Longevity 444510 Instructions / Assembly

160 SX/200SX AC/DC TIG STICK WELDER
Operating Manual
For
TIGWELD 160SX/200SX
INVERTER AC/DC TIG/STICK WELDERS
110V/220V
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160 SX/200SX AC/DC TIG STICK WELDER
Table of Contents:
PG. 2: Thank you From LONGEVITY
PG. 3-4: Warranty/Shipping Damage/Order Information
PG. 5-7: Warning and Safety Information
PG. 8: General Description
PG. 9: Specifications and Ratings
PG. 10-12: Front Panel Overview and Controls
PG. 13: Routine Maintenance
PG. 14-15: Troubleshooting
PG. 16: Thank You for Purchasing from LONGEVITY!
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160 SX/200SX AC/DC TIG STICK 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. 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: sales@longevity-inc.com
Customer Service: help@longevity-inc.com
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
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160 SX/200SX AC/DC TIG STICK WELDER
Warranty
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/
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 SX/200SX AC/DC TIG STICK WELDER
In Warranty Service
Customers, who own machines that are in warranty and require service, should contact our
Warranty Department by email at help@longevity-inc.com 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 help@longevity-inc.com
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160 SX/200SX AC/DC TIG STICK 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.
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.
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160 SX/200SX AC/DC TIG STICK 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.
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 SX/200SX AC/DC TIG STICK 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.
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 to

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.

Ensure proper ventilation through the machine’s louvers. Maintain a distance of at least
12 inches between this cutting equipment and any other objects in the work area.

