LOTOS MIG140 Manual - Lotos Technology Plasma Cutters and
Contents
1. Use the welding wire board Use the welding wire board with 8 200 mm in diameter with 4 100 mm in diameter Figure D 1 Figure D 2 Thread the Welding Wire through the Wire Feeder by following the instructions shown as below Figure D 3 1 Release the spring loaded pressure arm of the wire feeder and lift up the idle roll arm O Note the groove size in the feeding position on the drive roll matches the wire size being used see chapter describing the installation to wire feed roll Pull out the welding wire from the welding wire spool carefully To prevent the spool from unwinding maintain tension on the wire until after Step 5 Cut off the starting end of the welding wire from the wire spool and straighten the lead section of wire from the spool approximately 4 100mm Jong Thread the welding wire through and into the hole of the inlet guide tube threading it over the wire drive roll and into the hole of the outlet guide tube on the gun side Push the wire into the tailpiece of the gun approximately 6 inches Place the idle roll arm back to the operating position O and reset the spring loaded pressure arm D ofthe wire feeder No Je ES A PAG 6 4 Figure D 3 SHIELDING GAS INSTALLATION Compressed gas cylinder containing mixed gas 0f 7596 Argon and 25 CO should be2. Keep children away Children must be neyer be allowed in the work area Do not let them handle machines tools or extension cords Store idol equipment When not in use tools must be stored in a dry location to inhibit rust Always lock up tools and keep them out of the reach of children Do not force tool It will do the job better and safer at the rate for which it was intended Do not use inappropriate attachments in an attempt to exceed the tool capacity Use the right tool for the job Do not attempt to force a small tool or attachment to do the work of a larger industrial tool There are certain applications for which this welder was designed Do not modify this welder and do not use this welder for any other purposes for which it was not intended Dress properly Do not wear loose clothing or jewelry as they can be caught in moving parts Protective flame retardant electrically non conductive clothing and non skid footwear are recommended when working Wear restrictive hair covering to contain long hair Use eye and ear protection Always wear ANSI approved arc shaded impact safety face shield welding helmet Always use a full face shield when welding Always wear ANSI approved eyewear under face shield and while in the workplace Wear a NIOSH approved dust mask or respirator when working around metal chemical dusts fumes and mists Do not over reach Keep proper footing and balance at all times Do not reach over or across running ma
3. EQUIPMENT can be dangerous e gt Turn off input power using the disconnect switch at the fuse box before s working on the equipment gt Install equipment in accordance with the local codes and the manufacturer 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 Y 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 GENERAL DESCRIPTION The LOTOS MIGI140 features a 140 amp MIG welder that can weld at industrial quality and performance at a very affordable price The most versatile and perfect welder for do it yourself home users as well as professional users The LOTOS MIG140 is also spool gun capable for welding aluminum It can be easily connected to your existing 110V wall outlet and quickly setup within 10 minutes or less It handles industrial standard 4 or 8 wire spools and incorporates a thermal overload protection system to protect your welder Y 140 amp MIG Welder with mask etc Y Operates on 110V Single phase 60Hz Y Suitable for welding stainless steel mild steel aluminum with a spool gun and other metal m
4. be used to prevent hazardous situations 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 Always keep a fire extinguisher nearby while welding Yv Yv Use welding blankets to protect painted surfaces dashboards engines etc Please make sure there are no combustible items around your welding area 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 gt Cylinders should be located Away from areas wherethey 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 gt Never allow any electrically hot parts to touch a cylinder gt Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for us ELECTRICALLY POWERED
