Longevity 880160 Instructions / Assembly
Contents
1. Y ONGEVI The power to last www longevity inc com Operating Manual for ay gt 250 AMP MULTIPROCESS WELDER WITH IGBT AND PFC AUTO VOLTAGE TECHONOLOGY PROMTS 252 ONGEVIT Y www longevity inc com Table of Contents Table of Content Thank you From LONGEVITY Warranty Shipping Damage Order Information Safety Information Technical Specifications and Ratings What s Included Main Unit Knob Button Function Diagram MIG Operation MIG Welding Tips and Tricks Contact Info PROMTS 252 ONGEVIT Y www longevity inc com 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 1n understanding your new 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 2359 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 com2. 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 PROMTS 2521 ON GEVI Y www longevity inc com 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 1s 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 trac
3. 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 E601
4. 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 19 PROMTS 252 ONGEVITY www longevity inc com 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 1t 1s 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
5. 1 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 18 PROMTS 2521 ON GEVI Y www longevity inc com Stick Electrode Chart Example E 60 1 3 Strength 60 60 000 psi 70 70 000 psi Weld Position 1 positions Flat Vertical Horizontal amp 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
6. 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 23 PROMTS 252 ONGEVITY www longevity inc com LONGEVITY QG 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 Q Global Inc Toll Free 1 877 LONG INC 1 877 566 4462 Website www longevity inc com Sales sales 9 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 24
7. c com PROMTS 252i ONGEVIT Y Technical Specifications and Ratings Single phase 110V 220V 50 60Hz Processes Welding Capacity Mild steel MAX 3 8 9 5mm MIN 24 ga 0 8mm With Speedadjust Spoolgun 8M Aluminum MAX 4 6 4 mm MIN 18 ga 1 2 mm RATED DUTY CYCLE 110V MIG MAG 35 160A 22v 100 95A 18 5v TIG 35 140A 14 8v 100 90A 13 6v STICK 30 130A 25 2v 100 80A 23 2v 220V MIG 35 250A 27v 100 150A 21 5v TIG 35 250A 20v 100 150A 16v STICK 30 9 250A 30v 100 130A 25 2v Dimensions Length Width Height 20 5 L x 8 25 W x 13 75 H PROMTS 252i What s Included 1 10 FT 24KD 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 ONGEVITY The power to last www longevity inc com PROMTS 252 ONGEVIT Y www longevity inc com Main Unit Pictured PROMTS 2521 Multi Process Welder 2 NS ONGEVI y Pam di gt 4 7111071 8 7 0 0 0 0 LONGEVITY The power to las hi 21 20 Main Unit Knob Button Function PROMTS 2521 RUE oue o Nm NW NW WNW PO HW N HD n Nl A d WO N O UO WBN A WO Nme www longevity inc com Gas Connector From Tank To The Welder ON OFF Switch Power Cord MIG Gun Connection Positive Dinse Connec
8. d 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 Electrode Tip Length 10 PROMTS 252 ONGEVIT Y www longevity inc com Never let you electrode s distance from you contact tube exceed 74 to 4 If you do your weld will not be correct Too Short Normal Too Long e 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 11 PROMTS 252 ONGEVIT Y www longevity inc com RECOMMENDED WIRE SIZES Material MIG Solid Wire Gasless Flux Core Wire 22 Gauge 031 18 Gauge 050 16 Gauge 063 14 078 1 8 125 3 16 188 BEN 5 16 313 3 8 375 1 2 5 2 Recomended When welding materials that are thicker than 3 16 to use Multi pass or welding or beveled joint design depending on your machine 12 PROMTS 2521 Solid Carbon Steel ER70S 6 Flux Cored Carbon Steel E 1TGX Aluminum ER5356 Stainless Steel ER308L e Shielding Gas ONGEVITY The power to last www lon
9. es 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 15 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 PROMTS 252 ONGEVIT Y www longevity inc com 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 preci
10. g Pull Technique Perpendicular Technique 15 ONGEVITY PROMTS 252i e Fillet Welds The leg of your weld should be equal to the thickness of the materials you welded e Aluminum MIG Welding Tips e 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 e 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 e ER403 wire can be used for most projects ER4356 should be used when your weld needs to be stronger or rigid e 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 16 PROMTS 252i ONGEVITY www longevity inc com 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 Selec
