Longevity 880161 Instructions / Assembly

Operating Manual
for
200 AMP MULTIPROCESS WELDER WITH IGBT AND PFC AUTO
VOLTAGE TECHONOLOGY
PROMTS 200i
Table of Contents
Table of Content
Pg. 1
Thank you From LONGEVITY
Pg. 2
Warranty/Shipping Damage/Order Information
Pg. 3
Safety Information
Pg. 4-5
Technical Specifications and Ratings
Pg. 6
What’s Included?
Pg. 7
Main Unit Knob/Button/Function Diagram
Pg. 8-10
MIG Operation
Pg. 10
MIG Welding Tips and Tricks
Pg. 11-23
Contact Info
Pg.24
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PROMTS 200i
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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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.
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
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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.
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 it’s 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:
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Ensure that this welding equipment is installed in an area free of corrosive chemical gases,
flammable gases or materials, and explosive chemicals.
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The area should contain little dust, and have a humidity of no more than 80%.
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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;
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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.
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Always wear protective clothing and a welding mask to protect your skin.
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Wear safety goggles designed to darken the arc generated by your machine.
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Wear suitable noise protection to protect your hearing.
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Ensure that machine is grounded through the power cord or on the machine case.
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Never operate the machine in bare feet or on a wet floor.
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Never switch the machine off while it’s in use. Doing so will damage the internal circuitry.
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Ensure that your circuit breaker is rated to handle the current requirements of your machine.
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Use a UL approved receptacles and plugs with your machine. Never hard wire the machine to
main power.
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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.
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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.
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Use a screen or curtain designed to keep passers by from viewing the arc.
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The arc spray and metal spray from machine use may cause nearby fires. Use caution.
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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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Technical Specifications and Ratings
Input Power
Single-phase, 110V/220V,50/60Hz
Processes
MIG
FCAW
DC TIG
STICK
Welding Capacity
Mild steel MAX: 3/8” (9.5mm)
MIN:24 ga (0.8mm)
With Speedadjust Spoolgun 8M
Aluminum MAX: ¼” (6.4 mm)
MIN:18 ga (1.2 mm)
RATED DUTY CYCLE
110V
MIG/MAG: 30% @ 140A 21v 100%
@ 90A 18.5v
TIG: 40% @ 120A 14.8v 100% @
90A 13.6v
STICK: 30% @ 120A 24.8v 100% @
80A 23.2v
220V
MIG: 30% @ 200A 24v 100% @
125A 20v
TIG: 35% @ 200A 18v 100% @
130A 15.2v
STICK: 25% @ 200A 28v 100% @
110A 24.4v
Max no-load voltage
66 V
Weight
34.8 lbs
Dimensions (Length*Width*Height)
20.5”L x 8.25”W x 13.75”H
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What’s Included?
1 10 FT 15AK MIG GUN
1 13 FT GROUND CLAMP
1 5 FT AIR HOSE
1 5FT 220 TO 110 ADAPTER
1 CO2 REGULATOR
1 0.8,1.0 DRIVE ROLLER (INSIDE MACHINE)
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Main Unit
Pictured: PROMTS 200i Multi Process Welder
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Main Unit Knob/Button/Function:
1.
Process Selector: Press to select MIG, TIG or STICK.
2.
2T or 4T: Button for selecting 2T or 4T
3.
Welding Amps While Welding/ Set Amps Before Welding
4.
Wire Speed Indicator
5.
Amp Indicator: When the light is on it indicates that the amps are being displayed.
6.
Voltage Display: View and set amps.
7.
Voltage Indicator
8.
Arc Force:
9.
ON Led is lit when the machine is on
10. Fault Indicator indicates when the machine setting has too much voltage or too little
voltage. Also indicates if the duty cycle has been reached
11. Down Slope
12. MIG Gun Connector
13. Negative Connector
14. Trigger Connector
15. Positive Connector
16. Wire Speed Knob
17. Voltage (MIG) / Downslope (TIG) / Arc Force (STICK) MIG
18. Wave Form Knob
19. TIG Torch Gas Line Connector
20. Power Switch
21. Gas Line to CO2 Mix or 100% Argon Tank
22. Power Cord
23. Remote Switch
24. Spool Gun Switch
25. Burn Back Knob
26. Slow Feed Knob
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27. Manual Gas Check: Press and hold down. Wire Speed Test: Press and hold up.
