Longevity ForceCut LP-100, ForceCut LP-80, LP-70, ForceCut LP-60D, ForceCut LP-50D Operating Manual

Operating Manual

for

LP-40/50/60D

and

LP-70/80/100

Plasma Cutters

LP-40/50/60D & LP-100 Plasma Cutters

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

Routine Maintenance Pg. 31
Troubleshooting Pg. 32
Conclusion Pg. 33

Pg. 25-30

www.longevity-inc.com i

PLASMA CUTTERS www.LWELD.com

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

ii www.longevity-inc.com

Plasma Cutters www.LWELD.com

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.

www.longevity-inc.com 1

PLASMA CUTTERS www.LWELD.com

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 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]

2 www.longevity-inc.com

Plasma Cutters www.LWELD.com

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 safety­redundant 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 over­voltage, power spikes, tip blowouts and shorting
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.

. We hope you enjoy your

www.longevity-inc.com 3

PLASMA CUTTERS www.LWELD.com

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.

4 www.longevity-inc.com

Plasma Cutters www.LWELD.com

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

least 12 inches between this cutting equipment and any other objects in the

of at
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.

www.longevity-inc.com 5

PLASMA CUTTERS www.LWELD.com

Specifications and Ratings

Parameter

Input Voltage (V) 110/220v 1-Phase 220v 1-Phase

Cup Capacity max/sev

(in.)

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

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

LP-40D LP-50D LP-60D LP-70 LP-80 LP-100

Up to .75 Up to 1.0 Up to 1.5 Up to 1.75 Up to 2.0 Up to 2.5

Type

220v

(1Phase)

220v

(1Phase)

220v 3-

Phase

220v

(3Phase)

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

Suggest Air Pressure (psi) 70 70 75 75 75 80

Suggested Air Volume

(cfm)

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

HF Arc-

leading

2-4 2-4 3-4 3-6 3-6 5-7

HF Arc-

leading

HF Arc-

leading

HF Arc-

leading

HF Arc-

leading

HF Arc-

leading

19 x 13 x

15

6 www.longevity-inc.com

Plasma Cutters www.LWELD.com

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)

www.longevity-inc.com 7

PLASMA CUTTERS www.LWELD.com

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. Improperly connected wires will void the warranty, affect personnel
safety, and possibly damage your machine and electrical power outlet.

8 www.longevity-inc.com

Plasma Cutters www.LWELD.com

Identifying

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

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.

the Ground wire

the hot wire

www.longevity-inc.com 9

PLASMA CUTTERS www.LWELD.com

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 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.

10 www.longevity-inc.com

Plasma Cutters www.LWELD.com

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:

www.longevity-inc.com 11

PLASMA CUTTERS www.LWELD.com

Basic Instalation Insturctions Pictured
Model ForceCut™ 40D and 70D Models
(Note: All Models have the same
connections):

ForceCut™ 70D:

12 www.longevity-inc.com

ForceCut™ 40D:

Plasma Cutters www.LWELD.com

www.longevity-inc.com 13

PLASMA CUTTERS www.LWELD.com

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.

14 www.longevity-inc.com

Plasma Cutters www.LWELD.com

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.

www.longevity-inc.com 15

PLASMA CUTTERS www.LWELD.com

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.

16 www.longevity-inc.com

Plasma Cutters www.LWELD.com

Assembly of Consumables for the LP-60D

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.

Assembly of 70/80 AMP Torch for the LP-70/80

www.longevity-inc.com 17

PLASMA CUTTERS www.LWELD.com

This assembly is similar to the cutters described above, except it does use a swirl
ring.

1. Insert the electrode, and tighten with until snug.

2. Insert the swirl ring on top of the electrode.

3. Place the copper tip on the electrode/swirl ring, ensuring that is seated flat,

and tighten with wrench until snug.

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.

Assembly of 100 AMP Torch for LP-100:

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.

18 www.longevity-inc.com

Plasma Cutters www.LWELD.com

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 input side of the air regulator/filter.

