulse frequency from 0.5 to 200Hz. Only active when set to "Pulse" in TIG mode.
Only active when set to "Pulse" in TIG mode. Sets width of AC/DC Pulse from 10 to 90% of each
AC/DC pulse cycle.
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
on. High is 80% positive on. Large current small clear width and vice versa. This setting
depends on weld
penetration needed (current), tungsten diameter, gas flow (tungsten cooling), and existing
N/A
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
1--All positions: Flat, Vertical, Horizontal, & Overhead
2--Flat Position or Horizontal Fillets Only
is
hole
3--Flat Position Only
1--Non-low hydrogen, AC or DC Reverse polarity
2--Non-low hydrogen, AC or DC Straight polarity
6--Low-hydrogen, AC or DC Reverse polarity
7--Non-low hydrogen, iron powder coating, AC or DC Reverse polarity
Notes
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160/200/250PI AC/DC Series IGBT Machine
Plasma Cutter: Plasma Cutter Torch Assembly
www.LWELD.com
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. Secure all parts into place by turning the ceramic cup
clockwise until it is snug. Do not over tighten.
Page 24
160PI/200PI/250PI AC/DC Series IGBT Machines
after you read the manual and before you get started. Below are a list
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. Naturally, it is easy to understand how excited you
would be to see the delivery truck pull up with your brand new
Longevity Plasma Cutter and you should be. Congratulations is in
order and we want to ensure you have the best experience with your
Longevity Plasma Cutter. However, excited as we are you can't wait
to put your Longevity Plasma Cutter into action, we would like you
to consider these helpful tips and examples that will enable you to
get the most out of your Longevity Plasma Cutter and it's
consumables. So, before using your Longevity Plasma Cutter it is
extremely important to read the owner's manual all the way through
regardless of your experience level. Even if you are a seasoned
veteran, 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 assume that you have purchased the Longevity
Plasma Cutter that is right for you, and even though you did your
research already, it is always a good idea to revisit the safety
precautions, specifications and unique options ensuring you achieve
the most with your Longevity Plasma Cutter while staying safe. In
case you have not decided which Longevity Plasma Cutter is right
for you, please visit the Help Me Choose section and take advantage
of the Longevity Smart Selector.
In terms of safety, the price of carelessly cutting corners can be
extremely costly, not only to your health but to the people around
you as well. So, before you get started using your Longevity Plasma
Cutter to create your master piece, build a bridge, or whatever you
want to do, make sure you have a quality safety checklist you follow
of tips and safety measures you might find useful in developing your
safety checklist. Remember, in no way shape or form does this
checklist or any other check list ever replace the necessity of
thoroughly reading the owner's manual of your Longevity Plasma
Cutter.
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160/200/250PI AC/DC Series IGBT Machine
Cutter and consult your owner's manual to ensure the
Pilot Arc or High Frequency technology, comes with
make sure all of your consumables are clean, correct,
Now you are ready to use your Longevity Plasma
Check List Suggestions
Connect the air supply to your Longevity Plasma
correct PSI. The PSI is about 65-75.
Each Longevity Plasma Cutter, regardless if it uses
www.LWELD.com
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.
Check the torch of your Longevity Plasma Cutter
and make sure everything is in order. Reference the
owner's manual of your Longevity Plasma Cutter to
and pieced together securely before you begin
cutting.
Gouging or piercing can be achieved by simply
lowering the amperage output and keeping with the
recommended psi. Examples on how to achieve the
desired results can be referenced in the owner's
manual of your Longevity Plasma Cutter.
Cutter safely and efficiently. Turn the machine on
and enjoy the satisfying experience of a quality
Longevity Plasma Cutter.
Double check your air supply, air flow regulator and
water filter. (More on this below.)
All Longevity Plasma Cutters require a solid ground
connection as close to the work piece as practical.
Remember, even though your Longevity Plasma
Cutter can cut through paint and other coatings on
the metal, the ground connection requires a clean,
flush connection to the work piece.
