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User`s Manual - Lincoln Electric

1. a8 Laie This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 1 Section 7 Parts List Spirit Il User s Manual Power Supply BK300232 BK300239 Left Side View Item Part Number Quantity Description 4 BK707150 3 L1 L2 L3 Inductor 12 BK300101 1 Printed Circuit Board PCB Microprocessor DSP 16 BK300112 1 Printed Circuit Board PCB A C Detect 32 BK708118 2 CR3 PAR Relay 33 BK705011 1 PAT IGBT 34 BK702075 2 PAT IGBT Filter Capacitor 36 BK300108 1 Printed Circuit Board PCB I O 37 BK301200 1 Optional Printed Circuit Board PCB Voltage Divider 39 BK709117 1 O Terminal Block small 40 BK280003 2 Power Supply 24VDC 43 BK708105 2 Relay Hold Down Clip 44 BK200204 1 Fan 4 7 46 BK709252 1 I O Terminal Block large 47 BK709253 2 Strain Relief 50 BK284029 4 Current Sensor 51 BK300130 3 F9 F10 F11 Fuse 200A 52 BK300129 3 F9 F10 F
2. Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 2 D Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277283 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 158 105 155 250 300 095 3 8 25 80 26 80 162 90 180 275 400 098 1 2 165 70 195 300 500 100 Metric Material P Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 158 2710 3 8 6 3 300 2 4 10 25 80 26 80 162 2210 4 6 7 0 500 2 5 12 165 1890 4 9 7 4 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 71 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Aut
3. Part Number Part Number Length Non CSA Systems CSA Systems BK284306 XX BK288406 XX Where XX is the length in feet Available in 5 foot increments a RHF CONSOLE CONTROL CABLE ar POWER SUPPLY 4 i b lc RHF CONSOLE Ue POWER SUPPLY ELECTRODE LEAD POWER SUPPLY O RHF CONSOLE POWER SUPPLY NOZZLE LEAD POWER SUPPLY RHF CONSOLE POWER SUPPLY CTP SENSOR LEAD POWER SUPPLY RHF CONSOLE RHF CONSOLE RHF CONSOLE POWER SUPPLY COOLANT RETURN HOSE POWER SUPPLY POWER SUPPLY COOLANT SUPPLY HOSE POWER SUPPLY LD a Work Ground Lead Part Number Part Number Lendth Non CSA Systems CSA Systems g BK284318 XX BK288418 XX Where XX is the length in feet Available in 5 foot increments POWER SUPPLY STAR GROUND This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of th
4. N NI a_l n7 13 REMOTE ON OFF CORNER MARK HOLD STRT 2248 M M M M M BEE LI U Yu Yu Ya 5 a kg ve yee HE pi E zi EG 8 5 i fse 2 7 Pi x a i z S 5 g amp gg 3 g 8 a 3 z OEE 5 3 8 5 5 5 lt wa ges g ze 6 z 32 an1 7 z amp 5 lt 5 S a g 8 N D S k N gt i n gt p d Y1 r R125 i 3 wC i cr B Ll a a no a Re GSV_GND 4 GSV_GND GSV_24V g J 8 z o l uas z fog pg z Gsv 1 7 C174 wore oot R42 R269 R272 cas a u20 R58 wo o iL This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 16 Spirit II User s Manual Section 7 Parts List Power Supply Microprocessor DSP BK300101 Quadrant 2 i 8 8 amp Dido U28 Plasma U27 Preflow u27 d u19 N SOL R20 C12 C54 oD DA ae EEF Giir o c J12 Move U21 Mtr Sol U22 PAR 399583 zag A L E MOTOR A Ol RD MOVI U22 q 7 OGG O Be Gels Lis o DDA Ha O MOV3 U24 C NI PAR Co om U24 Surge FAN SURGE J16 U26 Fan CON Ce MOV4
5. Outer Shield Inner Nozzle Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK284150 BK277144 BK277110 BK277121 BK277138 BK277137 ope tO 30A Q 9 BK2841 50 BK277123 BK277142 si Q s KEEA 50 BK277125 BK277142 a Q 5 BKB 50 BK277284 BK277283 100A Q 9 O BKB 50 BK277293 BK277139 150A Q 9 BK 50 BK277289 BK277143 200A Q 9 9 BKOSA 50 BK277276 BK277258 275A 9 Brea 50 BK284157 BK284122 400A Q 9 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 8 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel Air or Nitrogen Plasma Silver Electrode Outer Shield Inner Nozzle Swirl Silver Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK279410 BK284150 BK277286 BK277151 BK279484 BK279483 brown o ring BK279060 100A Q e 9 D BK284150 BK27o493 BKo79489 K2T9420 150A 9 D BK277274 BK277266 BK279489 BK279443 Peer d J BK284150 BK279060 Q This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requir
6. Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 50 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 100 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 brown o ring D Ay E 4 D a Q Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 158 105 155 250 300 095 3 8 25 80 26 80 162 90 180 275 400 098 1 2 165 70 195 300 500 100 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm
7. Shield Cap Nozzle Electrode BK277145 BK277120 BK277130 2s a cm Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 2 120 105 080 2 036 100 062 18 048 121 97 090 16 060 125 78 110 06s 14 075 35 77 6 75 126 65 105 200 i 12 105 127 55 11 120 129 50 070 l t 120 125 300 10 135 131 40 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 120 2615 2 0 100 1 6 1 5 124 2020 2 6 2 8 7 2 35 77 6 75 1615 200 126 2 7 2 5 1455 18 3 128 1285 2 9 3 1 300 i Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 145 250 6350 177 4 5 100 2 5 0 Argon Air N A 50 25 N A 66 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 100 2 5 mm for cutting and marking Only available on systems with
8. Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 48 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 150 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 green o ring D gt y Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK279439 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 150 160 250 400 125 3 8 150 115 180 275 500 1 2 20 71 70 69 155 85 210 300 600 130 5 8 160 60 220 325 800 i 3 4 168 45 240 350 1200 135 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Hei
9. Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 23 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 70 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 z 6 y j Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Votage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 10 135 132 120 060 150 200 085 134 1 07 2 3 16 25 76 25 76 3 00 070 00 300 1 4 140 75 090 225 400 090 3 8 148 50 120 250 500 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height
10. ccccccceeeeeeeeeeneeeeeeeeeeeeeeeeeaaeeeeeeeeeeeeeseecaaeeeeeeeeeeeeeeee 6 1 Replacing the Torch Coolant and Filter eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeaes 6 4 Microprocessor DSP Status Indicators ce eeeceee eee eeeeeeeeeeeeeeeeeeeeeeeeteeeeeeeees 6 5 Microprocessor DSP Sequence of Operation eceeeeeeeeeeeeeeetteeeeeeeees 6 5 EEO Re EEA cciteciote ent A one A A stort coe bee A AE bee obec mex tote 6 7 General roubleShocing 2aitkaiai aia auaueiiaiaienakeiaianataineiias 6 9 Chopper Test Procedure v ce s2sc2st sects sosst at auect oat saat aides teatsessteatsasebeabaesemeaaaaed 6 11 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR iv Spirit II User s Manual Prologue Section 7 Parts List Power Supply BK300232 BK300239 cccceeeeecceeeeeeeeeeeeeeeeeeeeeeeseteeeeeees 7 1 Cooling Systemi BK300275 izicicccnscec cs scbieicse bisiceatiaicuei a 7 4 Manual Gas Console BK300615 cccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenneeeeeeeees 7 5 Impulse Start Console BK300505 ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 7 Torch and Manifold Assemblies ia cciccciscsceletace to ccavds ey lcteds taceteceieceivdatecaaedeivcaiecs ine 7 8 Sh
