User Manual
Contents
1. 77 1 1 80 03 5 Protecting Eyes from Flying Metal or 5 Pacemakers ee hh hh hh hee 5 Cylinder Handling acuario Roe aegra Farah dana 8 3d eode 3902 hoes aed Ar Rode TERES Erg is 5 Equipment 6 General Overview is icesoe rac A HE d Pad E etna d UP UE wad M aed dos dol Rao id dus M pana dut test dida eur dus d 6 Main 6 6 62 2000 6 1 rd EG RO 6 7 5 58 11 9 Power Cord Plug Connection 9 Connecting Cables to 6 6 10 s a 7 0 7 11 Instruction Notes 13 s eser 3 1 2 900 13 sc 111111111 9 13 Nores TOR cree ce sean 3 1111 090 0 13 Maintenance and Troubleshooting 13 Trouble Shooting GUICB S ces erra d R dee ees eee eens Tes tare i 14 7771 311111 1 11 111 0 15 please visit our website at http www uwelding com Introduction Overview Dear Valued Customer Thank you for purchasing a Lotos Technology plasma cutter Feel free to check out our other products at www uwelding com The User Manual documents policies and procedur2. Wear dry hole free insulated gloves Protect eyes from FLYING METAL or DIRT e Welding chipping wire e Wear approved safety glasses with side shields brushing and grinding cause even under your welding helmet sparks and flying metal PACEMAKERS AND WELDING MAGNETIC FIELDS can affect implanted devices Electric arc welding and cutting e Persons with a pacemaker should not go near L processes produce intense electric welding or cutting operations until they have and magnetic electromagnetic consulted their doctors and obtained information E M fields The function of pacemakers from the manufacturer of the device zs can be affected by strong electromagnetic fields CYLINDER HANDLING it can explode if damaged Shielding gas cylinders contain gas e Protect compressed gas cylinders from excessive under high pressure If damaged heat mechanical shocks physical damage slag a cylinder can explode Be sure to open flames sparks and arcs treat gas cylinders carefully Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent e Keep cylinders away from any welding or other falling or tipping electrical circuits If you encounter any difficulties during set up or operation e Consult this manual e Contact Lotos Customer Service by visiting http www uwelding com about us contact us LOTOS Eguipment General Overview The LT5000D e
3. d tos Technology LT5000D Quick Setup Instructions Power plug wiring identification For either 110 or 220VAC the GREEN wire with the yellow strip is ground wire The other two wires are hot wires 1 Wear a proper helmet Figure 1 1 to protect your eyes from harmful plasma cutting arc radiation Wear safety gloves to protect your hands during operation Figure 1 1 2 Connect the machine gas inlet on the back of the machine Figure 1 2 to an air compressor Figure 1 3 amp 1 4 and set the air pressure to 65 70 PSI The air regulator is optional as some air compressors provide air pressure control capability TURN TO GHANGE OUTLET PRESSURE GIRAR PARA VARIAR LA PRESION DE TRABAJ 65 70 PSI Figure 1 3 Gas Inlet Gas Inlet Output from Figure 1 2 Air Compressor DEL Br oD M 9004 j N Da AC 1 1 l a ECO dd EIU US i9 Figure 1 4 LOTOS 3 Connect your plasma cutting torch and ground cable to the front panel of the machine Figure 1 5 Air Power Output e 3 pin Switch Plug Ground o Cable Figure 1 5 4 Attach the ground clamp to the metal work piece that you plan to cut Grind the metal to make sure the clamp is securely attached Press the trigger of the torch and make sure there is air flow Finally move the torch head to the work piece and enjoy cutting 5 Change your consumables tip electrode and cup when they
4. LCON0190 LCON0220 Extended 3 prong LCON0240 LCON cutting torch a z LCON0290 Consumables Package 3 prong LCON cutting torch CLO103 Total Part Number Nozzle Electrode Shield Cup Swirl Ring Package Type LNO1 x 10 LCONO120 LNO1 ES LCO1 EROT LEO1x10 LNO1 x 10 LEO1 x 10 LCONO140 LNO1 PEOI LCO1 EROT LRO1 x 10 LCO1 x 10 LNO1 x 40 LEO1 x 20 LCONO0190 LNO1 LEO1 LCO1 EROT LRO1 x 20 LCO1 x 10 LCONO220 LNO2 LEO2 LCONO240 LNO2 LEO2 LNO2 x 10 LEO2 x 10 RO2 LRO2 x 10 LCO2 x 10 LNO2 x 40 LEO2 x 20 LCON0290 LNO2 LEO2 LRO2 LCO2 x 10 OTOS LNO2 x 10 m Production Cut Chart Thickness Current E Hes aer i ammi L ugue 3 I 9 Stainless MH 5 9 Steel WEM o Production cut thickness are the results of Lotos laboratory testing Production speeds are approximately 8096 of maximum For optimum cut quality cutting speeds may vary based on different cutting applications LOTOS Cutting Problem Current Indicator Adjust LED Power l Switch LOTOS e w a Q D Power amp Air Output Switch Plug Ground Connection Power Gas Cable Inlet Figure 2 2 Power Cord Plug Connection LT5000D Figure 2 1 Adjustor Diagram Rack l i Gas In
