Longevity TigWeld 200 AC/DC Operating Manual
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Longevity TigWeld 200 AC/DC Operating Manual

Ac/dc tig/stick welders
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Operating Manual
For
IGBT
200/250/315-AC/DC TIG/Stick Welders

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Summary of Contents for Longevity TigWeld 200 AC/DC

  • Page 1 Operating Manual IGBT 200/250/315-AC/DC TIG/Stick Welders...

  • Page 2: Table Of Contents

    PG. 24-26: Selecting the Right Tungsten Electrode and Filler Rod PG. 27: Machine Installation and Argon Set Up PG. 28-32: Basic TIG Operation PG. 33-38: Basic Stick/ARC Operation PG. 39: Routine Maintenance PG. 40: Thank You for Purchasing from LONGEVITY! Page 1 of 41 www.longevity-inc.com...
  • Page 3 200/250/315-AC/DC TIG/Stick Welders 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 In the event of product failure or malfunction, the purchaser/recipient must contact LONGEVITY™ GLOBAL, INC. to obtain an RMA (return or missing) number and a location of a designated repair facility. The welder, plasma cutter, multi-purpose unit, or any other welding related equipment comes with warranty on all internal components.
  • Page 5 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 6 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. Page 5 of 41 www.longevity-inc.com...
  • Page 7 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. Page 6 of 41 www.longevity-inc.com...
  • Page 8  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. Page 7 of 41...

  • Page 9: General Description

    These machines are water cooler compatible for welding thick material using high heat to penetrate. For more details on the water cooler system available for your machine, please contact us at our toll free # 877-566-4462 for details on price and availability. Page 8 of 41 www.longevity-inc.com...

  • Page 10: Specifications And Ratings

    -Minimum Generator KVA output for TigWeld 200 and 250: 9KVA continuous -Minimum Generator KVA output for TigWeld 315: 12KVA continuous -Generator must be fitted with AVR (Automatic Voltage Regulator). -Connecting to a generator without the above input requirements or AVR will void your warranty. Page 9 of 41 www.longevity-inc.com...

  • Page 11: Included Accessories

    Consumables: Electrodes, Clamps, and Collets (Note: Tungsten and filler rod is not  included) 220V power Plug  WP-26 TIG Torch (14ft.) 400 AMP Stick Holder (10ft.) Durable Ground Clamp (10ft.) Foot Pedal Amperage Regulator (8 ft. Cord) Page 10 of 41 www.longevity-inc.com...
  • Page 12 200/250/315-AC/DC TIG/Stick Welders Argon Regulator TIG Torch Parts 220V power Plug Page 11 of 41 www.longevity-inc.com...

  • Page 13: Recommended Optional Water Cooler

    LONGEVITY TIG welders. This unit will allow you to weld at high amperage settings for longer periods of time! (Note: Water cooler will adapt to unit using the LONGEVITY water cooled torch.
  • 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 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 17 200/250/315-AC/DC TIG/Stick Welders 110V Plug Diagram: Page 16 of 41 www.longevity-inc.com...
  • Page 18 200/250/315-AC/DC TIG/Stick Welders Page 17 of 41 www.longevity-inc.com...
  • Page 19 200/250/315-AC/DC TIG/Stick Welders Basic Diagram Pictured Model TigWeld™ 315 (Note: All IGBT AC/DC TigWeld series machines have same function adjustment knobs and settings at different amperage ratings.) Page 18 of 41 www.longevity-inc.com...
  • Page 20 200/250/315-AC/DC TIG/Stick Welders Basic Diagram Pictured Model TigWeld™ 315 (Rear) Page 19 of 41 www.longevity-inc.com...
  • Page 21 PULSE CURRENT: 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 Page 20 of 41 www.longevity-inc.com...
  • Page 22 Not enough post flow can cause weld contamination or torch overheating. Keep the TIG torch in position over the weld until the post flow ends. 5 to 10 seconds for TIG welding is a recommended starting point. Page 21 of 41 www.longevity-inc.com...
  • Page 23 GAS OUTLET: The TIG torch connects to this fitting for gas to be fed to the torch through the trigger controlled solenoid. 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. Page 22 of 41 www.longevity-inc.com...

  • Page 24: Setting Up Tig Torch

    200/250/315-AC/DC TIG/Stick Welders Setting Up TIG Torch: Page 23 of 41 www.longevity-inc.com...
  • Page 25 2% Thoriated Tungsten (TT2) – (red tipped) - This tungsten is the most common tungsten currently being used with LONGEVITY DC TIG. It is generally utilized for DC welding of mild steel, bronze, and stainless steel and basically all metals except aluminum and offers excellent performance.
  • Page 26 Remember, after sharpening to a pencil point, you want to flatten the bottom for a good arc. Page 25 of 41 www.longevity-inc.com...
  • Page 27 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 28 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. Page 27 of 41 www.longevity-inc.com...

  • Page 29: Basic Tig Operation

    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 Page 28 of 41 www.longevity-inc.com...
  • Page 30 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. 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 31 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. 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. Page 30 of 41 www.longevity-inc.com...
  • Page 32 200/250/315-AC/DC TIG/Stick Welders Fig.1 Figure 1: Comparison chart of welds Fig. 2 Page 31 of 41 www.longevity-inc.com...
  • Page 33 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 Page 32 of 41 www.longevity-inc.com...
  • Page 34 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. Page 33 of 41 www.longevity-inc.com...
  • Page 35 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 Page 34 of 41 www.longevity-inc.com...
  • Page 36 90 degrees. This destructive testing method will help you improve your skill by revealing faults and flaws in your welds. Page 35 of 41 www.longevity-inc.com...
  • Page 37 AC Welders. E7018AC Low-hydrogen electrode; for low, medium and high-carbon steels; 70,000 PSI tensile strength; ideal for out-of-position welding and AC,DCEP tacking; specially formulated to operate with small 208/230 volt AC welders. Page 36 of 41 www.longevity-inc.com...
  • Page 38 200/250/315-AC/DC TIG/Stick Welders Page 37 of 41 www.longevity-inc.com...
  • Page 39  (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...

  • Page 40: 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. Page 39 of 41 www.longevity-inc.com...
  • Page 41 Dealers: dealers@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 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!

This manual is also suitable for:

Tigweld 250 ac/dcTigweld 315 ac/dcTigweld 200Tigweld 250

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