11. BK284150 BK284156 BK284122 BK279100 Imperial Material i Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 105 190 300 600 165 5 8 165 90 180 350 800 175 3 4 75 170 400 1200 1 170 50 185 500 1500 200 30 80 82 96 1 25 175 40 210 700 2000 1 5 185 30 270 800 2500 225 1 75 193 23 300 235 350 1500 2 00 200 18 350 250 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Votage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 2750 4 8 7 3 600 4 2 16 165 2270 4 5 8 9 800 4 4 20 1810 4 3 10 5 SNNN 1500 25 169 1310 4 6 12 5 5 1 30 80 82 96 32 175 1005 5 3 18 0 2000 38 184 765 6 8 20 2 2500 5 7 45 193 570 7 6 7 8 6 0 S NN 1500 Iel 50 199 470 8 7 8 9 6 4 Marking For All Material Thicknesses Type of Gas Preflow Plasma Shield Postflow Tn he ret Aen cae Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 100 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 68 100 2540 160 4 1 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cu
12. 2 BURNY i KALIBURN A Lincoln Electric Company User s Manual Spirit II 400 High Current Density Plasma Cutting System with Manual Gas Console MGC BK718118 Rev F This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred y any means any location outside the United States contrary to the requirements of the EA lo ol heal Prologue Spirit II User s Manual Revision History Rev ECO Author Date Description of Change A CAD 02 04 2013 Initial Release Added 100A 150A silver electrodes replaced RHF with ISC B LAD0202 CAD 06 07 2013 corrected system interconnect diagrams changed rated inlet gas pressure to 115 psi added 100 psi minimum to inlet gas pressure Deionization filter cartridge 500510 replaced sediment filter 300152 Parts list updated Expanded notes on System Interconnection diagrams to clarify cabling requirements for various configurations Corrected contact ratings on page 3 19 D LAD0228 CAD 08 28 2013 Added pinouts to Cll Fil JII cables in Parts List Inductor 707150 replaced by 707155 ISC Console 300500 replaced by 300505 MGC 300600 replaced by 300615 Added notes about torch handle vent hole Updated Chopper Test Procedure Added BK prefix to all part numbers Added PCB Outline F LAD0264 CAD 03 31 2014 Dwgs and corrected electrode t
13. Power Supply Specifications mar Input Current at Power Supply Description Part Number Maximum Output 220 VAC 30 60Hz BK300232 262 amps 240 VAC 30 60Hz BK300233 240 amps 380 VAC 30 50 60Hz BK300234 152 amps 400 VAC 30 50 60Hz BK300235 144 amps 415 VAC 30 50 60Hz BK300236 140 amps 440 VAC 30 50 60Hz BK300237 131 amps 480 VAC 30 60Hz BK300238 120 amps 600 VAC 30 60Hz BK300239 96 amps Open Circuit Voltage eeeeeeeeeeeeeeeeeeeeeeees 370 VDC Output Current drooping characteristic 10 400 amps Maximum Output Voltage cceeeeeeeeeeeees 200 VDC D ty Cycle a osi enii leiden deesngess tec deoreeeneseneeics 100 80 kW Maximum Ambient Temperature 00 104 F 40 C AE a E sie cted coveted atereecetatereaeceeees 1922 Ib 872 kg 39 9 1013 HH Hi iy ial o of fe 34 2 869 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 49 5 125
14. 8 z 1 RIG cne c16 r235 g5 ANALOG MODULE C176 COOLENT MODULE This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 19 Section 7 Parts List Spirit II User s Manual Power Supply Output BK300108 TOYLNOS LHOIH a Q N 7 k etje2 LINCOLN ELECTRIC BLANK PCB P N 300107 REV C ASSEMBLY P N 300108 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 20 Spirit II User s Manual Section 7 Parts List Power Supply A C Detect BK300112 N 8 ta m lt a cal Fi vn lt KALIBURN NC This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 21 Section 7 Parts List
15. For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 145 250 6350 177 4 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 55 100 2540 140 3 6 100 2 5 0 Use an arc transfer height ignition height of 050 1 3 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 21 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 50 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277149 BK277123 BK277137 m F 9 C 3 j X j Ji Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277110 BK277142 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed He
16. Maintenance and Troubleshooting if replacement is necessary This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 2 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Maximizing Consumable Life Use the following guidelines to maximize consumable parts life 1 The Spirit system utilizes the latest advancement in technology for extending the life of the torch consumable parts To maximize the life of the consumable parts it is imperative that the shutdown procedure of the arc is carried out properly The arc must be extinguished while it is still attached to the workpiece A popping noise may be heard if the arc extinguishes abnormally Note that holes are usually programmed without lead outs to prevent loss of the arc during shutdown There is a time delay between the reception of a stop signal and when the arc is extinguished During this time the gases and cutting current are changed to optimum values for extinguishing the arc Ideally the x y machine controller should provide a plasma stop signal prior to the end of the cut path so the gases and current reach the shut off values at the same time that the part has been completely cut The shut down times are different for each current and are given bel
17. ipm in in msec in 1 4 95 250 250 400 195 3 8 75 150 275 500 1 2 25 77 75 81 165 60 165 300 600 140 5 8 50 185 325 800 3 4 40 250 350 1200 145 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 1845 3 8 7 0 3 4 600 12 155 1610 4 1 7 4 25 77 75 81 3 6 16 1260 4 7 8 3 800 20 167 940 6 9 9 0 1200 3 7 Marking For All Material Thicknesses P Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 81 100 2540 140 3 6 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 27 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual St
18. 305 13 50 343 p 1 e 1 e 10 00 254 5 35 136 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 8 Spirit II User s Manual Section 2 Specifications Torch and 2 Gang Manifold Specifications Part Number 2 Gang Manifold Assembly ccceeeeeeeeeeeeeeeeeneeeeeeeees BK284214 Torch Handle standard ices cscecces cdc eeevelauuds cascode wedaediececinet BK278001 Torch Handle short coches ates eer ieeeieeestets BK278018 Toreh BaS aoe oot Fe eee Nien eae ia AA BK279000 Torch Head Copper Electrode eeeeeeeeeeeeeeeeeeeeees BK279100 Torch Head Silver Electrode ceeeeeeeeeeeeeeeeeeeeeeeees BK279060 Max Weight Manifold Bracket Handle BK278001 Base and Head 8 3 lbs 3 8 kg Manifold 3 38 86 SS nA Torch Handle BK278001 9 46 240 BK278018 7 06 179 1 99 i 51 Torch Base Alignment Indicator 5 Attachment Ring o Ali
19. The warranty period starts three 3 months after the product ships from the factory This product is intended for commercial use and is not intended for personal family or household purposes There are no warranties that extend beyond the express limited warranty set forth immediately above All other warranties whether expressed implied statutory or made herein or in any other communication including any implied warranty of merchantability fitness for any particular purpose or non infringement are expressly excluded This warranty will be considered void if the Spirit II system is operated with non genuine KALIBURN torch consumables or if the equipment has been subjected to improper installation improper care or abnormal operation If this product or any component thereof is determined to be defective in materials or workmanship KALIBURN will repair or replace the defective component or product The buyer s remedies are limited to the return of the product for repair or replacement of any defective product or part at the sole discretion of KALIBURN No freight charges of any kind are covered under this warranty All returned goods shall be at the buyer s risk and expense In no event will KALIBURN be responsible for any special incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any equipment sold hereunder Returned Goods Procedure KALIBURN utilizes a returned goods proced
