Longevity ForceCut LP-100 User manual

Operating Manual
for
LP-40/50/60D
and
LP-70/80/100
Plasma Cutters

LP-40/50/60D & LP-100 PlasmaCutters
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
Installation, Wiring, and Setup Instructions Pg. 8-14
Main Unit Knob/Button/Function Pg. 15
Assembly of Plasma Cutter Torches Pg. 16-18
Basic Plasma Cutter Operation Pg. 19
Summary Chart of All LONGEVITY Plasma Cutters Pg. 20-21
Features Chart of All LONGEVITY Plasma Cutters Pg. 22
Typical Applications of All LONGEVITY Plasma Cutters Pg. 23
Cutting Methods Pg. 24
Tips and Advice for LONGEVITY Plasma Cutting by
www.plasma-cutters.com and www.freeweldingforum.com
Pg. 25-30
Routine Maintenance Pg. 31
Troubleshooting Pg. 32
Conclusion Pg. 33

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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: [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

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W arranty
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.

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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 [e-mail] 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 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]

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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.

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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 help@LONGEVITY®-inc.com.

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Specifications and Ratings
Type
Parameter LP-40D LP-50D LP-60D LP-70 LP-80 LP-100
Input Voltage (V) 110/220v 1-Phase 220v 1-Phase 220v 3-
Phase
Cup Capacity max/sev
(in.) Up to .75 Up to 1.0 Up to 1.5 Up to 1.75 Up to 2.0 Up to 2.5
Input KVA/AMPS 6/17 6/17 9/31 11/36 11/36 15/49
No-load Voltage (V) 110/220 110/220 110/220 220v
(1Phase)
220v
(1Phase) 220v
(3Phase)
Current Range (A) 10-40 10-50 10-60 10-70 10-80 20-100
Rated Output Voltage (V) 100 100 120 120 125 130
Rated Duty cycle (%) 60 60 60 60 60 60
Efficiency 85 85 85 85 85 85
Power Factor (Cos0) 0.93 0.93 0.93 0.93 0.93 0.93
Insulation Class B B B B B B
Protection Class IP21 IP21 IP21 IP21 IP21 IP21
Arc Starting HF Arc-
leading HF Arc- leading HF Arc- leading HF Arc- leading HF Arc- leading HF Arc- leading
Suggest Air Pressure (psi) 70 70 75 75 75 80
Suggested Air Volume
(cfm) 2-4 2-4 3-4 3-6 3-6 5-7
Machine Weight (lbs) 18 19 42 55 70 77
Size LxWxH (inches) 15 x 6 x 12 15 x 6 x 12 19 x 8 x 14 21 x 9 x 14 21 x 9 x 14 19 x 13 x
15

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What’s Included:
Main Unit
Cutting Torch
(Ground) Earth Clamp
Air Regulator with Water Separator and Bracket
Air Hose
Teflon Tape
Consumables: 2 piece tips, 2 piece electrodes, 1 piece gas diffuser, 1 piece
shield cups
Pictures of Accessories: (Note: Torch Picture
Various 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® LP-40/50/60D Plasma Cutters 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.

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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 usuallyone 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 anyreason, you cannot visually detect 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 usuallyone 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 anyreason, you cannot visually detect 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 Instalation Insturctions Pictured
Model ForceCut™ 40D and 70D Models
(Note: All Models have the same
connections):
ForceCut™ 70D:

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ForceCut™ 40D:

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Air Regulator Assembly to Unit (Pictured
ForceCut™ 40D Plasma Cutter):
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.

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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. Power Indicator (If applicable): Shows unit is powered on. Indicator is
present in some models with a green LED bulb. Other models that do not
feature this LED, will have a lighted power switch.
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. 2.5/5.0/Auto Second Flow Switch: Post Flow Switch that allows minimal or
maximum air through to cool your torch. Manual 2.5/5.0 selection available
in some units. Other units have automatic regulated POST FLOW.
6. AMP Adjustment Knob: Adjusts the amount of amps to desired AMP
setting.
7. Ground Clamp Din (+): Location of ground clamp to be plugged in.
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 Air Outlet: Connect torch for air to pass through the unit
and generate the arc at the torch tip.

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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 LP-40D/50D
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.