Lotos CT520D Multipurpose

Plasma Cutter/ Tig/ MMA Welder

Operating Manual
Rev.03 July, 2009

Introduction
Lotos' latest high frequency inverter technology utilizes V-MOSFETs along with PWM (Pulse Width Modulation) to deliver a far more constant, concentrated and precise current to the cutting surface. This technology has been substantially reduced in size and weight of Inverter Plasma Cutters. It helps you to easily achieve smooth, clean cuts of wide range of surfaces and material (e.g. stainless steel, alloy steel, brass, aluminum and other conductive material) with minimal heat input and without distortion of metal. Our plasma cutters are designed especially for those DIY (do-it-yourself) users, while fully accommodating the demands of professional operators.

Warranty
The machine is insured against damage upon shipping. If you machine is damaged in any way when you receive it, you must retain all shipping materials and packing. Contact us and report the damage immediately. There is a 1 year warranty on all internal electronic parts. The torch, power cord, clamps, air regulator, hoses, case & paint and consumables and cables are not covered under warranty. You must use dry gas in your machine and keep it indoors away from rain and moisture. This machine is designed to operate from 110-240vac at 50-60Hz Only. Operating outside of limits will void warranty. Warranty coverage covers repair or replacement of damaged machine or damaged circuit board. Within 30 days of purchase, the warranty does not cover shipping from the customer but does cover return shipping within the Cont. United States. After 30 days of purchase, the customer shall pay both way shipping fees. If you are going to return a machine to us for repairs, it must be well packed and insured with RAN (Return Authorization Number). Any package without RAN will be rejected and returned. Customers who own machines that require warranty coverage should contact our warranty department by email or phone call on www.uwelding.com to obtain a RAN. Customers who own an out-of-warranty machine that requires repairs should contact us for an estimate for repair cost.

Backup Welding Kit

INSTRUCTION MANUAL CT520D

CONTENTS
- Warning.............2 -General Description.....................3 - Main Parameter..........................4 - Installation...........................5 - Operation.............................7 -Caution....... ....................................7 - Maintenance...................................8 - Troubleshooting........8

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WARNING
Welding and cutting is dangerous to the operator, people in or near the working area, and the surrounding, if the equipment is not correctly operated. Therefore, the performance of welding/cutting must only be under the strict and comprehensive observance of all relevant safety regulations. Please read and understand this instruction manual carefully before the installation and operation. The switching of function modes is possibly damaging to the equipment, while the welding operation is performed. Do disconnect the electrode-holder cable with the equipment, before the performance of welding. A safety switch is necessary to prevent the equipment from electric-leakage. Welding tools should be of high quality. Operators should be qualified. Electric Shock: It may be fatal connect the earth cable according to standard regulation. Avoid all contact with live components of the welding circuit, electrodes and wires with bare hands. It is necessary for the operator to wear dry welding gloves while he performs the welding task. The operator should keep the working piece insulating from himself/herself. Smoke and Gas generated wile welding or cutting: harmful to peoples health. Avoid of breathing the smoke and gas of welding or cutting. Keep the working area in good ventilation. Arc light-emission: harmful to peoples eyes and skin Wear the welding helmet, anti-radiation glass and work clothes while the welding operation is performed. Measures also should be taken to protect people in or near the working area. Fire hazard The welding splash may cause fire, thus remove flammable material away from the working place. Have a fire extinguisher nearby, and have a train fire person ready to use it Noise: Possibly harmful to peoples hearing. Surface noise is generated while welding/cutting, the hearing aids is necessary in some cases. Machine Fault: Consult this instruction manual. Contact your local dealer or supplier for further advice.
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GENERAL DESCRIPTION
This welding & cutting equipment is manufactured with advanced inverter technology. With power component MOSFETS and by adopting PWM technology, the inverter converts DC voltage which is rectified from input AC voltage to the high 100KHz frequency AC voltage; as a consequence, the voltage is transformed and rectified. Therefore, it results the much more small-sized of the main transformer and lighter in weight of the inverter welding/cutting equipment, which rates the performance of cutting by 30%. The high frequency oscillation, which enables the output of the high frequency DC, is employed in the arc-starting system. The features of this product are as following: stable output, reliable, completely portable, efficient and low noise generated while cutting is performed. During the operation of MMA welding or TIG welding, this welding & cutting equipment is featured with the stability of output. The stability of welding current output is not frustrated by variation of arc length. During the plasma cutting operation, being compressed by high pressure of compressed air, the arc, of which the temperature rises rapidly up to 10000-15000, is of highly ionized status, as a consequent, it produces the powerful plasma arc for cutting. By the employment of plasma cutting, it is energy saving and efficient; the high speed of metal cutting and smooth incised surface is accessible. CT520D is applicable in welding and cutting of various kinds of metal materials, such as carbon steel, stainless steel, alloy steel, copper and other nonferrous metals etc. Also they are small in measurement, high efficient, energy saving, stable in output and reliable in quality; the ratio of input voltage and output voltage of this welding & cutting equipment is up to 85%. Guarantee of maintenance for main engine of this welding & cutting equipment is one year, excluding other spare parts.