5. NEE N Compress V T Pipe L Meter Ce 47 Jf Cup E 7 he Wi E Power Cable Gas Inlet Figure 2 3 Air Regulator Configuration i LOTOS Ground Use DI 1 P LT5000D ON d gy DC INVERTER AIR PLASMA CUTTER Ail TZ Power Output Ground Clamp Figure 2 4 Connecting Cables to Machine LOTOS 10 Installation 1 Be sure to connect the power cord plug to the appropriate power voltage and use a proper hookup to avoid damage to internal circuitry Typically the ground wire is GREEN with a YELLOW stripe 2 Ensure that the power cord is properly connected to the power switch to prevent oxidation Make sure the power voltage is within the specified safety range 3 Please refer to the Plug Wiring Instructions of this manual for detailed instructions on plug wiring 1 Properly connect the high pressure tube of pressed air to copper connector 2 Ensure that copper screw at the opposite end of the torch is securely connected to the torch To avoid gas leakage turn screw clockwise until it locks into position Connect the mobile plug at one end of the grounding cable pincer to the positive terminal located on the front panel and then tighten 3 Ensure that the air plug of the torch is connected to the switch connector on the panel For cutters with pilot arc connect the fork connector to the red terminal on the front panel 1 Ensure that th
6. become worn out The correct consumable type is LCON The metal protector on the tip is also replaceable All accessories and consumables can be purchased at www uwelding com or Lotos s authorized resellers Thank you for your business LOTOS TECHNOLOGY POWERFUL PORTABLE AND AFFORDABLE WELDING SOLUTIONS IS Contact us LOTOS 1155 Tasman Drive sunnyvale CA 94089 Tel 1 408 739 2329 E mail sales lotostecnnology com http www uwelding com 10 5 Plasma Cutters User Manual Version 2 0 May 2014 copyright Lotos Technology www uwelding com is operated by Lotos Technology LOTOS Table of Contents Introduction 3 6 3 AUdIENCE 1 11 1 1 1 1 1 3 Safety Precautions 4 OvervieW P 4 Caution Recommendations e hh hh hh hrs 4 Avoiding Fatal Electric Shock 4 amp 2 aio rsen SR ne SR RP PP Rp d Ecrire PES Rr RS E Sed 4 Avoiding Harmful Smoke Gases and Vapors ee eee a 4 Avoiding Harmful Arc Emissions Rays RR RR ns 4 Avoiding Harmful Noises llle Rh hehe 4 Fire or EXDIOBIOlL ce 71 1 ida due uiu S uad dau dd 7 1 1 1 5 BURG
7. e cutting machine is properly grounded 2 Ensure that all connectors are connected appropriately and firmly 3 Ensure that power voltages are correct 1 Make sure the machine on off switch is in the off position Plug the power cord plug into the outlet 2 Connect air compressor with air regulator filter 3 Connect the ground clamp to your work piece Caution Rust or paint on the work piece could create an open circuit therefore the contact point should be cleaned thoroughly to ensure a good connection between clamp and work piece 4 Turn on the power switch The cooling fan should start to operate and the LED should come on The front panel should show the machine s electrical current volume and you can adjust it by turning the nob below the display i LOTOS H 5 Adjust the air pressure your air compressor to 60 65 psi for the machine 6 Bring the torch tip into direct contact with your work piece edge or for thicker cutting over a pre drilled pilot hole Press the button on the torch to start cutting 7 Ensure that the cutting current is appropriate and adequate for the machine based on the rated thickness of the cutter Note Below is the consumable assembly on the torch head Figure 3 1 double sided copper eut electrode tip on off ceramic ceramic cup seat gie 8 cup torch body Figure 3 1 LOTOS 12 Instruction Notes Cutting Environment 1 The cutting mac
8. ervice personnel abnormal pilot light is not on cannot start the arc 4 The abnormal pilot light is 1 The welding cable is broken off no cutting voltage 2 The ground is improperly connected to the work piece output 3 The output terminal is not properly connected 5 The problem pilot light is 1 The nozzle is oxidized or too far away Remove the oxidization on not on the surface or shorten the distance to 1 mm 2 Otherwise contact the manufacturer or certified service personnel 6 The abnormal pilot light is 1 Over current protection may have initialized Either wait for 2 or 3 on minutes for the problem to go away or turn off the power wait until the abnormal pilot light is off and restart machine will recover automatically 2 Otherwise contact the manufacturer or certified service personnel 7 The output current is not 1 Check connections on the front panel stable 2 Otherwise contact the manufacturer or certified service personnel 8 The machine does notcut 1 The input voltage is too low metal properly or the arcis 2 The ground cable is not well connected not stable 3 The air pressure is too high or too low 4 The nozzle and electrode of the torch do not fit well or the input current is too low LOTOS 14 Plug Wiring Instruction Do not attempt to wire or handle high voltage without proper training Contact an electrician to help you install an electrical outlet or connect an elec