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. Bring the torch tip into contact with your work piece edge or, if cutting thick

material, over a pre-drilled pilot hole. See Cutting Guideline Table below.

8. Depress the button on your torch to start the arc and begin cutting.

9. The 2.5S and 5.0S (if applicable) on your is an air blow switch. If you are cutting

for short periods of time, leave the switch on 2.5s to allow a 2.5 second air delay
to pass through the torch. If you are cutting for long periods of time, leave the
unit on 5.0S to allow more air to pass through the torch. This feature protects the
torch from over heating. Some LONGEVITY® plasma cutters have automatic air
flow adjustments so the switch may not be required.

10. If necessary remove slag from the under part of the cut using a grinder or chisel.

www.longevity-inc.com 19

"Rated" Cutting Thicknesses at

Recommended

ForceCut®

ForceCut®

100% (230 V

100% (110 V

ForceCut®

100% (230 V

100% (110 V

ForceCut®

100% (230 V

100% (110 V

ForceCut®

PLASMA CUTTERS www.LWELD.com

Summary Chart of Plasma Cutters:

220 V (110V reduces power in

Plasma Cutters

LP-40D

Plasma
Cutters

Rated Output

40 A at 60%

(230 V Input)

30 A at 60%

(110 V Input)

40 A at 60%

or 30 A at

Mild
Steel

Stainless

Steel

1/2 in 1/2 in 1/4 in 2500 watts

half)*

Generator

Power

Aluminum

LP-40D

Pilot Arc

LP-50D

LP-50D

Pilot Arc

Plasma
Cutters

Plasma
Cutters

Plasma
Cutters

Input)

1/2 in 1/2 in 1/4 in 4000 watts

30 A at 60%

or 25 A at

Input)

50 A at 60%

or 40 A at

Input)

3/4 in 3/4 in 3/8 in 4000 watts

40 A at 60%

or 30 A at

Input)

50 A at 60%

or 40 A at

Input)

3/4 in 3/4 in 3/8 in 4000 watts

40 A at 60%

or 30 A at

Input)

60 A @ 60%

LP-60D

Plasma

Duty Cycle

(230 V Input)

Cutters

20 www.longevity-inc.com

1 in 1 in 1/2 in 10,000 watts

Plasma Cutters www.LWELD.com

40 A @ 100%

ForceCut®

ForceCut®

MaxArc®

60%

ForceCut®

60I Plasma

Duty Cycle

(110 V Input)

LP-70

Plasma

Cutters

LP-80

Plasma

Cutters

LP-100

Plasma

Cutters

70 A at 60%

(230 V Input)

80 A at 60%

(230 V Input)

100 A at

(230 V Input

1- phase)

1 1/4 in 1 1/4 in 5/8 in 8000 watts

1 1/2 in 1 1/2 in 3/4 in 9000 watts

2 in 2 in 1/4 in 10,000 watts

60 A @ 60%

Cutters

Duty Cycle

(220 V Input)

1 1/4 in 1 1/4 in 3/4 in 6500 watts

www.longevity-inc.com 21

25 lbs (28 lbs

40D Pilot

25 lbs (28 lbs

25 lbs (28 lbs

50D Pilot

25 lbs (28 lbs

Pilot Arc Starting Technology, 60% Duty

36 lbs (40 lbs

38 lbs (45 lbs

40 lbs (47 lbs

74 lbs (90 lbs

45 lbs (52 lbs

PLASMA CUTTERS www.LWELD.com

Features Chart of Plasma Cutters:

Technology Plasma Cutters

ForceCut®
LP-40D

ForceCut®
LP­Arc

ForceCut®
LP-50D

MOSFET
Technology

ForceCut®
LP­Arc

ForceCut®
LP-60D

Product

Weight

Boxed)

Boxed)

Boxed)

Boxed)

Boxed)

Highlighted Features

110/220 V Input, Portable, High
Frequency Start, Toshiba Mosfet
Technology

Pilot Arc Starting Technology, 110/220
V Input, Portable, Toshiba Mosfet
Technology

