Pro Mts 200 Manual

ProMTS 200 200AMP Synergic MIG/TIG/STICK

- 1 -

Operating Manual For

ProMTS 200 200 Amp Synergic MIG, DC TIG, STICK

Welder


- 2 -

Table of Contents: PG. 3: Thank you From LONGEVITY PG. 4-5: Warranty/Shipping Damage/Order Information PG. 6-8: Warning and Safety Information PG. 9: General Description PG. 9-: Specifications PG. 11: MIG gun dissection PG. 12-14: MIG Gun and Wire Mechanisim Instructions PG. 15-19: Operating Instructions PG. 20-21: Routine Maintenece PG. 22: Electronic Schematics PG. 23: THANK YOU! Enjoy your new welding machine from LONGEVITY!


- 3 -

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: [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

http://www.longevity-inc.com/

http://www.lweld.com/


mailto:[email protected]


http://www.freeweldingforum.com/


- 4 -

Warranty 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.


- 5 -

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]


http://www.longevity-inc.com/resources



- 6 -

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.


- 7 -

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.


- 8 -

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 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].



- 9 -

General Description:

The ProMTS 200 portable DC(Only) multi-process 200AMP MIG welder,200 Amp TIG welder and a 170A Stick Welder! This multipurpose welding machine has the full capability of welding any kind of metal including aluminum with Flux-Cored wire This machine is the total package! This welder is designed for light weight industrial welding, and perfect for the home or shop fabricator!

Installation and Adjustments Specifications:

Model

Parameters

ProMTS 200

Input Voltage（V） 1~220/230/240±10%

Input Current（A） MIG: 37 STICK: 33 TIG: 29

Input Power（KW） MIG: 5.9 STICK: 5.4 TIG: 4.5

Welding Current（A） STICK: 10-170 MIG/FLUX: 25-200 TIG: 10-200

No-load Voltage（V） 58 (STICK )

Duty cycle（40℃） TIG/MIG : 25%200A STICK: 30%170A ALL PROCESSES: 60%@115A 100@90A

MIG Wire Diameter(mm)

Fe ：0.6、0.8、0.9、1.0 Ss 0.8、0.9、1.0 AL：1.0

Protection class IP23S

Insulation class F

Dimensions（mm） 470*210*380

Weight（Kg） 13.5

Note: The above parameters are subject to change with the improvement of machines.


- 10 -

Dissection graphics for the MIG GUN

12

34

7

11

1213

14

151617

18

19

1095 6

8

3.1

The parts list for the MIG GUN

NO. Description QTY. Remark 1 Tip D.12 24KD 1 2 Electric nozzle 0.8/M6*25 1 3 24KD Swan gun neck（Hexangular adapter and Plastic adapter） 1 3.1 24KD Swan gun 1 4 Hexangular adapter 1 5 Plastic adapter 1 6 MIG blue Front handle 1 7 Torch Switch 21.8mm 1 8 Screw D.3*10 3 9 Handle locking ring 1 10 Cable fixing joint 24KD 1 11 Cable Assembly 1 12 Cable thimble 12-16-25 MMQ 1 13 CO2 Euro-rear thimble 1 14 Screw M4*6 UNI 6107 1 15 Torch locknut /plastic screw thread 1 16 Euro-main socket/flexibility pin 1 17 Feeding pipe locknut 1 18 Insulating feed pipe 0.6-0.8 3m, Blue 1 19 Spanner for the electric nozzle 1


- 11 -

Operation for the MIG GUN

1. Service the wire feed mechanism at least every time the reel is changed.

·Check the wear of the feed roll groove and change the feed roll when necessary.

·Clean the welding gun wire guide with compressed air.

2. Cleaning the wire guide

Pressure of the feed rolls remove metal dust from the filler wire’s surface which then finds its

way to the wire guide. If the wire guide is not cleaned, it gradually clogs up and causes wire feed

malfunctions. Clean the wire guide in the following manner：

Remove the welding gun’s gas nozzle, contact tip and contact tip’s adapter

with a pneumatic pistol, below compressed air through the wire guide.

Blow the wire feed mechanism and reel housing clean with compressed air.

Reattach the welding gun’s parts. Tighten the contact tip and contact tip’s adapter to spanner

tightness.

3. Changing the wire guide

If the wire guide is too worn or totally clogged, change it to a new one according to the

following instructions:

Open the mounting nut of the wire guide which exposes the end of the wire guide.

Straighten the welding gun’s cable and withdraw the wire guide from the gun.

Push a new wire guide in to the gun. Make sure that the wire guide enters all the way into the

contact tip’s adapter and that there is an O-ring at the machine-end of the guide.

