LOTOS LTPAC2500 5 IN 1 - Lotos Technology Plasma Cutters and
Contents
1. Welding curren1 AJ S ce LTPAC2500 Figure A 3 A WARNING The TIG torch foot pedal and ground cable are supplied with the welder To connect the cables turn the Power Switch OFF l Connect the gas inlet on the TIG torch cable to the CUT TORCH GAS OUTLET on the front of the welder and turn 1t clockwise using the plastic safe protector until snug do not over tighten Plug the 3 prong connector on the foot pedal cable into REMOTE CONTROL 3 pin socket turn the outer metal shell clockwise to tighten Plug the 2 prong connector on the foot pedal cable into TORCH CONTROL 2 pin socket turn the outer metal shell clockwise to tighten Connect the ground cable to the output terminal in the way indicated before To avoid receiving a high freguency shock keep the TIG torch and ground clamp amp cable insulation in good condition 13 gt OUTPUT CONNECTION FOR MMA WELDING Figure A 4 1 Determine the proper electrode polarity for the electrode to be used Consult the electrode data for this 0000 00 information mm 2 Connect the output cables of MMA electrode holder om ec Y Crpacasoo to the output terminals corresponding to this polarity Insert the connector and rotate to tighten 3 Connect the ground cable to the output terminal with opposite polarity in the same way For instance for DC welding connect the electrode cable which is connecte2. 53cfh 25L min 5 Adjust output current by Pulse Current Adjust Knob 12 The output pulse current can be adjusted from 10A to current level set by the user The maximum current value is 250A 6 Adjust base current by Base Current Adjust Knob 13 The base current can be 10 90 29 of the pulsed current value as desired Lower Base Current More Pulse Effect Higher Base Current Less Pulse Effect 7 Adjust pulse frequency by Pulse Frequency Adjust Knob 14 from 0 5Hz to 200 Hz Higher Pulse Frequency More Focused Arc Narrower Bead Faster Travel Speed Easier Directional Control More Productivity Less Heat Effect Lower Pulse Frequency Less Focused Arc Wider Bead Slower Travel Speed Easier Directional Control Less Productivity More Heat Effect 8 Adjust pulse duty by Pulse Duty Adjust Knob 15 to set the time for current staying in the peak value pulse current value It can be 10 90 of a pulse period Greater Pulse Duty More Penetration Less Pulse Duty More Cleaning 9 Adjust up slope time down slope time and post flow time by corresponding knobs 17 18 and 19 10 Adjust AC balance by AC Balance Adjust Knob 20 The AC Balance can be changed from 30 EP EP Electrode Positive to 70 EP Changing the wave balance alters the ratio between the cleaning and the penetrating current Greater EP Less EN More Cleaning Less EP Greater EN More Penetra
3. Plasma Cutting y 12 17 18 19 TIG DC PLL a a CUT Ac ALL DC TIG DC TIG Welding 12 17 18 19 LLUN FEL AC TIG AC TIG Welding 12 17 18 19 20 21 Pulsed DC TIG Pulsed DC TIG Welding 12 13 14 15 17 18 19 Pulsed AC TIG Pulsed AC TIG Welding 12 13 14 15 17 18 19 20 21 For definitions of up slope down slope pulse frequency post flow AC balance and AC frequency please refer to Appendix in the last section 19 OPERATION CUT PLASM CUTTING START UP 44 WARNING ELECTRIC SHOCK can be fatal Have an electrician install and service this equipment Turn the input power off at the fuse box disconnect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment Do not touch electrically hot parts Turn the input power OFF and unplug the machine from the receptacle before working on this equipment AN 1 Connect up the air compressor using air filter and regulator 2 Have LTPAC2500 ready for CUT function as Installation indicates turn the power ON 3 Set function buttons for CUT as Controls and Settings indicates the LTPAC2500 plasma cutting function is ready to use eee 8 GO mm o o ak DDED 4 W LTPAC2500 Welding current A BUTTON COMBINATION AND VALID KNOBS FOR CUT 4 Adjust the air
4. cable in DC MMA welding Connection for MMA electrode holder in DC MMA welding Digital Display Displays the values of output current 7 Under voltage Warning Light Indicates that the machine is operating under voltage Over current Over heating Warning Indicates over current over heating or other electrical 10 11 Pulse Non Pulse Changeover Switch Select the pulsed or non pulsed current mode for TIG welding 12 Pulse Current Adjust Knob Allows user to adjust the output current from 10A to maximum output current under different functions In PULSE mode for TIG welding it adjusts the output pulse peak current from 10A to 250A 13 Base Current Adjust Knob Allows user to continuously adjust the minimum current value base current value in PULSE mode from 10 to 90 of the pulse peak current value 14 Pulse Frequency Adjust Knob Adjusts the frequency of changeover between pulse current and base current 15 Pulse Duty Adjust Knob Adjusts the ratio of pulse width to pulse period 16 ARC Force Adjust Knob Adjusts the magnitude of ARC Force in MMA welding Increasing the value of ARC Force helps to avoid insufficient arc penetration and sticking electrode caused by low welding current l When current exceeds the limit the machine will stop supplying power If the unit is over heated the light will stay on until the machine has sufficiently cooled down Leave the power sourc