20. Time Width mm psi psi psi psi volts mm m mm mm msec mm 3 131 3210 1 4 3 3 200 a 5 25 76 25 76 134 2445 1 8 5 1 400 i 6 138 2050 2 1 5 5 2 3 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 096 2 4 100 2 5 0 Argon Nitrogen N A 50 25 N A 65 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 24 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 100 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode B
21. damaged gas hoses Torch Torch Leads and Gas Hoses 1 Verify that all torch lead and gas hose connections are tight and that there are no gas or water leaks Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened Verify that the braided shield of the torch leads is fastened securely to the brass shield adapter that connects to the impulse start console Also make sure the shield adapter is secured tightly to the impulse start console enclosure Inspect the braided shield for nicks or cuts and replace if necessary 4 Remove the torch handle and verify that the connections at the torch base are tightened securely Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened Coolant leaking from the drain hole in the torch handle indicates damaged or loose torch leads Make sure the torch lead insulating sleeves are positioned to properly cover the brass torch fittings at the torch base Inspect the outer sleeve on the torch base s electrode coolant supply lead If nicks cuts or holes are found replace the torch base Remove the torch consumables from the torch head and inspect all o rings Replace any o rings with cuts nicks abrasions or any other signs of wear Faulty o rings may cause gas or water leaks which will affect cut quality With the electrode removed inspect the cooling tube in the torch head
22. gt U31 Opto Postflow gt U28 Opto Plasma gt D41 Motion The following LEDs should turn OFF after the Motion Indicator turns ON gt U34 Opto ISC gt U27 Opto Preflow gt D43 PAT When the START signal is removed OPTO U30 Vent will illuminate It will then go out with the rest of the cut cycle indicators This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 6 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting Error Codes The following is a comprehensive list of error codes for the Spirit system When the system uses a Manual Gas Console only the numeric error code is displayed When an Automatic Gas Console is used the text description is also displayed Power Supply Code Short Description Long Description 10121 ISC Door ISC Door is open 10138 Stop Pressed Off Button OFF Button on Plasma Console or Manual Gas Console is pressed 10140 Phase R Transformer Secondary phase voltage is low 10150 Phase Y Transformer Secondary phase voltage is low 10160 Phase B Transformer Secondary phase voltage is low 10161 CON1 Main Contactor failed to open 10170 Coolant Level Coolant Level is low 1018
23. 12 2 12 2 4 1 Marking For All Material Thicknesses Type of Gas Preflow Plasma Shield Postflow V ee Mee p Gni os Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 120 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 62 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 45 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 275 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277263 BK279469 BK279450 red o ring F s y Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK279458 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Volt
24. 150 170 300 600 200 5 8 180 125 190 400 700 205 3 4 185 100 205 500 800 30 85 63 96 210 1 190 75 215 600 1200 1 25 200 55 220 700 1500 225 1 5 205 35 225 800 2000 240 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 173 3950 4 1 7 0 600 5 1 16 180 3150 4 8 10 3 800 5 2 2 185 2445 5 2 13 0 30 85 63 96 1200 5 3 25 189 1945 5 4 15 0 32 200 1375 5 6 17 9 1500 5 7 38 204 895 5 6 20 2 2000 6 1 Marking For All Material Thicknesses Type of Gas Preflow Plasma Shield Postflow Iie Miir n eini oe Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 106 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 75 100 2540 140 3 6 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 42 Spirit I
25. 155 60 190 350 800 155 3 4 160 50 200 400 1200 1 0 170 35 240 450 1500 160 Metric Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 154 2010 4 7 6 5 600 3 8 12 149 1935 3 6 7 3 16 37 72 79 68 155 1515 4 8 8 9 800 3 9 20 161 1215 5 2 10 3 1500 25 169 915 6 0 11 3 4 1 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 120 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 72 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 29 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 200 Amps Air Plasma Nitrogen Sh
26. 250 mm min as soon as the arc transfers to the plate After the arc completely penetrates the plate the torch should be positioned at the proper cutting height and the X Y machine speed should be increased to the correct level With an edge start the torch should be positioned at the edge of the material prior to starting the arc This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 5 Section 4 Operation with Manual Gas Console Spirit II User s Manual Cut Quality Before the optimum cutting condition can be achieved on a particular material type and thickness the machine operator must have a thorough understanding of the cutting characteristics of the Spirit system When the cut quality is not satisfactory the cutting speed torch height or gas pressures may need to be adjusted in small increments until the proper cutting condition is obtained The following guidelines should be useful in determining which cutting parameter to adjust Note Before making any parameter changes verify that the torch is square to the workpiece Also it is essential to have the correct torch parts in place and to ensure that they are in good condition Check the electrode for excessive wear and the nozzle and shield cap orifices for roundnes
27. 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 20 Spirit II Users M anual Section 5 Torch Consumables and Cutting Charts Stainless Steel 30 Amps Air Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277144 BK277121 BK277137 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277110 BK277138 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 2 2 02 2 03 71 o ues 100 065 18 048 165 35 81 30 85 035 050 16 060 74 125 200 068 14 075 75 90 025 070 Metric Material i Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 71 4855 0 6 100 35 81 30 85 1 3 1 7 1 5 73 3260 0 9 200 Marking
28. Argon Air N A 50 25 N A 60 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 43 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 150 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 green o ring 2 gt y Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK 277152 BK279439 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in Retaining Cap BK277151 1 4 118 165 105 200 300 105 3 8 20 71 30 69 123 125 135 250 400 i 1 2 125 90 140 300 500 130 Retaining Cap BK
29. BK279489 BK279440 yellow o ring Fa SD A y Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK279443 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Votage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 130 200 200 400 a 070 l 150 3 8 133 150 250 500 1 2 140 110 115 300 600 152 146 75 150 350 800 5 8 20 74 58 72 155 3 4 153 60 190 400 1200 1 0 158 40 210 450 160 1 25 170 20 250 350 1500 165 1 50 180 10 275 350 175 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 129 5220 1 8 4 9 400 3 8 1 134 1 0 3 3655 9 6 5 600 12 138 3020 2 6 7 3 16 146 1890 3 8 8 9 800 3 9 20 74 58 72 r gt E 20 153 1450 4 8 10 3 25 157 1050 5 2 11 3 4 1 N N 1500 eel 32 170 495 6 4 8 9 4 2 38 179 260 6 9 8 9 4 4 Marking For All Material Thicknesses f Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Tine Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 120 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 70 100 2540 100 25 100 2 5 0
