Longevity WeldMax 520D User manual

Operating Manual
for
416D/518D/520D
Multi-Purpose
Welding Machines

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com 1
Table of Contents
Table of Content Pg. 1
Thank you From LONGEVITY Pg. 2
Warranty/Shipping Damage/Order Information Pg. 2-4
Safety Information Pg. 5-6
General Description Pg. 7
Specifications and Ratings Pg. 8-9
What’s Included? Pg. 10
Installation, Wiring, and Setup Instructions Pg. 11-14
Main Unit Knob/Button/Function Diagram Pg. 15
Plasma Cutter Section: Torch Assembly Pg. 16-17
Air Regulator Assembly Pg. 18
Plasma Cutter Operation Tips and Advice Pg. 19-24
TIG Section: Torch Assembly Pg. 25
Selecting the Right Tungsten Pg. 26-27
Selecting the Right Filler Rods Pg. 28
Argon Regulator Installation Pg. 29
Basic TIG Operation Pg. 30-33
Basic Stick/Arc Welding Operation Pg. 34-38
Routine Maintenance Pg. 39
Troubleshooting Pg. 40-41

160/200/160P/200P AC/DC Series Machine
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 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: [e-mail]
Customer Service: [e-mail]
Dealers: [e-mail]
Complaints: [e-mail]
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

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com 3
W arranty
A manufacturer's limited warranty covers parts only, unless indicated below, and is furnished for five years
from the date of purchase warranting the product to be free of material defect or workmanship as follows:
Plasma Cutters, Welders, and Multi-Purpose Welders (Coverage for Parts and Labor for five years from the
purchase date at our facility).
In the event of product failure or malfunction, the purchaser/recipient must contact LONGEVITY™ GLOBAL,
INC. to obtain an RMA (return or missing) number and a location of a designated repair facility. The welder,
plasma cutter, multi-purpose unit, or any other welding related equipment comes with warranty on all internal
components. The torch, cables, power cord, clamps, air regulator, argon regulator, hoses, case, paint, and
consumables are not covered under warranty. Packages that are not pre-approved for return, and that do not
have an RMA number will be refused and returned to the purchaser/recipient at the purchasers/recipients own
cost. The product must be returned in its original packaging, with all accompanying components. Repair or
replacement of the defective product will be at our option. The repaired/replaced product will then be returned
to the purchaser. 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 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.

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com
In Warranty Service
Customers, who own machines that are in warranty and require service, should contact our Warranty
Department by email at [e-mail] 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 [e-mail]

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com 5
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.
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.

160/200/160P/200P AC/DC Series Machine
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 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 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
[e-mail].

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com 7
General Description
This WeldMax™ series welding machine, designed for welding low-carbon steel, alloy steel, and stainless steel,
uses advanced inverter technology, which allows us manufacture a unit that can also employ a Plasma Cutter.
By employing high-power MOSFETS and PWM technology, it converts DC voltage to high frequency AC
voltage. Subsequently, voltage is transformed and rectified, resulting in a small main transformer and a light-
weight inverter welder, which increases welding performance rates by 30%. High frequency oscillation,
enabling high frequency DC output, is used in the arc-starting system. This machine provides stable output, and
reliable, completely portable, efficient, and low noise generation, while welding or cutting.
The WeldMax™ series has three different functions: TIG, Arc, and plasma cutting. During ARC or TIG welding,
this equipment provides stable output with no arc-length variations. During plasma cutting, the arc, being driven
by highly compressed air, sees a rapid temperature rise up to 10,000 to 15,000 degrees, and becomes highly
ionized. Consequently, it produces the powerful plasma arc for cutting. Plasma cutting saves energy, is efficient,
and creates smooth, high-speed cuts. These machines weld and cut carbon steel, stainless steel, alloy steel, as well
as copper and other nonferrous metals. They are small, highly efficient, energy saving, stable in output, and
reliable. Their ratio of input voltage to output voltage approaches 85 percent.