5. least 5 minutes to allow time for the process to take place ROUTINE MAINTENANCE Routine maintenance will prevent metal powder from accumulating near the aeration fins and over them Carry out the following periodic controls on the power source gt Clean the power source inside by means of low pressure compressed air gt Check the electric connections and all the connection cables gt Always use gloves in compliance with the safety standards 31 TROUBLESHOOTING REPAIR SHOULD ONLY BE PERFORMED BY TRAINED PERSONNEL FOR YOUR SAFE PLEASE OBSERVE ALL SAFETY INFORMATION THROUGHOUT THIS MANUAL PLEASE READ AND UNDERSTAND THIS ENTIRE SECTION SERVICE AND A WARNING ELECTRIC SHOCK can kill Service and Repair should only be performed by Trained Personnel Have a qualified electrician install and service this equipment HOW TO USE TROUBLESHOOTING GUIDE This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMME
6. misadjustment have been voltage or output current checked and the problem Equipment Overheat persists Contact your No output current Allow machine to cool The power sales agency Power Light on should remain on so the fan can maintain airflow and cool the machine Input supply voltage too high or too low 34 OTHER ACCESSORIES The following accessories and consumables can be purchased on www uwelding com or call 408 739 2329 to order CONSUMABLES PCON150 PCON20 iodd ACCESSORIES ho Ml 7 gt l AIR FILTER amp TIG TORCH 3 WAY SWITCH HELMET REGULATOR Y AND MORE lt lt ON e www uwelding com Q TUNGSTEN ARC WELDING RODS WARRANTY 35 APPENDIX AC CURRENT T ld Alternating current AC is the flow of electric charge ts periodically reverses direction Usually the waveform of an AC power circuit is a sine wave but LTPAC2500 provides square waves as the left figure shows The current starts from zero and reaches to the target magnitude I then it 8 reserves direction but keeps the same magnitude I T is the time period for AC current to complete one direction change and go back to the former state AC freguency is the freguency of the oscillation of AC current can be calculated A by 1 T In one AC Time Period the time duration for current s to stay in negative is T2 The ratio of T2 to T is called AC T2 balance Since the electrode polar
7. pressure and make it is adequate to machine open the valve of pressed air The recommended air pressure 1s shown in table below 5 Adjust output current by Pulse Current Adjust Knob 12 The output current can be adjusted from 10A to current level set by the user The maximum current is 40A The scale of current value on the Knob in CUT function is Pulse current 6 Adjust up slope time down slope time and post flow time by corresponding knobs 17 18 and 19 The recommended post flow time is 5 10s 7 Press and hold the trigger to make a cut 20 gt MMA MMA WELDING START UP 1 Have LTPAC2500 ready for MMA function as Installation indicated and turn the power ON The following connections are for negative polarity and positive polarity a DC Electrode Negative Polarity Direct Current Straight Polarity While welding a continuous flow of electrons comes from the electrode to the ig piece he picture shows the a of DC welding an electrode with negative polarity which is mostly used Since the majority of S the heat concentrates on the anode work piece it ensures limited wear of the ee eo 606060 E m m m 8608 ce 5 N electrode Narrow and deep welds are obtained with high travel speeds Most materials except aluminum and magnesium can be welded with this polarity b DC Electrode Positive Polarity Direct Current Reverse Polarity The p
8. EMF fields in welding may have other health effects which are now not known gt All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit Route the electrode and work cables together Secure them with tape when possible Never coil the electrode lead around your body Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the work piece as close as possible to the area being welded Do not work next to welding power source ELECTRIC SHOCK can be fatal gt The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands gt Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the work piece or ground use the following equipment Semiau
9. LOTOS LTPAC2500 SIN 1 CUT MMA AC TIG DC TIG PULSE TIG TABLE OF CONTENTS SAFETY cove chicane DI o On as Oy O comes orate esac No 3 SPECIFICATIONS GG LG dad ESE RD NG 7 Wat Include dardo ad aU 7 Power supply Rato 8 INSTAELATION Loi is 9 Betor Installation anclada aa 9 Input Connect orn iawer FOAN 11 Output CONME CONi a E T 12 OPERATION 00 E ER 15 Betore Oper raO Nessie anu O R a OA 15 OD Oll ue a daa OG a a a ia 20 CUT Plasma Cunning SI U Daa tr ssa ad GROG aa 20 MMA MMA Welding Siarl UD ia 21 HG IG Welding Siart U peess aa ans GDG Rad 23 MAINTENANCE 22095 GG las 31 TROUBLESHOOTING 00d as 32 OTHER ACCESSORIES ui iii 35 APPENDIX A Y A RD OR 36 SAFETY 4d PLEASE READ AND UNDERSTAND THE FOLLOWING SAFETY HIGHLIGHTS BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS ARC AND TIG WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING ELECTRIC AND MAGNETIC FIELDS may be dangerous 9 gt Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding amp cables and welding machines HQ gt EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding gt Exposure to
