LOTOS LT5000D User manual

®
LOTOS TECHNOLOGY
Plasma Cutter LT5000D
www.uwelding.com

®
Lotos Technology LT5000D
Quick Setup
Power plug wiring idencaon:
For either 110 or 220VAC, the GREEN wire with the yellow strip is ground wire. The other two
wires are hot wires.
1
Instructions
1. Wear a proper helmet (Figure 1.1) to protect your eyes from
harmful plasma cung arc radiaon. Wear safety gloves to
protect your hands during operaon.
2. Connect the machine gas inlet (on the back of the machine, Figure 1.2) to an air compressor
(Figure 1.3 & 1.4) and set the air pressure to 65 - 70 PSI. (The air regulator is oponal as some air
compressors provide air pressure control capability).
Figure 1.1
Figure 1.2
Power
Cord Gas
Inlet
Gas
Inlet
Output
from
Air
Compressor
65 - 70 PSI
Figure 1.3
Figure 1.4

4. Aach the ground clamp to the metal work piece that you plan to cut. Grind the metal to make
sure the clamp is securely aached. Press the trigger of the torch and make sure there is air
ow. Finally, move the torch head to the work piece and enjoy cung!!
5. Change your consumables (p, electrode, and cup) when they become worn out. The correct
consumable type is LCON. The metal protector on the p is also replaceable. All accessories and
consumables can be purchased at www.uwelding.com or Lotos’s authorized resellers.
Thank you for your business!
3. Connect your plasma cung torch and ground cable to the front panel of the machine
(Figure 1.5) .
Figure 1.5
3-pin Switch
Plug
Air/Power
Output
Ground
Cable

®
LOTOS Plasma Cutters
User Manual
Version: 2.0, May 2014
copyright @ Lotos Technology
www.uwelding.com is operated by Lotos Technology

For more information and more of our products,
please visit our website at
http://www.uwelding.com/
Introducon 3
Overview ................................................................................
Audience................................................................................
Safety Precauons 4
Overview .................................................................................
Cauon Recommendaons .................................................................
Avoiding Fatal Electric Shock ................................................................
Avoiding Harmful Smoke, Gases, and Vapors ..................................................
Avoiding Harmful Arc Emissions/Rays ........................................................
Avoiding Harmful Noises ...................................................................
FireorExplosion..........................................................................
Burn Protecon ...........................................................................
Protecng Eyes from Flying Metal or Dirt .....................................................
Pacemakers..............................................................................
Cylinder Handling .........................................................................
Equipment 6
General Overview .........................................................................
Main Characteriscs .......................................................................
Specicaons .............................................................................
Adjustor Diagram ..........................................................................
Power Cord Plug Connecon ...............................................................
Connecng Cables to Machine..............................................................
Installaons ..............................................................................
Instrucon Notes 13
Cung Environment ......................................................................
Safety ...................................................................................
NotesforTorch...........................................................................
Maintenance and Troubleshoong ..........................................................
Trouble Shoong Guide ....................................................................
Plug Wiring Instrucons ....................................................................
Table of Contents
4
4
4
4
4
4
5
5
5
5
5
6
6
6
9
9
10
11
13
13
13
13
14
15
3
3

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3
Introduction
Overview
Dear Valued Customer:
Thank you for purchasing a Lotos Technology plasma cuer! Feel free to check out our other products at
www.uwelding.com.
The User Manual documents policies and procedures for proper operaon of the equipment.
IMPORTANT: Be sure to review the contents of this manual before aempng 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/cuer are able,
qualied, and/or cered to operate this type of machinery.