5. for safety warnings and precautions assembly instructions operating and maintenance procedures parts list and diagram Keep your invoice with this manual Write the invoice number and date of purchase on the inside of the manual Keep the manual and invoice in a safe and dry place for future use Operation Manual Carefully read the operation manual prior to using installing and maintaining the electric welding machine for the purpose of preventing damages such as fire electric shock and etc from occurring Please keep the manual for future reference SAFETY WARNINGS AND PRECAUTIONS 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 A WARNING WHEN USING THE WELDER ALL BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF PERSONAL INJURY AND DAMAGE TO EQUIPMENT READ ALL INSTRUCTIONS BEFORE USING THIS WELDER Keep work area clean Cluttered areas invite injuries Observe work area conditions Do not use machines or power tools in damp or wet locations Do not expose to rain Keep work area well lighted Do not use electrically powered tools in the presence of flammable gases or liquids
6. off 2 Unlatch the spring loaded pressure arm and Figure C 4 open the idle roll arm and lift up the idle roll arm 3 Loosen the plastic screw that attaches the wire drive roll 4 Remove the wire drive roll and flip the wire drive roll over so that the 030 0 8mm mark faces the user 5 Reinstall by putting back the wire drive roll and tighten the plastic screw WELDNG WIRE INSTALLATION The MIG140 welding machine can use wire spools up to 8 diameter 200mm and a maximum width under 2 50mm If you us the smaller 4 diameter 100mm wire spools the 2 50mm spindle adapter must removed For installation of a 8 200mm welding wire spool See Figure D 1 Install the 8 200mm welding wire spool on the wire spindle D O making sure the wire spool spindle tab engages the hole in the wire spool Note The wire spool will rotate clockwise when wire is de reeled For installation of a 4 diameter 100mm welding wire spool See Figure D 2 The 2 50mm diameter spindle must be removed O 0 Remove the wing screw and remove the outside plastic wire spool spindle 6 A 4 100mm diameter spool is mounted directly on a 5 8 16mm diameter shaft and held in place with the previously removed hardware CO NOTE The wire spool will rotate clockwise when wire is de reeled Also makes certain the start end of the welding wire which may protrude through the side of the spool does not contact any metallic case parts
7. there are electrically live parts inside the power source Carefully follow the instructions given in this manual FRONT CONTROL PANEL Potentiometer Knob Power Switch Wire Feed rate Adjustment Knob Gun Trigger Lead Connectors Latch Nn BR m SIDE COMPONENTS SIDE COMPONENTS 6 Wire Feed Gearbox 7 Wire Spool Spindle Shaft 8 9 Wing Screw to fasten welding gun Positive and Negative output terminals 10 Mode Switch for optional spool gun MACHINE REAR REAR COMPONENTS 11 Power Cord 12 gt Reset Overload Protective Device 13 Shielding Gas Inlet Fitting The protector will cut off the circuit if the welding machine goes overthe maximum load after which the switch must be reset manually 12 INSTALLATION PLEASE READ ENTIRE INSTALLATION SECTION BEFORE STARTING INSTALLATION BE SURE THAT ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION MACHINE SETUP 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 e on this equipment aN 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 gro
8. used when using the MIG GMAW GAS Metal Arc Welding The flow regulator and supply hose is included with your welder The compressed gas can be obtained from your local welding supplier 1 Fix the compressed gas cylinder with a chain or other method to the wall or other securing device to prevent the cylinder of falling After securing remove cylinder cap if there is one on your cylinder Install flow regulator CGA 580 to the supply valve on the cylinder and tighten with wrench ppp Install one end of the gas supply hose into the outlet ofthe flow egulator and tighten Connect the other end of the hose to the gas inlet located at the rear of the MIG140 welding machine The connector nipple 5 8 18 adapts to CGA 032 Ensure that the hose has no twisting or knotting 5 Slowly turn on the gas cylinder valve 6 Depress gun trigger switch and adjust the flow regulator to 25 30 cubic ft per hour CFH 12 14 l min 7 Shut off the valve of the gas cylinder Depress gun trigger to release the gas in system Power off MIG140 when welding process is finished 8 NOTE Always keep the valve of the gas cylinder closed when not in use Cylinder Valve e d e Regulator Flow Gauge D Hose fo N Inlet Connection For Shielding Gas e e OPERATION PLEASE READ AND UNDERSTAND THIS ENTIRE SECITON BEFORE A OPERATING YOUR MACHINE ONLY QUILIFIED PER