Block Diagram

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MAIN PARAMETER
Function Type
Power Requirements (Volts/Hz)

DC Tig
120/220 Volts 50/60 Hz +/- 15% Single phase

DC Stick Welder
120/220 Volts 50/60 Hz +/- 15% Single phase 10-160 Amps at 220 Volts 10-80 Amps at 110 Volts 1/16 to 1/18 27.5 Volts 3/16 inches

Plasma Cutter
120/220 Volts 50/60 Hz +/- 15% Single phase 10-50 Amps at 220 Volts 10-25 Amps at 110 Volts N/A 110 Volts Cut-sever 1 inches Rated inches

Rated Output Range Rod Size Rated Output Voltage (Volts) Max Rated Welding/Cutting Thickness (inches) Duty Cycle Efficiency Air Requirements Gas Flow (L/min) Housing Protection Insulation Weight and Dimensions

10-200 Amps at 220 Volts 10-100 Amps at 110 Volts N/A 18 Volts 5/16 inches

60% a 200 Amps 100% at 150 Amps 85% N/A 2-5 L/min IP21 B

60% at 160 Amps 100% at 120 Amps 85% N/A N/A IP21 B 27 Pounds, 8 x 17 x 12.5 Inches

60% at 50 Amps 100% at 40 Amps 85% 60-70 PSI at 4 CFM 80 L/min IP21 B

CIRCUIT DIAGRAM

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INSTALLATION
1. Power Plug Wiring Connect this welding & cutting equipment with the power supply of 110 or 220V AC. For the wiring, please note that: For 110VAC, The green wire with yellow stripe is the ground wire The red/brown wire is the hot wire The blue/black wire is the neutral For 220VAC, The green wire with yellow stripe is the ground wire The red/brown wire is positive 110VAC The blue/black wire is negative 110VAC Connect the earth terminal with the earth cable of minimum diameter of 2.5 mm 2. 2. Connection of the Output Cables 2a. Install welding torch according to the picture. 2b.Connect the one-knob connector, air plug to the corresponding connector on the panel board, and fasten the screw. 2c. Plug the air plug of the back cable to +of the air socket on the panel board, and fasten it in the clockwise direction. Connect earth clamp with work piece. 3. Power Supply Switch In case that power switch is on, built-in fan start work and current meter displays the current value. 4. Function Switch Function switch enables the option among MMA, TIG and CUT welding according practical welding task requirement. 4a.TIG Welding Function Connect with gas supply-Connect the argon hose to the copper nozzle of the back panel. The gas supply system includes the gas bottle, air regulator and gas hose. The connection of parts of gas system should be firm to prevent the gas leakage. Install the argon torch according to the drawing. Connect the copper screw on the cutting torch to the output terminal of the one-knob of the front panel, and fasten it toward clockwise direction to avoid gas leaking. Connect the plug of the closed circuit to the + socket on the panel board; Connect the earth clamp with the work piece. 4b.MMA Function --Connect the black fast plug of the electrode holder to the black fast socket of the front panel board. --Connect the other fast plug of the earth cable to the fast socket of the front panel board, Re: This connection is of positive connection, available for welding with acid rod, while negative connection is available for welding with material of alkaline or stainless steel. 4c.PLASMA Cutting Function --Connect the gas hose with the terminal IN of regulator and connect the OUT terminals of regulator with the copper tub. The pressure and volume of output gas should be sufficient. --Connect the copper nut of the cutting torch to the knob of the panel board; connect the fast plug with the plug of the panel board. --Connect the fast plug of earth cable with front panel of this welding & cutting equipment. 5. Welding Current Output Setting

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According to practical demand, set the parameters of current output by the operation ofARC,TIG, or CUT. INSTALLATION OF THE GAS REGULATOR: Please refer to the right drawing. The installation and operation of the air regulator 1) Seal the connection of the copper gas hose and the IN terminal and OUT terminals. 2) Connect the regulator seal to the installation place of the regulator. 3) Fix the rack with screw to the place of the air regulator at the back of the machine. 4) Remove the rubber nut. Connect the regulator with the track. 5) Release the gas valve, modulate the pressure of gas to stipulated pressure, and press the button. 6) The gas pressure is 4 times of normal atmospheric pressure. 7) In case that the water-filtering bottle is full with water, remove the water. Please note that: --Please choose the gas supply respectively for TIG welding and plasma cutting are different. --The duty cycle for cutting of CT416 is 40%.