®
Safety Precautions - Read Before Using
Overview
Cauon Recommendaons
Arc rays from the welding process
produce intense visible and invisible
rays that can burn eyes and skin.
Sparks y o from the weld.
CAUTION: Welding and arc cung
can cause bodily injury.
• 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 mes. 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
cered for welding/cung.
Avoiding Harmful Smoke, Gases, and Vapors that can injure or kill.
Avoiding Harmful Arc Emissions/Rays that can burn eyes and skin.
Avoiding Fatal Electric Shock
Protect yourself and others from injury — read and follow these precautions.
Welding produces fumes and gases.
Breathing these fumes and gases can
be hazardous to your health.
4
• Do NOT switch o the machine while machine is
in operaon for internal circuitry can be
damaged.
• Wear appropriate clothing and a welding or
cung mask to protect your eyes and skin.
• Use appropriate screen or curtain to prevent
emissions from reaching individuals near the
work area.
• Ensure that your working area contains no
ammable items; and that none are nearby.
Cauon: Welding and cung spray can ignite.
Avoiding Harmful Noises that can damage hearing.
Noise from some processes can
damage hearing.
• Wear protecve earplugs while operang
machine.
• Isolate yourself from both the
earth and the work piece.
• Make sure that your working area is
nonammable and explosive-free.

Burn Protecon: HOT PARTS can cause serious burns.
Protect eyes from FLYING METAL or DIRT.
PACEMAKERS AND WELDING: MAGNETIC FIELDS can aect implanted devices.
CYLINDER HANDLING: it can explode if damaged.
Welding or Cung can cause Fire or Explosion.
If you encounter any dicules during set up or operaon:
• Consult this manual.
• Contact Lotos Customer Service by vising
hp://www.uwelding.com/about-us/contact-us/.
The work piece and equipment
get hot. The hot metal, hot work
piece, and hot equipment can
cause burns.
• Welding, chipping, wire
brushing, and grinding cause
sparks and ying metal.
Electric arc welding and cung
processes produce intense electric
and magnec (electromagnec)
elds. The funcon of pacemakers
can be aected by strong
electromagnec elds.
Shielding gas cylinders contain gas
under high pressure. If damaged,
a cylinder can explode. Be sure to
treat gas cylinders carefully.
Welding, cung, and allied
processes can cause re or
explosion if precauonary
measures are not followed.
• Use approved helmets or hand shields that
provide protecon for the face, neck, etc.
• Wear approved safety goggles or glasses with
side shields, even under your helmet.
• Wear approved safety glasses with side shields,
even under your welding helmet.
• Persons with a pacemaker should not go near
welding or cung operaons unl they have
consulted their doctors and obtained informaon
from the manufacturer of the device.
• Protect compressed gas cylinders from excessive
heat, mechanical shocks, physical damage, slag,
open ames, sparks, and arcs.
• Install cylinders in an upright posion by securing
to a staonary support or cylinder rack to prevent
falling or pping.
• Develop adequate procedures, and use proper
equipment to do the job safely.
• Keep cylinders away from any welding or other
electrical circuits.
• Wear dry, hole-free insulated gloves.
• Remove combusble materials from a sphere
with a minimum radius of 35 feet around the
work area or move the work to a locaon well
away from combusble materials.

®
Equipment
General Overview
The LT5000D employs 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 reccaon current.
Using Pulse-Width-Modulaon (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 signicantly reduced; while eciency is increased by 30%.
Main Characteriscs
• Stabilizaon
• Reliability
• Portability
Suitable for stainless steel, alloy steel, mild steel, copper aluminum, and other metal materials;
there are many applicaons for plasma cuers.
Input voltages 110-220V, 1-PH, 50/60 Hz
Input current 110-220V, 1-PH, 20 A
Output current 10-50 A
Duty cycle @ 40°C (104°F)
60% @ 50A, 110V
60% @ 50A, 220V
Dimensions with handle 15’’ (381mm) L; 6’’ (152.4mm) W; 12’’ (304.8mm) H
Weight w/ 8'11’’ (2.7 m) torch 22.5 lbs (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 6’ (1.8 m)
Power supply type Inverter- IGBT
Accessories
Plasma Torch (9' 9")
Plasma Consumables (installed on the torch head)
Air Filter/Regtulator
Ground Clamp & Cable
Connections, (like Air Hose etc.)
User Manual
• Power eciency and low noise output
• High cung speed
• Smooth cuts
6
Specicaons