9. LOTOS MIG140 MIG Welder TABLE OF CONTENTS SAFETY A gt ERR 4 SPECIFICATIONS BEEN A Po ooocoococcocccccoconccancancnnnos 9 General Descriptions esses doo nooo ep II 9 What s Included W B B 1 4 N92 uLLuLuLuLLLLLuLuue 9 Power Supply RANE Saee t eee seen Gr Fr Ee ur as ra Re serores sesers SEE SERR EA UVP dada 10 Front Control Panel acere Y 11 Side COMPONER ARAN AAA 11 luErjuidiic cR is SSe 12 INSTALLATION lt q ME A Leser 13 Machine Setup Jn B suus 13 Grounding Work Clamp Installation eee eere eere 13 Welding Gun Installatiol asessc envase e rU din 14 Welding Drive Roll Insiillatign BR Bf PM Wo oooccccoccccocccnocccnnos 14 Welding Wire Install OM censor ener a van egeo een eae eee SE Eee eo Ea od TRA EM 15 shielding Cras InstallatlOri c iieeeueveae o ede ees pese EA rere e Ra arranca venias 17 OPERATION coronado coria vee AT KV RPAE E UPS Pd ap Age Ue Te 18 Welding Operas ese son assa vo c EE NN Ee Enoc dina seas 18 Welding Steps d diill J ADORA 18 Welding Process ZEE Lesser 19 Overload Protection WEE WEE 7 Luuuuuueluueee eere eee 19 OTHER ACGESSORITES ones se vea aee eoo oao aee aeuo a ue vao Eno se y aer sa dpa 20 MIG140 MIG WELDER Save this Manual You will need the manual
10. SONNEL SHOULD OPERATE THIS EQUIPMENT OBSERVE ALL SAFETY INFORMATION THROUGHOUT THIS MANUAL WELDING OPERATIONS 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 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 FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fires or explosions Keep flammable material away Do not weld cut or gouge on containers that have held combustibles F SE ARC RAYS can burn Wear eye ear and body protection WELDING STEPS Make sure power is off on the MIG140 welding machine Remove nozzle and contact tip Power on MIG140 welding machine Straighten welding gun PURO Br Hold trigger of the welding gun depressing trigger_will feed the welding wire into the welding gun When the welding wire is exposed at the outlet side of the welding gun release the trigger switch of the welding gun 6 Make sure power is off on the MIG140 welding machine Reinstall the nozzle and contact tip 8 Cut off the welding wire 1 4 1 2 6 10mm away from
11. aterials WHAT S INCLUDED Power Supply MIG Torch Ground Clamp and Cable Argon Hose Argon Regulator Chipping Hammer nd Steel Brush 2 Ib of 0 023 Spool Wire Hand Held Shield Wire Brush Etc VN V V Voy V V POWER SUPPLY MIG TORCH GROUND CABLE 8 CLAMP ARGON HOSE 2LB OF 0 023 HAND HELD SHIELD SPOOL WIRE WIRE BRUSH ETC ARGON REGULATOR POWER SUPPLY RATINGS MIG140 Output Power DC Input Voltages 110 V 1 PH 50 60 Hz General Dimensions O ai Specificati 9 6 244mm W Perg AR 14 5 367mm H Weight 54lbs 24 5kg Rated Duty Cycle 20 90A 18V Steel clean dry oil free 75 argon and Gas Suppl DOPRE 25 CO Weldi 12 14L mi y Ms Recommended gas inlet flow rate pressure Ton Specifications Wire R 025 030 0 6 0 8mm solid steel ire Range i 030 035 0 8 0 9mm Flux Cored Mild Steel 24 Gauge Y4 Material Stainless Steel 24 Gauge Y4 New Unit 1 Year Warranty Warranty Refurbished Unit 60 Day Warranty Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating 6096 duty cycle HR O 6 Minutes Welding Overheating ua 0 b gt I gt Md NA 4 Minutes Resting gt amp 524 Reduce Duty Cycle Minutes 10 FRONT CONTROL PANEL The unit is connected to the supply even if the Power Switch is in the OFF position and therefore
12. chines Maintain tools with care Keep tools sharp and clean for better and safer performance Follow instructions for lubricating and changing accessories Inspect tool cords periodically and if damaged have them repaired by an authorized technician The handles must be kept clean dry and free from oil and grease at all times Disconnect power Unplug tool when not in use Remove adjusting keys and wrenches Check that keys and adjustment wrenches are removed from the welder and work area before plugging in Avoid starting unintentionally Be sure the switch is in the off position when not in use and before plugging in Do not carry any tool with your finger on the trigger whether it is plugged in or not Stay alert Watch what you are doing Use common sense Do not operate any tool when tired Check for damaged parts Before using any tool any part that appears damaged should be carefully checked to determine that it would operate properly and perform its intended function Check for alignment and binding of moving parts any broken parts or mounting fixtures and any other condition that may affect proper operation Any part that is damaged should be properly repaired or replaced by a qualified technician Do not use the tool if any switch does not turn on and off properly Guard against electric shock Prevent body contact with grounded surfaces such as pipes radiators ranges and refrigerator enclosures Replacement parts and acces
