Longevity Forcecut 40D User manual

Operating Manual
For
FORCECUT 40D
40AMP Plasma Cutter 110v/220v

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Table of Contents:
PG. 3: Thank you From LONGEVITY
PG. 4-6: Warranty/Shipping Damage/Order Information
PG 7: General Description
PG. 8-9: Warning and Safety Information
PG. 10: Safety Tips
PG. 11: Technical Data/ Specifications
PG. 12: Front Panel
PG. 13: Basic Installation
PG. 14-15: Basic Operation
PG. 16: Troubleshooting
PG. 17: Enjoy your new plasma cutter 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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General Description:
The 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 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!

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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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MAIN TECHNICAL DATA
Data
Item
FORCECUT 40D
Power voltage (v)
1 phase 110V±10%
1 phase 220V±10%
Frequency (Hz)
50/60
No-load voltage (v)
370-405
Rated input current (A)
47.9
29.9
Rated output voltage (v)
93.2
96
Output current regulation (A)
14-33
14-40
Duty cycle
60%
Efficiency
80
Power factor
0.73
Pilot arc model
Low Frequency Pilot Arc
Burner inter diameter (mm)
1.0
Pressure of air compressor (kg)
4-5
Thickness (mm)
1-12
Weight (kg)
13.8
Dimensions (mm)
500×245×450

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Front Panel

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The panel picture above is for reference only. If any difference with the real machine, please follow with the
real machine.

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Check Prior to Use
1. Check if cutting machine is grounded securely according to standard.
2. Check if all connectors are connected firmly.
3. Check if power voltage is correct.
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.

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Operation environment
1. The cutting machine can perform in an environment where conditions are particularly harsh
and with outside temperature between –10 and +40 degrees centigrade with a dampness level
of max 80%.
2. Avoid using in sunshine and dropping environment.
3. Keep machine dry and avoid water in the machine.
4. Do not use the cutting machine in an environment where conditions are polluted with high
concentrations of dust or corrosive gas in the air.
CUTTING NOTES
1. Make sure copper tip does not come in direct contact to work piece when user is cutting.
Torch should be inclined and it is 1 mm from inter-hole of copper tip to work piece in order
to protect copper tip.

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Problems, Causes, and Solutions
Problems
Causes/
Solutions
Machine will not
turn on.
Check cords and breaker. If nothing is found, contact
LONGEVITY
The machine runs,
but nothing is
happening
Check to see if you have the air regulator to the correct pressure.
Make sure the regulator adjustment knob is turned clockwise and
allow pressure. Check the consumablesand make sure they are
properly assembled. Check the ground clamp and proper grounding
to the unit. Check pilot arc wire to insure it is properlyconnected to
the unit.
Consumables
(tips) are being
consumed
Improper air flow. Increase the PSI on the regulator, check for
leaks in the hose, maintain a distance of 1/8” from the torch tip or
work piece.
Heavy Underside
Slag (Cutting)
Slow travel speed. Increase travel speed or amperage on unit.
Poor Cut Quality
Check Air Pressure. Insure your unit is capable of cutting the desired
thickness of material. Check the consumables to insure they are
producing a stable arc. Replace Consumables and insure you have
the proper PSI at the regulator.
Inconsistent
Arc
Improper grounding or possible lack of air pressure. Check and
replace consumables and adjust the regulator to proper PSI
Plasma Cutter
Pilot Does not
Ignite
Check consumables to insure they are super tight. Possibly, replace
the tips. Insure that you have compressed air flowing to the unit.
Drop the PSI pressure.
O.C. Over
Current LED
Lights
The unit has reached its DUTY Cycle. Leave power of the machine
on and allow fans to cool the machine. You can also turn the
machine off to properly cool it. Do not continue to weld until light is
off.
Issue Not Listed
Contact LONGEVITY Toll Free 1-877-566-4462 or via email at
Trouble shooting
If your unit is not properly functioning, please call us immediately toll free at 1-877-566-4462 for support. We
have included a small table here to diagnose most common problems.
[e-mail]

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 plasma cutter machine from LONGEVITY! Thanks again!