®
Torch Type
Torch Type Model Amperage Consumable Type
3 prong LCON cutting torch CL0103 50
LCON0120
LCON0140
LCON0190
Extended 3 prong
LCON cutting torch CL0203 50
LCON0220
LCON0240
LCON0290
Consumables Package
Part Number Nozzle Electrode Shield Cup Swirl Ring Package Type Total
Pieces
LCON0120 LN01 LE01 LC01 LR01 LN01 x 10,
LE01 x 10 20
LCON0140 LN01 LE01 LC01 LR01
LN01 x 10,
LE01 x 10,
LR01 x 10,
LC01 x 10
40
LCON0190 LN01 LE01 LC01 LR01
LN01 x 40,
LE01 x 20,
LR01 x 20,
LC01 x 10
90
LCON0220 LN02 LE02 LC02 LR02 LN02 x 10,
LE02 x 10 20
LCON0240 LN02 LE02 LC02 LR02
LN02 x 10,
LE02 x 10,
LR02 x 10,
LC02 x 10
40
LCON0290 LN02 LE02 LC02 LR02
LN02 x 40,
LE02 x 20,
LR02 x 20,
LC02 x 10
90
7

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Producon Cut Chart
Material Thickness*Current
inches mm amps
Mild
Steel
10 gauge 3 50
1/4 6 50
3/8 10 50
1/2 12 50
5/8 16 50
Stainless
Steel
10 gauge 3 50
1/4 6 50
3/8 10 50
1/2 12 50
Aluminum
1/8 3 50
1/4 6 50
3/8 10 50
1/2 12 50
*Producon cut thickness are the results of Lotos’ laboratory tesng.
Producon speeds are approximately 80% of maximum.
For opmum cut quality, cung speeds may vary based on dierent cung applicaons.
8

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Power
Switch
Cung
Current
Adjust
Power
&
Air Output
Switch
Plug Ground
Connecon
Power
Cable
Gas
Inlet
Problem
Indicator
LED
Figure 2.1: Adjustor Diagram
9
Figure 2.2: Power Cord Plug Connecon Figure 2.3: Air Regulator Conguraon

®10
Air Compressor
Air/
Power
Output
3-pin
Switch
Plug
Filter
Ground
Torch
Ground Clamp
Work
Piece
Figure 2.4: Connecng Cables to Machine

®
Installaon
Power Cord Plug Connecon (Figure 2.2)
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 oxidaon.
Make sure the power voltage is within the specied safety range.
3. Please refer to the Plug Wiring Instrucons of this manual for detailed instrucons 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 unl it locks into posion. Connect the mobile plug
at one end of the grounding cable pincer to the posive terminal located on the front panel;
and then ghten.
3. Ensure that the air plug of the torch is connected to the switch connector on the panel. For
cuers with pilot arc, connect the fork connector to the red terminal on the front panel.
1. Ensure that the cung machine is properly grounded.
2. Ensure that all connectors are connected appropriately and rmly.
3. Ensure that power voltages are correct.
1. Make sure the machine on/o switch is in the o posion. Plug the power cord plug into the
outlet.
2. Connect air compressor with air regulator/lter.
3. Connect the ground clamp to your work piece. Cauon: Rust or paint on the work piece could
create an open circuit; therefore, the contact point should be cleaned thoroughly to ensure a
good connecon 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.
Connecng the Cables to the Machine (Figure 2.4)
Check-list before Operaon
Operang the Plasma Cuer
11

®12
Operang the Plasma Cuer
5. Adjust the air pressure on your air compressor to 60 – 65 psi for the machine.
6. Bring the torch p into direct contact with your work piece edge or, for thicker cung,
over a pre-drilled pilot hole. Press the buon on the torch to start cung.
7. Ensure that the cung current is appropriate and adequate for the machine based on
the rated thickness of the cuer.
Note: Below is the consumable assembly on the torch head (Figure 3.1).
Figure 3.1
cut
on/off
torch body
cup seat
double sided
electrode
ceramic
ring
copper
tip
ceramic
cup

