LOTOS LTP6000 Manual - Lotos Technology Plasma Cutters and
Contents
1. 30A INPUT Figure A 0 Hot Wire Brown Wire AC 220V Single 30A Blue Wire Phase SUPPLY Plasma Cutter Ground Wire Yellow amp Green Wire Figure A 0 Failure to wire as instructed may cause personal injury or A WARNING _ damage to equipment To be installed or checked by an electrician or qualified person only In all cases the green or green yellow grounding wire must be connected to the grounding pin of the plug usually identified by a green screw 10 OUTPUT CONNECTIONS ELECTRIC SHOCK can be fatal Keep the plasma cutting torch and ground cable amp clamp in good condition and in safe place Do not touch electrically live parts with skin or wet clothing Insulate yourself from work pieces Turn the machine off before connecting or disconnecting output cables or other equipment gt GAS CONNECTION AC230V a Air Compressor Figure A 1 CYLINDER could explode if damaged Obtain the necessary air Connect the cylinder of compressed air or air compressor with a pressure regulator and flow gage Install an air hose between the regulator and gas inlet located on the rear of the plasma cuter using air hose accessories The installed rear is shown in Figure A 1 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 l2. Power Switch d Air Inlet Air Hose Connection CONTROLS amp SETTINGS Ground Cable amp Clamp Connection Electrode Positive Torch Trigger Control Connection k Torch Power Connection Electrode Negative The annotation will be used later in Installation section to avoid confusions Switch between Cutting mode and Gas Checking mode i Warning light indicates over current over heating or other electrical problems with the unit when the light is on 7 INSTALLATION d 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 cutting 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 environments 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 is free circulation of clean air such that air movement in the back and
3. second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED 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 15 PROBLEMS IN PLASMA CUTTING TROUBLESHOOTING PLASMA CUTTING PROBLEMS PROBLEM CAUSE RECOMMENDED ACTION SYMPTOMS Fan power cord is off Reconnect the power cord F f Li Enclosure blocks the fan that causes Reform the enclosure an stops workin E i deformations Replace the fan The fan fails a Over heat Cut after cooling down Warning light on Over current Lower input voltage or replace machine Lower input voltage Over current protection l No output i Do maintenance in manufacturer or The machine fails service center decreased Input line is too thin Thicken power line Connecting line of the potentiometer Reconnection the line Current cannot be is off Replace the potentiometer regulated Potentiometer of current regulation fails The switch fails Replace the switch High frequency a oa be Incorrect selection for the air flow the Replace the electrode electrode fails Replace the high frequency arc generator generated High frequency arc generator fails 16 OTHER ACCESSORIES The following accessories and consuma
4. torch and ground clamp amp cable Insulation in good condition The number inside is the annotation in section Specifications Controls and Setting 12 OPERATION PLEASE READ AND UNDERSTAND THIS ENTIRE SECITON BEFORE OPERATING YOUR MACHINE ONLY QUILIFIED PERSONNEL SHOULD OPERATE THIS EQUIPMENT OBSERVE ALL SAFETY INFORMATION THROUGHOUT THIS MANUAL A WARNING ELECTRIC SHOCK can be fatal N 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 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 body protection 1 Connect up the air compressor using air filter and regulator as Installation indicates 2 Install LTP6000 plasma cutting torch and ground cable amp clamp as Installation indicates turn the power ON 3 Adjust the air pressure and make it is adequate to machine open the valve of
5. 230V Gas Supply Clean dry oil free air 0 2 0 4Mpa 4 0cfm 75psi ee Recommended Pressure Flow Rate o Specification Minimum working pressure 65psi Post flow Time Pilot Arc Start Mode High Frequency Maximum Severance Cutting Thickness 1 1 4 31mm Mild Steel Material Stainless Steel Ideal Cut 1 25mm 60A Aluminum Ww A New Unit 1 Year Warranty arran Refurbished Unit 60 Day Warranty Rated Duty Cycle Plasma Cutting 1 l Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating 60 duty cycle a e 3 K y F W f A Xx j j j E j P 3 J a Yy Fi ya aLa R a 6 Minutes Welding 4 Minutes Resting Jo Re Reduce Duty Cycle Overheating ba N Minutes 2 Production cutting thickness are the results of LOTOS s laboratory testing Production speeds are approximately 80 of maximum For optimum cut quality cutting speeds may vary based on different cutting applications REAR CONTROL PANEL FF AC230V o 4 m a CONTROLS AND SETTINGS CURRENT A CUTTING WARNING m GAS CHECKING 30 i 1 gt LTP6000 ce 6 The unit is connected to the supply even if the Power Switch is in the OFF position and therefore there are electrically live parts inside the power source Carefully follow the instructions given in this manual REAR CONTROL PANEL a PowerCord o SS b Unit
