Lotos LTP7000 Installation Guide

LOTOS LTP7000
Plasma Cutter
! TABLE OF
CONTENTS
SAFETY.........................................................................................................................2
SPECIFICATIONS ......................................................................................................5
GENERAL DESCRIPTION .......................................................................................................................5
WHAT’S INCLUDED .............................................................................................................................5
POWER SUPPLY RATINGS ....................................................................................................................6
REAR CONTROL PANEL .......................................................................................................................7
CONTROLS AND SETTINGS ...................................................................................................................7
INSTALLATION ..........................................................................................................8
BEFORE INSTALLATION .......................................................................................................................8
INPUT CONNECTIONS .........................................................................................................................10
OUTPUT CONNECTIONS .....................................................................................................................11
OPERATION ..............................................................................................................13
MAINTENANCE ........................................................................................................14
TROUBLESHOOTING .............................................................................................15
OTHER ACCESSORIES ...........................................................................................17
1
SAFETY
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
" Electric current flowing through any conductor causes localized Electric and Magnetic
Fields (EMF). Plasma cutting current creates EMF fields around plasma cutting cables and
plasma cutters.
" EMF fields may interfere with some pacemakers, and users of plasma cutter having
pacemakers should consult their physician before operating.
" Exposure to EMF fields in plasma cutting may have other health effects which are now not known.
" 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
"
"
"
"
"
" 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.
" 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.
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.
Ground the work metal to be cut to a good electrical (earth) ground.
Maintain the plasma cutting torch, work clamp, power cable and cutting machine in good, safe operating
condition. Replace damaged insulation.
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.
! ARC RAYS can burn
" 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.
" Use suitable clothing made from durable flame-resistant material to protect your skin
2
and that of your helpers from the arc rays.
" 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.
! FUMES AND GASES can be dangerous
" 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.
" 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.
" 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
" Remove fire hazards from the cutting area. If this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember 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.
" Where compressed gases are to be used at the job site, special precautions should be used to
prevent hazardous situations.
" 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”.
" 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.
" 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
" 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.
" Always keep cylinders in an upright position securely chained to an undercarriage or fixed
support.
" Cylinders should be located:
3
# 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.
" 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.
" Valve protection caps should always be in place and hand tight except when the cylinder is in use or
connected for use.
! ELECTRICALLY POWERED EQUIPMENT can be dangerous
" Turn off input power using the disconnect switch at the fuse box before working on the
equipment.
" Install equipment in accordance with the local codes and the manufacturer’s
recommendations.
" Ground the equipment in accordance with the manufacturer’s recommendations.
! MOVING PARTS can cause injury
"
"
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards closed and securely in place.
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.
4
SPECIFICATIONS
! GENERAL DESCRIPTION
The LOTOS LTP7000 IGBT Plasma Cutter is one of the most powerful inverter plasma cutters in the market.
The pilot arc feature is especially useful for continuous cutting on rough surfaces or dirty metal. It has been
redesigned to incorporate the latest high frequency inverter technology using V-MOSFETs, along with PWM
(Pulse Width Modulation), the combination of which help deliver a far more constant, concentrated and precise
current to the cutting surface. With this plasma cutter, the user can achieve smooth, clean and uniform cuts on
a wide range of surfaces with minimal heat input and without distortion of metal. It is very easy to use by the
DIY user, while fully accommodating the demands of professional operators.
$ 70-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
"
"
"
"
"
"
"
Power Supply
Plasma Cutting Torch
Plasma Cutting Consumables
Ground Clamp
Air Filter & Regulator
Air Hose
Air Hose Connections and Tools
5
! POWER SUPPLY RATINGS
LTP7000
220~240V
10%, 1-PH, 50/60Hz
30A
230V
≤90%
-10~40°C
19” (483mm) L
8” (203mm) W
12” (305mm) H
43lbs (19.5kg)
60% @70A
100% @50A
6’ (1.8m)
Input Voltage
Input Current
No-load Voltage
Working Environment Humidity
Ambient Temperature
General
Specification
Dimensions
Weight
Rated Duty Cycle1
Power Cable
Output Current
Open Circuit Voltage
Gas Supply
Plasma Cutting
Specification
20~70A
230V
Clean, dry, oil-free air
0.2~0.4Mpa
4.8cfm @75psi
10s
High Frequency
1.35” (34mm)
Recommended Pressure/Flow Rate
Post-flow Time
Pilot Arc Start Mode
Maximum Severance Cutting Thickness2
Material
2
Warranty
1
2
Mild Steel
Stainless Steel
Aluminum
Ideal Cut 1.15” (29mm) @70A
New Unit
Refurbished Unit
1-Year Warranty
60-Day Warranty
Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
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.