Utilizing the proper safety equipment is just as
important as understanding how to properly operate
your Longevity Plasma Cutter. Consult the owner's
manual of your Longevity Plasma Cutter to be sure
you are using the correct gloves, eye protection,
welding leathers, face shield, etc. You can find all of
the necessary equipment as stated in the owner's
manual of your Longevity Plasma Cutter in the
accessories section of our website.
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160PI/200PI/250PI AC/DC Series IGBT Machines
your Longevity Plasma Cutter
Longevity Plasma Cutter Tips
In order to successfully execute a clean cut with your Longevity
Plasma Cutter you must consider a combination of elements involved
in the cutting process:
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. If you are going to be cutting for a large
piece of metal, it can sometimes be difficult for even
the most experienced metal worker to cleanly stop
and start. We recommend you use the sample cut to
thoroughly rehearse the intended cut with your
Longevity Plasma Cutter.
The tip of your torch is designed to focus the plasma stream to the
work piece in accordance with the appropriate setting (see owner's
manual). Trying to use 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 abuse your torch tip and require it to be
replaced sooner than intended.
When cutting a thicker material with
it is important to use a torch tip designed for a higher-amp output.
Higher-amp tips have a larger opening than lower-amp tips.
Attempting to use a 40-amp tip to cut thick metal with a higheramp output will distort your 40-amp tip meaning it will need to be
replaced.
Each Longevity Plasma Cutter, both Pilot Arc and High Frequency
, allow you to cut different metals at different speeds. For example
to achieve a quality cut of 1/2in. thick steel with the Longevity
Force Cut LP-40D Pilot Arc your speed will be roughly 7 inches
per minute. Where as the Longevity Force Cut LP-80D will cut
1.25in. thick steel at the same rate.
Use extended tips on your Longevity Plasma Cutter for tough to
reach corners, tracing a pattern, or areas with tight spaces.
Pilot Arc technology allows you to ignite the arc without the tip
touching the metal. Use a torch guide or tip shield to protect your
consumable. The more often you drag your torch tip across the
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160/200/250PI AC/DC Series IGBT Machine
estart the Pilot Arc, the shorter the life span of
*
your Longevity Plasma Cutter torch tip. In order to maintain the quality
and take advantage of the protective gear you have like our guys on the
again. So, in situations when you are going to be cutting thick metals at
high amperage with your Longevity Plasma Cutter, we recommend you
material or stop and r
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.
The important things to consider while using your Longevity Plasma
Cutter to cleanly execute a cut is correct amperage of the torch tip,
thickness of the material, intended speed, proper technique, and
ultimately protecting the life of your consumables.
Cutting Posture
Sometimes you may find that you are unable to use a guide or shield
when operating your Longevity Plasma Cutter. In some instances a
project may be a very ornate design with different curves and
protrusions or the material is too thick to apply a shield or guard to
and consistency of your work we recommend that you use your other
hand as a guide. Give yourself a fighting chance to steady your hands
www.LWELD.com
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 you are cutting.
If you stop and start an arc in the middle of a cut, often the quality of
your cut will suffer and compromise the integrity of your so far clean
cut-line. Remember, even when we do facility testing, a suitable
method to apply when using your Longevity Plasma Cutter is
rehearsing the cut. Be sure you are going to be able to produce a
smooth continuous cut-line all the way through.
Along with rehearsing your cut, another equally good reminder is to
protect your consumables as much as possible. Often we can get
comfortable piercing right through thin steel with our Longevity
Plasma Cutters, but when cutting thicker metal often the intense back
splash from initial contact will rapidly wear down your torch tip and
other consumables. Even though the seeing the bright sparks show off
the awesome power of your Longevity Plasma Cutter, remember we
want you to be able to enjoy the results of your work time and time
start with the torch pointed at a 45 degree angle. This angled approach
allows for the first blast of metal to be released with out back splash on
to your valuable consumables.