10. NDED COURSE OF ACTION This column provides a course of action for the Possible Cause If you do not understand or are unable to perform the Recommended Course of Action safely contact your sales agency 32 PROBLEMS IN PLASMA CUTTING TROUBLESHOOTING PLASMA CUTTING PROBLEMS PROBLEM CAUSE RECOMMENDED SYMPTOMS COURSE OF ACTION The fan winds and no HF electricity releasing cannot start the arc The output current is not stable control of or out of the the potentiometer The cutting ability is insufficient and the arc is not constant Connections are not well connected in the machine The 2 2KQ potentiometer is broken renew it in time The connected esp the plug ins connections are not well The input voltage is too low The cable is too long or not well connected The air pressure is too high or too low The nozzle and electrode of the torch doesn t match well or not good enough and the given current is too small If all possible recommended areas of misadjustment have been checked and the problem Contact persists your sales agency PROBLEMS IN MMA WELDING TROUBLESHOOTING MMA WELDING PROBLEMS PROBLEM CAUSE RECOMMENDED SYMPTOMS COURSE OF ACTION Long arc Excessive spatter High current Fast movement of the electrode away Craters l from piece Poor cleanliness or distribution of the Welding passes Improper movement of the electro
11. allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment Do not touch electrically hot parts Do not touch electrically hot parts Turn the input power OFF and unplug the machine from the receptacle before working on this equipment The TIG Tungsten Inert Gas welding process is based on the presence of an electric arc between a non consumable electrode pure or alloyed tungsten with an approximate melting temperature of 3370 C and the work piece An inert gas typically argon atmosphere protects the weld pool To avoid inclusions of tungsten in the joint the electrode should not contact the work piece For this reason the arc is started through a high frequency generator To improve weld bead quality at the end of the weld it is important to carefully control the down slope of current and ensure proper gas coverage over the weld LTPAC2500 TIG function can weld most metals such as steel copper aluminum magnesium etc For these common metals the following table shows the typical current type to choose for each kind TIG Welding Common Materials amp Typical Current Type Choice Negative Argon Negative and Positive Argon Helium Argon Helium Negative and Positive Argon Helium Argon Helium For aluminum and magnesium TIG welding Argon is preferred due to its lower cost and Magnesium consumption rate This gas also tends to stabilize the arc thus
12. arc rays or to hot spatter or metal FUMES AND GASES can be dangerous gt Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the gases away from the breathing zone When welding with electrodes which 9 fume Use enough ventilation and or exhaust at the arc to Keep fumes and N o gt require special ventilation such as stainless or hard facing or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel gt gt Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe gt Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS f
13. ay fuses or delay type circuit breakers Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if not welding at high currents The Inverter LTPAC2500 are recommended for use on an individual branch circuit 220V INPUT Figure A 0 The eguipment is provided with a 220V Hot Wire cable 8 2ft 2 5m in length The rated Single Ir output of the LTPAC2500 is available when pee e Sees Phase Welder Brown Wire connected to a 40A branch circuit When Ground Wire connected to a branch circuit with lower alice Oren Nie amp rating lower welding current anu GU Finn cycle must be used An output guide is provided on the right The values are approximate and must be adjusted Output Guide Under Lower Amp Rating downward if the fuse or circuit breaker trips off Other loads on the circuit and fuse circuit breaker characteristics will affect the available output Please do not exceed the welding conditions indicated in Table 1 Table 1 Failure to wire as instructed may cause personal 44 WARNING injury or damage to equipment To be installed or checked by an electrician or qualified person only Also called inverse time or thermal magnetic circuit breakers These circuit breakers have a delay in tripping action that decreases as the magnitude of the current increases 11 In all cases the green or green yellow grounding wire must be con
14. d to the electrode holder to the output terminal and the ground cable which is connected to the work clamp to the output terminal Figure A4 gt SHIELDING GAS CONNECTION Obtain the necessary inert shielding gas Connect the cylinder of gas with a pressure regulator and flow gage Install a gas hose between the regulator and gas inlet located on the rear of the welder CYLINDER could explode if damaged Keep cylinder upright and chained to a support Keep cylinder away from areas where it could be damaged Never allow the torch or welding electrode to touch the cylinder Keep cylinder away from live electrical circuits 14 OPERATION PLEASE READ AND UNDERSTAND THIS ENTIRE SECITON BEFORE 4 OPERATING YOUR MACHINE ONLY OUILIFIED PERSONNEL SHOULD OPERATE THIS EOUIPMENT OBSERVE ALL SAFETY INFORMATION THROUGHOUT THIS MANUAL BEFORE OPERATION A WARNING ELECTRIC SHOCK can be fatal Do not touch electrically live parts such as output terminals electrode or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING AND CUTTING SPARKS can cause fires or explosions Keep flammable material away Do not weld cut or gouge on containers that have held combustibles ARC RAYS can burn Wear eye ear and bod