Use a screen or curtain designed to keep passer byes 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.
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160 SX/200SX AC/DC TIG STICK WELDER
Description of this welder
The TIGWELD 160SX and 200SX models are the newest additions to join the line of LONGEVITY
TIG welder/stick welder combination units!
LONGEVITY has both hobbyists and the professional welders in mind with the TIGWELD™ 160
SX and 200SX by combining AC/DC TIG welding with the capability of stick welding at an
affordable price with a DUAL-VOLTAGE capability. This compact, versatile unit offers the user a
simple array of controls to accurately set the welder to perform under a wide variety of
situations including fine aluminum welding. The TIGWELD™ 160 SX and 200 SX allows the
welder to easily switch from 220v to 110v with the adapter plug that is included while being
able to produce 160 amps or 200 amps on both AC and DC TIG and 140 amps or 160 amps on
the stick side with their respective models. Extremely user friendly, and portable makes this
your go to machine for TIG welding.
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160 SX/200SX AC/DC TIG STICK WELDER
Specifications and Ratings
model
parameter
Power voltage
TIGWELD 160SX
1phase110V±15
%
Frequency (Hz)
TIGWELD 200SX
1phase220V
±15%
1phase110V±
15%
50/60
TIG: 37.4
1phase220V±
15%
50/60
TIG: 20.4
TIG: 37.4
TIG: 28
Rated input current (A)
STICK:
Output current regulation
(A)
55.8
STICK:
TIG: 10~150
TIG: 10~160
STICK: 30~140
No-load voltage (V)
32.9 STICK:
58.2
STICK: 42.2
TIG: 10~150
TIG: 10~200
STICK: 30~160 STICK: 30~145 STICK: 30~195
50~80
50~80
TIG: 16
TIG: 16.4
TIG: 16
TIG: 18
Rated working voltage (V)
STICK: 25.6
STICK: 26.4 STICK: 25.8
Pre gas time(Seconds)
Duty cycle(%)
0-1
60% @ 160 amps @ 220v
STICK: 27.8
0-1
60% @ 200amps @ 220V
Post gas time(Seconds)
2-10
2-10
Foot Pedal
Yes
Yes
Arc Ignition Mode
High Frequency
Efficiency(%)
80
80
Load duration factor(%)
60
60
Power factor
0.73
0.73
Class of insulation
F
IP code
IP21
High Frequency
F
IP21
Weight(kg)
28.5
30.7
Overall dimension(mm)
705×300×565
705×300×565
Max welding thickness
(mm)
8
10
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160 SX/200SX AC/DC TIG STICK WELDER
SETUP:
Description of the panel function
Figure for TIGWELD 200SX panel
1.Current adjusting knob
2. Cleaning pulse width adjustment knob
3. Current meter
4. ARC/TIG change-over switch
5. HF/Life ARC change-over switch
6. Last flow time adjustment
7. Pre-flow time adjustment
8. Power switch
9. Pulse frequency change-over switch 10. AC/DC change-over switch
11. TIG welding torch interface
12. STICK welding interface
13. TIG welding torch switch/
14. Ground clamp interface
Remote control socket
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160 SX/200SX AC/DC TIG STICK WELDER
Controls/ Connections:
1) Amperage knob: The amperage knob controls the output amperage of the welding
machine. If the foot pedal is connected, the amperage is controlled with the foot
pedal, and not the Amperage knob.
2) Cleaning Effect Adjustment: The Clearance effect adjustment is used to control heat
between the workpiece and the tungsten. Turning it positive will allow for better
cleaning but less penetration, while dialing in a more negative setting allows for more
penetration but less cleaning. When at the “O” position, the ratio is 50% to 50%; at
“5” position, ratio is 80%, and at “-5” position, ratio is 20%
3) Digital Amperage Display: Using digital meters helps the user set amperage quickly
while STICK welding or TIG welding.
4) STICK/TIG switch: Rocker switch to control which process is used for welding.
5) Post-Flow Adjustment: Controls the seconds in which the shielding gas is allowed
to continue to flow through the torch after the foot pedal is trigger is depressed.
6) Pre-Flow Control: Controls the amount of time (measured in tenths of a second) that
the shielding gas is allowed to flow though the torch before the arc is ignited.
7) Power Switch: Located in the back of the machine. Powers the machine on or off.
8) Foot Pedal/ Panel Control Switch: Allows the user to select either option of
controlling the amperage, either through the control panel, or with the included foot
pedal.
9) AC/DC Switch: Easy switching between AC and DC welding. DC welding being
used for steel while the Ac setting is used for aluminum welding.
10) TIG Shielding Gas Connection: The shielding gas connection needs to be threaded
in tightly. (Avoid over-tightening)
11) Stick Welding Connection: Connect the included stinger for stick welding.
12) TIG Welding Panel Control: Connect the TIG torch connector in order to control
amperage via the panel controls.
13) Foot Pedal Connection: Connect the foot pedal connection in order to control
amperage with the included foot pedal.
14) Ground Clamp Control: Insert connector and twist clockwise to secure the ground
clamp.
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160 SX/200SX AC/DC TIG STICK WELDER
15) Overheat Protection Light: If the welding machine exceeds the duty cycle in
operation, it may go into a protective state and stop working. Under these
circumstances do not power off the machine. This allows the internal cooling fan to
continue working to cool your machine. Once the machine cools down to safe
temperatures, you can continue to safely operate the machine.
16) ** HF/Lift Start** : Some models may include a rocker switch which allows the
user to turn off the HF start and use Lift Arc to start the arc on the TIG torch
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160 SX/200SX AC/DC TIG STICK 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. 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.
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160 SX/200SX AC/DC TIG STICK WELDER
Troubleshooting
.
A、 Black welding spot
——This shows the welding spot is oxidized without being protected effectively and you can
make the following inspection :
1. Make sure that the valve of argon cylinder has been opened with sufficient pressure. As a rule,
if the pressure within the cylinder is lower than 0.5MPa, then it is necessary to refill the
cylinder.
2. Check if the argon flow-meter is turned on with sufficient flow. You can select different flow
rates in light of varying welding current, but too small flow may lead to inadequate gas
stiffness and thus failure to cover all the welded spots. We suggest argon flow should never be
lower than 3l/min no matter how weak the current will be.
3. The easiest way to check gas delivery is to touch the nozzle of welding torch to see whether
the gas passage of the welding torch is blocked.
4. Poor sealing of gas passage or lower gas purity will also give rise to welding quality trouble.
5. Strong air flow in the environment may also lead to deterioration of welding quality.
B、Difficulty in arc starting with easy arc breaking:
1. Make sure that the tungsten electrode in use is of good quality as discharge ability of inferior
tungsten electrode may fail
the requirement;
2. Tungsten electrode without sharpening treatment is also unable to start arc and leads to
unstable arc.
C、Output current can’t reach the rated value:
Deviation of power voltage from the rated value will lead to unconformity of output current
value with the set value. When power voltage is lower than the rated value, maximum output
current of the welder may also be lower than the rated value.
D、Unstable current in the operation of the welder:
This may be attributed to the following factors:
1.
Change in grid voltage;
2.
Interference from the power grid or other power equipments.
E、:Severely burn of the tungsten needle
The duty cycle is adjusted too large, causing emission from the workpiece to the tungsten
electron for too long, resulting in severe heat of the tungsten needles.
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160 SX/200SX AC/DC TIG STICK WELDER
F、The oxide film can’t be torn when welding aluminum:
1.
The welding gear is selected wrong.
2.
The duty cycle is adjusted too small;
3.
The secondary inverter has field pipe damage.
G、The abnormal pilot lamp is on:
1、The light is on when the welder work abnormally, please turn off the power switch and then
reboot the machine, it can continue to use if it return to normal,
2、If the light is on repeatedly, please refer to the professional or the manufacturer for repair.
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160 SX/200SX AC/DC TIG STICK 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@longevitywelding.com
LONGEVITY® Global, Inc.
Toll-Free 1-877-LONG-INC / 1-877-566-4462
Website: www.longevity-inc.com
Sales: sales@longevitywelding.com
Customer Service: help@longevitywelding.com
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!
Enjoy your new welding machine from LONGEVITY! Thanks again!
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