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160PI/200PI/250PI AC/DC Series IGBT Machines
you move on a material such as aluminum, the cleaner your cut will be.
accordingly. Thin material requires you to turn down the amperage and
st can be a daunting task
20 degree angle,
be wary of the torch tip because of electrical conductivity of aluminum.
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
Conversely, when using your Longevity Plasma Cutter to cut thicker
material, set your unit to full output and vary your travel speed
change to a lower-amperage to achieve a narrow kerf.
Figuring out if you are going too slow or too fa
that really only comes with time and experience. However, our guys in
the Longevity Facility Testing Team have a few pointers for you:
If your cut has a lot of spray back then you are probably going
too fast.
If the arc exits the material going straight down then you are
probably moving too slow and you will have an unnecessary
buildup of "dross" or "slag."
Your arc should be exiting the material at a 15 but opposite the direction of your cut path.
Using A Cutting Guide
First thing in using a torch guide with your Longevity Plasma Cutter is
make sure it isn't flammable! Aluminum works as a great torch guide,
but be sure it is attached to the torch cup and not the torch tip.
Aluminum is a great contact guide because of it's smooth surface but
It would be a terrible mess of a cut, loss of consumables, and overall
depressing mistake if your torch guide melted to the torch tip or the
project at hand. Next you want to mark the material to be cut with
either white chalk or a black marker. If you are unsure of how steady
your hands are, we recommend you try using a straight edge clamp
attached to the work piece or torch guide.
All articles are composed by the Longevity Facility Testing Team and
are written with expressed interest of maintain a strong standard in
Longevity Global Inc. quality, to help address topics, and answer
questions for amateur and experienced users alike. Please remember to
always exercise extreme causation and abide by all provided safety
specification.
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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:
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160PI/200PI/250PI AC/DC Series IGBT Machines
Sample Photo:
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160/200/250PI AC/DC Series IGBT Machine
TIG Function: Setting Up The TIG Torch
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160PI/200PI/250PI AC/DC Series IGBT Machines
with LONGEVITY DC TIG. It is generally utilized for DC welding of mild steel, bronze, and stainless steel and
low level radiation hazard and the fact that they no recommend to weld aluminum. We recommend this tungsten
ngsten requires less amperage to start so it is recommended for thinner metals. It offers a stable arc and can be
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. This leaves you with a variety sizes ranging from
1/16 to 1/8” and the types of tungstens such as the Pure Tungsten (TP), 2% Thoriated Tungsten (TT2), 2%
Ceriated Tungsten (TC2), and 2% Lanthanated Tungsten (TL2). Fortunately, LONGEVITY offers high quality
tungsten electrodes and explains which tungsten is required for the right application. Pure Tungsten (TP) –
(green tipped) - Pure tungsten readily forms a ball on the end. It is designed for use with transformer-based
power sources for AC welding of aluminum. Unfortunately, LONGEVITY does not carry transformer based
technology considering the size and weight of TRANSFORMER welders. Therefore, this tungsten is rarely sold
buy our sales staff
2% Thoriated Tungsten (TT2) – (red tipped) - This tungsten is the most common tungsten currently being used
basically all metals except aluminum and offers excellent performance. A drawback is that this tungsten has a
with our stand alone DC only TIG Welders, our WeldMax series multi-purpose welders, which feature DC TIG
welders. The 2% Thoriated Tungsten works well with Inverter Welders
2% Ceriated Tungsten (TC2) – (grey/orange tipped) – 2% ceriated is an excellent substitute for 2% thoriated
tungsten and is designed for transformer and inverter based power sources. For Transformer DC welding, this
tu
used for both AC and DC welding with inverter power sources and is our most popular sold tungsten because it
can be used to weld every type of metal in both AC / DC modes in our LONGEVITY INVETER TIG welders.
We recommend this unit with our ArcMate 200AMP ACDC TIG/STICK unit or our WeldAll series multi
functional welders and plasma cutters because of the versatility of AC DC welding.
