Longevity 880459 Instructions / Assembly
Contents
1. 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 HELP longevity inc com FORCECUT 62i Warnings and Safety LONGEVITY The power to last www longevity inc com 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 connected2. continuous arc when the trigger on 10 11 the torch is pressed Depress the button on your torch to start the arc and begin cutting You can test the air to insure that is it properly flowing by selecting Gas Air Test Air will pass through the torch If necessary remove slag from the under part of the cut using a grinder or chisel 10 FORCECUT 62i ON GEVI www longevity inc com Cutting Methods Different material thicknesses require different cutting techniques e 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 e Medium material Angle the torch tip to avoid damaging the tip Once the arc passes through the material you may begin cutting normally e 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 Cut Direcson gt Thick material Real me arc curve delay ray uly T
3. turn the switch to RUN when doing a gas test turn to the SET Cutting gun connector Connector for the PT 60 plasma torch CNC Port Ground Clamp Connect to the workpiece or a secure ground Power Switch turns on or off the machine Air Connector Power Cable Moister trap release ONGEVIT Y FORCECUT 62i eo www longevity inc com Assembly of Consumables for the 60AMP Torch Head Assemble the consumables as pictured above and described below 1 Screw on the electrode 2 Place the copper tip on the ring ensuring that is seated flat 3 Secure all parts into place by turning the grey shield cup clockwise until it is snug Do not over tighten The torch consumables are now successfully assembled Basic Operation 1 2 Ensure that all cables are connected to the machine 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 Turn the ON OFF switch to ON The cooling fans should operate and the ON indicator LED or power switch if applicable should illuminate 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 Connect the torch to the unit properly 8 With the pilot arc knob connected you should get a full
4. ONGEVI Y The power to last www longevity inc com Operating Manual for ae a a a I IGBT 60 Amp CNC Ready Plasma Cutter FORCECUT 62i Table of Contents ONGEVIT Y The power to last www longevity inc com Table of Content Pg 1 Thank you From LONGEVITY Pg 2 Warranty Shipping Damage Order Information Pg 3 Safety Information Pg 4 5 Specifications and Ratings Pg 6 What s Included Ps 7 Main Unit Knob Button Function Diagram Pg 8 Troubleshooting Pg 13 Routine Maintenance Pg 16 Contact Info Pg 17 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 FORCECUT 62i ONGEVITY www longevity inc 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 sales longevity inc com Customer Servi
5. ce help longevity inc com Dealers dealers longevity inc com Complaints complaints longevity inc com 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 62i ON GEVI www longevity inc 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 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 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 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
6. cing com Enjoy your new welding machine from LONGEVITY Thanks again 17
7. e 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 problem
8. h e Keep the machine exterior clean with mild soap and water e Do not walk on or store items on the cables or cords e Do not jar drop or stack items on top of the machine e Always connect the machine to a well grounded electrical outlet e Always check the torch consumables before and after use and ensure that they are clear of obstructions and that no parts are damaged e Replace any worn or damaged consumables before using machine e For periods of prolonged non use remove cables and store them in their original boxes in a cool dry place 16 FORCECUT 62i ONGEVITY www longevity inc com 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 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 com 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 ra
9. 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 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 62i ONGEVITY www longevity inc 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 th
10. o 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 Cut Directon __ Real fme arc 5 curve delay 11 FORCECUT 62i ON GEVI a www longevity inc com NGEVI The power to last Technical Data Compatible FORCECUT 42i FORCECUT 62i WELDMAX 185i Current 10 60 Amps Duty Cycle 60 Amps 80 Gas Air N2 Gas Pressure 65 75 psi 4 4 5 0 bar Gas Flow 230 scfh 110 Ipm Pilot Electrode to Tip Ignition Without HF 1 ELECTRODE 2 SWIRL RING SKU PRODUCT NAME BLOW BACK 741360255494 PT 60 CONSUMABLE SET 741360255500 PT 60 30 KIT 741360255517 PT 60 15 KIT 741360255524 PT 60 1 TIP 741360255531 PT 60 5 TIPS 741360255548 PT 60 10 TIPS 741360255555 PT 60 1 ELECTRODE 4 SHIELD CUP 741360255562 PT 60 5 ELECTRODES 741360255579 PT 60 10 ELECTRODES 741360255586 PT 60 1 SHIELD CUP 741360255593 PT 60 5 SHIELD CUPS 741360255609 PT 60 10 SHIELD CUPS 741360255616 PT 60 1 SWIRL RING 5 SPACER 741360255623 PT 60 5 SWIRL RINGS 741360255630 PT 60 TORCH SPACER 741360255647 PT 60 PILOT ARC CUTTING TORCH FORCECUT 62i ON GEN www longevity inc com Troubleshooting A WARNING There are extremel