9. es for proper operation of the equipment IMPORTANT Be sure to review the contents of this manual before attempting to operate the equipment This manual should be located where it can be easily referenced by all users of the machine Audience This manual assumes that all individuals reading the manual and using the welder cutter are able qualified and or certified to operate this type of machinery LOTOS 3 Safety Precautions Read Before Using Overview Protect yourself and others from injury read and follow these precautions Caution Recommendations CAUTION Welding and arc cutting can cause bodily injury e Do NOT switch off the machine while machine is in operation for internal circuitry can be damaged Avoiding Fatal Electric Shock ES e solate yourself from both the N earth and the work piece Connect the machine to a UL approved outlet only Do not hard wire the machine directly to the power source Wear safety goggles at all times This will dark en the arc that is generated by the machine and protect your eyes from harmful rays All machine operators should be technically certified for welding cutting e Make sure that your working area is nonflammable and explosive free Avoiding Harmful Smoke Gases and Vapors that can injure or kill Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Avoiding Harmful Arc Emissio
10. ground is the first wire you should connect in the plug Next connect the two live wires Generally it does not matter which one goes on which side As a general rule of thumb connect blue on the left and red on the right or black on the left and white on the right Figure 4 2 i LOTOS Plasma Tig Stick Combo PLASMA CUTTERS Powerful Portable amp Affordable x WELDING SOLUTION CHECK OUT ALL OUR PRODUCTS AT 47 WW W UWELDING COM LO TOS eBranding Inc 2014 All Rights Reserved
11. hine can perform in an environment where conditions are particularly harsh it can withstand outside temperatures between 14 and 104 degrees Fahrenheit and a humidity level of up to 8096 2 Please try to keep machine dry Safety 1 Working area MUST be adequately ventilated 2 No over load Your machine can be damaged by over loading 3 No over voltage Internal circuitry can be damaged by over voltage 4 An internal heat variable component is initialized if machine exceeds duty cycles The cutting machine will stop working immediately and an internal red diode will be lighted Note The user does not need to break the circuit the fan will continue working in order to cool the machine Once temperature is reduced to allowable range machine can be operated again Notes for Torch 1 Ensure that the copper tip is not in direct contact with the work piece while cutting To protect copper tip torch should be inclined and maintain a distance of 1 mm from inter hole of copper tip to the work piece 2 If pilot arcing functions improperly try to remove oxidization of the electrode on the torch with sand paper Maintenance and Troubleshooting 1 Dust created by compressed air should be removed regularly If work environment is polluted with smoke and dust daily maintenance is required 2 Ensure adequate air pressure exists to protect internal components 3 Check all connectors to ensure firm connections 4 Protect machine from
12. mploys state of the art inverter technology 50 60Hz frequency is inverted to high frequency over 100 KHz by V MOSFET followed by step down voltage and rectification current Using Pulse Width Modulation PWM technology the inverter power supply generates powerful DC welding currents By applying switch power inverter technology the dimensions and weight of the main transformer is significantly reduced while efficiency is increased by 30 Main Characteristics e Stabilization Power efficiency and low noise output e Reliability e High cutting speed e Portability e Smooth cuts Suitable for stainless steel alloy steel mild steel copper aluminum and other metal materials there are many applications for plasma cutters Specifications Input voltages 110 220V 1 PH 50 60 Hz Mputcurent 110 220V 1 PH 20A 10 50 A 60 50A 110V Duty cycle 40 C 104 F 60 50A 220V Dimensions with handle 15 e mmm ete EAn 2 Weight w 8 11 2 7 m torch 22 5 Ibs 10 2 kg Gas Supply Clean dry oil free air Recommended gas inlet flow rate pressure 3 6 scfm 65 psi Input power cable length 13m Power supply type Inverter IGBT Plasma Torch 9 9 Plasma Consumables installed on the torch head rd Air Filter Regtulator Ground Clamp amp Cable Connections like Air Hose etc User Manual LOTOS Torch Type Torch Type Model Amperage Consumable Type LCON0120 LCON0140