15. de If all Inclusions recommended High progression speed possible areas of Insufficient penetration Welding current too low misadjustment have been Narrow chamfering Current too low Humidity in electrode Current too high checked and the problem persists Contact your sales agency Dirty materials Hydrogen in weld present on electrode coating 33 PROBLEMS IN TIG WELDING TROUBLESHOOTING TIG WELDING PROBLEMS PROBLEM CAUSE RECOMMENDED SYMPTOMS COURSE OF ACTION Odio LU NU gas No protection on the back side Incorrect electrode sharpening Electrode too small If all recommended Tungsten inclusions Operating failure contact of the tip possible areas of with the work piece misadjustment have been Dirt on the edges checked and the problem Porosity Dirt on the filler material persists Contact your Excessive travel speed sales agency Current intensity too low Unsuitable filler material Hot cracking High heat supply Dirty materials ELECTRICAL FAILURES TROUBLESHOOTING ELECTRICAL FAILURES PROBLEMS PROBLEM CAUSE RECOMMENDED SYMPTOMS COURSE OF ACTION Machine fails to come SO DDYNODI FAU ly pl le on Power Light off aulty supply plug or cable Internal fuse blown Power output incorrect Low mains supply voltage If all recommended Power Light on possible areas of Instantaneous error relating to input
16. e ON ceece 660 eee ee wm m 0980 o 9 9 cm um 89089 ce LTPAC2500 With Foot Pedal Without Foot Pedal 3 Set function buttons for DC TIG pulsed as Controls and Settings indicates the LTPAC2500 plasma cutting function is ready to use Welding current A Erraczs00 BUTTON COMBINATION AND VALID KNOBS FOR CUT 4 Adjust the gas pressure and make it is adequate to machine open the valve of pressed gas The recommended gas pressure is shown in table below 50 100A 150 200A 200 250A 29cfh 14L min 42cfh 20L min 53cfh 25L min 27 5 6 1 8 9 Adjust output current by Pulse Current Adjust Knob 12 The output pulse current can be adjusted from 10A to current level set by the user The maximum current value is 250A Adjust base current by Base Current Adjust Knob 13 The base current can be 10 90 of the pulsed current value as desired Lower Base Current More Pulse Effect Higher Base Current Less Pulse Effect Adjust pulse frequency by Pulse Frequency Adjust Knob 14 from 0 5Hz to 200 Hz Higher Pulse Frequency More Focused Arc Narrower Bead Faster Travel Speed Easier Directional Control More Productivity Less Heat Effect Lower Pulse Frequency Less Focused Arc Wider Bead Slower Travel Speed Easier Directional Control Less Productivity More Heat Effect Adjust pulse duty by Pulse Duty Adjust Kn
17. e on to allow the fan to cool the unit Do not change mode while welding cutting otherwise it will damage the unit gt For the maximum output current value please refer to Specifications or Operation Output Limitations The maximum value is scaled to 250A on the knob mark For definitions of pulse current base current pulse frequency pulse duty pulse width pulse period and ARC force please refer to Appendix in the last section 18 CONTROLS AND SETTINGS continued 17 Up Slope Adjust Knob Adjusts the time for output current increasing from zero to the target current value as set by Pulse Current Adjust Knob when user presses and holds the torch trigger to start cutting welding 18 Down Slope Adjust Knob Adjusts the time for output current decreasing from the target current value as set by Pulse Current Adjust Knob to zero when user releases the torch trigger or foot pedal to stop cutting welding Adjusts the time duration for gas continuing flowing out after the arc is turned OFF Adjusts the time percentage of positive electrodes negative current in one AC current period from 30 to 70 50Hz to 70Hz when operating under AC current Different functions have different valid knobs to control the output The following table shows how to select different functions and what the responsible knobs are for each function Function Selection amp Knob Combination Valid Knobs Ng gm CUT AC CUT
18. he building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail CYLINDER may explode if damaged gt Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition gt Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder gt Keep your head and face away from the cylinder valve outlet when opening the cylinder valve gt Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use ELECTRICALLY POWERED EQUIPMENT can be dangerous gt Turn off input power using the disconnect switch at the fuse box before working on the equipment gt Install equipment in accordance with the local codes and the manufactu
19. icture shows the theory of DC welding an electrode with positive polarity which is usually alloy covered with a layer of refractory oxide z z AE With this polarity the aan 0000 electrode functions as anode a LTPAC2500 and is subjected to a high degree of heat the work piece is bombardment by positive ions sent from the electrode which break the surface oxide In electrode positive polarity high currents cannot be used since they would cause an excessive wear of the electrode 21 2 Set function buttons for MMA as Controls and Settings indicates the MMA function is ready to use Welding current A reacas00 BUTTON COMBINATION AND VALID KNOBS FOR CUT 3 Adjust output current by Pulse Current Adjust Knob 12 The output current can be adjusted from 10A to current level set by the user The maximum output current is 200A The scale of current value on the knob in MMA function is Pulse current 4 Adjust ARC force by ARC Force Adjust Knob 16 Increasing the value of ARC Force helps to avoid insufficient arc penetration and sticking electrode caused by low welding current 5 Attach the welding rod to the work piece to start MMA welding 22 gt TIG TIG WELDING START UP A WARNING ELECTRIC SHOCK can be fatal Have an electrician install and service this equipment Turn the input power off at the fuse box disconnect or unplug supply lines and
