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Longevity WeldMax 520D Operating Manual

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Operating Manual
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416D/518D/520D
Multi-Purpose
Welding Machines

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Summary of Contents for Longevity WeldMax 520D

  • Page 1 Operating Manual 416D/518D/520D Multi-Purpose Welding Machines...

  • Page 3: Table Of Contents

    160/200/160P/200P AC/DC Series Machine 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 What’s Included? Pg. 10 Installation, Wiring, and Setup Instructions Pg.

  • Page 4: Thank You From Longevity

    160/200/160P/200P AC/DC Series Machine 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 5: Warranty/Shipping Damage/Order Information

    The repaired/replaced product will then be returned to the purchaser. LONGEVITY Global, Inc. will cover the return and replacement shipping charges (both ways) for units in need of warranty within and only for the first 30 days from the purchase date. After the 30 days from the purchase date, the purchaser shall be responsible for all shipping and handling costs of returning (both ways) the defective/faulty products for repair or replacement.
  • Page 6 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 help@longevity-inc.com...

  • Page 7: Safety Information

    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. www.longevity-inc.com...
  • Page 8 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. If, after reviewing this manual, you have any problems in setting up or operating your machine, contact us at  help@longevity-inc.com. www.longevity-inc.com...

  • Page 9: General Description

    These machines weld and cut carbon steel, stainless steel, alloy steel, as well as copper and other nonferrous metals. They are small, highly efficient, energy saving, stable in output, and reliable. Their ratio of input voltage to output voltage approaches 85 percent. www.longevity-inc.com...

  • Page 10: Specifications And Ratings

    Arc Starting Mode High Frequency No Load Voltage 60 – 80V Base Current Adjusting Range 10 – 160A 10 – 160A 10 – 160A (Amps) DC ARC/STICK Rated Output Current (Amps) 160A 160A 160A Rated Duty Cycle at Max www.longevity-inc.com...
  • Page 11 160/200/160P/200P AC/DC Series Machine Amps Base Current Range (Amps) 20 – 40A 20 – 50A 20 – 50A PLASMA Rated Duty Cycle at Max CUTTER Amps Arc Starting Method High Frequency www.longevity-inc.com...

  • Page 12: What's Included

    160/200/160P/200P AC/DC Series Machine What’s Included? www.longevity-inc.com...

  • Page 13: Installation, Wiring, And Setup Instructions

    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 110/220v plug match at your operating facility. Remember 220v plugs come with 3 or 4 prongs on them.
  • Page 14 Note: Hot Wires May also be WHITE and BLACK if a GREEN WIRE is one of the three wires. Therefore, GREEN is ALWAYS GROUND. NOTE: LONGEVITY® recommends a 50 AMP breaker on 220v, but you can operate on 30AMP breaker. Finished Plug:...
  • Page 15 Selecting the correct ground wire is important for proper machine operation and personnel safety. Ground wires on LONGEVITY® Welding 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 16 160/200/160P/200P AC/DC Series Machine Main Unit Pictured: WeldMax 416D Multi-Purpose Unit www.longevity-inc.com...

  • Page 17: Main Unit Knob/Button/Function Diagram

    16. Ground Lug: An additional safety grounding lug. You can earth this wire or properly ground it to your electricians specifications. Grounding the unit and yourself during cutting is extremely important 17. Air Inlet: Attach air compressor hose to the air inlet here. 18. Machine/Pedal: Select Pedal, when pedal is plugged into the machine. www.longevity-inc.com...

  • Page 18: Plasma Cutter Section: Torch Assembly

    3. Place the copper tip on the ring, ensuring that is seated flat. 4. Secure all parts into place by turning the ceramic cup clockwise until it is snug. Do not over tighten. The torch consumables are now successfully assembled. www.longevity-inc.com...
  • Page 19 2. Place the copper tip on the ring, ensuring that is seated flat. 3. Secure all parts into place by turning the pink ceramic cup clockwise until it is snug. Do not over tighten. The torch consumables are now successfully assembled. www.longevity-inc.com...