2% Lanthanated Tungsten (TL2) – blue tip – 2% lanthanated is probably the most popular substitute for 2%
thoriated tungsten. Offering a longer life span than the 2% thoriated tungstens, it is a nice a nice alternative, but
not as recommended as our 2% Thoriated Tungsten. This tungsten can be used with both transformer and
inverter technology on both AC DC modes.
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160/200/250PI AC/DC Series IGBT Machine
or you can simply use a grinding wheel to sharpen your tungsten. Remember,
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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
Amperage-AC
TL2-7040 TL2-7116 TL2-7332 TL2-718
20-30 30-80 60-130 120-200
Amperage-DC 15-50 50-120 80-150 130-250
Sharpening a Tungsten
Sharpening a tungsten is very important for a nice fine arc strike. There are auto sharpeners to place the perfect
sharpening point on your tungsten
after sharpening to a pencil point, you want to flatten the bottom for a good arc.
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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.
Part # Application:
4043-1/16-1 4043 Alloy Aluminum Wire 1/16" X 36"
4043-3/32-1 4043 Alloy Aluminum Wire 3/32" X 36"
5356-1/16-1 5356 Alloy Aluminum Wire 1/16" X 36"
5356-3/32-1 5356 Alloy Aluminum Wire 3/32" X 36"
308L-035-1 308L Stainless Steel Wire .035” x 36”
308L-1/16-1 308L Stainless Steel Wire 1/16" X 36"
70S6-1/16-1 ER70S-6 Steel Wire 1/16" X 36"
70S6-3/32-1 ER70S-6 Steel Wire 3/32" X 36"
70S2-1/16-1 ER70S-2 Steel Wire 1/16" X 36"
80SD2-1/16-
1
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 your weld.
ER80SD-2 Steel Wire
E1/16" X 36"
Your choice of filler rod is extremely important to the strength and matter density of your weld. You can
determine the diameter of the filler rod needed, by the thickness of the material that you will be welding. Here
are some pointers in deciding how to choose the correct filler rod for your weld.
1. 4043 is a general filler rod for most aluminum welding.
2. 5356 is perfect for 5xxx series aluminum. If you are planning on anodizing the finished piece, this rod
should be used for the weld.
3. ER70S-6 is designed for welding mild steel.
4. ER70S-2 is recommended for welding 4130 chrome moly tubing in most applications.
5. ER80S-D2 is for welding 4130 chrome moly tubing if a higher strength weld is required.
6. 1/16” diameter filler rod 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.
You can find more discussions on filler rods at our welding forum via this link.
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160/200/250PI AC/DC Series IGBT Machine
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.
Refer to past image:
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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. Remember, that you also have
a post flow setting on the unit to pass more argon after the arc to cool the electrode.
Argon Regulator Assembled
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160/200/250PI AC/DC Series IGBT Machine
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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., AC balance (start adjustments
around 30%). Post flow 5-10 seconds, Pulse Mode off.
AC TIG Pulse (Aluminum & Magnesium): Select TIG on the function switch. The AC function will be
required for aluminum welding. Pulse Mode will be set to on. Set the Pulse cur. knob to full left, then the
desired low amperage using the Base cur knob. Now adjust the high amperage using the Pulse cur. knob, Pulse
frequency, Pulse width, AC frequency, AC balance (start adjustments around 30%). Post flow 5-10 seconds.
DC TIG: Select TIG, DC, Pulse Mode off, desired amps using Base cur knob, Post flow 5-10 seconds.