20. ing these members radiating antennas Keep all panels securely in place All electrical conductors within 50ft 15 2m of the welder should be enclosed in grounded rigid metallic conduit or eguivalent shielding Flexible metallic conduit is generally not suitable When the welder is enclosed in a metal building several earth driven electrical grounds connected as in 5b above around the periphery of the building are recommended Failure to observe these recommended installation procedures can cause radio or TV interference problems 10 INPUT CONNECTIONS A WARNING ELECTRIC SHOCK can be fatal Have a qualified electrician install and service this equipment Turn the input power OFF and unplug the machine from the receptacle before working on this equipment Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment Do not touch electrically hot parts Machine must be plugged into a receptacle that is grounded according to the National Electrical Code and local codes Do not remove or defeat the purpose of the power cord ground pin Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the backboard of the machine CONNECTION PROCEDURE The Inverter LTPAC2500 must be connected to AC220V 10 230V 10 240V 2 1096 50 60Hz Single phase supply Fuse the input circuit with time del
21. ion 0 35 0 4Mpa 30A 0 4 0 45Mpa 40A Recommended Post flow 5 10s Pilot Arc Start Mode High Frequency Maximum Cutting Thickness 0 5 12 7mm AC TIG 20 250A DC TIG 10 250A Open Circuit Voltage 60 80V AC TIG Output Frequency 50 70Hz Square Waves TIG Welding AC TIG AC Balance 30 70 Electrode Positive Specification Gas Supply Clean dry oil free argon or helium gas 14L min 50 100A Output Current Recommended Gas Flow Rate 20L min 150 200A 25L min 250A Maximum Welding Thickness 0 3 8mm 20 200A 60 80V 0 50A Output Current MMA Welding Specification Open Circuit Voltage ARC Force 10 250A Pulse Duty 1090 9090 Pulse Mode Pulse Freguency 0 5 200Hz 10 90 INSTALLATION PLEASE READ ENTIRE INSTALLATION SECTION BEFORE STARTING INSTALLATION BE SURE THAT ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION BEFORE INSTALLATION 44 WARNING ELECTRIC SHOCK can kill Turn the input power OFF and unplug the machine from the receptacle before working on this equipment Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment Insulate yourself from the work and ground Always wear dry insulating gloves Always connect the welding machine to a power supply grounded according to the National Electrical Code and local codes gt SELECT SUITABLE LOCATION The Inverter will operate in harsh en
22. ipment per the following instructions should minimize problems Keep the welder power supply lines as short as possible and enclose as much of them as possible in rigid metallic conduit or equivalent shielding for a distance of 50 feet 15 2m There should be good electrical contact between this conduit and the welder case ground Both ends of the conduit should be connected to a driven ground and the entire length should be continuous Keep the work and electrode leads as short as possible and as close together as possible Lengths should not exceed 25 ft 7 6m Tape the electrode and work leads together into one bundle when practical Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high freguency leakage Keep the torch in good repair and all connections tight to reduce high frequency leakage The work terminal must be connected to a ground within ten feet of the welder using one of the following methods a A metal underground water pipe in direct contact with the earth for ten feet or more b A 3 4 19mm galvanized pipe or a 5 8 16mm solid galvanized iron steel or copper rod driven at least eight feet into the ground The ground should be securely made and the grounding cable should be as short as possible using cable of the same size as the work cable or larger Grounding to the building frame electrical conduit or a long pipe system can result in re radiation effectively mak
23. ity is positive when e the current is positive AC balance can also be viewed as a percentage of electrode positive in o o e one period 30 EP 70 EN 50 EP EN 70 EP 30 EN EP Electrode Positive EN Electrode Negative PULSE CURRENT When LTPAC2500 operates under pulse current the output me pa Curran current changes its magnitude periodically As shown in left l bo geill A E Figure once the current reaches the maximum current value the output current jumps between the maximum and minimum values The maximum current value Ip is called pulse current or pulse peak current The minimum current value Ip is the base current For LTPAC2500 the base current is adjusted by percentage of the pulse current The time for pulse current and base current to complete one exchange is a pulse period T The pulse frequency of t pulse current and base current exchange is 1 T The time T duration that the current stays in the state of pulse peak current in a pulse period is the pulse width T1 The ratio of T1 to T is pulse duty 36 UP SLOPE DOWN SLOPE POST FLOW CURRENT 0 DC Not Pulsed DC Pulsed Up slope Down postFlow oo m2tl j j Slope p _ _ lm i I l l The current type above can be any of the four types shown on the right I l AC Not Pulsed l AC Pulsed For every circuit when the user presses and holds the torch trigger the time for current to rise fr