60% Duty at 50A & 100% Duty at 40A,
110/220 V Input, Portable, High
Frequency Start, Toshiba Mosfet
Technology

at 50A & 100% Duty at 40A, 110/220 V
Input, Portable, Toshiba Mosfet
Technology

Powerful and Versatile! 110/220 V Input
with 1" Cut Capability, Toshiba Mosfet
Technology

IGBT
Technology

ForceCut®
LP-70

ForceCut®
LP-80

MaxArc®
LP-100

ForceCut®
60I

Boxed)

Boxed)

Boxed)

Boxed)

Commercial Grade, Powerful, 220 V
Input, Toshiba Mosfet Technology

Most Powerful 1-Phase 220 V Input, 1
1/2 in Rated, Toshiba Mosfet Technology

Industrial Grade, 220 V Input 3-phase, 2
in Rated, Portable

Commercial Plasma Cutter, Portable,
Industrial Grade, 220 V Input 1-Phase,

1.25" Cut Power

22 www.longevity-inc.com

Plasma Cutters www.LWELD.com

lot Arc enables easier Arc Starting25

ForceCut® 60I

Manufacturing, Thick metal cutting, Commercial Use,

Typical Applications Chart of Plasma Cutters:

Technology Plasma Cutters

ForceCut®
LP-40D

ForceCut®
LP-40D Pilot
Arc

ForceCut®
LP-50D

ForceCut®

MOSFET
Technology

LP-50D Pilot
Arc

ForceCut®
LP-60D

ForceCut®
LP-70

ForceCut®
LP-80

MaxArc® LP­100

Typical Applications

Hobbyist, Auto-Body, Plumbers, Sheet Metal Work,

Thin Material, HVAC

Hobbyist, Auto-Body, Plumbers, Sheet Metal work,

Thin materials. Pi

lbs (28 lbs Boxed)

Hobbyist, Light Industrial, Commercial, Fabrication,

Maintenance, Light Construction

Hobbyist, Light Industrial, Commercial, Fabrication,

Maintenance, Light Construction

Boat Repair, Commercial, Light Industrial, Body

Shops, Repair

Commercial, Industrial, Repair, Fabrication

Manufacturing, Repair, Heavy Fabrication,

Construction, Industrial

Manufacturing, Industrial, Construction, Heavy Duty

Fabrication, Automation

IGBT
Technology

Portable Fabrication, Industrial Repair, Heavy

Construction, Fab Work

www.longevity-inc.com 23

PLASMA CUTTERS www.LWELD.com

Cutting Methods

Different material thicknesses require different cutting techniques.

 Thin material: Start perpendicular to the work piece. It is unnecessary to

angle or start on the edge, as the arc will pass through quickly.

 Medium material: Angle the torch tip to avoid damaging the tip. Once the

arc passes through the material, you may begin cutting normally.

 Thick material: Drill a pilot hole through which to start your arc, or start on

the edge of the work piece.

Never cut material on a flat surface. Raise the work piece above the surface to avoid
blow back which may burn you or cause fires.

Real Time Arc-Curve Delay

When cutting thick materials you must maintain a steady even motion in the
direction of the cut. Moving the torch too quickly causes an arc-curve delay. An
arc-curve delay can leave the work piece with uncut sections, requiring you to re-cut
those sections, which could distort or damage the work piece.

To avoid arc-curve delay, allow the arc to pass completely through the work piece
before moving too far ahead. The arc-curve should lag not more than the thickness of
the material being cut. In other words, if the work piece is one-half inch thick, the arc
curve should lag not more than one-half inch behind the torch, as shown below.