®
Instruction Notes
13
1. The cung machine can perform in an environment where condions are parcularly harsh:
it can withstand outside temperatures between 14 and 104 degrees Fahrenheit and a humidity level
of up to 80%.
2. Please try to keep machine dry.
1. Working area MUST be adequately venlated.
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 inialized if machine exceeds duty cycles. The cung 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 connue working in order to cool the machine. Once temperature is
reduced to allowable range, machine can be operated again.
1. Ensure that the copper p is not in direct contact with the work piece while cung. To protect copper
p, torch should be inclined and maintain a distance of 1 mm from inter-hole of copper p to the work
piece.
2. If pilot arcing funcons improperly, try to remove oxidizaon of the electrode on the torch with sand
paper.
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 rm connecons.
4. Protect machine from water or dampness.
5. When machine is not in use for a long period of me, it should be properly packed and stored in a dry
environment.
6. Replace any worn consumables to avoid damage.
Safety
Notes for Torch
Maintenance and Troubleshoong
Cung Environment

®
Faults Possible Causes/Soluons
1. The power pilot light is o,
the fan doesn’t work, and
there is no cung voltage
output.
1. The power switch is broken.
2. There is no electrical power.
3. The input cable is short-circuited.
2. The power switch is on,
the fan doesn’t work. No
voltage is indicated on the
front panel.
1. There is an improper connecon to the plug or the plug is
improperly connected to the 380V power supply, causing over-voltage
protecon. For laer case, wait for 8 minutes, reconnect to 220V power
supply, and restart the machine.
2. The transformer is broken.
3. Voltage deciency protecon has been acvated.
4. The wire from the switch to the boom board has loosened. Tighten it.
5. The relay on the boom board is damaged. Replace with a new relay.
3. The fan is on, the
abnormal pilot light is not
on, cannot start the arc.
Contact the manufacturer or cered service personnel.
4. The abnormal pilot light is
o, no cung voltage
output.
1. The welding cable is broken.
2. The ground is improperly connected to the work piece.
3. The “+” output terminal is not properly connected.
5. The problem pilot light is
not on.
1. The nozzle is oxidized or too far away. Remove the oxidizaon on
the surface, or shorten the distance to 1 mm.
2. Otherwise, contact the manufacturer or cered service personnel.
6. The abnormal pilot light is
on.
1. Over-current protecon may have inialized. Either wait for 2 or 3
minutes for the problem to go away, or turn o the power, wait unl
the abnormal pilot light is o, and restart (machine will recover
automacally).
2. Otherwise, contact the manufacturer or cered service personnel.
7. The output current is not
stable.
1. Check connecons on the front panel.
2. Otherwise, contact the manufacturer or cered service personnel.
8. The machine does not cut
metal properly, or the arc is
not stable.
1. The input voltage is too low.
2. The ground cable is not well-connected.
3. The air pressure is too high or too low.
4. The nozzle and electrode of the torch do not t well, or the input
current is too low.
14
The following trouble shoong guide is for your reference only. Lotos Technology will NOT take any
liability or responsibility for any injury or damage caused in such acon(s). Always turn o electrical
power and air supply before performing inspecon and reconnecon.
CAUTIONS: Only qualied technicians are authorized to undertake the repair of this equipment in the
case of machine failure.

®
15
Plug Wiring
Instrucon
Do not aempt to wire or handle high voltage without proper training. Contact an electrician to help you
install an electrical outlet or connect an electrical 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 unl 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.) Connecng these wires properly is very
important, and improper wiring could cause damage
and void product warranty.
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 dicult to
dierenate 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 nd 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 qualied professional about which plug you will need.
The ground is the rst wire you should connect in the
plug. Next connect the two live wires. Generally it
does not maer which one goes on which side. As a
general rule of thumb, connect blue on the le and
red on the right, or black on the le and white on the
right.
Figure 4.1
Figure 4.2

®