Operating Manual for ForceCut™ 60i and 80i IGBT Pilot Arc Plasma Cutters
ForceCut™ 60i and 80i 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. 7-8 Basic Diagram, Wiring, and Setup Instructions Pg. 9-12 Main Unit Knob/Button/Function Pg. 13 Assembly of Plasma Cutter Torches Pg. 14-15 Basic Plasma Cutter Operation Pg.
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.
Plasma Cutters www.LWELD.com Warranty 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.longevityinc.com/terms/ . Shipping Damage Your machine is insured against damage during shipping.
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 help@longevity-inc.com to obtain a return authorization code. When doing so, please provide the following information: Order No.
Plasma Cutters www.LWELD.com Introduction The LONGEVITY® ForceCut™ series plasma cutters offer a revolutionary new approach to plasma cutting technology with IGBT internal chips. LONGEVITY® plasma cutters use the newest technology available in the welding industry with the help of IGBT internal components allowing us to push the standards of plasma cutting technology to the next level.
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.
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.
PLASMA CUTTERS www.LWELD.com Specifications and Ratings Type Parameter ForceCut 60i Input Voltage (V) ForceCut 80i Single Phase 220/230/240V Cup Capacity max/sev (in.) Up to 1 ¼” Up to 1 5/8” Input Current (Amp) 50 70 Output Current (Amps) 60 80 No-load Voltage (V) 200v 200v Current Range (Amp) 20-60 20-80 Rated Duty Cycle (%) 60 60 Efficiency 85 85 Power Factor (Cos0) 0.93 0.
Plasma Cutters www.LWELD.com What’s Included: Main Unit Cutting Torch (Ground) Earth Clamp Water Separator and Bracket Air Hose Consumables: 2 piece tips, 2 piece electrodes, and 2 piece shield cups Power Plug CNC Plug Pin Adapter Pictures of Accessories: (Note: 60i accessories pictured) Plasma Torch (Note: Torch will vary by model) Ground Clamp www.longevity-inc.
PLASMA CUTTERS www.LWELD.com 60i and 80i Included Accessories: 8 www.longevity-inc.
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.
PLASMA CUTTERS www.LWELD.com 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.
Plasma Cutters www.LWELD.com Basic Diagram Pictured Model ForceCut™ 60i (Note: Both 60i and 80i models have the same connections) www.longevity-inc.
PLASMA CUTTERS www.LWELD.com Rear View (Pictured ForceCut™ 60i Plasma Cutter) 12 www.longevity-inc.
Plasma Cutters www.LWELD.com Main Unit Knob/Button Functions/Inlets: 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 : Shows unit is powered on. Indicator is present in some models with a green LED bulb. 3. O.C. Over Current Light: Illuminates when the duty cycle has been exceeded or the machine has overheated due to improper ventilation. Discontinue use until lamp goes out.
PLASMA CUTTERS www.LWELD.com Plasma Torch Assembly: 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 for the ForceCut™ 60i model. Assemble the consumables as pictured above, and described below. 1. Insert the electrode. 2.
Plasma Cutters www.LWELD.com Assembly of ForceCut 80i Plasma Cutter Assemble the consumables as pictured above, and described below. 1. Insert the electrode. 2. Place the copper tip over the electrode ensuring that is seated flat. 3. Secure all parts into place by turning the ceramic cup clockwise until it is snug. Do not over tighten. 4. If your unit comes with a torch spacer, you can properly attach it to your torch. 5. Remember to properly secure all connections of the torch to the unit.
PLASMA CUTTERS www.LWELD.com Basic Operation 1. Ensure that all cables are connected to the machine. 2. Ensure that the machine’s OFF/ON switch is set to OFF, and plug the machine into the electrical outlet. 3. Connect the air compressor supply line to the air input side on the unit. 4. Turn the ON/OFF switch to ON. The cooling fans should operate and the ON indicator LED or power switch (if applicable) should illuminate. 5. Clean the contact point on the work piece to ensure a good electrical connection.
Plasma Cutters www.LWELD.com Summary Chart of Plasma Cutters: Plasma Cutters ForceCut® LP-40D Plasma Cutters ForceCut® LP-40D Pilot Arc Plasma Cutters ForceCut® LP-50D Plasma Cutters ForceCut® LP-50D Pilot Arc Plasma Cutters ForceCut® LP-60D www.longevity-inc.
PLASMA CUTTERS www.LWELD.com Plasma Cutters (230 V Input) 40 A @ 100% Duty Cycle (110 V Input) 18 ForceCut® LP-70 Plasma Cutters 70 A at 60% 1 1/4 in (230 V Input) 1 1/4 in 5/8 in 8000 watts ForceCut® LP-80 Plasma Cutters 80 A at 60% 1 1/2 in (230 V Input) 1 1/2 in 3/4 in 9000 watts MaxArc® LP-100 Plasma Cutters 100 A at 60% (230 V Input 1- phase) 2 in 1/4 in 10,000 watts ForceCut® 60I Plasma Cutters 60 A @ 60% Duty Cycle 1 1/4 in (220 V Input) 1 1/4 in 3/4 in 6500 watts 2 in www.
Plasma Cutters www.LWELD.
PLASMA CUTTERS www.LWELD.com Typical Applications Chart of Plasma Cutters: Technology Plasma Cutters ForceCut® LP-40D Typical Applications Hobbyist, Auto-Body, Plumbers, Sheet Metal Work, Thin Material, HVAC ForceCut® Hobbyist, Auto-Body, Plumbers, Sheet Metal work, LP-40D Pilot Thin materials.
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.
PLASMA CUTTERS www.LWELD.com Tips For Plasma Cutting provided by: www.plasma-cutters.com 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.
Plasma Cutters www.LWELD.com Check List Suggestions Connect the air supply to your LONGEVITY Plasma Cutter and consult your owner's manual to ensure the correct PSI. The PSI is about 65-75. Each LONGEVITY Plasma Cutter, regardless if it uses Pilot Arc or High Frequency technology, comes with an air flow regulator and water catcher. Reference the owner's manual of your LONGEVITY Plasma Cutter for specifications and care instructions of your air flow regulator and filter.
PLASMA CUTTERS www.LWELD.com 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.
Plasma Cutters www.LWELD.com 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 material or stop and restart the Pilot Arc, the shorter the life span of your consumables will be.
PLASMA CUTTERS www.LWELD.com 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 to be cutting thick metals at high amperage with your LONGEVITY Plasma Cutter, we recommend 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.
Plasma Cutters www.LWELD.com 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 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. 28 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.
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, Causes, and Solutions 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 www.
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 help@longevity-inc.com. LONGEVITY® Global, Inc. Toll-Free 1-877-LONG-INC / 1-877-566-4462 Website: www.longevity-inc.com Sales: sales@longevity-inc.com Customer Service: help@longevity-inc.com Dealers: dealers@longevity-inc.