6. LOTOS LTP6000 Plasma Cutter TABLE OF CONTENTS SAFETY o E EA 2 SPECIFICATTO DNS badness saath nies bee scneesieesiankk 5 GENERAL DESCRIPTION a add ios 5 WHAE INCL PD dualidad india 5 POWER SUPPLY RATING a de edite ed 6 REAR CONTROL PANEL lees loto ced clea asado chili eN 7 CONTROESANDSETTINO Sci dabiads 7 INSTALLATION siaccaucndnaieasbocacaiisesestsideieeds S BEFORE INSTALLAT ON ens cc dices 8 INPUT ONNE TION Disc io ainia 10 OUTPUT CONNECTION Sd to 11 OPERA DTO Ns eo e OO 13 MAENTENANC Ea dat acc 14 TROUBLESHOOTING porras N ds 15 OTHER ACCESSORIES ona EEI 17 SAFETY d 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 gt Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Plasma cutting current creates EMF fields around plasma cutting cables and 3 N l plasma cutters N gt EMF fields may interfere with some pacemakers and users of plasma cutter having F a Y pacemakers should consult their physician before operating gt Exposure to EMF fields in plasma cutting may have other health effects which are now no
7. bles can be purchased on www uwelding com or call 408 739 2329 to order CONSUMABLES a Piar all ee Vo ue Bra hd bet meee Sree Dt b Dd Dd b RARAN d e SS ARAARA RA N EAS we Ws ARARAS RS AS 8 WY PE ARRAY SN o naaa RY LP Pv PCON20 PCON40 PCON90 PCON150 ACCESSORIES w S wo 5 A AIR FILTER amp WG10 PCK HELMET REGULATOR AND MORE ON www uwelding com CP132 CP242
8. emember that cutting 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 gt Where compressed gases are to be used at the job site special precautions should 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 gt Sparks and spatter are thrown from the cutting 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 plasma cutting area gt Connect the work cable to the work as close to the cutting area as practical Work cables connected to the building framework or other locations away from the cutting area increase the possibility of the cutting 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 regulat
9. ety instructions provided for your own protection SPECIFICATIONS GENERAL DESCRIPTION The LOTOS LTP6000 Plasma Cutter is a heavy duty machine with a duty cycle of 60 at maximum output The pilot arc feature is especially useful for continuous cutting on rough surfaces or dirty metal The arc is started by high frequency which is known for producing more reliable consistent and cleaner cuts without having to spend extra time on cleaning It is an ideal choice for factory maintenance fabrication work farm work and auto body repairs Y Y Y Y 60 Amp pilot arc plasma cutter Automatic dual frequency 50 60Hz High frequency start and contact start hand torch Suitable for stainless steel alloy steel mild steel copper and aluminum etc WHAT S INCLUDED gt Power Supply gt Plasma Cutting Torch gt Plasma Cutting Consumables gt Ground Clamp gt Air Filter amp Regulator gt Air Hose gt Air Hose Connections POWER SUPPLY PLASMA CUTTING TORCH GROUND CABLE amp CLAMP PLASMA CUTTING CONSUMABLES AB o ll a AIR HOSE AIR FILTER amp REGULATOR AIR HOSE CONNECTIONS POWER SUPPLY RATINGS LTP6000 Input Voltage Input Current No load Voltage Working Environment Humidity Ambient Temperature General 19 483mm L Specification Dimensions 8 203mm W 12 305mm H Weight 40lbs 18 1kg 60 60A 100 40A Power Cable 6 1 8m Output Current 20 60A Open Circuit Voltage
10. ic 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 feet 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 frequency 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 plasma cutter 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 making these members radiating antennas Keep all panels securely in place All electrical conductors within 50ft 15 2m of the plasma cutter should be enclosed in grounded rig
11. id metallic conduit or equivalent shielding Flexible metallic conduit is generally not suitable When the plasma cutter 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 INPUT CONNECTIONS 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 e 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 gt CONNECTION PROCEDURE The Inverter LTP6000 must be connected to AC220V 10 230V 10 240V 10 50 60Hz Single phase supply The rated output of the LTP6000 is available when connected to a 30A branch circuit When connected to a branch circuit with lower amp rating lower welding current and duty cycle must be used Plug Wire Connection Example 220V
12. ine 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 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 14 TROUBLESHOOTING PLEASE READ AND UNDERSTAND THIS ENTIRE SECTION SERVICE AND REPAIR SHOULD ONLY BE PERFORMED BY TRAINED PERSONNEL FOR YOUR SAFE PLEASE OBSERVE ALL SAFETY INFORMATION THROUGHOUT THIS MANUAL ELECTRIC SHOCK can kill Service and Repair should only be performed by Trained Personnel Have a qualified electrician install and service this equipment JIN 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
