Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Longevity 160
Summary of Contents for Longevity 160
- Page 1 Operating Manual 160 and 205 IGBT MIG Welder/ARC Welder...
-
Page 2: Table Of Contents
PG. 20: Main Unit Knob/Button/Function PG. 21: Welding Wire Installation PG. 22: Setting Up Argon Regulator PG. 23-29: MIG Welding Process PG. 30-35: Stick/ARC Welding PG. 36: Routine Maintenance PG. 37: Enjoy your new welding machine from LONGEVITY! Page 1 of 37 www.longevity-inc.com... - Page 3 160/205 MIG Welder/ARC 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.
- Page 4 Dealers: dealers@longevity-inc.com Complaints: complaints@longevity-inc.com 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 Page 3 of 37 www.longevity-inc.com...
- Page 5 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/...
- Page 6 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.
- Page 7 160/205 MIG Welder/ARC Welder 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.
- Page 8 160/205 MIG Welder/ARC Welder 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.
- Page 9 160/205 MIG Welder/ARC 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.
-
Page 10: General Description
This machine is competitively priced, including a free 5 Year parts and labor warranty! Please contact LONGEVITY customer service toll free 877-566-4462 for more details on this model or the product of your choice! Page 9 of 37... -
Page 11: Specifications And Ratings
160/205 MIG Welder/ARC Welder Specifications and Ratings Parameter Specifications and Ratings Model Input Voltage 1 phase 220v ; 50/60hz Input Current 22amps 35amps Rated Input Power 4.8 KVA 7.7 KVA No Load Voltage 55~75V Current Output Range (MIG) 30-160Amps 40-200Amps... -
Page 12: Included Accessories
160/205 MIG Welder/ARC Welder Included Accessories: ArcMate MIG Welder / Stick welder MIG Torch with contact tips (10ft.) Earth/Ground Clamp (10 ft.) 300amp Stick holder (10ft.) Hose for argon hook up 220V Power Plug For Power Cord (110v will work on a model that specifies 110v/220v on... - Page 13 160/205 MIG Welder/ARC Welder Included Parts Continued... Durable Ground Clamp Gas Hose for Connection to Machine 220V Power Plug for Power Cord Page 12 of 37 www.longevity-inc.com...
- Page 14 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.
- Page 15 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.
- Page 16 160/205 MIG Welder/ARC Welder Basic Diagram Pictured Model ArcMate™ 160 (Note: All IGBT ArcMate series machines have same function adjustment knobs and settings at different amperage ratings and positions on front panel.) Page 15 of 37 www.longevity-inc.com...
- Page 17 160/205 MIG Welder/ARC Welder Basic Diagram Pictured Model ArcMate™ 160 (Rear of Unit): Page 16 of 37 www.longevity-inc.com...
- Page 18 160/205 MIG Welder/ARC Welder Basic Diagram Pictured Model ArcMate™ 160 (Internal Wire Feed Compartment): Page 17 of 37 www.longevity-inc.com...
- Page 19 160/205 MIG Welder/ARC Welder Reversible Internal Wire Size Selector Ring: 0.8mm (.030”) Side of Wire Size Selector Ring Side View Showing Grooves for 0.8mm and 1.0mm Wire Size Page 18 of 37 www.longevity-inc.com...
- Page 20 160/205 MIG Welder/ARC Welder 1.0mm (.035”) Side of Wire Size Selector Ring Page 19 of 37 www.longevity-inc.com...