30. CONSOLE 2 P5 P5 REMOTE REMOTE o o P4 B89 X Y MACHINE E La P7 IPG P4 s RS 422 RS 422 X Y IP6 BES P7 RS 422IN Sey amp OUT IN MACHINE O Ve oO IP7 PI6 RS 422 OUT ow o Spirit II 150 275 Spirit Il 400 Unique Interconnect Cables Two unique interconnect cables are required for this option with the Spirit II system The FII cable is used to connect the Spirit Il internal Inova console IP4 to the X Y Machine CNC controller The JII cable is used to connect multiple Spirit II internal Inova consoles IP8 See the parts list in Section 7 for more details on these cables This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 1 Section 8 Internal Inova Console Option Spirit II User s Manual Grounding The internal Inova console must be connected to the same protective earth ground as the plasma power supply and in accordance with national or local codes The figures below describe two methods Use a minimum of 8AWG 10 mm wire Note the customer must supply the ground cable Direct to star ground Ground Yat Point rare PEO wi te TT x aaa A SF SssssssssE mio 0 a Aa e I pm AT EEEEEEEEEEK mite _ o o e Spirit II 150 275 Spirit II 400 Jumper to the work g
31. Cutting Charts Mild Steel 70 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 m 5 F 9 C v yy Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 8 35 110 190 150 100 100 080 3 16 113 130 200 200 25 76 74 1 4 40 116 120 110 225 300 08s 3 8 122 75 140 250 400 i Metric Material 3 Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voitage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 3 35 109 4995 3 6 100 2 5 2 0 5 25 76 74 113 3265 5 1 40 300 6 115 3105 2 7 5 5 2 2 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 096 2 4 100 2 5 0 Argon Air N A 50 25 N A 62 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition he
32. Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 120 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 71 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 53 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 275 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277263 BK279469 BK279450 red o ring h op Q yoj Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK279458 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 160 160 160 275 400 160 1 2 165 125 180 300 500 i 5 8
33. Observe the following guidelines to protect against electric shock e A wall mounted disconnect switch should be installed and fused according to local and national electrical codes The disconnect switch should be located as close as possible to the power supply so it can be turned off in case of an emergency e The primary power cord should have a 600 volt minimum rating in order to protect the operator In addition it should be sized according to local and national electrical codes Inspect the primary power cord frequently Never operate the system if the power cord is damaged in any way e Make sure the primary power ground wire is connected to the input power ground stud on the power supply Make sure the connection is securely tightened e Make sure the positive output work ground of the power supply is connected to a bare metal area on the cutting table A driven ground rod should be placed no further than five feet from this connection Make sure this ground point on the cutting table is used as the star ground point for all other ground connections e Inspect the torch leads frequently Never use the system if the leads are damaged in any way e Do not stand in wet damp areas when operating or performing maintenance on the system e Wear insulated gloves and shoes while operating or performing maintenance on the system e Make sure the system is switched off at the wall disconnect before servicing the power supply or torch Thi
34. RHF HF transformer energized This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 5 Section 6 Maintenance amp Troubleshooting Spirit II User s Manual Microprocessor DSP Sequence of Operation The following DSP Indicators should illuminate after primary power is applied gt D77 3 3V Supply gt D78 1 8V Supply gt D50 ISC Door gt D33 Coolant Level gt D37 Arc Hold if INOVA is being used gt D10 RS232 T1 Out Blinking gt D11 CAN RXD Dim Flashing gt D12 CAN TXD Dim Flashing The following DSP Indicators should illuminate when the OFF Button is released gt D40 OFF Button The following DSP Indicators should illuminate when the ON Button is activated gt U21 Opto Motor Solenoid gt U19 Opto Solenoid not used gt U26 Opto Fan gt D42 Plasma Ready The following DSP Indicators should illuminate when a START signal is applied begin cut cycle gt D36 Start gt U27 Opto Preflow gt U29 Opto Shield gt U24 Opto Surge only over 100 amps gt U23 Opto Contactor gt D24 PWM Chopper ON gt U22 Opto Pilot Arc Relay ON gt D43 PAT ON Blinks during a START gt U34 Opto ISC Blinks during a START The following DSP Indicators should illuminate with an arc transfer
35. S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 3 Section 6 Maintenance amp Troubleshooting Spirit II User s Manual Replacing the Torch Coolant and Filter A WARNING Do not touch the fans inside the cooling system Important Never turn on the system when the coolant reservoir is empty Important When handling coolant wear nitrile gloves and safety glasses Important Only use Kaliburn approved coolant Commercially available antifreeze contains corrosion inhibitors that will damage the cooling system See Section 2 for more information The torch coolant should be flushed out of the system every six months and replaced with new coolant Replace the coolant filter deionization cartridge at the same time SP ook dae Wn a 9 Remove primary power from the Spirit system Ensure the torch base and torch head with consumables are properly installed Ensure the coolant supply in and out hoses are properly installed Remove the coolant reservoir cap level gauge Remove the cover from the cooling system Connect a 3 8 ID hose and bucket to the drain petcock on the bottom of the reservoir Unscrew the petcock to drain the reservoir Leave the hose and bucket in place after the coolant drains out Remove the coolant supply hose coolant out from the rear of the cooling system Note that the coolant supply hose has right hand threads Be prep
36. SELECT the ON Button to energize the system After the gases set prepare to apply a start signal to the unit This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 11 Section 6 Maintenance amp Troubleshooting Spirit II User s Manual 8 With a start signal applied check the three phase voltage input to each chopper at the diode bridge terminals three screws on the left side of each chopper Refer to TABLE 1 for the proper three phase AC voltage Note that the system will only energize for approximately two seconds each time a start signal is applied If the voltage is not present check for primary voltage on the main contactor CON 1 and on the primary side of the power transformer Ole O o Diode Bridge Terminals 6 o O lA N OO Oo 6 ol o Jio Oi fo o Chopper PCB gt J1 Plug lt lt _ D2 Green LED is under J1 Plug Top View of Chopper 9 With a start signal applied che