LP-

40D

24 www.longevity-inc.com

Plasma Cutters www.LWELD.com

the owner's manual all the way through regardless of your experience

Tips For LONGEVITY Plasma
Cutting provided by www.plasma-

cutters.com and
www.freeweldingforum.com

Using a LONGEVITY Plasma Cutter with either High Frequency or
Pilot Arc technology is very easy to use, and since each
LONGEVITY unit is quality tested at our in house testing facility
before it is shipped , most of our customers take right out of the box,
plug it in and get to work. Naturally, it is easy to understand how
excited you would be to see the delivery truck pull up with your
brand new LONGEVITY Plasma Cutter and you should be.
Congratulations is in order and we want to ensure you have the best
experience with your LONGEVITY Plasma Cutter. However,
excited as we are you can't wait to put your LONGEVITY Plasma
Cutter into action, we would like you to consider these helpful tips
and examples that will enable you to get the most out of your
LONGEVITY Plasma Cutter and it's consumables. So, before using
your LONGEVITY Plasma Cutter it is extremely important to read

level. Even if you are a seasoned veteran, give it a once through and
keep it near by in case you, someone you know or someone you
work with has a question about the use or specifications of your
LONGEVITY Plasma Cutter.

At this point, let us assume that you have purchased the
LONGEVITY Plasma Cutter that is right for you, and even though
you did your research already, it is always a good idea to revisit the
safety precautions, specifications and unique options ensuring you
achieve the most with your LONGEVITY Plasma Cutter while
staying safe. In case you have not decided which LONGEVITY
Plasma Cutter is right for you, please visit the Help Me Choose
section and take advantage of the LONGEVITY Smart Selector.

In terms of safety, the price of carelessly cutting corners can be
extremely costly, not only to your health but to the people around
you as well. So, before you get started using your LONGEVITY
Plasma Cutter to create your master piece, build a bridge, or
whatever you want to do, make sure you have a quality safety
checklist you follow after you read the manual and before you get
started. Below are a list of tips and safety measures you might find
useful in developing your safety checklist. Remember, in no way
shape or form does this checklist or any other check list ever replace
the necessity of thoroughly reading the owner's manual of your

www.longevity-inc.com 25

Plasma

Cutter and consult your owner's manual to ensure the

or High Frequency technology, comes

Plasma Cutter for specifications and care instructions

Now you are ready to use your

PLASMA CUTTERS www.LWELD.com

LONGEVITY Plasma Cutter.

Check List Suggestions

Connect the air supply to your LONGEVITY

correct PSI. The PSI is about 65-75.
Each LONGEVITY Plasma Cutter, regardless if it

uses Pilot Arc
with an air flow regulator and water catcher.
Reference the owner's manual of your LONGEVITY

of your air flow regulator and filter.
Check the torch of your LONGEVITY Plasma

Cutter and make sure everything is in order.
Reference the owner's manual of your LONGEVITY
Plasma Cutter to make sure all of your consumables
are clean, correct, and pieced together securely
before you begin cutting.

Gouging or piercing can be achieved by simply
lowering the amperage output and keeping with the
recommended psi. Examples on how to achieve the
desired results can be referenced in the owner's
manual of your LONGEVITY Plasma Cutter.

LONGEVITY
Plasma Cutter safely and efficiently. Turn the
machine on and enjoy the satisfying experience of a
quality LONGEVITY Plasma Cutter.

Double check your air supply, air flow regulator and
water filter. (More on this below.)

All LONGEVITY Plasma Cutters require a solid
ground connection as close to the work piece as
practical. Remember, even though your
LONGEVITY Plasma Cutter can cut through paint
and other coatings on the metal, the ground
connection requires a clean, flush connection to the
work piece.

Utilizing the proper safety equipment is just as
important as understanding how to properly operate

26 www.longevity-inc.com

Plasma Cutters www.LWELD.com

Plasma Cutter

amp tips.

your LONGEVITY Plasma Cutter. Consult the
owner's manual of your LONGEVITY
to be sure you are using the correct gloves, eye
protection, welding leathers, face shield, etc. You
can find all of the necessary equipment as stated in
the owner's manual of your LONGEVITY Plasma
Cutter in the accessories section of our website.