13. ense and caution are factors which cannot be built into this product but must be supplied by the operator ARC WELDER SAFETY WARNINGS AND PRECAUTIONS Warning This product when used f r welding and similar applications produces chemicals to cause cancer and birth defects or other reproductive harm 4 ELECTRIC SHOCK can be fatal lt a The electrode and work or ground circuits are electrically hot when the machine is on Do not touch these hot parts with your bare skin or wet clothing Protective clothing should be hole free dry and ANSI approved Wear dry hole free gloves to insulate hands gt Do not permit electrically live parts cables or electrodes to contact skin clothing or gloves gt This unit draws enough current to cause serious injury and or death gt Before turning the welder on check the welder gun to be sure that there are no protruding screw heads and that all insulation is secure 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 gt Always be sure the work cable makes a good electrical connection with the metal being cut The connection should be as close as possible to the area being cut gt Ground the work metal to be cut to a good electrical earth ground Maintain the welding torch work clamp power cable and cutting machine in good safe operating condition R
14. eplace damaged insulation gt Never dip the electrode in water for cooling gt When working above floor level use a safety belt to protect yourself from a fall should you get a shock FUMES AND GASES can be dangerous gt Plasma cutting may produce fumes and gases hazardous to health Avoid 23 M Uu cutting on galvanized steel breathing these fumes and gases When cutting keep your head out of the fume Use enough ventilation and or exhaust at the arc to k ep fumes and gases away from the breathing zone In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when gt Do not cut 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 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 forms are available from your welding distributor or from the manufacturer ELECTRIC AND MAGNETIC FIELDS may be dangerous e The EMF field that is generated during arc welding may interfere with various electrical and electronic devices such as cardiac pacemakers Anyone using such devices should consult with their physician prior to per
15. forming any electric welding operations e Exposure to EMF fields while welding may have other health effects which are not known ARC RAYS can burn gt Avoid eye and body damage Arc rays and infrared radiation can cause injury to the yes and burn the skin Wear ANSI approved eye and body p protection Do not allow viewing by visitors without proper eye and body ES Ve protection gt Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when plasma cutting or observing open arc plasma cutting gt Use suitable clothing made from durable flame resistant material to protect 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 arc rays or to hot spatter or metal WELDING SPARKS can cause fire or explosion gt Remove fire hazards from the cutting area If this is not possible cover a a them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from cutting can easily go through small cracks and openings to adjacent areas Avoid cutting near hydraulic lines Have a fire extinguisher readily available Do not operate the electric arc welder in areas where flammable or explosive vapors are present Where compressed gases are to be used at the job site special precautions should
16. his lug and placed on the negative terminal See Reference Table T 1 WELDING GUN INSTALLATION See Figure C 1 C 2 and C 3 There is one spool of 025 0 6mm solid welding wire included with the welder The welding gun comes with a 025 0 6mm contact tip installed If 030 035 0 8 0 9mm wire is to be used change the contact tip to the appropriate size CONNECT THE WELDING GUN TO THE WELDING MACHINE 1 Power off the welding machine switch is positioned at O 2 Plug the welding gun into the access hole D and plugit into to the connector block Also thread the control wire of the welding gun through the access hole D and inset the control wire into the gun trigger connector terminals 3 Tighten the wing screw attached to the connector block of the wire feed gearbox 4 Make sure the Gun changing switch O is in the correct position MIG for standard welding and Spool Gun if optional gun is installed Figure C 2 WIRE DRIVE ROLL INSTALLATION The reversible dual groove wire drive roll attached to MIG140 has two wire grooves One for 025 0 6mm solid welding wire and the other for 030 035 0 8 0 9mm solid or flux cored welding wire The factory default installation is 025 0 6mm In the event that 030 0 8mm 035 0 9mm welding wires are used the wire feed roll groove must be changed ST 1 Ensure that the MIG140 welding machine is powered