-
Page 21: Recommended Optional Accessories
160/205 MIG Welder/ARC Welder Recommended Optional Accessories: Argon Regulator for Gas Bottle! SpeedAdjust 8M Spool Gun for Welding Aluminum or Stainless! Page 20 of 37 www.longevity-inc.com... -
Page 22: Main Unit Knob/Button/Function
7 MIG/Stick Selector Switch: Toggle switch for MIG or Stick setting. 8 Spool Gun Connection: LONGEVITY offers an optional 8 meter speed adjustable spool gun for the MIG welder function of this machine. This option will allow you to weld aluminum and stainless steel. -
Page 23: Welding Wire Installation
160/205 MIG Welder/ARC Welder Welding Wire Installation: Open the wire feed compartment and locate the wire spool mount assembly shown on internal wire feed compartment diagram on page 12. Remove the Wing nut to from the wire spool mount assembly and remove the round collar plate. Locate the end of the wire on the spool and mount the spool so that it runs counter clockwise into the wire feed inlet of the wire feeder mechanism. -
Page 24: Setting Up Argon Regulator
160/205 MIG Welder/ARC Welder Setting Up Argon Regulator: The argon regulator pictured below is a standard size regulator for most argon tank setups. Setting it up to your argon bottle is easy. Simply screw in the valve fitting securely to the gas bottle. -
Page 25: Mig Welding Process
160/205 MIG Welder/ARC Welder MIG Welding Process Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun. - Page 26 160/205 MIG Welder/ARC Welder Welding gun and wire feed unit GMAW torch nozzle cutaway image: (1) Torch handle (2) Molded phenolic dielectric (shown in white) and threaded metal nut insert (yellow) (3) Shielding gas diffuser (4) Contact tip (5) Nozzle output face A GMAW wire feed unit The typical GMAW welding gun has a number of key parts—a control switch, a contact tip, a...
- Page 27 160/205 MIG Welder/ARC Welder The wire feed unit supplies the electrode to the work, driving it through the conduit and on to the contact tip. Most models provide the wire at a constant feed rate, but more advanced machines can vary the feed rate in response to the arc length and voltage. Some wire feeders can reach feed rates as high as 30.5 m/min (1200 in/min), but feed rates for semiautomatic GMAW typically...
- Page 28 160/205 MIG Welder/ARC Welder contain deoxidizing metals such as silicon, manganese, titanium and aluminum in small percentages to help prevent oxygen porosity. Some contain denitriding metals such as titanium and zirconium to avoid nitrogen porosity. Depending on the process variation and base material being welded the diameters of the electrodes used in GMAW typically range from 0.7 to 2.4 mm...
- Page 29 160/205 MIG Welder/ARC Welder held the same. As the carbon dioxide content increases over 20%, spray transfer GMAW becomes increasingly problematic, especially with smaller electrode diameters. Argon is also commonly mixed with other gases, oxygen, helium, hydrogen, and nitrogen. The...
- Page 30 160/205 MIG Welder/ARC Welder Operation GMAW weld area: (1) Direction of travel (2) Contact tube (3) Electrode (4) Shielding gas (5) Molten weld metal (6) Solidified weld metal (7) Work piece For most of its applications gas metal arc welding is a fairly simple welding process to learn requiring no more than a week or two to master basic welding technique.
- Page 31 160/205 MIG Welder/ARC Welder of shielding gas used—with pure inert gas’s, the bottom of the torch is often slightly in front of the upper section, while the opposite is true when the welding atmosphere is carbon dioxide. Quality Two of the most prevalent quality problems in GMAW are dross and porosity. If not controlled, they can lead to weaker, less ductile welds.
-
Page 32: Stick/Arc Welding
160/205 MIG Welder/ARC Welder STICK/ARC 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). - Page 33 160/205 MIG Welder/ARC Welder 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.
- Page 34 160/205 MIG Welder/ARC Welder 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. Keep the welding electrode or the TIG tungsten and welding arc within the weld joint to prevent overlap.
- Page 35 160/205 MIG Welder/ARC Welder 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.
- Page 36 160/205 MIG Welder/ARC Welder Page 35 of 37 www.longevity-inc.com...
- Page 37 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.
-
Page 38: Routine Maintenance
160/205 MIG Welder/ARC Welder 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. -
Page 39: Enjoy Your New Welding Machine From Longevity
160/205 MIG Welder/ARC 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 help@longevity-inc.com.