28. Post Flow Knob
29. Pre Flow knob
MIG Operation:
1. Shielding Gas Choice
1)When the wire material is Fe, the shielding gas should be 75% Ar + 25% CO2
2)When the wire material is Ss, the shielding gas should be 75% Ar + 25% CO2
3)When the wire material is Al, the shielding gas should be 100% Ar
2) spool gun switch off(down) on (up)
3) Manual wire switch & air check, Burn back adjust, Slow feed adjust, Post flow adust, Pre flow
knob adjust.
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MIG Welding Tips and Tricks
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MIG Welding Tips
1. Direct your wire at the leading edge of your weld pool for the most control of
your weld bead.
2. For the most bead control when doing more difficult welds such as; Vertical,
horizontal, and overhead welds, use the smallest wire diameter possible, and
keep you weld pool small.
3 Your contact tube, gun liner, and drive rolls should coincide with your wire.
4. Keep your gun liner, drive rolls, and gun nozzles clean. Contact tips should be
replaced if there is blockage, or not feeding the way it should.
5. Your gun should stay straight, ensuring the wire will feed properly.
6. Steady the gun with both hands.
7. Do not over tighten wire feeder hub tension and drive roll pressure.
8. Store your wire in a place that is contaminant free.
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Electrode Tip Length
Never let you electrode’s distance from you contact tube exceed ¼” to ¾”. If you
do your weld will not be correct.
Too Short
Normal
Too Long
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Welding Wire
Thin Metal= Thin Diameter.
Thick Metal= Larger wire, with a larger machine.
Us the wire that matches your metal.
Don’t use aluminum with stainless, or vice versa
RECOMMENDED WIRE SIZES
Material
Thickness
MIG Solid Wire
.024”
.030”
.035”
Gasless Flux-Core Wire
.045”
.030”
.035”
.045”
24 Gauge (.025)
22 Gauge (.031)
20 Gauge (.037)
18 Gauge (.050)
16 Gauge (.063)
14 Gauge (.078)
1/8” (.125)
3/16” (.188)
1/4” (.25)
5/16” (.313)
3/8” (.375)
1/2” (.5)
= Recomended
*When welding materials that are thicker than 3/16” you may need to use Multipass or welding, or beveled joint design (depending on your machine).
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WELDING WIRES
Shielding gas- C02 or 75%Argon/25%
Solid
Carbon-Steel
ER70S-6
CO2 is recommended and will give you deeper penetration
75%Argon/25% will give you less splatter and a nicer
lookingbead
Should be used indoors, where wind cannot harm you weld.
Allows you to weld materials thinner than what you would
weld with flux cored wires
Great for auto body work
.
Shielding gas- not needed
Flux Cored/
Carbon-Steel
E71TGX
Can be used outside, wind will not harm your weld
Great for use on aged or rusty metals
Burns hotter than solid wires, allowing for welding of
materials thicker than 18 gauge
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Aluminum
ER5356
Shielding gas- Argon only
Should be used with a spool gun
Gives you a strong weld
.
Stainless Steel
ER308L
Shielding gas- Trimix
Use on stainless metals 301-305 and 308
.
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Shielding Gas
Co2 should be used with thick materials, but is too hot for thinner materials.
Thin steel should be used with 75% Argon/25% Co2.
Aluminum should be used with Argon.
Stainless steels can be used with a triple-mix, or Helium+Argon+Co2
Steel Penetration Patterns
Argon + CO2
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CO2
Gun Techniques
Drag/Pull= More penetration with a more narrow bead
Push= Less penetration with wider bead
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Fillet Welds
The leg of your weld should be equal to the thickness of the materials you
welded.
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Aluminum MIG Welding Tips
• It is highly recommended to use a spool gun when welding with aluminum.
However, if you don’t have access to one, you can try using an extremely short
gun.
• Keep your gun straight.
• Use Argon as your shielding gas
• Push gun away from you as you weld (Push gun technique)
• Feeder Problems? A possible solution to feeder problems is using a contact tip
that is one size larger than your wire.
• ER403 wire can be used for most projects. ER4356 should be used when your
weld needs to be stronger, or rigid.
• Always clean your aluminum before welding, using a stainless steel wire brush.
This brush should only ever be used for cleaning aluminum wire to prevent
contamination.
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• Fill the crater at the end of the weld to avoid a crack. One way to do this is to
dwell in the weld pool for a second at the end of the weld.
STICK Welding Tips and Tricks
(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).
DC Stick - Select Stick, DC, desired amps using Base cur knob, Pulse Mode off.
1. Insert electrode into electrode holder. Position the electrode for the most comfortable
position so that the electrode can be held directly over the work piece with a slight angle.
2. Set Amperage to the recommended amperage by the electrode manufacturer. Strike an arc
by swiping it briskly across the work piece in the same manner as one would strike a match.