DC TIG Pulse: Select TIG, DC, Pulse Mode on, set Pulse cur. knob to full left, then the desired low amperage
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:
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 Ceriated tungsten (grey or orange) for TIG welding with our AC/DC TIG
welders. Ceriated tungsten’s will work for both AC and DC welding. Use smaller diameter electrodes for
thinner metal (low amperage), thicker electrodes for thicker metals that require more amperage. When using a
higher AC balance setting in AC mode, a thicker electrode will be required due to more heat moving into the
electrode. For the right tungsten electrode, please refer to earlier in this manual or go to www.longevity-
inc.com
Filler Rod Selection: Depending upon the metal to be welded, filler rod selection is critical. Consult with your
local welding supplier for the optimum filler rod to properly complete the weld. In certain applications, TIG
welding can be performed without the use of a filler rod. Use a 5356 filler rod for most Aluminum. For more
detailed Filler Rod info, please read the filler section of this manual or go to www.longevity-inc.com.
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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. Sharpening an electrode consistently will cause an unstable, wandering arc, making it
more difficult 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 generally
recommended for most DC welding applications. For high amperage DC welding, do not over sharpen the
point, but leave a slight truncation on the end of the tungsten. This prevents the tungsten tip from breaking away
and falling into the weld. AC TIG welding may cause a formation of a ball to develop on the end of the
tungsten. This is normal. However, if a large globular ball begins to form, re-sharpen the tungsten and adjust the
AC balance. It is also normal for a slight dome to form on the tungsten in DC mode. However, if the arc
becomes erratic or the arc is difficult to start, regrinding the tungsten will be necessary. If the tungsten is
accidentally dipped into the weld puddle, regrinding the tungsten will be necessary to eliminate contamination,
particularly on aluminum. Grind tungsten’s only on a dedicated stone, free of contamination from other metals.
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. Set the machine for TIG operation then select the desired amperage. Grasp the torch in a manner that is
comfortable 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 the high
frequency arc. A small blue glowing cone may be observed. This is the high frequency arc. Immediately after
that, you should see a strong and stable arc flowing from the torch. As the arc begins to grow, a molten puddle
will appear. If it does not appear, stop your weld and increase the amperage. Repeat the start sequence.
1. To help the molten puddle form, slowly make small circles with the torch to build the heat in the weld area. A
bright, fluid puddle will begin to form.
2. Once a uniform puddle is established, tilt the torch head about 75 degrees from the weld surface into the
direction of the weld. This will direct the arc to the front of the weld puddle.
3. Grip the filler rod at a 15 degree angle to the weld surface with the other hand. Hold the rod in the iridescent
cone of gas that surrounds the weld puddle. Do not hold it in the arc. Keep it close to the weld. A “skeleton”
keyhole will begin to form in front of the weld. The keyhole is evidence that you are ready to add filler material
and move forward. Introduce the filler 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 cone. The molten
drop of filler metal should blend quickly into the puddle.
5. Move the torch forward slightly, carrying the keyhole with the weld. If the key hole is lost, then forward
travel was too fast or too far. When the keyhole shows good development, repeat the steps 3-5 until you have a
proper weld bead established.
6. Weld termination. When the weld bead has reached the desired length, add a final drop of filler and slowly
circle the torch over the end of the weld to fill the crater. If the weld crater is not correctly filled, cracking and
weld failure may occur. This is a small but important step to properly completing a weld. Release the foot pedal
or release the trigger to stop. Keep the TIG torch in place until the post flow ends--usually around 5 seconds.
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160/200/250PI AC/DC Series IGBT Machine
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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. When an arc is too short, it fails to generate enough heat to melt the base metal
properly, causes the electrode Setting the length of an arc to stick frequently to the base 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.
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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. In either position, a shorter arc is desirable because it gives better control of the molten puddle and
prevents atmospherical impurities from entering the weld.
Sample of a quality stainless steel weld:
TALLATION
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160/200/250PI AC/DC Series IGBT Machine
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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.
AC Stick - (Aluminum) Select Stick, AC, desired amps using Base current knob, Pulse Mode off, AC frequency.
AC Balance (start at approximately 30%)
1. Insert electrode into electrode holder. Position the electrode for the most comfortable position so that the
electrode can be held directly over the work piece with a slight angle.
