LOTOS LTP5000D User manual

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LOTOS TECHNOLOGY
www.uwelding.com

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Lotos Technology LTP5000D
Quick Setup
Instructions
Power plug wiring identification:
The GREEN wire with the yellow strip is ground wire. The other two wires have equal
usage. They are both hot wires for 240 V. And one is hot one is netural under 120 V.
Quick Setup:
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.
2. Connect the machine air inlet (on the back of the machine, use stand NPT 1/4” industry
type D coupler, Figure 1.2) to an air compressor (Figure 1.3 & 1.4) and set the air
pressure to 65 - 70 PSI. (The capacity of air compressor should be larger than 4.0 SCFM
@ 65 PSI).
Figure 1.1
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Figure 1.2
Power
Cord
Air In
Air
Inlet
65 - 70 PSI
Figure 1.3
Figure 1.4
Air
Inlet

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3. Connect your plasma cutting torch and ground cable to the front panel of the machine
(Figure1.5).
4. Attach the ground clamp to the metal work piece that you plan to cut. Make sure that
you cannot pull out the ground connection from the machine input. The metal work
piece should be securely attached.
5. Make sure the consumables are properly assembled on the torch head.
6. Press the trigger of the torch and make sure there is air flow through it.
7. Move the torch head to the work piece, press the trigger (for spacing from the work
piece, maintain a slight distance approx. 1 mm) and you will find that the torch will
ignite. Enjoy cutting!!
8. Change your consumables (tip, electrode, and cup) when they become worn out. The
correct consumable type for this machine is PCON20, PCON40, PCON90 etc. All
accessories and consumables can be purchased at www.uwelding.com or Lotos’s
authorized resellers.
Thank you for your business!
Figure 1.5
3-pin Switch
Plug
Air/Power
Output
Ground
Cable
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LOTOS Plasma Cutters
User Manual
Version: 3.0, July 2017
Copyright © Lotos Technology
www.uwelding.com is operated by eBranding Inc.
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http://www.uwelding.com/
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Table of Contents
Introduction 5
Overview ..................................................................... . . 5
Users ........................................................................ . .5
Safety Recommendations 6
Overview . .....................................................................6
Safety Recommendations ...................... ............................... . . .6
Avoiding Fatal Electric Shock .................................................6
Avoiding Harmful Smoke, Gases, and Vapors .........................................6
Avoiding Harmful Arc Emissions/Rays .............................................6
Avoiding Harmful Noises ...
......................................................6
Fire or Explosion . ............................................................. . 7
Burn Protection ...............................................................7
Protecting Eyes from Flying Metal or Dirt .... ..................... ................7
Pacemakers ......................... . .........................................7
Cylinder Handing ...............................................................7
Cralifornia Proposition 65 Warnings ...............................................8
Equipment 9
General Overview ..............................................................9
Main Characteristics ...... . . ....................................................9
Specifications ...............................................................9
Ideal Cutting Chart . . . . . . . . . ...................................................10
Front Panel Diagram ...........................................................11
Power Cord Plug Connection ...................................................12
Installation .................................................................13
Instruction Notes 15
Cutting Environment .................................................... . ......15
Safety ...................................................................... . .15
Maintenance and Troubleshooting ...............................................15
Plasma Cutter LTP5000D Troubleshooting Flowchat ...................... . ...........16
Plasma Cutter LTP5000D Connections .............................................18
Plasma Cutter LTP5000D Fan Troubleshooting .. . . . .................................19
Plasma Cutter LTP5000D Other Accessories ....................... . . . . . . . . . . . . . . 20