6
! REAR CONTROL PANEL
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.
a
b
c
d
e
REAR CONTROL PANEL
Power Cord
Unit Power Switch
Cooling Fan
Air Inlet / Air Hose Connection
Air Regulator Mounts
! CONTROLS AND SETTINGS
1
2
3
4
5
6
7
8
CONTROLS & SETTINGS
Digital Display
Cutting/Gas Checking Switch1
Warning Light2
Current Adjust Knob
Ground
Cable&
Clamp
Connection (Electrode Positive)
Torch
Trigger
Control
Connection
Pilot Arc Connection
Torch
Power
Connection
(Electrode Negative)
The annotation will be used later in Installation section to avoid confusions.
1
Switch between Cutting mode and Gas Checking mode.
2
Warning light indicates over-current, over-heating or other electrical problems with the unit when the light is on.
7
INSTALLATION
PLEASE
READ
ENTIRE
INSTALLATION
SECTION
BEFORE
STARTING
INSTALLATION. BE SURE THAT ONLY QUALIFIED PERSONNEL SHOULD PERFORM
THIS INSTALLATION.
! BEFORE INSTALLATION
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.
" 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 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.
" STACKING
LTP7000 cannot be stacked.
" TILTING
Place the machine directly on a secure, level surface. The machine may topple over if this procedure is not
followed.
" 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.
" 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:
8
1. Direct interference radiated from the plasma cutter.
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 metallic 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, rigid
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.
9
! 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.
% 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.
" CONNECTION PROCEDURE
The Inverter LTP7000 must be connected to AC220V 10%, 230V 10%, 240V 10%, 50/60Hz Single
phase supply. The rated output of the LTP7000 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, 30A INPUT
(Figure A.0)
Failure to wire as instructed may cause personal injury or
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 & 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.
" GAS CONNECTION
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.
CYLINDER could explode if damaged
% 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 live electrical circuits.
The installed rear is shown in Figure A.1.
" CONSUMABLES INSTALLATION
The consumables set of electrode, nozzle and cup should install in
order as shown in Figure A.2.
The LTP7000 can only use genuine LOTOS brand consumables sets
of BCON serial.
One set of consumables has already been installed in the torch head.
11
" OUTPUT AND GAS CONNECTION FOR PLASMA CUTTING (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)1. 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 & clamp to the “+” output terminal (5)
and turn it clockwise to tighten.
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
cutting torch and ground clamp & cable Insulation in good
condition.
1
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.
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.
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) Have LTP7000 plasma cutting torch and ground cable & clamp ready as Installation indicates, turn the power
ON.
3) Adjust the air pressure and make it is adequate to machine, open the valve of pressed air.
4) The recommended air pressure is 0.2~0.4Mpa, gas flow is 4.8cfm @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 70A.
8) Press and hold the trigger to make a cut.
13
MAINTENANCE
PLEASE READ AND UNDERSTAND THIS ENTIRE SECTION BEFORE DOING
MAINTENANCE FOR YOUR MACHINE. ONLY QUALIFIED PERSONNEL SHOULD
OPERATE THIS EQUIPMENT. OBSERVE ALL SAFETY INFORMATION THROUGHOUT
THIS MANUAL.
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.
! 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 machine 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:
" Clean the power source inside by means of low pressure compressed air.
" Check the electric connections and all the connection cables.
" 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.
! 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 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
PROBLEMS
(SYMPTOMS)
Fan stops working
Warning light on
No output
Output
current
decreased
Current cannot be
regulated
High
frequency
arc cannot be
generated
TROUBLESHOOTING PLASMA CUTTING
PROBLEM CAUSE
RECOMMENDED ACTION
% Fan power cord is off
% Enclosure blocks the fan that causes
deformations
% The fan fails
% Over heat
% Over current
% Over current protection
% The machine fails
% Input voltage is too low
% Input line is too thin
% Connecting line of the potentiometer
is off
% Potentiometer of current regulation
fails
% The switch fails
% Incorrect selection for the air flow, the
electrode fails
% High frequency arc generator fails
16
% Reconnect the power cord
% Reform the enclosure
% Replace the fan
% Cut after cooling down
% Lower input voltage or replace machine
% Lower input voltage
% Do maintenance in manufacturer or
service center
% Increase input voltage
% Thicken power line
% Reconnection the line
% Replace the potentiometer
% Replace the switch
% Replace the electrode
% Replace the high frequency arc generator
OTHER ACCESSORIES
The following accessories and consumables can be purchased on www.uwelding.com, or call 408-739-2329 to
order.
CONSUMABLES
ACCESSORIES
17