2. Set Amperage to the recommended amperage by the electrode manufacturer. Strike an arc by swiping it briskly
across the work piece in the same manner as one would strike a match. Alternatively, you may strike an arc with
firm tapping motion against the work piece. Either method is acceptable. An arc should initiate. Continue to keep
the arc going by holding the electrode off the work piece no more than the electrode width.
3. Continue the arc by feeding the electrode into the weld puddle while moving the electrode forward. This will
take some coordination, but will be fairly easy to do after practice. Do not allow the arc to become too long,
because air and slag can 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 stick to the work piece. If the electrode sticks, immediately release the electrode from the electrode
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 atmosphere or the weld will fail.
4. Use the Basic Current control to change arc qualities. Adjust the amperage according to the recommendations
of the electrode (welding rod) manufacturer for the type and size of the electrode used. When welding in the AC
mode the AC Frequency control will affect how crisp the arc is, whether it is smooth and buttery or deeply
penetrating. Use it to suit the desired weld finish. Experimentation will be required to find the optimal setting
desired. It is an excellent tool for out of position welding.
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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. Each
manufacturer has their individual name and terminology as well. As there is no general recommendation that can
be made about a particular electrode selection, except for practice welds, a electrode designated by the AWS as E
6011, E 6013, E 7014, or E 7018 may be used, each having its own distinct features and purpose. These are
among the most common electrodes used in the industry and are not difficult to find. E 6011 electrodes are not as
smooth running as some of the other electrodes, but offer the advantage of being able to weld on rusty metal and
contaminated surfaces. It is widely used and requires very little skill to begin using. This is not a particular
endorsement of an E6011, rather a simple example of what may be used in developing proficient technique. It is
recommended that a variety of electrodes be used and practiced with. Consultation with an experienced local
welding supplier will help greatly in determining what welding electrode is the best for your given situation.
Many times, samples or small packages of electrodes are available at relatively low cost to determine for yourself
the best electrode to use.
Stick Electrode Chart Example: E 60 1 3
Strength
60--60,000 psi,
70--70,000 psi
Weld Position
1--All positions: Flat, Vertical, Horizontal, & Overhead
2--Flat Position or Horizontal Fillets Only
3--Flat Position Only
Weld Characteristics
0--Non-low hydrogen, DC Reverse polarity
1--Non-low hydrogen, AC or DC Reverse polarity
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)
electrode positive = reverse polarity
Be sure to observe the electrode manufacturer recommendations regarding polarity. If the weld appears lumpy,
porous or otherwise malformed, change the polarity of the ground cable and the 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
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160/200/250PI AC/DC Series IGBT Machine
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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. If it is possible, with any practice weld,
cut the joint down the middle, lengthwise, or place the weld in a vice and use a hammer to bend the metal over the
weld area until it is either broken or bent 90 degrees. This destructive testing method will help you improve your
skill by revealing faults and flaws in your welds.
Stick (SMAW)Electrode Welding
Stick, the most basic of welding processes, offers the easiest option for joining steel and other metals. Although
it produces the least pretties or cleanest welds, ARC/STICK welding gets the job done! Stick welding power
sources deliver inexpensive options for welding versatility, portability and reliability. Stick joins metals when
an arc is struck between the electrode and the work piece, creating a weld pool and depositing a consumable
metal electrode into the joint. The electrode's protective coating also acts as a shielding gas, protecting the weld
and ensuring its purity and strength. Best for windy conditions and adverse environments.
If you’re not familiar with Stick (SMAW) welding basics, the following information can make choosing
an electrode easier.
AWS
Class
E6010
E6011
E6013
E7014
E7018
E7018AC
Position
Polarity Usage
All DCEP
All AC,DCEP
All AC,DCEN,DCEP
All AC,DCEN,DCEP
All DCEP
All AC,DCEP
A great choice for welding on dirty, rusty, greasy or
painted steel - especially in vertical or overhead
applications.