11. gevity inc com WELDING WIRES m Shielding gas C02 or 75 Argon 25 m CO2 is recommended and will give you deeper penetration 75 Argon 25 will give you less splatter and a nicer lookingbead m Should be used indoors where wind cannot harm you weld m Allows you to weld materials thinner than what you would weld with flux cored wires Great for auto body work Shielding gas not needed 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 m Shielding gas Argon only Should be used with a spool gun m Gives you a strong weld m Shielding gas Trimix Use on stainless metals 301 305 and 308 Co2 should be used with thick materials but is too hot for thinner materials Thin steel should be used with 7596 Argon 25 2 13 PROMTS 252 ONGEVITY www longevity inc com Aluminum should be used with Argon Stainless steels can be used with a triple mix or Helium Argon Co2 Steel Penetration Patterns Argon CO PAJA e Gun Techniques Drag Pull More penetration with a more narrow bead Push Less penetration with wider bead 14 PROMTS 252 ONGEVIT Y www longevity inc com Perpendicular Electrode Electrode ahead of bead back into bead Welding Direction 2 SN LN EN BO aS A Push B Gun C Dra
12. k 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 PROMTS 2521 Warnings and Safety ONGEVITY The power to last www longevity inc com Welding and plasma cutting may be dangerous to the operator and to bystanders if the equipment 1s 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 accordance with applicable safety codes Never touch electrod
13. l cast iron nickelsome nickel alloys and copper some copper alloys Brazing fuels are needed axyacetylene etc Good for use on bulldozer blades plow shears and metal to earth applications Aluminum A043 Flat horizontal and vertical aluminum welding jobs ngih 5556 nickel on cast inan Nickel 53 A High strength stronger than nickel 99 ut iron Machinable geras nickel on cast iron Hickel 90 A Ductle strength is higher than nickel 55 Cont iron Easier ip machine than nickel 55 Chrome coated steels Hard Surfacing Overlay Wear and impact resistarit 21 PROMTS 252 ONGEVITY www longevity inc com Electrode Polarity Chart Electrode pc ac Position Penetration Usage EP Deep Min Prep Rough 900 EP Min e ir Fillet Faster xa e tw Electrode Positive Reverse Polarity EN Electrode Negative Straight Polari Electrode Amperage Chart Amperage Range 27 PROMTS 2521 Striking an Arc 1 Electode 2 Workpiece 3 Arc ONGEVITY The power to last www longevity inc com Helpful Hints e Use a drag technique for most applications e Take precautions with flying materials when chipping slag e Keep electrodes clean and dry follow manufacturer instructions e Common steel electrodes refer to chart above e Penetration DCEN Less penetration AC Medium can be more spatter also
14. pitation 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 passers by 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 in
15. t 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 15 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 1s 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 17 PROMTS 252 ONGEVITY www longevity inc com flux and bare metal meet A welding rod must have flux to shield the weld from
16. ter Gas Connector TIG Negative Dinse Connector Process Selector Press to select MIG TIG or STICK Wire Speed Or Amps Display Wire Speed Indicator Light Amp Indicator Light Voltage Arc Force Down Slope Arc Force Indicator Light Voltage Indicator Light Down Slope Indicator Light Power ON Indicator Light Thermal Overload Protection Indicator Light Wave Control Knob Voltage Arc Force Down Slope Knob Wire Test Hold Up Gas Test Hold Down Remote ON OFF Spool Gun Switch ON OFF Wire Speed And Amps Knob 2T or Button for selecting 2T or 4T Burn Back Knob Slow Feed Knob Post Flow Knob Pre Flow knob ONGEVI Y PROMTS 2521 Re www longevity inc com MIG Operation 1 Shielding Gas Choice I 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 AI the shielding gas should be 100 Ar MIG Welding Tips and Tricks 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 an
17. 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 20 PROMTS 252 ONGEVIT Y www longevity inc com Recommended Stick Electrodes Common Steel Elecitrodes Deep penetrating All purpose stick electrode Used on carbon galvanized steel Does great with medium rusty or painted metals gt Mild medial penetrating all purpose stick electrode TUE Best when you have High Depositan rates Good for light penetration and fast speeds 70 000 PSI tensile strength Low Hydrogen stick electrode All carbon steels Great for tack welding or welds that are in awkward positions 70 000 PSI tensile strength Low Hydrogen stick electrode Good for medium and high carbon steels on medium high voltage AC welders 70 000 PSI tensile strength T P zt i 3 Usage G25 G85 301 305 and 308 base metal Great for build up and cladding Slag easiby removed eg fej 5 EU 3 i gt gt gt Cuttingibeveling of all metals which include stainless steels aluminum and copper Great for weld joint removal Brazing of stee
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