24. ket turn the outer metal shell clockwise to tighten 3 Connect the ground cable to the output terminal in the way indicated before To minimize high frequency interference refer to Machine Grounding and High Frequency Interference Protection section of this manual for the proper Figure A 1 procedure on grounding the work clamp and work piece To avoid receiving a high frequency shock keep the 44 WARNING plasma cutting torch and ground clamp amp cable Insulation in good condition 12 gt OUTPUT AND GAS CONNECTION FOR TIG WELDING Figure A 2 ee eo 600 nn BOBO bd ce LTPAC2500 Figure A 2 A WARNING The TIG torch and ground cable are supplied with the welder To connect the cables turn the Power Switch OFF l Connect the gas inlet on the TIG torch cable to the CUT TORCH GAS OUTLET on the front of the welder and turn it clockwise using the plastic safe protector until snug do not over tighten Plug the 2 prong connector on the torch cable into TORCH CONTROL 2 pin socket turn the outer metal shell clockwise to tighten Connect the ground cable to the output terminal in the way indicated before To avoid receiving a high frequency shock keep the TIG torch and ground clamp amp cable insulation in good condition gt OUTPUT AND GAS CONNECTION FOR TIG WELDING USING FOOT PEDAL Figure A 3 DOA 66 LO 26 m m m LII
25. le below 50 100A 150 200A 200 250A 29cfh 14L min 42cfh 20L min 53cfh 25L min 5 Adjust output current by Pulse Current Adjust Knob 12 The output current can be adjusted from 10A to current level set by the user The maximum current value is 250A 6 Adjust up slope time down slope time and post flow time by corresponding knobs 17 18 2 and 19 7 Adjust AC balance by AC Balance Adjust Knob 20 The AC Balance can be changed from 30 EP EP Electrode Positive to 70 EP Changing the wave balance alters the ratio between the cleaning and the penetrating current Greater EP Less EN More Cleaning Less EP Greater EN More Penetration 8 Adjust AC frequency by AC Frequency Adjust Knob 21 The AC frequency can be changed from 50Hz to 70Hz The AC frequency controls the width of the arc cone comes out from the torch head Higher Frequency More Focused Arc Narrower Bead Lower Frequency Less Focused Arc Wider Bead 9 Hold the torch trigger or press foot pedal then initiate the arc TIPS FOR AC TIG WELDING AC Inverter TIG power sources offer two significant advantages over conventional Silicon Controlled Rectifier SCR transformer power sources 1 The AC wave balance can be set to a higher percentage electrode negative lower percentage electrode positive which minimizes tungsten heating and erosion 2 The AC frequency can be varied to focus the arc The AC freque
26. making it easy to operate For some applications the use of helium or argon helium blends is recommended due to better weld penetration and faster travel speed Helium is especially suitable for welding thick workpieces For steel TIG welding since the process does not include the removal of impurities proper cleaning and preparation of the edges is required The filler rods must deposit welds with mechanical characteristics appropriate for the application For copper TIG welding considering the fluidity of molten copper the use of backup support may prove useful In order to avoid the oxidation of molten materials filler materials containing phosphorus silicon or other deoxidizing materials are typically used The mechanical properties can also be improved through the use of silver l LTPAC2500 cannot be used for Electrode Positive TIG welding without special adaptors 23 DC Non pulsed TIG WELDING 1 Connect up the shielding gas typically argon using an appropriate regulator 2 Connect the torch and ground clamp amp cable to power source as Installation indicates Connect the foot pedal if necessary Turn the power source ON 660 660 ceece eceec amp e ore 8888 Welding corres Al 2 9 cm mm 9809 00 ce F LTPAC2500 Without Foot Pedal With Foot Pedal 3 Set function buttons for DC TIG non pulsed as Controls and Settings indicates the LTPAC2500 plasma cutting func
27. ncy above 60Hz will narrow the cone shape arc from the tungsten s tip This benefit can be used to maintain a tight focus of the arc for precise heat control and tight joint access Because of the AC inverters abilities in these areas the following recommendations are made as a starting point v A 2 Thoriated tungsten is recommended instead of the pure tungsten that is normally recommended for AC welding Thoriated tungsten emits electrons more easily and therefore will improve starting Sharpen the tungsten to a point Normally it is recommended to pre ball a pure tungsten when AC welding with a conventional power source However the AC inverter with it is extended AC balance control minimized tungsten heating thus allowing for a pointed tungsten to be used 26 DC Pulsed TIG WELDING The use of pulsed direct current allows better control of the weld pool during certain operating conditions Comparing with the traditional TIG welding performed at the same average current pulsed welding results in a smaller heat affected zone which results in fewer deformations and reduced chance of cracking and gas entrapment Increasing the frequency constricts the arc increases stability and improves weld quality 1 Connect up the shielding gas typically argon using an appropriate regulator 2 Connect the torch and ground clamp amp cable to power source as Installation indicates Connect the foot pedal if necessary Turn the power sourc