37. TE 38 184 640 7 5 8 9 i Marking For All Material Thicknesses f Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 108 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 55 100 2540 130 3 3 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 32 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 400 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode BK284155 BK284158 BK284159 7 TP y Outer Cap Retaining Cap Swirl Ring Torch Head
38. Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 145 250 6350 147 3 7 100 2 5 0 Argon Air N A 50 25 N A 77 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 100 2 5 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 36 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 70 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 080 130 250 050 150 100 080 1 8 135 160 070 175 3 16 145 80 100 200 200 25 76 25 76 085 1 4 150 50 060 250 300
39. User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 70 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277150 BK277124 BK277132 4 f 9 Y j S M Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277113 BK277140 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 16 35 65 30 60 135 80 100 200 300 090 Metric Material y Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voitage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 5 35 65 30 60 135 2030 2 5 5 1 300 2 3 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 096 2 4 100 2 5 0 Argon Nitrogen N A 50 25 N A 80 100 2540 130 3 3 100 2 5 0
40. for Welding and Cutting of Containers and Piping obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 AWS Standard ULR Ultraviolet Reflectance of Paint obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 AWS ANSI Standard Z49 1 Safety in Welding Cutting and Allied Processes obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 ANSI Standard Z41 1 Standard For Men s Safety Toe Footwear obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 ANSI Standard 249 2 Fire Prevention in the Use of Cutting and Welding Processes obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 ANSI Standard 287 1 Safe Practices For Occupation and Educational Eye and Face Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 ANSI Standard Z88 2 Respiratory Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 OSHA Standard 29CFR 1910 252 Safety and Health Standards obtainable from the U S Government Printing Office Washington D C 20402 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the Unite
41. msec mm 6 158 2710 3 8 6 3 300 2 4 10 25 80 26 80 162 2210 4 6 7 0 500 2 5 12 165 1890 4 9 7 4 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 71 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 51 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 150 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 green o ring 2 6 pa y Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK279439 BK279060 Imperial Material Arc Travel Cutting Pie
42. other equipment being used in the environment is compatible this may require additional protection measures h the time of day that plasma cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Plasma cutting equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed plasma cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the plasma power source so that good electrical contact is maintained between the conduit and the plasma power source enclosure Maintenance of the Plasma Cutting Equipment The plasma cutting equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the plasma cutting equipment is in operation The plasma cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer
43. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 14 Spirit II User s Manual Section 7 Parts List Section 7 Parts List Power Supply BK300232 BK300239 Right Side View Item Part Number Quantity Description 4 BK707155 3 L1 L2 L3 Inductor 5 BK500557 2 T2 T3 Control Transformer 208 220 240 460 V 60 Hz BK706410 T2 T3 Control Transformer 600 V 60 Hz 6 BK706406 1 T1 Main Transformer 208 220 240 460 V 60 Hz 30 BK706503 T1 Main Transformer 600 V 60 Hz 30 15 BK709296 1 Strain Relief 30 BK708120 1 CON 1 Main Contactor 31 BK702076 1 EMI Filter 380 415 V units only 35 BK709251 2 TB5 3 Phase Input Power Terminal Block 38 BK300250 3 Chopper Assembly 44 BK200204 3 Fan 4 7 59 BK284031 2 Fan 10 60 BK500526 2 Fan guard Mounted Outside a M F a M 6 SS f J
44. re rene Ae aA Air or Nitrogen Shield gas types WINGS Se cteceerte tesserae settee redereeptbenieasdes Oxygen or Air Stainless Steel cccceeccceeeeeeeeeeeeeeeeeees Air or Nitrogen PRU IA eeens a Air or Nitrogen Preflow gas type vs c2 is ees te ac sxe pc eved ince cted eee Oxygen and Nitrogen Marking gas WWDG ace hehe ile eet eee te kets Nitrogen Plasma gas flow rate maximum OXJ oDer iiaea a aa EEEE 78 scfh 2209 liters hour Moe E ASIA ea E ha Bia ha alas a 67 scfh 1897 liters hour H17 or ANIL FOGS Mies ecatte See eth e te keds 106 scfh 3002 liters hour Shield gas flow rate maximum OXVOCM egiteticteirtintes a A 19 scfh 538 liters hour Asaa e a a ested 258 scfh 7306 liters hour Nitrogen tetra otis heey ivan ore OS sha ec 326 scfh 9231 liters hour Preflow gas flow rate maximum 60 scfh 1699 liters hour Marking gas flow rate maximum 06 89 scfh 2520 liters hour Rated Inlet gas PreSSUre ccceceeeeeeeeeeeeeeees 115 psi 7 9 bar Minimum Inlet gas PreSSUre ceceeeeeeeeeees 110 psi 7 6 bar Maximum Inlet gas PreSSUre cceeeeeeeeeeeeees 145 psi 10 0 bar Oxygen and nitrogen should be supplied with a purity of at least 99 5 H17 should be supplied with a purity of at least 99 995 A potential fire hazard exists when cutting with oxygen KALIBURN recommends that an exhaust ventilation system be used when cutting with oxygen Flashback arrestors must be supplied unless t
45. s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Plasma Cutting Cables The plasma cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 2 Spirit II User s Manual Appendix A Electromagnetic Compatibility EMC Equipotential Bonding Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to use
46. the requirements of the EAR 5 4 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Selecting Consumables Mild Steel Copper Electrode Outer Shield Inner Nozzle Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 a D BK277140 BK284150 BK277122 BK277142 BK277131 50A Q 9 6J op BK284150 BK277125 BK277142 BK277131 70A Q a Q op BK284150 BK277284 BK277283 BK277282 100A Q a OWD D BK277151 BK284150 BK277117 BK277152 BK277293 BK277139 BK277292 150A Q oy OD OD D BK284150 BK277289 BK277143 BK277291 200A 9 LHD BK284150 BK277269 BK277258 BK277270 275A Q 9 O op BK284150 BK284125 BK284122 BK284124 BK279100 400A Q 9 D y y N This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 5 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel Silver Electrode Outer Shield Inner Nozzle Swirl Silver Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK27941 BK284150 BK277286 BK277151 BK279484 BK279483 fenton BK279060 m O
