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Lotos Technology LTP5500D, Owner'S Manual

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TABLE OF CONTENTS 

SAFETY WARNINGS AND PRECAUTIONS

 ............................................................................................................................. 1 

READ ALL INSTRUCTIONS BEFORE USING THIS WELDER. ............................................................ 1

 

ARC WELDER SAFETY WARNINGS AND PRECAUTIONS................................................................. 3

 

CALIFORNIA PROPOSITION 65 WARNINGS

 ......................................................................................................................... 5 

SPECIFICATIONS

 ................................................................................................................................................................................ 6 

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GENERAL DESCRIPTION ......................................................................................................... 6

 

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WHAT’S INCLUDED ................................................................................................................... 7

 

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POWER SUPPLY RATINGS...................................................................................................... 8

 

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PANEL EXPLANATION .............................................................................................................. 9

 

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DISASSEMBLY DIAGRAM ...................................................................................................... 10

 

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CONSUMABLE TYPE AND INSTALLATION ......................................................................... 11

 

QUICK SETUP GUIDE

 ......................................................................................................................................................................12 

INSTALLATION

 ....................................................................................................................................................................................14 

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MACHINE SETUP ..................................................................................................................... 14

 

OPERATION

..........................................................................................................................................................................................16 

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SAFETY OPERATIONS ........................................................................................................... 16

 

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OPERATION STEPS ................................................................................................................ 17

 

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STARTING A CUT ..................................................................................................................... 20

 

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PIERCE A WORK PIECE ......................................................................................................... 21

 

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CUT QUALITY RELATED FACTORS .......................................................................................... 22

 

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CAUSES OF COMMON HAND-CUTTING ISSUES ............................................................. 24

 

MAINTENANCE

 ...................................................................................................................................................................................25 

TROUBLESHOOTING

 ......................................................................................................................................................................26 

REFERENCE

 ........................................................................................................................................................................................27 

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PSI SETTING REFERENCE TABLE ...................................................................................... 27

 

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CUTTING SPEED REFERENCE TABLE ............................................................................... 27

 

CONSUMABLES

 .................................................................................................................................................................................28 

 

Summary of Contents for LTP5500D

Page 1: ...peration manual prior to using installing and maintaining the electric welding machine The contents of this manual may be revised without prior notice and without obligation This instruction manual is issued on 1st Jan 2018 Rev 01 Conforms with EMC Directives 73 23 EEC and 89 336 EEC European Standard EN IEC60974 ...

Page 2: ...al Write invoice number and date of purchase on the inside of the manual Keep the manual and invoice in a safe and dry place for the future 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 as a reference in the fu...

Page 3: ...WER SUPPLY RATINGS 8 PANEL EXPLANATION 9 DISASSEMBLY DIAGRAM 10 CONSUMABLE TYPE AND INSTALLATION 11 QUICK SETUP GUIDE 12 INSTALLATION 14 MACHINE SETUP 14 OPERATION 16 SAFETY OPERATIONS 16 OPERATION STEPS 17 STARTING A CUT 20 PIERCE A WORK PIECE 21 CUT QUALITY RELATED FACTORS 22 CAUSES OF COMMON HAND CUTTING ISSUES 24 MAINTENANCE 25 TROUBLESHOOTING 26 REFERENCE 27 PSI SETTING REFERENCE TABLE 27 CUT...

Page 4: ...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 we...

Page 5: ...se 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 tech...

Page 6: ...tion wherever it is needed Never dip the electrode in water for cooling When working above floor level use a safety belt to protect yourself from a fall should you get a shock 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 f...

Page 7: ...her 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 CYLINDER may explode if damaged 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...

Page 8: ...rth defects or other reproductive harm Wash hands after handling For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 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 OPERATIO...

Page 9: ...gn you are able to cut on any metal surface without having to contact to strike an arc which is ideal for cutting items like expanded metal or uneven surfaces This Cutting machine has a wide range of uses which is suitable for cutting stainless steel alloy steel mild steel copper and other color metal materials There are several other key features on the LTP5500D plasma cutter With the reliable Bl...

Page 10: ...7 28 WHAT S INCLUDED Power Supply 20ft Torch with Central Connector 10ft Ground Clamp Cable Air Hose Consumables Instruction Manual ...

Page 11: ...w Timer 15 Seconds Minimum Air Compressor Requirement 4 5 CFM 80 psi 30 60 Gallon reserve Duty Cycle Over Current Protection Yes Minimum Operating Air Pressure Safety Cut Out Threshold 35 psi Recommended Operating Air Pressure Set with Air Flow set to Constant Flow 40 70 psi Maximum Supplied Air Pressure From Compressor Tank 75 psi Ideal Cut Thickness Hand Torch 5 8 16mm 1 3 8mm Max Severance Cut ...

Page 12: ... 4 Air check indicator it illuminates when the machine is under air check status At this moment the machine cannot cut Normal cutting mode the machine can cut when this indicator illuminates 5 2T indicator torch switch when the machine is under 2T status With the 2T option selected press the trigger to fire the torch You need to hold the trigger while continuing to cut Release the trigger to stop ...

Page 13: ...10 28 DISASSEMBLY DIAGRAM ...

Page 14: ... 28 CONSUMABLE TYPE AND INSTALLATION The LOTOS LTP5500D uses the high quality stand PT60 Non HF Plasma torch with EU type central adaptor Standoff guide Shield Cup Cutting Nozzles Cutting Electrodes Swirl ...