Tighten the wire guide in place with the mounting nut.

Cut the wire guide 2mm from the mounting nut and file the sharp edges of the cut round.

Reattach the gun in place and tighten the parts to spanner tightness.


- 12 -

Maintenance of the wire feed mechanism


- 13 -

NO. Parts Qty NO. Parts Qty

1 Wire feed motor 1 10 Locking cover 1

2 Key 1 11 Spring 1

3 Feed roller 1 12 Reel cover 1

4 Locking screw 1 13 Screw washer 1

5 Machine 1 14 Wire guide tube 1

6 Connector 1 15 Wire reel shaft 1

7 Screw thimble 1 16 Shaft core 1

8 Screw nut 1 17 Washer 1

9 Feed strut 1 Changing the feed roll groove

The feed roller (No.3 in the picture) is factory set for welding filler wires of 08-1.0mm and

0.6mm diameter on the other side. The feed roller side must be changed if you use 0.6mm thick

filler wire.

Threading the filler wire

Threading the filler wire as the follow steps:

Open the reel housing by pressing on the opening button and install the wire reel in such a way

that it rotates counter clockwise. You can use either a diameter 200mm or 100mm wire reel in the

machine.

Attach the reel with a reel lock.

Unfasten the wire end from the reel, but do not let go of the wire.


- 14 -

Straighten the wire end for approximately 20 cm and cut the wire in the straightened location.

Open the pressure control level which then opens the feed gear.

Thread the wire through the wire’s rear guide to the gun’s wire guide.

Close the feed gear and fasten it with the pressure control lever. Make sure that the wire runs in

the feed roll groove.

Adjust the compression pressure with the pressure control lever no higher than to the middle of

the scale. If the pressure is too high, it removes metal fragments from the wire surface and may

damage the wire. On the other hand, if the pressure is too low, the feed gear slips and the wire

does not run smoothly.

Press the welding gun trigger and wait for the wire to come out.

Close the reel housing cover.

Note：When driving the wire into the gun, do not point the gun at yourself or others.


- 15 -

Operation Layout for the front panel


- 16 -

1. Welding Process Selection: Pressing the button selects between MIG/TIG and STICK

2. Current display: Welding amperage display when machine is working, Set amperage

display before welding.

3. Voltage display: Welding voltage display when machine is working, Set voltage

display when in MIG mode before welding.

4. Wire Material Selection: Pressing button selects the type of wire material while in

MIG mode.

5. Wire Diameter Selection: Pressing button selects the welding wire diameter while in

MIG mode.

6. Wave Form knob: Controls arc characteristics while in MIG mode only. Lower wave

form settings make the arc softer with less weld spatter. Higher wave form settings

give a stronger driving arc which can increase weld penetration.

7. Voltage (MIG)/Down slope (TIG)/Arc force(STICK) control: On MIG, When the

program voltage can’t perfectly match the welding current, the knob can adjust

voltage .When TIG process is selected, the knob can adjust the current down slope

time. When STICK process is selected, the knob can adjust the arc force.

8. TIG/STICK Amps /MIG Wire Speed: Set the welding current.

9. 2T/4T Selection: Allows to alternate between 2T or 4T mode in either TIG or MIG

modes.

10. MIG GUN Connectors

11. TIG Torch Connection: When in TIG mode, this polarity must be used to ground to

your workpiece.

12. TIG gun control connecter

13. Output cathode：When in MIG mode, this polarity must be used to ground the work

piece


- 17 -

Welding operation

MIG mode operation:

1. Shielding Gas choice

• When the wire material is Fe, the shielding gas is 80%Ar + 20%CO2 ；

• When the wire material is Ss, the shielding gas is 98%Ar + 2%O2 ；

• When the wire material is Al, the shielding gas is 100%Ar.

2. Welding state choice

• Press the Welding Process Selection button, choose MIG manner and the MIG

LED is lighted；

MMA

TIG

MIG

• Press the wire diameter key, choose the wire diameter from (0.6—1.0)；

0.6

0.8

0.9

1.0

SPL

• Press the wire material key, choose the wire from (Fe/Ss/Al) ；

Ss

Al

Fe

• Press the welding mode key, choose 2T or 4T；

4T

2T

• When the worker needn’t automatic welding, they can choose SPL by pressing


- 18 -

the wire diameter key to choose the manual mode. SPL state is manual mode,

the wire feed speed and welding voltage is adjusted separately.

Note：The current display is the wire feed speed (cm/min).

