Longevity WeldMax 164i Operating Manual

Multi-purpose welding machines

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Operating Manual

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Summary of Contents for Longevity WeldMax 164i

Page 1 Operating Manual 164i/205i/250i Multi-Purpose Welding Machines...
Page 3 Selecting the Right Filler Rods Pg. 28 Argon Regulator Installation Pg. 29 Basic TIG Operation Pg. 30-33 Basic Stick/Arc Welding Operation Pg. 34-38 Routine Maintenance Pg. 39 Troubleshooting Pg. 40-41 Enjoy your new welding machine from LONGEVITY Pg. 42 www.longevity-inc.com...
Page 4 WeldMax 164i/205i/250i Multi-Purpose Machines 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 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 WeldMax 164i/205i/250i Multi-Purpose 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.
Page 8 WeldMax 164i/205i/250i Multi-Purpose Machines 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 9 WeldMax 164i/205i/250i Multi-Purpose Machines General Description This WeldMax™ series IGBT welding machine, designed for welding and cutting low-carbon steel, alloy steel, and stainless steel, uses advanced inverter technology, which allows us manufacture a unit that can also employ a Plasma Cutter. By employing high-output IGBT technology, it converts DC voltage to high frequency AC voltage.
Page 10 WeldMax 164i/205i/250i Multi-Purpose Machines Techinical Specifications and Ratings Type Parameter MODE WeldMax® 164i WeldMax® 205i WeldMax® 250i Power Voltage AC 220/230/240V Input Frequency 50/60 Hz 50/60 Hz 50/60 Hz Rated Input Current 30A 220v 30A220v 30A 220v Power Capacity 4.8KVA 5.0KVA...
Page 11 WeldMax 164i/205i/250i Multi-Purpose Machines Base Current Range (Amps) 20 – 40A 20 – 50A 20 – 50A PLASMA Rated Duty Cycle at Max CUTTER Amps Arc Starting Method HF Continuous Pilot Arc Start www.longevity-inc.com...
Page 12 WeldMax 164i/205i/250i Multi-Purpose Machines Included Accessories: Upgraded 60AMP Plasma Torch 400AMP Stick Holder LONGEVITY TIG Torch Durable Ground Clamp Foot Pedal Argon Regulator www.longevity-inc.com...
Page 13 WeldMax 164i/205i/250i Multi-Purpose Machines Water Separator 220V Power Plug With Clamps Argon/Air Hose TIG Torch Accessories Extra Accessories Including Consumables and Fuses 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 110/220v plug match at your operating facility. Remember 220v plugs come with 3 or 4 prongs on them.
Page 15 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 16 WeldMax 164i/205i/250i Multi-Purpose Machines Basic Diagram Pictured Model WeldMax™ 205i (Note: All IGBT WeldMax series machines have same function adjustment knobs and settings at different amperage ratings. ) www.longevity-inc.com...
Page 17 WeldMax 164i/205i/250i Multi-Purpose Machines Basic Diagram Pictured Model WeldMax™ 205i (Rear) www.longevity-inc.com...
Page 18 WeldMax 164i/205i/250i Multi-Purpose Machines Main Unit Knob/Button/Function: 1. On/Off Breaker or Switch: Either breaker or switch located on the back or front of the unit will control the unit to be turned on or off. 2. Power Indicator : Shows unit is powered on. Indicator is present in some models with a green LED bulb.
Page 19 WeldMax 164i/205i/250i Multi-Purpose Machines Assembly of Plasma Torch Consumables: The plasma cutter torch handle is made of fire and heat resistant materials. Avoid dropping the torch or striking anything with it. For convenience and ease of use, the torch’s ON/OFF switch can be positioned on the top, the side, or the bottom of the torch body.
Page 20 Water Separator Diagram and Assembly to Unit: LONGEVITY® includes an air regulator and water filter 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.
Page 21 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 WeldMax 164i/205i/250i Multi-Purpose Machines 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 WeldMax 164i/205i/250i Multi-Purpose Machines TIG Section: Setting Up The TIG Torch www.longevity-inc.com...
Page 28 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 WeldMax 164i/205i/250i Multi-Purpose Machines 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 TL2-7040 TL2-7116 TL2-7332 TL2-718 Lanthanated Amparage-Ac 20-30 30-80...
Page 30 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 WeldMax 164i/205i/250i Multi-Purpose 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 CFH (cubic feet per hour).
Page 32 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 WeldMax 164i/205i/250i Multi-Purpose Machines 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.
Page 34 WeldMax 164i/205i/250i Multi-Purpose Machines Length of Arc When an arc is too long, the metal melts off the electrode in large globules and the arc may break frequently. This produces a wide, spattered, and irregular deposit with insufficient fusion between the base metal and the weld. When an arc is too short, it fails to generate enough heat to melt the base metal properly, causes the electrode Fig.
Page 35 WeldMax 164i/205i/250i Multi-Purpose Machines Sample of a quality stainless steel weld: TALLATION www.longevity-inc.com...
Page 36 WeldMax 164i/205i/250i Multi-Purpose Machines 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).
Page 37 WeldMax 164i/205i/250i Multi-Purpose Machines 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.
Page 38 WeldMax 164i/205i/250i Multi-Purpose Machines 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 39 WeldMax 164i/205i/250i Multi-Purpose Machines 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 WeldMax 164i/205i/250i Multi-Purpose 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.
Page 42 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 WeldMax 164i/205i/250i Multi-Purpose Machines Problems, Causes, and Solutions Causes/ Problems Solutions STICK Welder Having a Hard Check the ground. Check the work piece and clean it. Increase Time Striking an the Arc Force on the unit. STICK Welder Producing Poor Use the proper rod and polarity.
Page 44 WeldMax 164i/205i/250i Multi-Purpose Machines 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.

This manual is also suitable for:

Weldmax 205i Weldmax 250i