  • Page 20: Air Regulator Assembly

    160/200/160P/200P AC/DC Series Machine Air Regulator Assembly to Unit LONGEVITY® includes an air regulator/filter with your machine. You must attach the bracket to the machine, and fasten the regulator to the bracket so it looks as pictured 1. Locate the INLET and OUTLET labeled on the regulator picture above and attach the Air Compressor to the inlet and the OUTLET to the INLET on Unit with the provided hose to back of the machine, where shown, and secure it with a hose tie.

  • Page 21: Plasma Cutter Operation Tips And Advice

    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.
  • Page 22 Examples on how to achieve the desired results can be referenced in the owner's manual of your Longevity Plasma Cutter. Now you are ready to use your Longevity Plasma Cutter safely and efficiently. Turn the machine on and enjoy the satisfying experience of a quality Longevity Plasma Cutter.
  • Page 23 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.
  • Page 24 Longevity Plasma Cutter torch tip. In order to maintain the quality and consistency of your work we recommend that you use your other hand as a guide.
  • Page 25 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.
  • Page 26 160/200/160P/200P AC/DC Series Machine specification. Sample Photos: For more information on plasma cutting from professionals go to www.freeweldingforum.com www.plasma- cutters.com www.longevity-inc.com...

  • Page 27: Tig Section: Torch Assembly

    160/200/160P/200P AC/DC Series Machine TIG Section: Setting Up The TIG Torch www.longevity-inc.com...

  • Page 28: Selecting The Right Tungsten

    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.
  • Page 29 Sharpening a tungsten is very important for a nice fine arc strike. There are auto sharpeners to place the perfect sharpening point on your tungstens or you can simply use a grinding wheel to sharpen your tungsten. Remember, after sharpening to a pencil point, you want to flatten the bottom for a good arc. www.longevity-inc.com...

  • Page 30: Selecting The Right Filler Rods

    E1/16" X 36" ER80SD-2 Steel Wire 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.

  • Page 31: Argon Regulator Installation

    We recommend about 18 CFH. 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. www.longevity-inc.com...

  • Page 32: Basic Tig Operation

    Use free welding forum at www.freeweldingforum.com to gather advice or go to www.longevity-inc.com. 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.
  • Page 33 Keep the TIG torch in place until the post flow ends--usually around 5 seconds. 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. Basic Diagrams of Welding Fig.1 Figure 1: Comparison chart of welds Fig. 2 www.longevity-inc.com...
  • Page 34 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. www.longevity-inc.com...
  • Page 35 160/200/160P/200P AC/DC Series Machine Sample of a quality stainless steel weld: TALLATION www.longevity-inc.com...

  • Page 36: Basic Stick/Arc Welding Operation

    It is widely used and requires very little skill to begin using. This is not a particular www.longevity-inc.com...
  • Page 37 90 degrees. This destructive testing method will help you improve your skill by revealing faults and flaws in your welds. www.longevity-inc.com...
  • Page 38 AC Welders. E7018AC Low-hydrogen electrode; for low, medium and high- carbon steels; 70,000 PSI tensile strength; ideal for AC,DCEP out-of-position welding and tacking; specially formulated to operate with small 208/230 volt AC welders. www.longevity-inc.com...
  • Page 39 160/200/160P/200P AC/DC Series Machine www.longevity-inc.com...
  • Page 40 - 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 41: Routine Maintenance

     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. www.longevity-inc.com...

  • Page 42: Troubleshooting

    Do not continue to weld until Lights light is off. Contact LONGEVITY Toll Free 1-877-566-4462 or via email at Issue Not Listed help@longevity-inc.com Check ground connection, torch setup, and check if you are in Unit Will Not the proper mode ARC/TIG.
  • Page 43 Causes/ Problems Solutions STICK Welder Having a Hard Check the ground. Check the workpiece and clean it. Increase Time Striking an the Arc Force on the unit. STICK Welder Producing Poor Use the proper rod and polarity. Quality Welds www.longevity-inc.com...

This manual is also suitable for:

Weldmax 518dWeldmax 416d

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