3. Adjusting Welding parameters

1) Different wire diameter, the minimum welding current is different；

2) Adjust the current knob; the corresponding welding voltage is changed automatically；

3) When the programmable welding voltage isn’t the perfect for the operator, the voltage

can be changed tinily by adjusted the knob；

4) If the operator adjusts the wave control knob, the arc characteristics can be controlled；

Note：With the ProMTS200, the burn back time is adjusted by the burn back knob under

the wire feed mechanism.

TIG mode operation:

1. Press the Welding Process Selection button, choose TIG process；

2. Press the welding mode key, choose 2T or 4T；

3. Adjust the current knob to control the welding current；

4. Adjust the down slope knob to control the welding current descend time.

STICK mode operation:

1. Press the Welding Process Selection button, choose STICK process

2. Adjust the current knob to control the welding current；

3. Adjust the welding arc force knob to control the arc force current.

Note：The current display is preset current before welding and is welding current when

welding. The voltage display is real voltage.


- 19 -

Welding parameters Wire diameter (mm) Welding current (A) Plate thickness (mm)

0.6 25-110 1.0-1.6

0.8 35-160(200) 1.0-2.3

0.9 45-160(200) 1.0-2.3

1.0 45-160(200) 1.2-6

.


- 20 -

Routine Maintenance The life of your machine and the quality of the work performed using your machine, will be enhanced by practicing periodic routine maintenance.

• At regular intervals, clear dust that may accumulate in the machine using clean and dry compressed air. If the working condition has heavy smoke and pollution, the welding machine should be cleaned once a month.

• Keep the machine exterior clean with mild soap and water.

• Do not walk on or store items on the cables or cords.

• Do not jar, drop, or stack items on top of the machine.

• Always connect the machine to a well-grounded electrical outlet.

• Always check the torch consumables before and after use and ensure that they are clear of obstructions, and that no parts are damaged.

• Replace any worn or damaged consumables before using machine.

• For periods of prolonged non-use, remove cables and store them in their original boxes in a cool dry place.

•

Date Maintenance items

Daily examination

Observe that whether panel knob and switch in the front and at the back of arc welding machine are flexible and put correctly in place. If the knob has not been put correctly in place, please correct; If you can't correct or fix the knob , please replace immediately;

If the switch is not flexible or it can't be put correctly in place, please replace immediately; Please get in touch with maintenance service department if there are no accessories.

After turn-on power, watch/listen to that whether the arc welding machine has shaking, whistle calling or peculiar smell. If there is one of the above problems, find out the reason to get rid of; if you can't find out the reason, Please contact local this area agent or the branch company.

Observe that whether the display value of LED is intact. If the display number is not intact, please replace the damaged LED. If it still doesn’t work, please maintain or replace the display PCB.

Observe that whether the min/max value on LED accords with the set value. If there is any difference and it has affected the normal welding craft, please adjust it.

Check up that Whether fan is damaged and is normal to rotate or control. If the fan is damaged, please change immediately. If the fan does not rotate after the arc welding machine is overheated , observe that whether there is something blocked in the blade, if it is blocked, please get rid of ; If the fan does not rotate


- 21 -

after getting rid of the above problems, you can poke the blade by the rotation direction of fan. If the fan rotates normally, the start capacity should be replaced; If not, change the fan.

Observe that whether the fast connector is loose or overheated. if the arc welding machine has the above problems, it should be fastened or changed.

Observe that Whether the current output cable is damaged. If it is damaged, it should be wrapped up, insulated or changed.

Monthly examination

Using the dry compressed air to clear the inside of arc welding machine. Especially for clearing up the dusts on radiator, main voltage transformer, inductance, IGBT module, the fast recover diode and PCB, etc.

Check up the bolt in arc welding machine, if it is loose, please screw down it. If it is skid, please replace. If it is rusty, please erase rust on bolt to ensure it works well.

Quarter- yearly

examination

Whether the actual current accords with the displaying value. If they did not accord, they should be regulated. The actual current value can be measured by the adjusted plier-type ampere meter.

Yearly examination

Measure the insulating impedance among the main circuit, PCB and case, if it below 1MΩ, insulation is thought to be damaged and need to change , and need to change or strengthen insulation.


- 22 -

Electrical schematic drawing

43

2

ZBYQ

OC1OC2

QD2

QD1

OUT+

OUT-

- 23 -

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 [email protected].

LONGEVITY® Global, Inc.

Toll-Free 1-877-LONG-INC / 1-877-566-4462

Website: www.longevity-inc.com

Sales: [email protected]

Customer Service: [email protected]

Dealers: [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

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!






http://www.freeweldingforum.com/

Pro Mts 200 Manual

Documents

Transcript of Pro Mts 200 Manual