Page 15: ...12 28 QUICK SETUP GUIDE PLEASE READ ENTIRE INSTALLATION SECTION BEFORE STARTING INSTALLATION BE SURE THAT ONLY QUALIFIED PERSONNEL PERFORM THIS INSTALLATION ...

Page 16: ...the IPT60 Plasma torch to the machine Insert the torch connection into the torch connection receptacle at the front of the machine and fasten tightly Caution Do not to bend the pins located inside the torch connector 2 Connect the earth lead to the output terminal of the machine and Tighten 4 Connect the machine to the correct power supply and switch on the machine using the on off switch located ...

Page 17: ...ne is long lasting and reliable in operation The machine must be located where there is open space such that the air circulation in the back and out the front will not be restricted Avoid getting dirt and dust in the machine Failure to observe these precautions can result in excessive operating temperatures and the machine will shut down by itself ENVIRONMENTAL AREA Keep the machine dry Do not pla...

Page 18: ...onnector is fully seated against the stop in order to achieve an optimal electrical connection Caution Ensure the work lead is fully seated in the receptacle to prevent overheating CHECK Check if cutting machine is grounded reliably and according to standard Check if all connectors are connected firmly Check if power voltage is correct NOTE THE FOLLOWING Ensure that the work clamp and the work pie...

Page 19: ...ow machine to sit for a minimum of five minutes to allow the power capacitors to discharge before working inside this machine 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 SPARK...

Page 20: ...ut Release the trigger to stop the arc Adjust the air flow Set the mode switch to Air Check mode Adjust your air compressor s output air flow and pressure and make it is adequate to machine open the valve of your air compressor Adjust the Pressure Reducing Valve 11 and set the input PSI for your cutting Set the output AMPs Turn the adjustment knob 7 to change the amperage Make sure cutting current...

Page 21: ...ar eyes protection a 5 shade is the minimum eyes protection with other shade required depending on amperage a face shield is also recommended 2 Connect the earth clamp securely to the work piece or the work bench 3 place and hold the torch vertical at the edge of the plate 4 Pull the trigger to energize the pilot arc The cutting arc will start when the nozzle is moved closer to the edge of the wor...

Page 22: ...ure that sparks exit from the bottom of the work piece The sparks should lag slightly behind the torch as you cut 15 30 angle from vertical If sparks spray up from the work piece move the torch at a slower pace or set the output current higher With either the 75 degree or 15 degree hand torch hold the torch nozzle perpendicular to the work piece so that the nozzle is at a 90 angle to the cutting s...

Page 23: ...k piece 3 Drag the torch across the work piece to proceed with the cut smoothly Maintain a steady even pace Make sure the arc cuts completely through the work piece When cutting make sure that sparks are exiting from the bottom of the work piece If sparks are spraying up from the work piece you are moving the torch too fast or you don t have enough amps set Hold the torch vertical and watch the ar...

Page 24: ...and the work piece should be within 1 16 inch 1 5 mm 2 Fire the torch Slowly rotate the torch to from 30 to 90 3 Hold the torch in place while continuing to press the trigger When the arc goes completely through the work piece then the arc has pierced the material 4 When the pierce is complete drag the torch lightly along the work piece to proceed with the cut ...

Page 25: ...material without cutting all the way through Because the arc trails at an angle at the end of a cut slow your cutting speed and angle the torch in to cut through the last bit of metal Direction It is easier to pull the torch towards you than push it The plasma stream swirls as it exits the tip biting one side and finishing off on the other leaving a beveled edge and a straight edge The bevel cut e...

Page 26: ... consumable life span Compressors take in air at atmospheric pressure and increase the pressure and store it in a tank Humidity in the air is condensed in the tank and in the airlines producing water more so in humid environments Moisture that forms in air lines has a tendency to condense into larger drops when the air pressure decreases as it is entering the plasma torch When these droplets enter...

Page 27: ... piece Gouging consumables are installed instead of cutting consumables The work clamp is not attached properly to the work piece The air pressure is too low or the air flow rate is not high enough Cut quality is poor This can be caused by The amperage setting is too low for the thickness of the work piece Your cutting speed is too quick or too slow Consumables life is shorter than expected This c...

Page 28: ... components Check the electric connectors and make sure the connectors are connected firmly specially connect and insert components tighten the connectors Avoid water getting into machine and prevent machine becoming damp or the machine must be dried in time and measured insulation by meter After there is no problem the machine can be operated If the machine will not be used for a long time it sho...

Page 29: ...king However pressing the trigger of the torch there is no arc striking and inter red LED light is on need to remove the cover 1 The IGBT on the PCB board is damaged driver module is damaged 2 Voltage rising transformer on the PCB board is damaged 3 Control module is damaged Contact LOTOS for repair Digital display is on fan is working and Airflow comes out while press the trigger on the torch How...

Page 30: ... 86 61 2200 45 60 3 16 5 62 99 1600 45 60 1 4 6 47 24 1200 50 65 1 3 8 43 31 1100 55 70 2 5 10 39 37 1000 Stainless AMPS PSI Material Thickness Torch to Work Distance Optimum Cut Speed Inch mm Inch mm IPM mm min 20 30 26GA 0 5 0 06 1 5 188 98 4800 30 40 16GA 1 6 88 19 2240 40 55 10GA 3 4 69 29 1760 45 60 3 16 5 50 39 1280 45 60 1 4 6 37 80 960 50 65 1 3 8 34 65 880 55 70 2 5 10 31 50 800 Aluminum ...

Page 31: ...28 28 CONSUMABLES The following accessories and consumables can be purchased on www uwelding com or call 408 739 2329 to order Cutting Consumables Set NCON21 NCON12 ...

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