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OPERATION
1. TIG Welding Function 1) While this welding & cutting equipment is operated, power supply indicator is on, and the built-in fan is functioning. 2) Opt the TIG welding function mode. 3) Press the gas-releasing button, and modulate the volume of gas output to the required value. 4) Press the button of welding torch, and the electromagnetic valve functions. The sound of electricity releasing is audible and there is gas out from welding torch. Please note that: before the initial welding operation, press the button of welding torch for several seconds in order to remove the gas inside the gas tub, and the welding operation is accessible. There is gas output within a few seconds after the welding operation, that is special design to protect the welding point before it is cooling down. Therefore, after the extinction of arc, maintain the welding position to abstract the heat produced during the welding operation. 5) The welding current output is adjustable, according to the thickness of welding material and required craftsmanship. 6) Maintain the distance of 1-4mm between the tungsten electrode and the work piece. Press the button of welding torch. HF electricity releasing between the welding electrode and the work piece occurs; after the arc starting, the splash of HF arc starting will vanish and the welding operation is available. 2. MMA Function Opt MMA welding mode. While this welding & cutting equipment is operated, the power supply indicator is on, and the built-in fan is functioning. According to the thickness of work piece, adjust the welding current output and choose the rod, then the MMA welding is accessible. 3. PLASMA Cutting Function Opt the plasma-cutting mode. While this welding & cutting equipment is operated, the power supply indicator is on, and the built-in fan is functioning. Release the regulator valve, and modulate the pressure and volume of output gas. Press the button of the cutting torch, the sound of electricity releasing is audible and there is gas out from welding torch. According to the thickness of work piece, adjust the current output, and then the plasma cutting is accessible. Contact the nozzle of the cutting torch with the work piece, press the button of the welding torch, the sound of HF arc starting vanishes and the cutting operation is accessible. After the arc starting, maintain the distance of about 1mm, in order to protect the nozzle from possible damage. In case of difficulty in arc starting, it is recommended to reduce the pressure of gas output. If the nozzle is damaged, adjust the pressure of gas output.

CAUTIONS
1. Working environment 1.1 The location in which this welding & cutting equipment is installed should be of little dust, corrosive chemical gas, flammable gas or materials, and of maximum 80% humidity

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1.2 Avoid the operation of welding & cutting in the open air unless sheltered from the sun shining, rain water and snow etc; the temperature of working environment should be maintained within -10C to +40C 1.3 Keep this welding & cutting equipment 30cm distant from the wall; 1.4 Keep the working environment in good ventilation. 2. Safety tips 2.1 Ventilation This welding & cutting equipment is small-sized, compact in structure, and of excellent performance in current output. Fans are required to abstract heat generated by this cutting equipment while the operation of welding is carried out. CautionsMaintain good ventilation of the louvers of this welding & cutting equipment. The minimum distance between this welding & cutting equipment and any other objects in or near the working area should be 30 cm. Good ventilation is of critical importance for the normal performance and service life of this welding & cutting equipment. 2.2 Welding operation is forbid while this welding & cutting equipment is of over-load. A sudden halt may occur while the cutting operation is carried out while this welding and cutting machine is of over-load status. Under this circumstance, it is unnecessary to restart this welding & cutting equipment. Keep the built-in fan working to bring down the temperature inside this welding & cutting equipment. 2.3 Over-voltage is forbid. Regarding the power supply voltage range of the welding & cutting machine, please refer toMain parametertable. This welding & cutting equipment is of automatic voltage compensation, which enables the maintaining of the voltage range within the given range. In case that the voltage of input power supply current exceeds the stipulated value, it is possibly damaging to the components of this welding & cutting equipment. 2.4 An earth terminal available for this welding & cutting equipment. Connect with the earth cable to avoid the static and electric shock. It is strongly forbid to contact the output terminal when the welding & cutting operation is performed. An electric shock possibly occurs.

MAINTENANCE
Exposure to extremely dusty, damp, or corrosive air is damaging to this welding & cutting machine. In order to prevent any possible failure or fault of this welding & cutting equipment, clean the dust at regular intervals with clean and dry compressed air of required pressure. Please note that: lack of maintenance can spell to the unavailability and cancellation of the guarantee; the guarantee of this welding & cutting equipment will be no longer available in case that it has been attempted to take the machine apart or the open the factory-made sealing of the machine.

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TROUBLESHOOTING
CAUTIONSOnly the qualified technicians are authorized to undertake the repair task of this welding & cutting equipment in case of machine fault. - CT520D

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