Longevity 880134 Instructions / Assembly

Operating Manual
For
MigWeld 200S
200 AMP Inverter MIG/STICK Welder 220v
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Table of Contents:
PG. 3: Thank you From LONGEVITY
PG. 4-6: Warranty/Shipping Damage/Order Information
PG. 7-9: Warning and Safety Information
PG. 10: General Description
PG. 11: Specifications and Ratings
PG. 12-13: Operations and Controls
PG. 14-15: Set-Up for Different Processes
PG. 16: Operating the MIgWeld 200S
PG. 17: Enjoy your new welding machine from LONGEVITY!
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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!
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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
Check out LONGEVITY Racing at www.longevity-racing.com
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. We are not responsible for lost returns. The
labor coverage only applies if the unit is serviced at our facility or one of our authorized dealers. We will
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not reimburse the labor if your wish to have a third-party or unauthorized repair technicians work on the
product.
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.
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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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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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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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 -10 C
to +40
C;
•
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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WARNING: The warnings, cautions and instructions discussed in this instruction manual cannot
cover all possible conditions and situations that may occur. It must be understood, by the operator,
that common sense and caution are factors, which cannot be built into this product, but must be
supplied by the operator.
ARC WELDER SAFETY WARNINGS AND PERCAUTIONS
Warning: This product, when used for welding and similar applications, produces chemicals to
cause cancer and birth defects (or other reproductive harm).
Avoid electrical shock. Do not permit electrically live parts,
cables, or electrodes to contact skin, clothing or gloves.
Protective clothing should be hole free, dry and ANSI
approved. This unit draws enough current to cause serious
injury or death. Before turning the welder on, check the
welder gun to be sure that there are no protruding screw
heads and that all insulation is secure. Do not weld unless
you are insulated from the ground and the work piece.
Avoid breathing fumes or gases. These gases can cause
serious health problems. Use an active ventilation system
directly above the welding area. Keep your head out of the
fumes.
Avoid eye and body damage. Arc rays and infrared radiation
can cause injury to the eyes and burn the skin. Wear ANSI approved eye and body protection. Do not allow viewing by visitors
without proper eye and body protection.
Know proper arc welding practices. Read and understand the manufacture’s instructions, as well as your employer’s safety
practices for arc welding.
Connect only to a code approved power source. Connect only to a grounding power source conforming to the National
Electrical Code and Local Codes.
Avoid fire and explosion. Remove flammable and explosive material to a minimum of 35 feet from the welding arc to prevent
welding sparks or molten metal from starting a fire. Keep a type ABC fire extinguisher within easy reach. Thoroughly clean the
object being welded of any paint, grease or other foreign material.
Avoid being burned. Always wear ANSI approved welding gear: eye wear, leather gloves, leather apron and shoes.
WARNING
ARC WELDING CAN BE HAZARDOUS
WARNING: THIS WELDING MACHINE MUST BE CONNECTED TO POWER SOURCE IN ACCORDANCE WITH
LOCAL ELECTRICAL CODES
WARNING: DISCONNECT POWER SOURCE BEFORE DISASSEMBLY OF THE TORCH
WARNING: THE SHIELD NOZZLE MUST BE INSTALLED PRIOR TO OPERATION OF THE TORCH
WARNING: ALL INSTALLATION, MAINTENANCE, REPAIR OPERATION OF THIS EQUIPMENT SHOULD BE
PREFORMED BY QUALIFIED PERSONS ONLY IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL CODES
ELECTRIC SHOCK CAN KILL.
Improper use of electric arc welders can cause electric shock, injury and death! Take all precautions described in this manual to
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reduce the possibility of electric shock.
The MigWeld140 power switch is to be in the OFF (“O”) position when installing work cable and gun and when connecting
power cord to input power.
Always wear dry, protective clothing and welding gloves and insulated footwear.
Always operate the welder in a clean, dry, well-ventilated area. Do not operate the welder in humid, wet, rainy or poorly
ventilated areas.
Be sure that the work piece is properly supported and grounded prior to beginning the electric arc welding operation.
The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with
your bare skin or wet clothing.
Ground the work or metal to be welded to a good electrical (earth) ground.
FUMES AND GASES can be dangerous.
Do not breathe fumes that are produced by the arc welding operation. These fumes are dangerous.
Keep the head and face out of the welding fumes.
Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation.
WELDING SPARKS can cause fire or explosion.
Do not operate electric arc welder in areas where flammable or
explosive vapors.
Always keep a fire extinguisher accessible while performing arcwelding operations.
ARC RAYS can burn.
Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or observing
open arc welding.
Use suitable clothing made from durable flame-resistant material to
protect your skin and that of your helpers from the rays.
Protect other nearby personnel with suitable non-flammable
screening or warn them not to watch the arc nor expose themselves
to the arc rays or to hot spatter or metal.