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com
Techinical Specifications and Ratings
MODE Parameter
Type
WeldMax® 416D WeldMax® 518D WeldMax® 520D
416/518/520D
Units
Power Voltage AC110/220v
Input Frequency 50/60 Hz 50/60 Hz 50/60 Hz
Rated Input Current 20A 110v/50A
220v 20A 110v/50A220v 20A 110v/50A 220v
Power Capacity 4.8KVA 5.0KVA 5.0KVA
No load Voltage 80v/200v
Working Voltage 26.4V 28.1V 29.0V
Efficiency% >80% >80% >80%
Power Factor 0.93 0.93 0.93
Insulation Class F F F
Protection Class IP21S IP21S IP21S
Weight 38lbs 38lbs 39lbs
Size 18.9 X 9.4 X 13.0
in. 19.4 X 13.0 X 12.6 in. 22.0 X 14.4 X 14.0 in.
Welding Thickness (Steel) .31 in. .39 in. .5 in.
Cutting Thickness (Steel) Up to .5 in. Up to .79 in. Up to .79 in.
DC TIG (GTAW)
Base Current Adjusting Range 5 – 160A 5 - 200A 10 - 200A
Pulse Current Adjusting
Range 5 – 160A 5 - 200A 10 - 200A
Rated Duty Cycle at Max
Amps 60% 60%
Current Down-Slope Time 0-10 Seconds
Remote Control/Pedal Yes
Arc Starting Mode High Frequency
DC ARC/STICK
No Load Voltage 60 – 80V
Base Current Adjusting Range
(Amps) 10 – 160A 10 – 160A 10 – 160A
Rated Output Current (Amps) 160A 160A 160A
Rated Duty Cycle at Max 60%

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com 9
Amps
PLASMA
CUTTER
Base Current Range (Amps) 20 – 40A 20 – 50A 20 – 50A
Rated Duty Cycle at Max
Amps 60%
Arc Starting Method High Frequency

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com
What’s Included?

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com 11
Installation, Wiring, 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.
The LONGEVITY® WeldMax Plasma Cutter/Welder Combo units are dual voltage and can be connected to
either 110 or 220VAC.
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 for 220 Volt
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 110/220v plug match at your operating facility. Remember 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 these wires properly is extremely important. Improperlyconnected wires will void the
warranty, affect personnel safety, and possiblydamage your machine and electrical power outlet.
Identifying the Groundwire
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® Welding 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 easilydistinguish the colors. The best and safest way to determine which

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com
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 visuallydetect 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 are 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.
NOTE: LONGEVITY® recommends a 50 AMP breaker on 220v, but you can operate on 30AMP breaker.
Finished Plug:

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com 13
Wiring Introduction for 110 Volt - 20amp Breaker
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® Welding 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 easilydistinguish 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 visuallydetect the ground wire or do not feel comfortable with your
selection, ask an electrician for help.
Identifying the Neutral Wire
For 110vac service, the brown wire is is a hot wire. As you may know, 110vac features one hot wire, a
neutral wire, and a ground wire. If you are wiring to 110vac, your blue wire is neutral, brown is hot and
the green with yellow or SOLID GREEN is the ground.
Note: Hot Wires May also be WHITE and BLACK if a GREEN WIRE is one of the three wires. Therefore,
GREEN is ALWAYS GROUND. In this case one of the wires is neutral and one is hot.
NOTE: LONGEVITY® recommends a 20 AMP breaker on 110v
110V Plug Diagram:

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com
Main Unit
Pictured: WeldMax 416D Multi-Purpose Unit