All-purpose stick electrode; used for carbon and
galvanized steel; 60,000 PSI tensile strength; deep
penetration and ideal for welding light to medium
amounts of dirty, rusty or painted materials.
Light to medium penetrating all-purpose stick
electrode; for use on carbon steel; 60,000 PSI tensile
strength; good for general all-purpose applications
and joints with poor fit-up.
For higher-deposition requirements; 70,000 PSI
tensile strength; ideal for applications requiring light
penetration and faster travel speeds.
Low-hydrogen electrode; for low, medium and high-
carbon steels; 70,000 PSI tensile strength; ideal for
out-of-position welding and tacking; not
recommended for low-voltage AC Welders.
Low-hydrogen electrode; for low, medium and high-
carbon steels; 70,000 PSI tensile strength; ideal for
out-of-position welding and tacking; specially
formulated to operate with small 208/230 volt AC
welders.
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160PI/200PI/250PI AC/DC Series IGBT Machines
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160/200/250PI AC/DC Series IGBT Machine
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. Stick welders come in two basic
classifications; 115V stick welders and 230/460V
stick welders. Stick Electrodes or welding rod for
stick welding are available in stainless steel, carbon
steel, low alloy steel, maintenance alloy, hard facing,
nickel alloy, and magnesium
www.LWELD.com
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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.
Do not walk on or store items on the cables or cords.
Do not jar, drop, or stack items on top of the machine.
Always connect the machine to a well grounded electrical outlet.
Always check the torch consumables before and after use and ensure that they are clear of obstructions,
and that no parts are damaged.
Replace any worn or damaged consumables before using machine.
For periods of prolonged non-use, remove cables and store them in their original boxes in a cool dry
place, free of bug infestation.
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160/200/250PI AC/DC Series IGBT Machine
Problems, Causes, and Solutions
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
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. Over
Current LED
Lights
Issue Not Listed
Unit Will Not
Weld
Tungsten is
Melting or Being
Consumed
Quickly
Contaminated
Tungsten
Poor Weld Quality
Causes/
Solutions
Check cords and breaker. If nothing is found, contact
LONGEVITY
Check to see if you are in the right mode, plasma cutter, tig,
stick. Check the torches and your ground. Make sure there is argon
or compressed air for plasma and tig.
Check the ground connection. Check the torch for proper
consumables installation. Replace consumables.
Improper air/gas flow. Increase the PSI on the regulator, check
for leaks in the hose, maintain a distance of 1/8” from the torch tip
or workpiece
Slow travel speed. Increase travel speed or amperage on unit.
Check Air Pressure. Insure your unit is capable of cutting the
desired thickness of material. Check the consumables to insure they
are producing a stable arc. Replace Consumables and insure you
have the proper PSI at the regulator.
Improper grounding or possible lack of air pressure. Check and
replace consumables and adjust the regulator to proper PSI
The unit has reached its DUTY Cycle. Leave power of the
machine on and allow fans to cool the machine. You can also turn
the machine off to properly cool it. Do not continue to weld until
light is off.
Contact LONGEVITY Toll Free 1-877-566-4462 or via email at
Check ground connection, torch setup, and check if you are in
the proper mode ARC/TIG. If you are TIG Welding check to see if
you have the proper TUNGSTEN and FILLER ROD.
Low Argon Gas flow. Check the Argon Gas flow. Turn up post
flow. Incorrect Tungsten or Incorrect Tungsten Size. Possible
small size shield cup. Read selecting the right tungsten on
www.longevity-inc.com/resources
If the Tungsten is dipping or melting inside the weld. Use
larger tungsten and fewer amps on the unit. Sharpen tungsten.
Remember to clean welding material prior to welding with
acetone. Practice on the form and technique. Use the right tungsten
and filler rod.
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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
Causes/
Solutions
Check the ground. Check the work piece and clean it. Decrease
amps.
Use the proper rod and polarity.
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160/200/250PI AC/DC Series IGBT Machine
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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
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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