28. nected to the grounding pin of the plug usually identified by a green screw OUTPUT CONNECTIONS A WARNING ELECTRIC SHOCK can be fatal Keep the electrode holder TIG torch and cable insulation in good condition and in place Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Turn the input line Switch on the Inverter welding machine off before connecting or disconnecting output cables or other equipment gt GROUND CABLE CONNECTION To connect the ground cable turn the Power Switch OFF Connect the cable to the output terminal by plugging the cable end directly into the front receptacle marked as To minimize high freguency interference refer to Machine Grounding and High Freguency Interference Protection section of this manual for the proper procedure on grounding the work clamp and work piece OUTPUT AND GAS CONNECTION FOR PLASMA CUTTING Figure A 1 The plasma cutting torch and ground cable are supplied with the welder To connect the cables turn the Power Switch OFF 1 Connect the gas inlet on the torch cable to the eee ant CUT TORCH GAS OUTLET on the front of the ce i ia 8899 i gt 0 a welder and turn 1t clockwise using the plastic safe ce 4 LU LTPAC2500 protector until snug do not over tighten 2 Plug the 2 prong connector on the torch cable into TORCH CONTROL 2 pin soc
29. ob 15 to set the time for current staying in the peak value pulse current value It can be 10 90 of a pulse period Greater Pulse Duty More Penetration Less Pulse Duty More Cleaning Adjust up slope time down slope time and post flow time by corresponding knobs 17 18 and 19 10 Hold the torch trigger or press foot pedal then initiate the arc 28 AC Pulsed TIG When AC welding a pulsed current can be used with similar effects to those described in pulsed direct current welding 1 Connect up the shielding gas typically argon using an appropriate regulator 2 Connect the torch and ground clamp amp cable to power source as Installation indicates Connect the foot pedal if necessary Turn the power source ON 660 660 ce 6060 o ane ann BEE Without Foot Pedal With Foot Pedal 3 Set function buttons for AC TIG pulsed as Controls and Settings indicates the LTPAC2500 plasma cutting function is ready to use as ostflowis 0 Y Q Y cur ac JIUL y o i 7 M SPA 7 lt 7 M Pulse freq Pu A Duty gt y a f Pam 0 N TIG DC Welding current A o 10s i y 08 Up siope ce l BUTTON COMBINATION AND VALID KNOBS FOR CUT 4 Adjust the air pressure and make it is adequate to machine open the valve of pressed air The recommended a pressure is shown in table below 50 100A 150 200A 200 250A 29cfh 14L min 42cfh 20L min
30. om zero to the desired value is the up slope time After the user releases the trigger the time for current to decrease to zero is the down slope time The air supply does not cut off immediately as current becomes zero The time for air continuing flowing is the post flow time 37
31. ore there are electrically live parts inside the power source Carefully follow the instructions given in this manual Figure B 1 l Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating 60 duty cycle gt D 6 Minutes Welding 4 Minutes Resting Overheating gt el 0 y A Reduce Duty Cycle Minutes 16 gt CONTROLS AND SETTINGS Figure B 2 All operator controls and adjustments are located on the case front of the LTPAC2500 machine Refer to Figure B 2 and the corresponding explanations 2 amp Ce D et 10 A 250 di an g y mn 30 o a o Pulse current Base current Arc force Post flow s AC balance AC freg Hz 5HZ 0 5 Pulsefreg Q oe eo O A 0 EA Y NI os ov os wW W Welding current A Y o c at is o Down slope o mn O Tm CUT TORCH GAS OUTLET YO eo e2 ce Figure B 2 CONTROLS AND SETTINGS Electrode Connection Positive Connection for ground clamp amp cable in CUT TIG mode and DC MMA welding Connection for MMA electrode holder in DC MMA welding Torch Control Connector 2 pin socket for the control of CUT TIG torch trigger or foot pedal CUT Torch Gas Outlet Torch gas outlet for air used in CUT plasma cutting AA O I and for protective gas used in TIG welding Electrode Connection Negative Connection for ground clamp amp
32. orms are available from your welding distributor or from the manufacturer WELDING SPARKS can cause fire or explosion gt Remove fire hazards from the welding area If this is not possible cover them Ml to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and Openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available gt Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations gt When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard gt Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned gt Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuff less trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area gt Connect the work cable to the work as close to the welding area as practical Work cables connected to t
33. rer s recommendations gt Ground the equipment in accordance with the manufacturer s recommendations MOVING PARTS can cause injury gt Keep away from moving parts such as fans gt Keep all doors panels covers and guards closed and securely in place qe Please read this Operation Manual carefully and thoroughly before attempting to operate this machine Keep this manual handy for quick reference Pay close attention to the safety instructions provided for your own protection SPECIFICATIONS WHAT S INCLUDED Power Supply Plasma Cutting Torch TIG Welding Torch MMA Electrode Holder Ground Clamp TIG Torch Accessories Foot Pedal Air Filter amp Regulator Air Hose Air Hose Connections PLASMA CUTTING TORCH TIG WELDING TORCH MMA ELECTRODE HOLDER eo et tet VV VV VV VV V WV POWER SUPPLY GROUND CLAMP amp CABLE TIG TORCH ACCESSORIES FOOTPEDAL gt e al AIR HOSE AIR HOSE CONNECTIONS AIR FILTER amp REGULATOR POWER SUPPLY RATINGS LTPAC2500 Input Voltage AC 220 240V 10 1 PH 50 60Hz Power Efficiency 80 20 5 530mm L Dimensions 8 7 220mm W 15 8 400mm H 731bs 33kg Duty Cycle 60 Power Cable 8 2 2 5m General Specification Output Current 10 40A Open Circuit Voltage 235V Gas Supply Clean dry oil free air 0 25 0 3Mpa 15A Plasma Cutting 0 3 0 35Mpa 20A Recommended Pressure Specificat