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com 15
Main Unit Knob/Button/Function:
1. On/Off Breaker or Switch: Either breaker or switch located on the back or front of the unit will control the unit to
be turned on or off.
2. Power Indicator : Shows unit is powered on. Indicator is present in some models with a green LED bulb.
3. O.C. Over Current Light: Illuminates when the duty cycle has been exceeded or the machine has overheated due
to improper ventilation. Discontinue use until lamp goes out. Allow the fan to continue to run. Once lamp goes out,
you may resume using the unit.
4. Digital Display: Displays the approximate amount of amperage set to on the unit.
5. Gas (Air) Test/Cutting: This mode allows you to test air pressure and release air through the torch. Selecting Gas
(Air) Test, you should have air passing through the torch as long as the compressor is on. Cutting mode allows you
to use the plasma cutter normally.
6. AMP Adjustment Knob: Adjusts the amount of amps to desired AMP setting.
7. Ground Clamp Connector (+): Location of ground clamp to be plugged in and ran to the workpiece.
8. Stick Connector (-): Connect the stick welding rod here. You can also reverse polarity by switching the ground
clamp
9. Torch Remote Connector: 2 or 7 pin torch connector plugs here to activate the torch relay once the trigger is
pressed on the torch.
10. Torch Connector: Connect torch for air to pass through the unit and generate the arc at the torch tip.
11. Torch Air Outlet: This is only used with specific torches that require water cooling. Your unit does not come with
this feature as it is not required.
12. Air Regulator Pressure Gauge: Shows the amount of pressure at the torch in PSI.
13. Pressure Regulator Adjustment Knob: Adjust the amount of pressure at the unit. Pull the knob towards you or
up to unlock, turn clockwise for more pressure and counter clockwise for less pressure. Once the desired pressure
is reached, pop the knob back in place to lock it in place.
14. Thermal Protection Fan: Cools your unit during operation. Fan should be operating once the power is turned on
and the unit power indicator is lit.
15. 110/220v Power Cord: Attach the power cord to the wall outlet for unit power.
16. Ground Lug: An additional safety grounding lug. You can earth this wire or properly ground it to your
electricians specifications. Grounding the unit and yourself during cutting is extremely important
17. Air Inlet: Attach air compressor hose to the air inlet here.
18. Machine/Pedal: Select Pedal, when pedal is plugged into the machine.

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com
Assembly of Plasma Torches:
The plasma cutter torch handle is made of fire and heat resistant materials. Avoid dropping the torch or striking
anything with it. For convenience and ease of use, the torch’s ON/OFF switch can be positioned on the top, the
side, or the bottom of the torch body.
Assembly of Consumables for the 40/50AMP Torch Heads
Assemble the consumables as pictured above, and described below.
1. Insert the electrode.
2. Seat the ring on the electrode.
3. Place the copper tip on the ring, ensuring that is seated flat.
4. Secure all parts into place by turning the ceramic cup clockwise until it is snug. Do not over tighten.
The torch consumables are now successfully assembled.

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com 17
Assembly of Consumables for the 60AMP Torch Head
Assemble the consumables as pictured above, and described below.
1. Insert the electrode.
2. Place the copper tip on the ring, ensuring that is seated flat.
3. Secure all parts into place by turning the pink ceramic cup clockwise until it is snug. Do not over
tighten.
The torch consumables are now successfully assembled.

160/200/160P/200P AC/DC Series Machine
www.longevity-inc.com
Air Regulator Assembly to Unit
LONGEVITY® includes an air regulator/filter with your machine. You must attach the bracket to the machine,
and fasten the regulator to the bracket so it looks as pictured
1. Locate the INLET and OUTLET labeled on the regulator picture above and attach the Air Compressor
to the inlet and the OUTLET to the INLET on Unit with the provided hose to back of the machine,
where shown, and secure it with a hose tie.
2. Set the air compressor to about 60-75 PSI depending on the thickness of your cut. If you are getting a
poor cut quality, try adjusting the PSI on the regulator to see if the cut quality improves.
3. Periodically, after long periods of use, you must remove water from the air by pushing the water release
button inward to release water from the water separator section of the regulator.