47. to the shield gas fitting on the torch base 2 Connect the other end of the 7 5 foot 2 3 m shield gas hose to the shield gas outlet on the 5 gang manifold 17 Inch Plasma Gas Hose E 1 Route one end of the 17 inch 432 mm plasma gas hose through the torch handle and connect to the plasma gas fitting on the torch base 2 Thread the torch handle onto the torch base being careful not to twist the torch leads and gas hoses when tightening the torch handle 3 Tighten the base to the handle using a pin style adjustable spanner wrench fits 2 diameter with 1 4 diameter pin 4 Attach the 2 gang manifold assembly to the torch handle The top of the manifold bracket should be flush with the top of the torch handle 5 Connect the other end of the 157 inch 432 mm plasma gas hose to the plasma gas outlet on the 2 gang manifold 6 Mount the torch handle base manifold to the positioner Note the alignment indicators on the torch base slot and torch head circle These aid in aligning the quick disconnect torch base and head and should be oriented so they are clearly visible when the operator is changing heads Foot Preflow Postflow Marking Gas Hose 22 Connect one end of the 6 foot 1 8 m preflow postflow marking gas hose to the preflow postflow marking outlet on the 5 gang manifold 2 Connect the other end of the 6 foot 1 8 m preflow postflow marking gas hose to the preflow postflow marking inlet on the 2 gang manifold sig G
48. unit on a weekly basis Verify the ground and primary three phase A C voltage connections are tight Verify all PC board connectors are installed securely Verify all rear cable connectors are installed securely Verify the electrode lead and work ground lead are secure and free from corrosion Cooling System 1 2 Remove the cover on the cooling system Check the torch coolant filter deionization cartridge and replace if dirty Flush the cooling system every six months and replace the coolant and coolant filter deionization cartridge This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 1 Section 6 Maintenance amp Troubleshooting Spirit II User s Manual Manual Gas Console MGC 1 Remove the cover of the manual gas console Using clean dry compressed air blow out all accumulated dust inside the unit In an excessively dirty environment blow out the unit on a weekly basis 2 Verify that all PC board connectors are installed securely 3 Verify that all gas hose connectors are tight and that there are no leaks Only tighten the gas fittings enough to make a gas seal The fittings are subject to damage if over tightened Inspect all gas hoses to ensure no damage exists Immediately replace any
49. 0 Coolant Flow Low Coolant flow is low 10190 Coolant Flow High Coolant flow is high 10220 Coolant Temperature High The coolant temperature is high 10290 GC Quiet Lost CAN communication with Gas Console 10300 PC Quiet Lost CAN communication with Plasma Console 10320 FCC Invalid Final Cut Current invalid 10330 PAC Invalid Pilot Arc Current invalid 10340 AH IHS Timeout Arc Hold for Initial Height Sense has timed out 10350 PAT Not Established Pilot Arc Current not established within 2 seconds 10360 TAC Not Established Transferred Arc Current not established within 2 seconds 10370 Current Unbalanced Current is not balanced between chopper assemblies 275A and 400A systems 10380 TAC Lost 1 Transferred Arc lost during TAC hold time 10390 TAC Lost 2 Transferred Arc lost during Upslope 10400 TAC Lost 3 Transferred Arc lost during Cutting 10410 TAC Lost 4 Transferred Arc lost during Downslope 10420 FCC Unreached Did not achieve final cut current 10430 Output Over Current Chopper has exceeded its maximum rated current 10432 Output Over Current TZ Instantaneous Over Current detected 10440 Output Over Voltage Maximum Cutting Voltage has been exceeded 10450 Start Premature Removal Start Signal removed prior to completion of upslope 10461 Chopperi Temp Chopper 1 maximum operating temperature exceeded 10462 Chopper2 Temp Chopper 2 maximum operating temperature exceeded 10463 Chopper3 Temp Choppe
50. 0 Amps Air Nitrogen Page 5 24 Stainless Steel 100 Amps H17 Nitrogen Page 5 25 Stainless Steel 100 Amps Air Nitrogen Page 5 26 Page 5 48 Stainless Steel 150 Amps H17 Nitrogen Page 5 27 Stainless Steel 150 Amps Air Nitrogen Page 5 28 Page 5 49 Stainless Steel 200 Amps H17 Nitrogen Page 5 29 Stainless Steel 200 Amps Air Nitrogen Page 5 30 Page 5 50 Stainless Steel 260 Amps H17 Nitrogen Page 5 31 Stainless Steel 275 Amps Air Nitrogen Page 5 32 Stainless Steel 400 Amps H17 Nitrogen Page 5 33 Stainless Steel 400 Amps Nitrogen Air Page 5 34 Aluminum 30 Amps Air Nitrogen Page 5 35 Aluminum 50 Amps Air Nitrogen Page 5 36 Aluminum 70 Amps Air Nitrogen Page 5 37 Aluminum 100 Amps Air Nitrogen Page 5 38 Page 5 51 Aluminum 150 Amps Air Nitrogen Page 5 39 Page 5 52 Aluminum 200 Amps Air Nitrogen Page 5 40 Page 5 53 Aluminum 275 Amps Air Nitrogen Page 5 41 Page 5 54 Aluminum 400 Amps Nitrogen Air Page 5 42 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 12 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 30 Amps Oxygen Plasma Oxygen Shield Copper Electrode
51. 0570 1 Postflow Regulator 0 125 PSI 11 BK300414 1 Manifold Block Gas Inputs i OOA EA Ore This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 6 Spirit II User s Manual Section 7 Parts List Impulse Start Console BK300505 Item Part Number Quantity Description 1 BK715051 2 Coolant Return Fitting left hand 2 BK715050 1 Coolant Supply Fitting right hand 3 BK715021 1 Coolant Supply Fitting right hand 4 BK709001 1 4 Pin Receptacle 5 BK708057 1 Door Interlock Switch 6 BK500503 1 Cathode Manifold T BK980200 1 Printed Circuit Board PCB Impulse Start 8 BK980201 1 Impulse Start Manifold 9 BK707300 1 Inductor 3 6 7 8 5 This information is subject to the controls of th
52. 1 PAT MOTION PLASMA RDY 3 PHAC SEE EE j J15 J14 1 J1 gA A s00 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 17 Section 7 Parts List Spirit II User s Manual Power Supply Microprocessor DSP BK300101 Quadrant 3 Oa a H aa aa E Oia q i m SEEN oeae T ollollo llo N NI BLANK PCB P N 300100 REV A J18 J11 z ASSEMBLY P N 300101 p p m SS a a3 2 PRESS AUXI3 AUX I2 AUX J1 RHF LEVEL Cra OTe D52 LD C Teeth umu na ng EFES ili C gega gn ge ge ge ge eL boi a g ee KALIBURN c e G o This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 18 Spirit II User s Manual Section 7 Parts List Power Supply Microprocessor DSP BK300101 Quadrant 4 IF i lee ore ig PCB Quadrant Map
53. 11 Fuse Holder 53 BK300153 1 Off Relay 54 BK300156 1 Off Relay Socket 55 BK701165 2 R1 R2 Resistor 300W 3 Ohm 56 BK701141 1 R3 Resistor 300W 2 Ohm 57 BK701083 3 Resistor Mounting Hardware C G0 Go This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 2 Spirit II User s Manual Section 7 Parts List Power Supply BK300232 BK300239 Top View Item Part Number Quantity Description 1 BK501163 1 Light Housing 2 BK501 164 1 Bulb 3 BK501162 1 White Lens 5 BK500557 2 T2 T3 Control Transformer 208 220 240 460 V 60 Hz BK
54. 168 105 190 350 600 165 3 4 20 73 65 75 172 85 200 800 i 1 00 180 60 240 c l 400 170 1 25 185 45 260 1000 1 50 190 25 270 180 Metric Material P Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 160 3930 4 1 7 1 N 500 4 1 12 163 3375 4 4 7 4 1 1 264 4 6 68 645 8 8 9 800 42 20 20 73 65 75 173 2055 5 3 25 179 1565 6 0 ____ N 10 2 4 3 322 185 1120 6 6 1000 38 189 645 6 8 4 6 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 108 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 56 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 275 7 0 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of th
55. 277139 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in Retaining Cap BK277151 1 4 118 165 105 200 300 125 3 8 20 71 30 69 123 125 135 250 400 i 1 2 125 90 140 300 500 130 Retaining Cap BK277152 5 8 127 70 140 325 600 130 3 4 130 55 i 350 1000 135 1 20 71 45 69 134 40 150 400 1 25 145 25 200 350 1500 140 1 50 155 15 225 350 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm Retaining Cap BK277151 6 117 4305 2 6 4 9 300 32 10 20 71 30 69 123 3040 3 4 6 5 500 i 12 124 2485 3 5 7 3 3 3 Retaining Cap BK277152 16 127 1760 56 8 3 1000 3 3 20 130 1340 i 9 0 3 4 25 20 71 45 69 133 1040 3 7 10 1 1500 32 145 625 5 1 8 9 3 6 38 154 385 5 6 8 9 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 61 100 2540 100 2 5 100 2 5 0 Use an arc transf
