Longevity WeldAll 160PI/200PI/250PI User Manual

Page 22

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Stick (SMAW )

TIG (GTAW )

Plasma

Welding Method

Cutting

Notes

Cutting any

Process used for Steel, Aluminum

Steels

Aluminum

Steel, Stainless

Steel

contuctive

material

AC TIG preferred for Aluminum, DC TIG/Stick preferred for Steels

Gas used

N/A

Argon

Compressed Air

purge hose with Argon using trigger on gun before beginning TIG welding

Torch used Electrode Clamp

Electrode Clamp

TIG

Plasma

Ground cable and clamp used for all. Plasma and Tig Torch share connections welding unit.

Ceriated (grey)

tungesten,

Grey is typically for aluminum. Red usually indicates 2% thoriated for steel and stain less steel.

tungsten

N/A

ball/flat end

Ceriated/thoriate

d, (red or grey)

sharp tip

N/A

Sharpen to point grinding axially with taper with length of taper = 2.5 x Diameter

10-25 cu-ft/hr

start

10-25 cu-ft/hr

start

40-70 PSI

Gas pressure/flow

N/A

at 20

start at 65 psi

Start with Argon at 18 CFM for TIG. Start with compressed air at 60-75 psi for Plasma

ARC/TIG/Plasma

ARC

TIG

Plasma

select welding type
desired

AC/DC

select DC or AC welding current

Normally set to 2T where trigger pulled = on, released = off. Setting to 4T causes the trigger switch
to latch on until

4T/2T

N/A

2T see note

triggered a second
time

select as

While in DC/TIG mode this switch will provide pulsed DC or constant DC. It switches between the
peak current and

Pulse

N/A

select as

appropriate

N/A

base current at the selected frequency.

Recommended to pre purge weld area for before current starts when TIG welding to help
prevent oxidation, set

Gas Preflow

N/A

Set 0-1 sec

N/A set to 0

between 0 and 1 seconds. Purge with Argon before starting first TIG weld.

0-200 Amps as

0-50 Amps as

0-200 Amps as

appropriate for

0-200 Amps as

appropriate for

workpiece/

appropriate zero

for

workpiece/

Current (Amps)

workpiece/

electrode

for foot switch

foot switch

electrode

Set current as recommended for material and thickness. If using foot pedal set to zero -- foot pedal
adjusts current

Only active when set to "Pulse" in DC/TIG mode. Sets lower (trough/valley) current (percentage
of the "current"

Base Current

N/A

set 20-90%

N/A

above) that is seen during each DC pulse cycle

Rate at which current is dropped after you release the weld trigger. Adjusts time from 0 to 10
seconds. If using

Slope Down Control

N/A

set 0-10 sec

N/A

foot pedal, set to zero as foot pedal is used to reduce current.

Designed for use when Stick welding, but influences maximum current of all modes. Also called
Dig or Arc Force

Control. Gives a welder variable additional amperage during low voltage (short arc length)
conditions while welding.

Helps avoid "sticking" stick electrodes when a short arc length is used and gives stick operator
some heat control.

This must be set to maximum to achieve maximum power for all modes, but variable voltage/arc-
length dependent

Arc Force

set 0-100%

N/A set to max

current is only active while stick welding.

Set from 0.3 to

200

Pulse Frequency

N/A

pulses/sec

N/A

Adjusts pulse frequency from 0.5 to 200Hz. Only active when set to "Pulse" in TIG mode.

Only active when set to "Pulse" in TIG mode. Sets width of AC/DC Pulse from 10 to 90% of each
AC/DC pulse cycle.

Pulse Duty

N/A

set 10-90%

N/A

This is the duration as % of pulse width (one pulse cycle) of the higher current pulse

Only active in AC welding. Biases the AC current by varying the percentage of current going in
each direction. This

balances the weld heat penetration (DCEN) and cleaning action (DCEP). This setting can help
prevent overheating

and damaging the tungsten vs cleaning oxidation on the work pieces. Middle setting is 50/50. Low
is 20% positive

Set 20-80%,

neutral

on. High is 80% positive on. Large current small clear width and vice versa. This setting
depends on weld

Clear Width

set to 50%

N/A

Set 20-80%

N/A

penetration needed (current), tungsten diameter, gas flow (tungsten cooling), and existing
work oxidation.

Controls gas flow duration after trigger is released. Higher time uses more gas but helps prevent
oxidation of hot

TIG weld material. Also helps cool weld pool, tungsten electrode, and ceramic cups. Post flow can
also cool freshly

Gas Post Flow

N/A

Set 1-10 sec

cut work pieces and plasma torch parts.

Strength

Electrode Chart Example: E 60 1 3

60--60,000 psi,

Distance between

70--70,000 psi

Weld Position

tungsten and

1--All positions: Flat, Vertical, Horizontal, & Overhead

workpiece should

Distance between

Notes

2--Flat Position or Horizontal Fillets Only

2-4 mm, either set

tungsten and

lower current if

cut is

requires slag

removal

current or use

foot

workpiece should

too wide. Air flow

3--Flat Position Only

with chipping

pedal recommend

2-4 mm, either set

critical to prevent

Weld Characteristics

hammer, use AC for

requires slag

removal

5356 filler rod,

current or use foot

damage to tip. Tilt

0--Non-low hydrogen, DC Reverse polarity

less spatter

(depends

with chipping

remember to

allow

pedal remember

nozzle to start

hole

1--Non-low hydrogen, AC or DC Reverse polarity

on electrode

chosen)

hammer

post flow

allow post flow

in thicker

materials.

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)

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