11. ool down for at least 5 minutes Make sure the unit has not been operated beyond Duty Cycle limit refer to technology parameters in Section 2 4 Faulty components in unit return for repair or have qualified technician repair per Service Manual F Torch fails to ignite the arc when torch switch is activated 1 System is in SET mode change to RUN mode 2 Faulty torch parts inspect torch parts and replace if necessary 3 Gas pressure too high or too low adjust to proper pressure 4 Faulty components in unit return for repair or have qualified technician repair per Service Manual G No cutting output Torch activated power source on Gas flows Fan operates 1 Torch not properly connected to power supply check that torch leads are properly connected to power supply 2 Work cable not connected to work piece or connection is poor make sure that work cable has a proper connection to a clean dry area of the workpiece 3 Faulty components in unit return for repair or have qualified technician repair per Service Manual 4 Faulty Torch return for repair or have qualified technician repair 14 FORCECUT 62i ONGEVITY www longevity inc com H Low cutting output 1 Incorrect setting of CURRENT A control check and adjust to proper setting 2 Faulty components in unit return for repair or have qualified technician repair I Difficult Starting 1 Worn torch parts consumables shut off input power Rem
12. ove and inspect torch shield cup tip and electrode Replace electrode or tip if worn replace shield cup if excessive spatter adheres to it J Arc shuts off during operation arc will not restart when torch switch is activated 1 Power Supply is overheated OC OT lamp on let unit cool down for at least 5 minutes Make sure the unit has not been operated beyond Duty Cycle limit Refer to Section 2 for duty cycle specifications 2 Gas pressure too low the TIP GUN GAS lamp on when press on torch switch is on check source for at least 4bar 60psi adjust as needed It is need to open the machine cover L Torch cuts but cuts are of low quality 1 Amperage control set too low increase current setting 2 Torch is being moved too fast across workpiece reduce cutting speed 3 Excessive oil or moisture in torch hold torch 1 8 inch 3 mm from clean surface while purging and observe oil or moisture buildup do not activate torch If there are contaminants in the gas additional filtering may be needed 15 FORCECUT 62i ON GEVI www longevity inc 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 e Atregular 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 mont
13. s in setting up or operating your machine contact us at help longevity inc com FORCECUT 62i ON GEV www longevity inc com Techinical Specifications and Ratings Rated input Single phase 220V 50 60Hz Rated input current 55 Amps Rated input power KW 7 5 KW Adjustment range of current A 20 60 220V Duty cycle 40 C 10 minutes 95 220V Max no load voltage V 315 volts Weight 48 Ibs Dimensions Length Width Height 27 5 L x 13 75 W x 20 5 H FORCECUT 62i ON GEVI a www longevity inc com What s Included 1 20 5 ft PT 60 PLASMA CUTTING TORCH 1 16 5 FT GROUND CLAMP 1 AIR HOSE 2 EXTRA TIPS 2 EXTRA ELECTRODES FORCECUT 62i ON GEVI www longevity inc com Main Unit Pictured FORCECUT 62i Plasma Cutter Main Unit Knob Button Function 1 Power Light The light will illuminate when the unit is powered on 2 Temperature Over Heat Light When the duty cycle is reach the TEMP will turn on Once it is safe to operate the machine the light will turn off If duty cycle is reached allow machine to run with the fan on to accelerate cooling 3 Tip Air Light When adequate air pressure is reached the Tip Air light should turn on 4 Pilot Voltage Light The Pilot Voltage light is illuminated when the machine is ready to use 5 Amperage Control Knob ONGEVIT Y FORCECUT 62i comer 10 11 12 13 www longevity inc com RUN SET When cutting the
14. y dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques A The cutting torch fails to ignite the arc when press on the torch switch the TIP GUN GAS light on 1 Gas pressure too high gas test then adjust gas pressure to 4bar 60psi B The cutting torch fails to ignite the arc when the torch switch is pressed the TIP GUN GAS lamp turns on 1 The shield cup is improperly installed Turn off the power source install the shield cup properly and then turn on the power source C The cutting torch fails to ignite the arc when press on the torch switch the TIP GUN GAS lamp on and air feed intermittently 1 The electrode or nozzle improper installation turn off the power source install the electrode or nozzle and screw shield cup down properly then turn on the power source D The cutting torch fail to ignite the arc when press on the torch switch the TIP GUN GAS lamp on and air feed intermittently 1 Short circuit for burned out and other abnormal situation turn off the power source and change the electrode and nozzle 13 FORCECUT 62i ONGEVITY www longevity inc com E Power lamp and temperature lamp on 1 Air flow blocked check for blocked air flow around the unit and correct condition 2 Fan blocked check and correct condition 3 Unit is overheated let unit c
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