56. 277152 5 8 127 70 140 325 600 130 3 4 130 55 f 350 1000 135 1 20 71 45 69 134 40 150 400 1 25 145 25 200 350 1500 140 1 50 155 15 225 350 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm Retaining Cap BK277151 6 117 4305 2 6 4 9 300 32 10 20 71 30 69 123 3040 3 4 6 5 500 j 12 124 2485 3 5 7 3 3 3 Retaining Cap BK277152 16 127 1760 ais 8 3 1000 3 3 20 130 1340 i 9 0 3 4 25 20 71 45 69 133 1040 3 7 10 1 1500 3278 145 625 5 1 8 9 3 6 38 154 385 5 6 8 9 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 61 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any m
57. 3 8 155 40 075 275 400 090 1 2 162 30 115 300 500 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 2 12 4 1 2 WA 3 ene 3 100 2 0 3 134 4420 1 7 4 3 145 1920 2 3 5 2 3 25 76 25 76 300 2 2 6 148 1440 1 7 6 1 10 156 975 2 0 7 0 500 2 3 12 160 820 2 6 7 4 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 096 2 4 100 2 5 0 Argon Air N A 50 25 N A 69 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 37 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 100 Amps Air Plasma Nitrogen Shield Copper Electrode
58. 5 1 4 117 75 i 225 400 087 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm Cold Rolled Steel Oxygen Shield Swirl Ring BK277140 2 5 121 1895 2 9 100 1 9 25 74 12 72 3 4 3 125 1555 3 1 200 2 0 Hot Rolled Steel Air Shield Swirl Ring BK277142 2 5 4885 100 1 9 106 2 5 3 4 3 4660 200 2 0 25 74 19 72 113 2555 5 1 3 6 400 2 2 6 116 2075 5 5 Marking For All Material Thicknesses F Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 145 250 6350 147 3 7 100 2 5 0 Argon Air N A 50 25 N A 71 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 135 3 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 14 Spirit II User s Manual Section 5 Torch Consumables and
59. 50 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 138 4205 3 6 7 3 500 3 8 16 145 3405 3 3 8 9 800 3 9 20 2700 3 4 10 5 1000 4 1 25 149 2200 4 0 12 5 4 6 32 155 1500 4 4 15 3 1500 48 38 159 1275 5 6 17 7 2000 i 45 30 79 70 76 162 995 6 6 20 5 3000 5 1 50 164 860 6 8 25 4 4500 5 3 55 168 620 6 9 11 9 1000 6 0 60 175 450 7 2 1300 62 65 182 365 7 7 8 9 1500 3 70 185 300 8 3 75777 193 220 8 7 2009 at Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 112 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 53 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to th
60. 69 162 2430 5 5 7 4 3 3 16 170 1630 8 3 3 4 6 4 1200 20 170 990 9 0 3 6 Marking For All Material Thicknesses F Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 69 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 39 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 200 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277274 BK277289 BK277291 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277143 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shie
61. 7 2 3 Section 2 Specifications Spirit II User s Manual Cooling System Specifications Part NUMber w 2 8 05 625 6 onto deck Oendedhseandereaeae dds BK300275 Discharge pressure ecceeeeeeeeeeeeeeeeeeees 150 psi 10 2 bar FloW rato n sede sities a aR acta E ceded 2 1 gal min 7 9 liters min Coolant uid arigua irana eee Propylene glycol solution Coolant tank Capacity ceeeeeeeeeeeeeeeeeeeeeeeee 3 2 gal 12 liters Weight aai a athe lett cd a dahil tate Seabee ER aS 141 lb 64 kg without coolant pasi BKALIBURN i N e i A N f A h N 36 0 914 8 i N h A N h A N in 23 0 584 15 8 401 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 4 Spirit II User s Manual Section 2 Specifications Torch Coolant Specific
62. 706410 T2 T3 Control Transformer 600 V 60 Hz 7 BK709359 1 F3 Fuse 5A Slow Blow 8 BK709358 1 F4 Fuse 5A Medium Blow 9 BK709358 1 F5 Fuse 5A Medium Blow 10 BK709360 1 F6 Fuse 6 3A 11 BK709360 1 F7 Fuse 6 3A 13 BK709061 4 F1A F1B and F2A F2B Fuse Holder 14 BK709128 4 F1A F1B and F2A F2B Fuse FNM 6 25A 38 BK300250 3 CA1 CA2 CA3 Chopper Assembly 41 BK708103 1 Fan Relay 42 BK708104 1 Relay Socket 43 BK708105 2 Relay Hold Down Clip z Im 5 o e o o alels Orn eF TOT SOG e K F3 F4 F5 F6 F7 pos 1 pos 4 pos 12 pos 17 pos 19 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requireme
63. Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277263 BK277269 BK277270 x p ay z 4 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277258 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 125 140 300 500 139 165 5 8 105 135 325 600 3 4 138 90 120 350 800 170 1 144 65 160 400 1000 185 1 25 150 45 175 500 f 20 81 70 79 1 50 163 25 235 1 75 170 20 290 350 190 1500 2 00 180 15 350 2 25 185 13 375 375 260 2 50 190 9 385 385 275 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 139 3290 3 6 7 4 500 a3 16 138 2650 3 3 8 3 800 2 21 A 4 0 90 3 9 0 1000 3 25 143 1690 4 0 10 1 iz 32 150 1120 4 4 12 8 j 20 81 70 79 38 162 645 5 9 45 170 495 7 5 8 9 4 8 1500 50 178 395 8 7 55 183 345 9 2 9 2 6 6 60 187 285 9 6 9 6 6 9 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas
64. Control Cable and ISC Ground Connections Perform the following steps to connect the ISC control cable and ISC ground See Figure 5 on the next page ISC Control Cable 1 Connect the ISC control cable plug labeled P16 to the connector labeled P16 on the rear of the power supply 2 Connect the ISC control cable plug labeled P1 to the connector labeled P1 on the impulse start console ISC Ground Cable 6 1 Connect one end of the ISC ground cable to the ground stud on the impulse start console 2 Connect the other end of the ISC ground cable to the star ground on the cutting table Make sure that good metal to metal contact is made Cooling System Connections Perform the following steps to connect the cooling system to the power supply and the impulse start console See Figure 5 on the next page Coolant Supply Hose 1 Connect one end of the coolant supply hose to the coolant out fitting on the rear of the cooling system Note that the coolant out fitting has right hand threads 2 Connect the other end of the coolant supply hose to the coolant in fitting on the impulse start console Note that the coolant in fitting has right hand threads Coolant Return Hose 1 Connect one end of the coolant return hose to the coolant in fitting on the rear of the cooling system Note that the coolant in fitting has left hand threads 2 Connect the other end of the coolant return hose to the coolant out fitting on the impulse start console
65. I User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 100 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 brown o ring 2 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 150 090 200 300 3 8 130 100 130 250 400 090 1 2 25 83 26 81 65 155 300 500 5 8 143 47 325 800 185 095 3 4 145 35 350 1000 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 3950 2 1 4 9 300 10 2405 3 3 6 5 2 3 130 _ _ ____ 500 12 25 83 26 81 1850 3 7 7 3 16 143 1180 8 3 N 47 1000 2 4 20 145 800 9 0 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0
66. ITTI This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 8 Spirit II User s Manual Section 7 Parts List Shielded Torch Leads Part Number Length BK284304 XX_ Where XX is the length in feet Available in 5 foot increments up to 40 feet Bry CAN Communication Cable and Termination Plug Item Part Number Length CAN Termination Plug BK300408 N A CAN Cable BK300177 XX Where XX is the length in feet Available in 5 foot increments Manifold Control Cables Item Part Number Length 2 Gang Manifold BK280312 XX Where XX is the length in feet 5 Gang Manifold BK280321 XX Available in 5 foot increments 2 GANG MANIFOLD CONTROL CABLE POWER SUPPLY i ie i 5 GANG MANIFOLD CONTROL CABLE i 2 GANG MANIFOLD POWER SUPPLY 5 GANG MANIFOLD This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contr