34. tion 10 Adjust AC frequency by AC Frequency Adjust Knob 21 The AC frequency can be changed from 50Hz to 70Hz The AC frequency controls the width of the arc cone comes out from the torch head Higher Frequency More Focused Arc Narrower Bead Lower Frequency Less Focused Arc Wider Bead 11 Hold the torch trigger or press foot pedal then initiate the arc 30 MAINTENANCE MAINTENANCE FOR YOUR MACHINE ONLY QUALIFIED PERSONNEL SHOULD OPERATE THIS EQUIPMENT OBSERVE ALL SAFETY INFORMATION THROUGHOUT THIS MANUAL PLEASE READ AND UNDERSTAND THIS ENTIRE SECTION BEFORE DOING A WARNING ELECTRIC SHOCK can be fatal Have a qualified electrician install and service this equipment Turn the input power off at the fuse box disconnect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment Do not touch electrically hot parts INPUT FILTER CAPACITOR DISCHARGE PROCEDURE The machine has internal capacitors which are charged to a high voltage during power on conditions This voltage is dangerous and must be discharged before the machine can be serviced Discharging is done automatically by the machine each time the power is switched off However the user must allow the machine to sit for at
35. tion is ready to use Welding current A BUTTON COMBINATION AND VALID KNOBS FOR CUT 4 Adjust the gas pressure and make it is adequate to machine open the valve of pressed gas The recommended gas pressure is shown in table below 50 100A 150 200A 200 250A 29cfh 14L min 42cfh 20L min 53cfh 25L min 5 Adjust output current by Pulse Current Adjust Knob 12 The output current can be adjusted from 10A to current level set by the user The maximum current value is 250A 6 Adjust up slope time down slope time and post flow time by corresponding knobs 17 18 and 19 7 Hold the torch trigger or press foot pedal then initiate the arc 24 AC Non pulsed TIG WELDING 1 Connect up the shielding gas typically argon using an appropriate regulator 2 Connect the torch and ground clamp amp cable to power source as Installation indicates Connect the foot pedal if necessary Turn the power source ON 600 600 eee OOG s c mn sn BEE Welding cwremi Al e ce LTPAC2500 ce F LTPAC2500 Without Foot Pedal With Foot Pedal 3 Set function buttons for AC TIG non pulsed as Controls and Settings indicates the LTPAC2500 plasma cutting function is ready to use Welding current AJ BUTTON COMBINATION AND VALID KNOBS FOR CUT 4 Adjust the gas pressure and make it is adequate to machine open the valve of pressed gas The recommended gas pressure is shown in tab
36. tomatic DC Constant Voltage Wire Welder DC Manual MMA Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock ARC RAYS can burn gt Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Use suitable clothing made from durable flame resistant material to protect E Z y your skin and that of your helpers from the arc rays gt Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the
37. vironments Even so it is important that simple preventative measures are followed in order to assure long life and reliable operation The machine must be located where there 1s free circulation of clean air such that air movement in the back and out the front will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown STACKING LTPAC2500 cannot be stacked TILTING Place the machine directly on a secure level surface The machine may topple over if this procedure 1s not followed gt ENVIRONMENTAL AREA Keep the machine dry Do not place it on wet ground or in puddles gt MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION The Capacitor Discharge Circuit used in the high frequency generator may cause many radio TV and electronic equipment interference problems These problems may be the result of radiated interference Proper grounding methods can reduce or eliminate radiated interference Radiated interference can develop in the following four ways 1 Direct interference radiated from the welder 2 Direct interference radiated from the welding leads 3 Direct interference radiated from feedback into the power lines 4 Interference from re radiation of pickup by ungrounded metallic objects Keeping these contributing factors in mind installing equ
38. y protection GENERAL DESCRIPTION LOTOS LTPAC2500 a 5 in 1 multi functional plasma cutting and welding machine It combines functions of CUT plasma cutting AC TIG welding DC TIG welding Pulsed AC DC TIG welding and DC MMA welding The LTPAC2500 cutting function uses LOTOS s latest high freguency inverter technology utilizes IGBT to deliver more constant concentrated and precise current to the cutting surface It can easily achieve smooth and clean cuts of wide range of surfaces and materials such as stainless steel alloy steel brass aluminum and other conductive materials The welding function can switch between AC DC Pulsed TIG welding and DC MMA welding quickly and easily The square waveforms inventor for AC TIG welding enables the user to accurately weld aluminum A foot pedal can be used in the operation to increase ease and precision The welding function is great for aluminum steel stainless steel and copper materials LTPAC2500 has a duty cycle of 60 at 200 Amps and 18 Volts under TIG welding It is capable of higher duty cycles at lower output currents i e 100 at 105 Amps gt APPLICATION LIMITATIONS The inverter LTPAC2500 is not recommended for pipe thawing gt OUTPUT LIMITATIONS AC and DC Pulsed TIG Welding Plasma Cutting DC MMA Welding 250amps max 200amps max gt REAR CONTROL PANEL Figure B 1 The unit is connected to the supply even if the Power Switch is in the OFF position and theref
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