HOT METAL can burn
Electric arc welding operations cause sparks and hot metal to
temperatures that can cause severe burns! Use protective
gloves and clothing when performing any metal working operations.
Make sure that all persons in the welding area are protected from
heat, sparks and ultraviolet rays. Use additional face shields and
flame resistant barriers as needed.
Never touch work piece until completely cooled.
ELECTRIC AND MANGETIC FIELDS may be dangerous
The electric magnetic field that is generated during arc
welding may interfere with the operation of various electrical and
electronic devices such as cardiac pacemakers. Persons using such
devices should consult with their physician prior to performing any
electric welding operations .Exposure to electromagnetic fields during
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welding may have other health effects, which are not known.
Model
MIGWELD200S
Rated Input Voltage
220V/1Phase
Frequency (Hz)
50/60
No-Load Loss
50W
Efficiency
0.80
Power Factor
0.73
No-load output voltage
50-80V
MIG
STICK
Rated Input Current
37.4A
Output Voltage
adjustment Range
15.5-24V
Output Current Range
30-200A
Load Duty Cycle
60%@200A/24V
Rated Input Current
38.1A
Output Voltage
21.2-27.2V
Output Current Range
30-180A
Load Duty Cycle
60%@180A/27.2V
Anti-sticking Function
YES
Protection Class
IP21
Cooling method
Fan-cooled
Standard
GB15799.1-2004
Size
Weight
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OPERATION AND CONTROLS
Diagram of panel
1. QC/STICK/MIG Indicator
Light indicators which demonstrate which welding process is selected and if the duty cycle has been
reached.
2. MIG/ STICK Selction Knob
Allows easy selection of the welding process desired.
3. Wire Feed/ Spool Gun Knob
Easily switches between the wire feed and spool gun functions of the MigWeld 200S
4. Voltage/ Arc Force Knob
When the unit is in MIG mode, this knob adjusts the welding voltage. If the unit is in STICK mode,
the knob adjusts the amount of arc force.
5. Wire Speed / Stick Amps
Allows the user to control the wire speed function when in MIG mode or to adjust the amperage
when in STICK mode
6. Wave Form
Controls arc characteristics while in MIG mode only. Lower wave form settings make the arc
softer with less weld spatter. Higher wave form settings give a stronger driving arc which can
increase weld penetration.
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OPERATION AND CONTROLS
Operation and controls
1.
Set the power switch of the welding machine at "ON” position, open the valve of gas cylinder and
adjust the flow meter to required setting.
2. Select the diameter of welding wire on welding feeding machine according to specified value.
3. Select bore diameter of welding torch contact tube according to diameter of wire.
4. According to the thickness, adjust VOLTAGE knob and SPEED knob to required position.
5. Press the switch on welding torch to make the welding wire extend out of gun head, and then the
machine is ready to work.
6. Reference table for welding conditions
Thickn
Diameter of
Welding
ess
wire
Parent metal
method
(mm)
(Φ)
Carbon steel,
common low
alloy steel
0.8-8.0
CO2/MAG
0.8/1.0/1.0
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Welding
current
range (A)
Applicable to OUR
welding machine's
model
60--230
MigWeld 200S
Set-up for using MIG function:
Power supply
CO2 meter
STICK
ON
Gas
cylinder
OFF
AC 220V
50/60Hz
CO2
Back
Earth clamp
Work piece
Mig torch
Set-up for using Spool Gun Function:
Power supply
meter
STICK
ON
OFF
AC 220V
50/60Hz
CO2
Back
Earth clamp
Work piece
Pull mig torch
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Gas
cylinder
Set-up for using Stick welding function:
Power supply
STICK
MIG
ON
OFF
AC 220V
50/60Hz
CO2
Back
Earth clamp
Work piece
Electrode holder
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Operation
1.
Turn the power switch to the “ON” setting, the LCD display will show set current volume and the
cooling fan will beginning to revolve.
2.
Adjust the Voltage/ Arc Force Knob and the Wire Speed / Stick Amps according to your needs.
3. Generally, welding current is adequate to welding electrode according with as following:
Specification
φ2.5
φ3.2
φ4.0
φ5.0
Current
70-100A
110-140A
170-220A
230-280A
4. The Arc Force knob is used to adjust welding function, specially in low current arrange, that is
cooperated with knob of welding current adjustment, they may adjust current of arc striking and be
out of control of knob of welding current adjustment .So machine can grain powerful energy and push
current can achieve effect that may.
5. VRD equipment is installed in the machine. When the switch of back panel is put "ON" position, the
VRD indictor is lit and the no-load voltage changes to be less than 15V, which is safe for people; and
when the switch is put "OFF" position, the VRD indicator is off.
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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.
LONGEVITY® Global, Inc.
Toll-Free 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
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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