Longevity WeldAll 160 User manual

Operating Manual
For
160 and 205
IGBT MIG Welder/ARC Welder

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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. 10-11: Included Accessories
PG. 12-13: Wiring and Setup Instructions
PG. 14-18: Diagram of Main Unit and Internal Components
PG. 19: Recommended Optional Accessories
PG. 20: Main Unit Knob/Button/Function
PG. 21: Welding Wire Installation
PG. 22: Setting Up Argon Regulator
PG. 23-29: MIG Welding Process
PG. 30-35: Stick/ARC Welding
PG. 36: Routine Maintenance
PG. 37: 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: [email protected]
Customer Service: [email protected]
Dealers: [email protected]
Complaints: [email protected]
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

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W arranty
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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In Warranty Service
Customers, who own machines that are in warranty and require service, should contact our
Warranty Department by email at [email protected] 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 [email protected]

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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 - 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 [email protected].

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General Description:
160/205 - MIG/ARC welders are the newest models in the LONGEVITY
IGBT MIG welder line up! These machines are new and improved from our previous model
M200 MIG welder! With an improved internal wire feed system and adjustable spool gun
compatibility, The ArcMate series machines compete with top model MIG welders in the
industry! This MIG welder / Stick welder combo requires a 220V single phase power supply
which can easily be found in most house power supplies or small generators! This machine
comes with full amperage and speed adjustments for faster or slower hand speeds on thicker or
thinner material! Gas shielding will be required for this machines MIG welder giving you the
best looking weld possible! Stick welder is built in for those quick and easy jobs needed to be
done with a plug and play welder. This machine is great for hobby or industrial use. This Gas
shielded MIG welder can be equipped with a Separate hand speed controlled spool gun for
welding aluminum or other materials. This machine is competitively priced, including a free 5
Year parts and labor warranty!
Please contact LONGEVITY customer service toll free 877-566-4462 for more details on this
model or the product of your choice!

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Specifications and Ratings
Parameter
Specifications and Ratings
Model
160
205
Input Voltage
1 phase 220v ; 50/60hz
Input Current
22amps
35amps
Rated Input Power
4.8 KVA
7.7 KVA
No Load Voltage
55~75V
Current Output Range (MIG)
30-160Amps
40-200Amps
Current Output Range (ARC)
30-135Amps
40-160Amps
Suitable Wire (Flux Cord or Solid Wire)
.025" (0.6 mm)
.030" (0.8 mm)
.035" (1.0 mm)
.025" (0.6 mm)
.030" (0.8 mm)
.035" (1.0 mm)
Duty Cycle
30% - 160A, 60% -
115A, 100% - 90A
35% - 200A, 60% -
155A, 100% - 120A
Efficiency
0.85
0.85
Power Factor
0.8
0.8
Insulation Class
F
F
Protection Class Of Shell
Fan Cooling
Fan Cooling
MIG shielding gas information:
Use a blended Argon/CO2 gas for best results.
100% CO2 is only used for low value welds.
A 75/25 Argon/CO2 mix is the most versatile and most common mixture.
Other mixes are available such as 85/15 Argon/CO2 to further improve weld quality.
Do not use pure Argon on mild steel.
Do not attempt to weld without a shielding gas unless a flux cored wire is used.

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Included Accessories:
ArcMate MIG Welder / Stick welder
MIG Torch with contact tips (10ft.)
Earth/Ground Clamp (10 ft.)
300amp Stick holder (10ft.)
Hose for argon hook up
220V Power Plug For Power Cord (110v will work on a model that specifies 110v/220v on
the back of the unit)
Pictures of Accessories: (Note: ArcMate 205 Accessories Pictured)
Superior MIG Gun Lead 400AMP Stick Holder

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Included Parts Continued...
Durable Ground Clamp Gas Hose for Connection to Machine
220V Power Plug for Power Cord

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Installation and Setup Instructions:
The item numbers referenced in the following paragraphs, refer to the numbered parts display in the
diagrams shown below. Longevity has an instructional setup installation video on our website at
www.longevity-inc.com, which we ask that you view prior installing the unit. The video shows the
complete assembly of the machine. The video is located in the Resources section of the website under
manuals and installation/set-up videos.
Connecting the electrical plug to the unit
Connecting the power plug to the unit is important. Please view the proper connection instructions below:
Wiring Introduction:
Danger: Read this manual completely before having your electrician attempt to wire up or connect your
machine to an electrical power source. Longevity units should be wired by a certified electrician to insure
your safety and a proper 220v plug match at your operating facility. 220v plugs come with 3 or 4 prongs
on them. Have the electrician check your existing receptacle.
Note: The power cord on single-phase machines has one ground wire and two hot wires when
connecting to 220vac. Connecting the plug connection to these wires is extremely important.
Improperly connected wires will void the warranty, affect personnel safety, and possibly damage your
machine and electrical power outlet.

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Identifying the Ground wire:
Caution: The machine may appear to operate with an incorrectly connected ground wire, but it will not
operate properly. Selecting the correct ground wire is important for proper machine operation and
personnel safety.
Ground wires on Longevity™ machines are usually one of the following colors:
The ground wire is a dark green with a yellow stripe. The wire may also be just SOLID GREEN.
Clean the ends of the wires to more easily distinguish the colors. The best and safest way to determine
which wire is ground is to measure the resistance between the machine chassis and the selected wire,
using an ohmmeter. Another method is to check the continuity between the chassis and the wire, using a
continuity meter. If the selected wire is ground, the connection between the chassis and the wire will
cause the meter to illuminate. If, for any reason, you cannot visually detect the ground wire or do not feel
comfortable with your selection, ask an electrician for help.
Identifying the hot wire:
For 220vac service, both the brown and blue wire will be positive wires. As you may know, 220vac
features two hot wires. If you are wiring to 220vac, your blue and brown wires are both hot. The
green with yellow or SOLID GREEN is the ground. Remember, any hot wire can be attached to
either hot leg on the plug.
Note: Hot Wires May also be WHITE and BLACK if a GREEN WIRE is one of the three
wires. Therefore, GREEN is ALWAYS GROUND.
Finished Plug:

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Basic Diagram Pictured Model ArcMate™ 160
(Note: All IGBT ArcMate series machines have same function adjustment knobs
and settings at different amperage ratings and positions on front panel.)

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Basic Diagram Pictured Model ArcMate™ 160
(Rear of Unit):

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Basic Diagram Pictured Model ArcMate™ 160
(Internal Wire Feed Compartment):

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Reversible Internal Wire Size Selector Ring:
0.8mm (.030”) Side of Wire Size Selector Ring
Side View Showing Grooves for 0.8mm and 1.0mm Wire Size

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1.0mm (.035”) Side of Wire Size Selector Ring