Longevity Forcecut 40D User manual

Operating Manual
for
ForceCut™40i/50i
Constant Arc Pilot Arc
Plasma Cutters

ForceCut 40i and 50i plasma cutters
www.longevity-inc.com i
Table of Contents
Table of Content
Pg. i
Thank you From LONGEVITY®
Pg. ii
Warranty/Shipping Damage/Order Information
Pg. 1-2
Introduction
Pg. 3
Warning and Safety Tips
Pg. 4-5
Specifications and Ratings
Pg. 6
What’s Included?
Pg. 7
Basic Installation, Wiring, Air Regulator Assembly, and Setup Instructions
Pg. 8-13
Main Unit Knob/Button/Function
Pg. 14
Assembly of Plasma Cutter Torches
Pg. 15
Basic Plasma Cutter Operation
Pg. 16
Summary Chart of All LONGEVITY Plasma Cutters
Pg. 17-18
Features Chart of All LONGEVITY Plasma Cutters
Pg. 19
Typical Applications of All LONGEVITY Plasma Cutters
Pg. 20
Cutting Methods
Pg. 21
Tips and Advice for LONGEVITY Plasma Cutting by
www.plasma-cutters.com and www.freeweldingforum.com
Pg. 22-27
Routine Maintenance
Pg. 28
Troubleshooting
Pg. 29
Conclusion
Pg. 30

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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!
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

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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. When doing so, please provide the following information:
Order No.: _________________________________
Serial No: _________________________________
Date of Purchase: ____________________________
Warranty Period: ____________________________
Unit Tested Prior to Shipment By: _____________________________
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® is here to help. 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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Introduction
The LONGEVITY® ForceCut™ series plasma cutters offer a revolutionary new
approach to plasma cutting technology. LONGEVITY® plasma cutters use the
newest technology available in the welding industry with the help of Toshiba internal
components. By producing the units with inverter technology, we are able to produce
smaller and more efficient units. During the manufacturing process, we kept the
maintenance and repair in mind by enabling the internal components of the machine
to be a simply plug and operate circuitry enabling all mother boards to be simply
replaced and swapped out. The ForceCut™ series plasma cutters use special safety-
redundant circuitry with built in auto-protection and self-adjusting circuitry to keep
the machine running at a safe threshold. This helps protect the machine from over-
voltage, power spikes, tip blowouts and shorting . We hope you enjoy your
LONGEVITY® ForceCut™ series plasma cutter. We are proud of
our achievements in the welding industry, we are thankful you have
chosen to use the LONGEVITY® ForceCut™ series. These Pilot
Arc plasma cutters are superior to High Frequency plasma cutters
because they generator a pilot arc enabling for you to start cutting
without making any contact with the metal workpiece.

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Warning
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.
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.

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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 -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 [email protected].

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Specifications and Ratings
Type
Parameter
ForceCut 40D Pilot Arc
ForceCut 50D Pilot Arc
Input Voltage (V)
220v 1-Phase 50amp
Cup Capacity max/sev (in.)
Up to ½”
Up to 5/8”
Input Current (Amp)
20Amp 110v/30Amp220v
20Amp 110v/30Amp220v
Output Current (Amps)
40
50
No-load Voltage (V)
100/200v
100/200v
Current Range (Amp)
10-40
10-50
Rated Duty Cycle (%)
60
60
Efficiency
85
85
Power Factor (Cos0)
0.93
0.93
Insulation Class
B
B
Protection Class
IP21
IP21
Arc Starting
Pilot Arc
Pilot Arc
Suggest Air Pressure (psi)
60-75
60-75
Suggested Air Volume (cfm)
3.5-4.5
3.5-4.5
Post Flow Time (Seconds)
10
10
Machine Weight (lbs)
22
23
Size LxWxH (inches)
15 x 6 x 12
15 x 6 x 12

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What’s Included:
Main Unit
Cutting Torch
(Ground) Earth Clamp
Water separator with bracket
Air Hose
Teflon Tape
Air Hose Valves (2)
Consumables: 1 piece tip, 1 piece electrode
20amp Power Plug
Pictures of Accessories: (Note: Torch Picture
Varies on Model Purchased)

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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.
The LONGEVITY® 40i/50i Pilot Arc Plasma Cutters may or may not be dual
voltage varying by machine of purchase. Please check the back of your machine for
the noted input requirement or contact your LONGEVITY dealer for specifications.
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. Improperly connected wires will void the warranty, affect personnel
safety, and possiblydamage your machine and electrical power outlet.

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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 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 anyreason, 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.

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Finished Plug:
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 anyreason, you cannot visuallydetect the
ground wire or do not feel comfortable with your selection, ask an electrician for
help.

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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:

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Basic Installation Instructions Pictured
Model ForceCut™ 50i (Note: All Models
have the same connections):
ForceCut™ 50i Pilot Arc:

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Water Separator Assembly to Unit
(Pictured ForceCut™ 50i Plasma Cutter):
LONGEVITY® includes a Water separator with the ForceCut 40i and 50i. You must
attach the bracket to the machine, and fasten the separator to the bracket.
Locate the INLET and OUTLET labeled on the separator and attach the Air line
coming from the Compressor to the INLET side of the separator. Attach the clear
hose that comes with the machine to the OUTLET side of the separator. Air direction
may also be indicated with arrows rather than writing.
Set the air compressor to 75 PSI +. Rember that air pressure is key to a proper, clean
cut and consumable life. Make sure that your air pressure is consistent at 75 PSI at
all times. You can set your compressor at a higher volume setting and regulate to 75
PSI with the regulator on the front of the machine.
1. 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 sectioned with moisture.
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.

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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. Torch Remote Connector: 2 or 7 pin torch connector plugs here to activate the torch
relay once the trigger is pressed on the torch.
9. Torch Connector: Connect torch for air to pass through the unit and generate the arc
at the torch tip.
10. Pilot Arc Torch Connector: Connect the torch pilot arc wire coming from the torch to
this knob for proper arching.
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 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. 220v Power Cord: Attach the power cord to the wall outlet for unit power. Required
30amp breaker on 220v side.
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 to avoid shock and damage to the unit.
17. Air Inlet: Attach air compressor hose to the air inlet here.

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Assembly of Plasma Torch:
The plasma cutter torch handle is made of fire and heat resistant materials. Avoid
dropping the torch or striking anything with it. Assemble the consumables as
pictured above, and described below.
1. Insert the electrode. Tighten it with pliers.
2. Seat the swirl ring on the electrode.
3. Place the copper tip on the ring, ensuring that is seated flat.
4. Place the shield cup over the tip and secure. Secure all parts into place by
turning the ceramic cup clockwise until it is snug. Do not over tighten.

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7
Basic Operation
1. Ensure that all cables are connected to the machine.
2. Ensure that the machine’s OFF/ON switch is set to OFF, and plug the machine
into the electrical outlet.
3. Connect the air compressor supply line to the air input side on the unit.
4. Turn the ON/OFF switch to ON. The cooling fans should operate and the ON
indicator LED or power switch (if applicable) should illuminate.
5. Clean the contact point on the work piece to ensure a good electrical connection.
Ensure that no rust of paint is present that could create an open circuit.
6. Connect the ground clamp to the work piece to be cut.
7. Connect the torch to the unit properly.
8. With the pilot arc knob connected, you should get a full continuous arc when the
trigger on the torch is pressed.
9. Depress the button on your torch to start the arc and begin cutting.
10. You can test the air to insure that is it properly flowing by selecting Gas (Air)
Test. Air will pass through the torch.
11. If necessary remove slag from the under part of the cut using a grinder or chisel.