13. ive electrical circuits gt CONSUMABLES INSTALLATION TORCH ELECTRODE NOZZLE CUP Figure A 2 The consumables set of electrode nozzle and cup should install in order as shown in Figure A 2 The LTP6000 can only use genuine LOTOS brand consumables sets of PCON serial One set of consumables has already been installed in the torch head 11 gt OUTPUT CONNECTION Figure A 3 The plasma cutting torch and ground cable are supplied with the plasma cutter To connect the cables turn the Power Switch OFF 1 Plug the major power connector the widest wire from the torch cable to the output terminal 8 Turn it clockwise using the plastic safe protector until snug do not over tighten 2 Plug the 2 prong connector from the torch cable into the 2 pin socket 6 Turn the outer metal shell clockwise to tighten 3 Take off the cap of the pilot arc socket 7 on the inverter attach the connector with a metal chip from the torch cable to the socket put the cap back on and turn clockwise to tighten 4 Connect the ground cable amp clamp to the output terminal 5 and turn it clockwise to tighten Figure A 3 To minimize high frequency interference refer to Machine Grounding and High Frequency Interference Protection section of this manual for the proper procedure on grounding the work clamp and work piece To avoid receiving a high frequency shock keep the plasma A WARNING ae cutting
14. nt material to protect your skin z P and that of your helpers from the arc rays gt Protect other nearby personnel with suitable non flammable screening and or warn 2 them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 9 MN gt Do not cut in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying gt Plasma cutting may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When cutting keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep 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 cutting on galvanized steel 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 CUTTING SPARKS can cause fire or explosion gt Remove fire hazards from the cutting area If this is not possible cover them to prevent the es ad welding sparks from starting a fire R
15. ors 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 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 3 gt Never allow any electrically hot parts to touch a cylinder 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 v 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 n 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 K 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 saf
16. 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 gt STACKING LTP6000 cannot be stacked gt TILTING Place the machine directly on a secure level surface The machine may topple over if this procedure is not followed gt ENVIRONMENTAL AREA Keep the machine dry Do not place it on wet ground or in puddles Avoid rain water Operating in rain is not allowed 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 plasma cutter 8 2 Direct interference radiated from the plasma cutting 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 equipment per the following instructions should minimize problems Keep the plasma cutter power supply lines as short as possible and enclose as much of them as possible in rigid metall
17. pressed air 4 The recommended air pressure is 0 2 0 4Mpa gas flow is 4 0cfm 75psi 5 Set the function button to GAS CHECKING check the torch head to confirm air flows out 6 If gas does not flow out turn the power OFF to check gas connections and air compressor Then repeat 4 7 If gas flows out smoothly set the function button to CUT Adjust output current by Current Adjust Knob The output current can be adjusted from 20A to current level set by the user The maximum current is 60A 8 Press and hold the trigger to make a cut 13 MAINTENANCE MAINTENANCE FOR YOUR MACHINE ONLY QUALIFIED PERSONNEL SHOULD OPERATE THIS EQUIPMENT OBSERVE ALL SAFETY INFORMATION THROUGHOUT THIS MANUAL y PLEASE READ AND UNDERSTAND THIS ENTIRE SECTION BEFORE DOING 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 A 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 mach
18. t known gt Use the following procedures in order to minimize exposure to EMF fields from the cutting circuit Connect the work cable to the work piece as close as possible to the area being cut Do not work next to power source ELECTRIC SHOCK can be fatal e gt 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 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 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 gt Maintain the plasma cutting torch work clamp power cable and cutting machine in good safe operating condition Replace 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 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 plasma cutting or observing open arc plasma cutting gt Use suitable clothing made from durable flame resista
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