Alternatively, you may strike an arc with firm tapping motion against the work piece. Either
method is acceptable. An arc should initiate. Continue to keep the arc going by holding the
electrode off the work piece no more than the electrode width.
3. Continue the arc by feeding the electrode into the weld puddle while moving the electrode
forward. This will take some coordination, but will be fairly easy to do after practice. Do not
allow the arc to become too long, because air and slag can become entrapped in the metal. The
sound of a proper arc will be similar to a gentle frying sound. A long arc will emit a humming
sound. An arc that is too short may be extinguished and the electrode may stick to the work
piece. If the electrode sticks, immediately release the electrode from the electrode holder and
break the electrode loose by hand. If the flux breaks off, simply trim off the excess rod until
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flux and bare metal meet. A welding rod must have flux to shield the weld from the
atmosphere or the weld will fail.
4. Use the Current control to change arc qualities. Adjust the amperage according to the
recommendations of the electrode (welding rod) manufacturer for the type and size of the
electrode used. Experimentation will be required to find the optimal setting desired. It is an
excellent tool for out of position welding.
5. Electrode selection. Electrodes are usually given performance and characteristic ratings
using a system of letters and numbers determined by the American Welding Society (AWS).
The rating system includes the minimum tensile strength of the finished weld, the weld
position (flat, vertical, horizontal, or overhead or a combination of two or more positions) and
the flux type. Additional information may be given. Each manufacturer has their individual
name and terminology as well.
As there is no general recommendation that can be made about a particular electrode selection,
except for practice welds, a electrode designated by the AWS as E 6011, E 6013, E 7014, or E
7018 may be used, each having its own distinct features and purpose. These are among the
most common electrodes used in the industry and are not difficult to find. E 6011 electrodes
are not as smooth running as some of the other electrodes, but offer the advantage of being
able to weld on rusty metal and contaminated surfaces. It is widely used and requires very little
skill to begin using. This is not a particular 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.
Many times, samples or small packages of electrodes are available at relatively low cost.
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Stick Electrode Chart Example: E 60 1 3
Strength
60--60,000 psi,
70--70,000 psi
Weld Position
1--All positions: Flat, Vertical, Horizontal, & Overhead
2--Flat Position or Horizontal Fillets Only
3--Flat Position Only
Weld Characteristics
0--Non-low hydrogen, DC Reverse polarity
1--Non-low hydrogen, AC or DC Reverse polarity
2--Non-low hydrogen, AC or DC Straight polarity
3--Non-low hydrogen, AC or DC Either polarity
4--Non-low hydrogen, iron powder coating, AC or DC Reverse polarity
5--Low-hydrogen, DC Reverse polarity
6--Low-hydrogen, AC or DC Reverse polarity
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
Be sure to observe the electrode manufacturer recommendations regarding polarity. If the weld
appears lumpy, porous or otherwise malformed, change the polarity of the ground cable and the
electrode holder cable. Many electrodes run with in reverse polarity, (DCEP) setting. A few run
with a straight polarity (DCEN). Some will run either way. For reverse polarity (DCEP) stick
welding, swap the electrode holder and ground cable connections.
Proper weld identification: Overlap and undercutting are two main causes of weld failure. Proper
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washing of the weld bead into the sides or “toes” of the weld is important. Keep the welding
electrode or the TIG tungsten and welding arc within the weld joint to prevent overlap. Pausing on
the sides of the welds to wait for the sides to fill reduces the chance of undercutting, even if the
current is a little too high. If it is possible, with any practice weld, cut the joint down the middle,
lengthwise, or place the weld in a vice and use a hammer to bend the metal over the weld area until
it is either broken or bent 90 degrees. This destructive testing method will help you improve your
skill by revealing faults and flaws in your welds.
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. Stick joins metals when an arc is struck between the electrode and the
work piece, creating a weld pool and depositing a consumable metal electrode into the joint. The
electrode's protective coating also acts as a shielding gas, protecting the weld and ensuring its
purity and strength. Best for windy conditions and adverse environments.
If you’re not familiar with Stick (SMAW) welding basics, the following information can
make choosing an electrode easier.
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Helpful Hints
 Use a drag technique for most applications.
 Take precautions with flying materials when
chipping slag.
 Keep electrodes clean and dry - follow
manufacturer instructions.
 Common steel electrodes (refer to chart
above).
 Penetration:
DCEN- Less penetration; AC -
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. Stick Electrodes or
welding rod for stick welding are available in stainless
steel, carbon steel, low alloy steel, maintenance alloy,
hard facing, nickel alloy, and magnesium
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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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