13. ns Rays that can burn eyes and skin Arc rays from the welding process produce intense visible and invisible rays that can burn eyes and skin Sparks fly off from the weld Wear appropriate clothing and a welding or cutting mask to protect your eyes and skin Avoiding Harmful Noises that can damage hearing Noise from some processes can damage hearing e Use appropriate screen or curtain to prevent emissions from reaching individuals near the work area e Ensure that your working area contains no flammable items and that none are nearby Caution Welding and cutting spray can ignite Wear protective earplugs while operating machine i LOTOS Welding or Cutting can cause Fire or Explosion Welding cutting and allied Remove combustible materials from a sphere processes can cause fire or with a minimum radius of 35 feet around the explosion if precautionary work area or move the work to a location well measures are not followed away from combustible materials Wi A Develop adequate procedures and use proper equipment to do the job safely Burn Protection HOT PARTS can cause serious burns The work piece and equipment e Use approved helmets or hand shields that get hot The hot metal hot work provide protection for the face neck etc piece and hot equipment can e Wear approved safety goggles or glasses with lem cause burns side shields even under your helmet
14. trical plug to your machine Regardless of which machine you have it will require power to operate properly Do not assume you know which wires to connect until you read this manual completely as colors may be deceiving All of our machines are either 110VAC or 220VAC The 110VAC machines will operate at 100V 120VAC and 50 60Hz the 220VAC machines will operate at 200 240VAC and 50 60 Hz All machines are 1 phase unless otherwise stated 1 phase means the power cord will have 1 ground wire and two hot wires Figure 4 1 Connecting these wires properly is very important and improper wiring could cause damage and void product warranty Figure 4 1 he ground wires on most machines are dark green Some of them are green with a yellow twisted line in them Some of the machines have blue dark green and dark red wires and it may be difficult to differentiate which wire is ground because the blue and dark green looks similar The best way to test for proper ground is to test the ohms between the machine chassis ground to the wire ground Note When ground wire is incorrectly connected even the machine and the fan can turn on but the machine would not operate properly You may need to consult with an expert to find the proper plug for your machine First you will need to know the maximum amperage draw of your machine which should be in your manual Write it down and consult a qualified professional about which plug you will need The
15. water or dampness 5 When machine is not in use for a long period of time it should be properly packed and stored in a dry environment 6 Replace any worn consumables to avoid damage i LOTOS 13 The following trouble shooting guide is for your reference only Lotos Technology will NOT take any liability or responsibility for any injury or damage caused in such action s Always turn off electrical power and air supply before performing inspection and reconnection CAUTIONS Only qualified technicians are authorized to undertake the repair of this equipment in the case of machine failure Faults Possible Causes Solutions 1 The power pilot light is off 1 The power switch is broken the fan doesn t work and 2 There is no electrical power there is no cutting voltage 3 The input cable is short circuited output 2 The power switch is on 1 There is an improper connection to the plug or the plug is the fan doesn t work No limproperly connected to the 380V power supply causing over voltage voltage is indicated on the protection For latter case wait for 8 minutes reconnect to 220V power front panel supply and restart the machine 2 The transformer is broken 3 Voltage deficiency protection has been activated 4 The wire from the switch to the bottom board has loosened Tighten it 5 The relay on the bottom board is damaged Replace with a new relay 3 The fan is on the Contact the manufacturer or certified s
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