Longevity Forcecut 40D User manual

LP-40/50/60D & LP-100 Plasma Cutters
Operating Manual for
40D/50D Constant Pilot Arc
Plasma cutters

ForceCut 40D and 50D plasma cutters
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Table of Contents:
PG. 2: Thank you From LONGEVITY
PG. 3-4: Warranty/Shipping Damage/Order Information
PG. 5: General Description
PG. 6-7: Warning and Safety Tips
PG. 8: Specifications and Ratings
PG. 9-11: Included Accessories
PG. 12-14: Wiring and Setup Instructions
PG. 15-16: Diagram of Main Unit
PG. 17: Main Unit Knob/Button/Function
PG. 18: Torch Consumables Assembly
PG. 19-26: Basic Operation and Cutting Methods
PG. 27: Routine Maintenance
PG. 28: Trouble Shooting Chart
PG. 29: Enjoy Your New Plasma Cutter!

ForceCut 40D and 50D plasma cutters
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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: [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

ForceCut 40D and 50D plasma cutters
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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.

ForceCut 40D and 50D plasma cutters
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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]

ForceCut 40D and 50D plasma cutters
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General Description:
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 IGBT internal components. By producing the units with inverter
technology, we are able to produce smaller and more efficient units. During the manufacturing
process, we keep maintenance and repair in mind by enabling the internal components of the
machine to be simple 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!

ForceCut 40D and 50D plasma cutters
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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.

ForceCut 40D and 50D plasma cutters
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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].

ForceCut 40D and 50D plasma cutters
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Specifications and Ratings
Parameter
Type
Model
ForceCut 40D
ForceCut 50D
Input Voltage (V)
Single Phase 110V or 220/230/240V
Input Current (Amp)
30Amp
39Amp
Cup Capacity max/severance (in.)
Up to ½”
Up to 5/8”
Output Current (Amps)
40
50
No-load Voltage (V)
200V
200V
Current Range (Amp)
20-40
20-50
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
HF Constant Pilot Arc
HF Constant Pilot Arc
Suggest Air Pressure (psi)
45-70psi
45-70psi
Suggested Air Volume (cfm)
2.0-3.0
2.0-3.0
Adjustable Post Flow Time (Seconds)
1-10
1-10
Machine Weight (lbs)
22
23
Size LxWxH (inches)
15 x 6 x 12
15 x 6 x 12

ForceCut 40D and 50D plasma cutters
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Included Accessories:
Main Unit
60Amp Pilot Arc Cutting Torch
(Ground) Earth Clamp
Water separator with bracket
Air Hose
Spare Fuses for Machine
Air Hose Valves (2)
Consumables: 3 piece tips, 3 piece electrodes
Pictures of Accessories: (Note: Torch Picture Varies
on Model Purchased)
60Amp Pilot Arc Cutting Torch (Ground) Earth Clamp

ForceCut 40D and 50D plasma cutters
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ForceCut 40D and 50D plasma cutters
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Water Separator Diagram for Installation:

ForceCut 40D and 50D plasma cutters
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The LONGEVITY® 40D/50D 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.
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 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 possibly damage your
machine and electrical power outlet.

ForceCut 40D and 50D plasma cutters
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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® 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 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 wires
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 30 AMP breaker on 220v, but you can operate on a
larger AMP breaker.
Finished Plug:

ForceCut 40D and 50D plasma cutters
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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 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 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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ForceCut 40D and 50D plasma cutters
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Pictured ForceCut™ 50D (Rear):

ForceCut 40D and 50D plasma cutters
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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. Warning Indicator: 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.
3. Digital Amperage Display: Displays the approximate amount of amperage set to on the unit.
4. Auto Gas Flow/ Manual Gas Flow: This mode allows you to test air pressure and release air
through the torch. Selecting Auto Gas (Air) Flow, you should have air passing through the torch as
long as the compressor is on. Manual mode allows you to use the plasma cutter with a trigger switch
activation.
5. AMP Adjustment Knob: Adjusts the amount of Amps to desired Amp setting.
6. Ground Clamp Connector (+): Location of ground clamp to be plugged in and ran to the work
piece.
7. Torch Remote Connector (Control): 2 or 7 pin torch connector plugs here to activate the torch
relay once the trigger is pressed on the torch.
8. Pilot Arc Torch Connector: Connect the torch pilot arc wire coming from the torch to this knob
for proper arching.
9. Fuse: Fuse Completes circuit for pilot arc. If machine will not strike or hold and arc, check fuse.
Replace with applicable fuse only. Contact your dealer for more details on specific fuse to be used.
10. Air Regulator Pressure Gauge: Shows the amount of pressure at the torch in PSI.
11. 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.
12. 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.
13. 220v/110v Power Cord: Attach the power cord to the wall outlet for unit power.
14. Ground Lug: An additional safety grounding lug. You can earth this wire or properly ground in
accordance with local electrical code. Grounding the unit and yourself during cutting is extremely
important to avoid shock and damage to the unit. Grounding Unit may also help reduce high
frequency interference.
15. Air Inlet: Attach air compressor hose to the air inlet here.

ForceCut 40D and 50D plasma cutters
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Assembly of Consumables for the 60 Amp
Torch:
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.

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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 water separator.
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 Auto Gas (Air) Flow. Air
will pass through the torch continuously.
11. If necessary remove slag from the under part of the cut using a grinder or chisel after your
cut.