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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 procedures 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.
Users
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.
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S a f e t y R e c o m m e n d a t i o n s - R e a d B e f o r e U s i n g
Overview
Protect yourself and others from injury — read and follow these precautions.
Caution Recommendations
CAUTION: Welding and arc cutting
can cause bodily injury.
• Do NOT switch off the machine while machine is in
operation since internal circuitry can be damaged.
• 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.
Avoiding Fatal Electric Shock
• Isolate yourself from both the
ground and the work piece.
• 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.
• Keep your head away from any smoke, gases, or
vapors.
Avoiding Harmful Arc Emissions/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.
• Use appropriate safety screen or curtain to
prevent emissions from reaching individuals
near the work area.
• Ensure that your working area contains no
flammable items; and that none are nearby.
Caution: Welding and cutting spray can ignite.
Avoiding Harmful Noises that can damage hearing.
Noise from some processes can
damage hearing.
• Wear protective earplugs while operating
machine.
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Welding or Cutting can cause Fire or Explosion.
Welding, cutting, and allied
processes can cause fire or
explosion if precautionary
measures are not followed.
• Develop adequate procedures, and use proper
equipment to do the job safely.
• Remove combustible materials fro
m a sphere
with a minimum radius of 35 feet around the
work area or move the work to a location well
away from combustible materials.
Burn Protection: HOT PARTS can cause serious burns.
The work piece and equipment get
hot. The hot metal, hot work piece,
and hot equipment can cause burns.
• Use approved helmets or hand shields that
provide protection for the face, neck, etc.
• Wear approved safety goggles or glasses with
side shields, even under your helmet.
• Wear dry, hole-free insulated gloves.
Protect eyes from FLYING METAL or DIRT.
• Welding, chipping, wire brushing,
and grinding cause sparks and
flying metal.
• Wear approved safety glasses with side shields,
even under your welding helmet.
PACEN MAKERS AND WELDING: MAGNETIC FIELDS can affect implanted devices.
Electric arc welding and cutting
processes produce intense electric
and magnetic (electromagnetic)
fields. The function of pacemakers
can be affected by strong
electromagnetic fields.
• Persons with a pacemaker should not go
near welding or cutting operations until they
have consulted their doctors and obtained
information from the manufacturer about the
device.
CYLINDER HANDLING: Tank can explode if damaged.
Shielding gas cylinders contain gas
under high pressure. If damaged, a
cylinder can explode. Be sure to
treat gas cylinders carefully.
• Keep cylinders away from any welding activities or
other electrical circuits.
• Protect compressed gas cylinders from
excessive heat, mechanical shocks, physical
damage, slag, open flames, sparks, and
arcs.
• Install cylinders in an upright position by
securing to a stationary support or cylinder
rack to prevent falling or tipping.
If you encounter any difficulties during set up or operation:
• Consult this manual.
• Contact Lotos Customer Service by visiting
http://www.uwelding.com/contact/.
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California Proposition 65 Warnings
Welding or cutting equipment
produces fumes or gases which
contain chemicals known to the State
of California to cause birth defects
and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Engine exhaust contains chemicals
known to the State of California to
cause cancer, birth defects, or other
reproductive harm.
Battery posts, terminals and related
accessories contain lead and lead
compounds, chemicals known to the
State of California to cause cancer and
birth defects or other reproductive
harm. Wash hands after handling.
For Diesel Engines:
Diesel engine exhaust and some of
its constituents are known to the
State of California to cause cancer,
birth defects, and other
reproductive harm.
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.
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Equipment
General Overview
The LTP5000D 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
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
• Stabilization • Power efficiency and low noise output
• Reliability • High cutting speed
• Portability • 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 120-240 V, 1-PH, 50/60 Hz
Input current 120 V @ 40 A; 240 V @ 30 A
Recommended breaker 50 A @ 120 V; 40 A @ 240 V
Output current 10-50 A
Duty cycle @ 40°C (104°F) 60% @ 35 A, 120 V
60% @ 50 A, 240 V
Dimensions with handle 15’’ (381 mm) L; 6’’ (152.4 mm) W; 12’’ (304.8 mm) H
Weight w/ 8'11’’ (2.7 m) torch 22.5 lbs (10.2 kg)
Gas Supply Air
Recommended gas inlet
flow rate / pressure 3.6s cfm @ 65 psi
Input power cable length 6’ (1.8 m)
Power supply type MOSFET
Accessories
Plasma Torch (9' 9")
Plasma Consumables (installed on the torch head)
Air Filter/Regulator
Ground Clamp & Cable
Connections, (like Air Hose etc.) User
Manual
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Ideal Cutting Chart
Material
Thickness*Current
Inches mm Amps
Under 240 V
Amps
Under 120 V
Mild Steel
10 Gauge 315 A-50 A 15 A-35 A
1/4 625 A-50 A 30 A-35 A
3/10 835 A-50 A 35 A
3/8 10 45 A-50 A Not Support
1/2 12 50 A Not Support
Stainless
Steel
10 Gauge 315 A-50 A 15 A-35 A
1/4 625 A-50 A 30 A-35 A
3/10 835 A-50 A 35 A
3/8 10 45 A-50 A Not Support
1/2 12 50 A Not Support
Aluminum
10 Gauge 315 A-50 A 15 A-35 A
1/4 625 A-50 A 30 A-35 A
3/10 835 A-50 A 35 A
3/8 10 45 A-50 A Not Support
1/2 12 50 A Not Support
*Production cut thickness are the results of Lotos’ laboratory testing.
For optimum cut quality, cutting speeds may vary based on different cutting applications.
*All the recommended current values are tested under 240 V. While using under 120 V,
please appropriately adjust the current.
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Cutting
Current
Adjust
Power
Switch
OC
Light
Power
&
Air Output
Switch
Plug
Ground
Connection
Figure 2.1: Front Panel Diagram
Figure 2.2: Power Cord Plug Connection Figure 2.3: Air Regulator Configuration
Pilot Arc
Connection
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Power
Cable
Air
Inlet
Rack
Air In
Compress
Meter
Cup
Power
Cable
Air Inlet

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Figure 2.4: Connecting Cables to Machine
Air Compressor
Filter
Ground
Torch
Ground Clamp
Work
Piece
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Installation
Power Cord Plug Connection (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
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.
Connecting the Cables to the Machine (Figure 2.4)
1. Properly connect the air hose of compressed air to air inlet.
2. To avoid air leakage, turn screw clockwise until it locks into position. Connect ground
cable pincer to the positive terminal located on the front panel; then tighten.
3. Ensure that the switch plug of the torch is connected to the switch plug on the panel.
Check-list before Operation
1. Ensure that the cutting machine is properly grounded.
2. Ensure that all connectors are connected appropriately and firmly.
3. Ensure that power voltages are correct.
Operating the Plasma Cutter
1. Make sure the machine on/off switch is in the off position. Plug the power cord plug
into the electrical 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 power light
should come on. You can adjust the current by turning the cutting current knob on
the front panel.
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Operating the Plasma Cutter
1. Adjust the air pressure on your air compressor to 60 – 65 psi for the machine.
2. 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.
3. 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).
Figure 3.1
Electrode
Torch
Nozzle Cup Stand
Guard
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Instruction Notes
Cutting Environment
1. The cutting machine 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 80%.
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 lit.
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.
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 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.
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.
CAUTION: Only qualified technicians are authorized to undertake the repair of this
equipment in the case of machine failure.
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Plasma Cutter LTP5000D Troubleshooting Flowchat
Note: If the O.C. light turns on before operating the machine, please call us at [phone].
If the O.C. light turns on while operating the machine, please let the machine take a rest,
as this is normal operating procedure.
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1.1 Plasma Cutter LTP5000D Connections
First make sure all the connection are corrected (as depicted in the diagram below); Set the
air compressor's PSI at 65 PSI.
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