17. sories When servicing use only identical replacement parts Use of any other parts will void warranty Only use accessories intended for use with this welder Approved accessories are available from www uwelding com Do not operate tool if under the influence of alcohol or drugs Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs If there is any doubt do not operate the welder Maintenance For your safety service and maintenance should be performed regularly by a qualified technician Use proper size and type extension cord If an extension cord is required it must be of the proper size and type to supply the correct current to the welder without heating up Otherwise the extension cord could melt and catch fire or cause electrical damage to the welder This welder requires use of an extension cord of 20 amps minimum capability up to 30 feet with a wire size rated at 12 AWG Longer extension cords require larger size wire If you are using the welder outdoors use an extension cord rated for outdoor use signified by WA on the jacket Performance of this welder may vary depending on condition in local line voltage Extension cord usage may also affect welder performance A WARNING The warnings cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be understood by the operator that common s
18. t the circuit breaker button gt THERMAL PROTECTION The MIG140 has a rated output duty cycle of 20 If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools to a reasonable operating temperature This is an automatic function and does not require user intervention The fan continues to run during cooling gt OVERLOAD PROTECTION TO WIRE FEEDER The MIG140 model has two automatic circuits to protect the motor of the wire drive OTHER ACCESSORIES The following accessories and consumables can be purchased on www uwelding com or call 408 739 2329 to order MIG SPOOL GUN The LOTOS MIG140 has a factory installed option to allow you to install and operate a hand held spool gun This will allow you to do welding of both Aluminum and Steel To install the spool gun you must first Power Down the welder remove the standard MIG gun and install the Spool Gun using the same installation process as described on page 9 You must push Switch 7 from MIG to Spool Gun This will disable the drive system of the welder and enable the Spool Gun s drive system CONSUMABLES NOZZLES ACCESSORIES e AND MORE 9 ON www uwelding com HELMET 20
19. the tip end of the welding gun and get ready for welding 18 AA gt WELDING PROCESS Please refer to Welding Control Guide that is located inside the welding machine door for the output voltage and wire feed rates Inspect output polarity according to the welding wire being used and ensure whether or not shielding gases are needed Connect the ground work clamp to the piece s to be welded there should be a good connection for the ground work clamp to the piece s The welding gun should be able to move freely in the area of the piece s to be welded Power on the MIG140 welding machine Pull down welding protective helmet press the trigger of the welding gun and begin to weld Keep the contact tip of the welding gun at around 3 8 to 1 2 10 13mm away from piece s to be welded Release trigger of the welding gun and the welding is stopped After welding turn off the valve of the compressed gas cylinder if gas is used and then press trigger of the welding gun to release compressed gas in system Finally power off the MIG140 welding machine OVERLOAD PROTECTION Overload protection for power supply to welding The MIG140 Welding Machine is equipped with a circuit breaker and a thermostat which protects the machine from damage if maximum output is exceeded The circuit breaker button will extend out when tripped The circuit breaker must be manually reset Wait for several minutes while the welding machine cools down and rese
20. unded according to the National Electrical Code and local codes Do not remove or defeat the purpose of the power cord ground pin gt SELECT SUITABLE LOCATION The machine will operate in harsh environments Even s it is important that standard measures are followed in order to assure the machine is long lasting and reliable operation The machine must be located where there is open space such that the air circulation in the back and out the front willnot be restricted Avoid getting dirt and dust in the machine Failure to observe these precautions can result in excessive operating temperatures and shutdown by itself ENVIRONMENTALAREA Keep the machine dry Do not place it on wet ground or in puddles Avoid rainwater Operating in rain is not allowed GROUNDING WORK CLAMP INSTALLATION ial e See Figure C 1 Figure C 2 1 Open the right side door of the welding machine Insert the lug end of the ground clamp through access hole 2 3 Route the cable of the ground clamp around the wire feed gearbox and connect it to the negative output terminal of the welding machine 4 Tighten the lug plate attached to the Oo end of the wire with wing screw Figure C 1 NOTE This above method of connection is GMAW When gasless flux cored wires are used Connect the cable of the ground clamp to the positive output terminal of the welding machine The short power cable must be removed from t
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