The old adage says to measure twice and cut once,
but we want to go ahead and suggest you make a
sample cut (of the same caliber as the intended use)
with your LONGEVITY Plasma Cutter before you
get started. Use this rehearsal just to be sure you
have correctly calibrated all the settings to work as
desired. If you are going to be cutting for a large
piece of metal, it can sometimes be difficult for even
the most experienced metal worker to cleanly stop
and start. We recommend you use the sample cut to
thoroughly rehearse the intended cut with your
LONGEVITY Plasma Cutter.

LONGEVITY Plasma Cutter Tips
In order to successfully execute a clean cut with your LONGEVITY

Plasma Cutter you must consider a combination of elements involved
in the cutting process:

The tip of your torch is designed to focus the plasma stream to the
work piece in accordance with the appropriate setting (see owner's
manual). Trying to use a 80-amp torch tip at a 40-amp setting will
not focus the energy of your torch accurately and thus lead to a
wider kerf. And the opposite scenario of using an 80-amp setting
with a 40-amp tip will abuse your torch tip and require it to be
replaced sooner than intended.

When cutting a thicker material with your LONGEVITY Plasma
Cutter it is important to use a torch tip designed for a higher-amp
output. Higher-amp tips have a larger opening than lower­Attempting to use a 40-amp tip to cut thick metal with a higher­amp output will distort your 40-amp tip meaning it will need to be
replaced.

Each LONGEVITY Plasma Cutter, both Pilot Arc and High
Frequency , allow you to cut different metals at different speeds.
For example to achieve a quality cut of 1/2in. thick steel with the
LONGEVITY Force Cut LP-40D Pilot Arc your speed will be
roughly 7 inches per minute. Where as the LONGEVITY Force

www.longevity-inc.com 27

material or stop and restart the Pilot Arc, the shorter the life span of

*

Plasma Cutter. In some instances a

Plasma Cutter

PLASMA CUTTERS www.LWELD.com

Cut LP-80D will cut 1.25in. thick steel at the same rate.
Use extended tips on your LONGEVITY Plasma Cutter for tough

to reach corners, tracing a pattern, or areas with tight spaces.
Pilot Arc technology allows you to ignite the arc without the tip

touching the metal. Use a torch guide or tip shield to protect your
consumable. The more often you drag your torch tip across the

your consumables will be.
Using a torch guide or tip shield is a great way to protect the

consumables of your LONGEVITY Plasma Cutter. Remember to
maintain a 1/16in. - 1/8in. distance from the material when cutting.

The important things to consider while using your LONGEVITY
Plasma Cutter to cleanly execute a cut is correct amperage of the torch
tip, thickness of the material, intended speed, proper technique, and
ultimately protecting the life of your consumables.

Cutting Posture
Sometimes you may find that you are unable to use a guide or shield

when operating your LONGEVITY
project may be a very ornate design with different curves and
protrusions or the material is too thick to apply a shield or guard to
your LONGEVITY Plasma Cutter torch tip. In order to maintain the
quality and consistency of your work we recommend that you use your
other hand as a guide. Give yourself a fighting chance to steady your
hands and take advantage of the protective gear you have like our guys
on the LONGEVITY Facility Testing Team .

One of the reasons you purchase a LONGEVITY
is because of it's quality. Therefore, we think you should have a
few quality reminders to think about when you are cutting.

If you stop and start an arc in the middle of a cut, often the the quality
of your cut will suffer and compromise the integrity of your so far
clean cut-line. Remember, even when we do facility testing, a suitable
method to apply when using your LONGEVITY Plasma Cutter is
rehearsing the cut. Be sure you are going to be able to produce a
smooth continuous cut-line all the way through.

Along with rehearsing your cut, another equally good reminder is to
protect your consumables as much as possible. Often we can get
comfortable piercing right through thin steel with our LONGEVITY
Plasma Cutters, but when cutting thicker metal often the intense back

28 www.longevity-inc.com

Plasma Cutters www.LWELD.com

o be cutting thick metals at

Plasma Cutter, we recommend

you move on a material such as aluminum, the cleaner your cut will be.

accordingly. Thin material requires you to turn down the amperage and

Figuring out if you are going too slow or too fast can be a daunting task

20 degree angle,

splash from initial contact will rapidly wear down your torch tip and
other consumables. Even though the seeing the bright sparks show off
the awesome power of your LONGEVITY Plasma Cutter, remember
we want you to be able to enjoy the results of your work time and time
again. So, in situations when you are going t
high amperage with your LONGEVITY
you start with the torch pointed at a 45 degree angle. This angled
approach allows for the first blast of metal to be released with out back
splash on to your valuable consumables.

Know Your Amperage, Know Your Metal
At www.longevity-inc.com, you can see the cutting thickness

capability.
Understanding the amperage in relation to your cut speed is important.

Some metals respond differently than others. For example the faster

Conversely, when using your LONGEVITY Plasma Cutter to cut
thicker material, set your unit to full output and vary your travel speed

change to a lower-amperage to achieve a narrow kerf.

that really only comes with time and experience. However, our guys in
the LONGEVITY Facility Testing Team have a few pointers for you:

If your cut has a lot of spray back then you are probably going
too fast.

If the arc exits the material going straight down then you are
probably moving too slow and you will have an unnecessary
buildup of "dross" or "slag."

Your arc should be exiting the material at a 15 ­but opposite the direction of your cut path.

Using A Cutting Guide
First thing in using a torch guide with your LONGEVITY Plasma

Cutter is make sure it isn't flammable! Aluminum works as a great
torch guide, but be sure it is attached to the torch cup and not the torch
tip. Aluminum is a great contact guide because of it's smooth surface
but be wary of the torch tip because of electrical conductivity of
aluminum. It would be a terrible mess of a cut, loss of consumables,
and overall depressing mistake if your torch guide melted to the torch
tip or the project at hand. Next you want to mark the material to be cut
with either white chalk or a black marker. If you are unsure of how

www.longevity-inc.com 29

PLASMA CUTTERS www.LWELD.com

steady your hands are, we recommend you try using a straight edge
clamp attached to the work piece or torch guide.

All articles are composed by the LONGEVITY Facility Testing Team
and are written with expressed interest of maintain a strong standard in
LONGEVITY Global Inc. quality, to help address topics, and answer
questions for amateur and experienced users alike. Please remember to
always exercise extreme causation and abide by all provided safety
specification.

Sample Photos:

For more information on plasma cutting from professionals go to

www.freeweldingforum.com and
www.plasma-cutters.com

30 www.longevity-inc.com

Plasma Cutters www.LWELD.com

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.

www.longevity-inc.com 31

Problems, Causes, and Solutions

PLASMA CUTTERS www.LWELD.com

Troubleshooting

If your unit is not properly functioning, please call us immediately toll free at 1-877­566-4462 for support. We have included a small table here to diagnose most
common problems.

Problems

Machine will not
turn on.

The machine runs,
but nothing is
happening

Consumables
(tips) are being
consumed

Heavy Underside
Slag (Cutting)

Poor Cut Quality

Inconsistent
Arc

O.C. Over
Current LED
Lights

Issue Not Listed

Causes/

Solutions

Check cords and breaker. If nothing is found, contact

LONGEVITY

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 consumables and make
sure they are properly assembled. Check the ground clamp and
proper grounding to the unit

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
workpiece. If your unit comes with a manual Post Flow 2.5 or 5.0
switch make sure you leave it on 5.0 for more air to pass cooling
your torch tips.

Slow travel speed. Increase travel speed or amperage on unit.

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.

Improper grounding or possible lack of air pressure. Check and
replace consumables and adjust the regulator to proper PSI

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.

Contact LONGEVITY Toll Free 1-877-566-4462 or via email at

[email protected]

32 www.longevity-inc.com

Plasma Cutters www.LWELD.com

LONGEVITY® Global, Inc. thanks you for your purchase and 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

www.longevity-inc.com 33