67. K277146 BK277126 BK277133 E N 9 1H I J Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277113 BK277141 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 16 138 115 105 200 300 100 1 4 28 72 40 67 140 100 125 225 400 105 3 8 152 65 180 250 500 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 5 138 2865 2 7 5 1 2 5 28 72 40 67 400 6 139 2625 3 0 5 5 2 7 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 80 100 2540 110 28 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall n
68. L E l T l l l Ka lt Ka l l 1 barr tt tt tt L J RV16 RV17 RV9 RV10 RV12 RV11 CG oo H GH GH OG G G R166 D72 FD2 J31 J28 PLAN J31 i i or i i N2 SHL O2SHL N2 SHL O2SHL H17 PLM AIRPLM N2PLM O2PLM EXFAN This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 23 Section 7 Parts List Spirit II User s Manual Gas Supply Microprocessor DSP BK300301 Quadrant 3 J19 I L J20 LI L J21 J19 J20 J21 ist a a o z MH3 o o S Q H E D2 K D1 F D1 E D E 026 D2 E Dee 29 ce7 EMI18 g gt o to oO pe a N o a a e C86 t oO a Oo n oo o o os Ym ooga Hgv Dang a o l Sre ee28 46 8 e5 LJ orgo POR Ree E Sgro LJ ores 8 BRE I g x l i m A 30 C84 C77 D17 C75 mm w Soot N ops u12 gye ont og mo N U14 Beg ory co FERRED FBG cns 2RERB EED SregB PBE B l Sio ie g Swi R25 L2 DE C105 g Uy OOK LJ Oo E EANA l2 3 E 7 8 Ee 22 2 r2 CI R183_ R40 i PTS J17 t D res C gL c sis R182 R42 Ri i ra L E LJ R43 C163 Q L37 TP14 fes C10
69. Note that the coolant out fitting has left hand threads Cooling System Control Cable 9 1 Connect the cooling system control cable plug labeled P14 to the connector labeled P14 on the rear of the power supply 2 Connect the cooling system control cable plug labeled P1 to the connector labeled P1 on the cooling system Cooling System Ground Connection Customer Supplied The Cooling System must be connected to protective earth ground in accordance with national or local codes The Cooling System receives its power from the plasma power supply and as such must be connected to the same protective ground as the plasma power supply Use a minimum of 8 AWG 10 mm wire connected from the cooling system grounding stud to the plasma power supply protective earth ground Note the customer must supply grounding wire This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 9 Section 3 Installation Spirit II User s Manual r H itt alre 44 Figure 5 Cooling System Connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons o
70. On the MGC main menu move the pointer to On Press SELECT to start the coolant pump circulating coolant through the system Note The coolant pump will turn off automatically if the coolant level drops below the minimum level inside the reservoir If this happens add more coolant 10 With the coolant pump running locate the small red push button on top of the coolant filter housing Press and hold the red button until no air or bubbles are seen inside the filter housing Dry any coolant that leaks out 11 Check for coolant leaks at all hose connections the impulse start console and at the torch 12 Push the OFF Button on the MGC to stop the coolant pump 13 Remove primary power from the Spirit system 14 Fill the reservoir with coolant until the coolant gauge indicates full 15 Replace the cooling system cover and replace the coolant reservoir cap level gauge 16 End of procedure This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 20 Spirit II User s Manual Section 4 Operation with Manual Gas Console Section 4 Operation Operating the Manual Gas Console MGC The Manual Gas Console MGC is the interface to the entire Spirit system when the MGC is used instead of the Automatic Gas Console AGC OFF Button
71. P O Op a o BK284150 BK277117 BK279493 BK279439 gine 150A Q a OP D BK284150 BK279489 BK279443 B 200A Q a D D BK284150 BK279469 BK279458 Nee 275A Q 9 D D BK284150 BK284125 BK279422 a ee bay 400A Q 9 Cp D This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 6 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel H17 Plasma Copper Electrode Outer Shield Inner Nozzle Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK284150 BK277150 BK277113 BK277124 BK277140 BK277132 BK279100 70A Q 9 6 BK2841 50 BK277126 BK277141 100A 9 BK 50 BK277297 BK277139 150A Q 9 BKB 50 BK277287 BK277259 200A Q 9 O BKB 50 BK277118 BK277139 zi Q D BK 50 BK284158 BK284122 400A Q 9 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 7 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel Air or Nitrogen Plasma Copper Electrode
72. Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 108 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 54 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 19 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 400 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK284123 BK284125 BK284124 m 5 P 9 D 3 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK284121 BK284122 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in i
73. Push to disable the Spirit system Release turn to the right to enable the system which can then be energized by choosing ON and then SELECT Up Down Select Buttons Press the up or down button to move the pointer F accordingly on the display These buttons are represented as UP and DOWN throughout this manual Press the select button to access menu items or settings identified by the pointer This button is shown as SELECT throughout this manual Display The display turns on automatically when AC power is applied to the Spirit system It displays the menu tree which is navigated using the Up Down Select buttons and is used to control the entire Spirit system Pressure Regulator Knobs Turn to the left or right to adjust the amount of output gas pressure for PreFlow PostFlow Plasma and Shield gases This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 1 Section 4 Operation with Manual Gas Console Spirit II User s Manual Setting up to Cut The following procedure uses the information from the cutting charts in Section 5 to prepare the system to cut Press the UP or DOWN button on the MGC to move the pointer throug
74. S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 4 Spirit II User s Manual Section 8 Internal Inova Console Option Location in Spirit II 400 SRA NI Ss Wy 546 F7 F8 pos A pos B This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 5 Section 8 Internal Inova Console Option Spirit II User s Manual Location in Spirit Il 400 Continued This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 6 Spirit II User s Manual Appendix A Electromagnetic Compatibility EMC Appendix A Electromagnetic Compatibility EMC Background The 380V 50 60Hz and 415V 50 60Hz CE marked Spirit plasma cutting systems are manufactured to comply with the European standard EN 60974 10 Electromagnetic compatibility EMC Product standard for arc welding equipment The sys
75. SITION NO TERMINAL BK709018 SOCKET 1 RED _ 3 BK709365 PIN 2 BLACK _ 4 7 3 WHITE 12 4 BLACK 14 5 GREEN 10 6 BLACK 11 BK709365 PIN BK709018 SOCKET 8 BK709019 KEY 9 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 13 Section 7 Parts List Spirit Il User s Manual FII Cable for Optional Internal Inova Part Number Length BK300903 XX Where XX is the length in feet Available in 10 foot increments INOVA CONSOLE BURNY PHANTOM IP4 28 POS 11 RECP PLASMA CONTROL 37 POS CABLE BK711002 Note Add Label ae Wired for Phantom Controller PLUG BK709364 STRAIN RELIEF BK709025 PLUG BK709095 STRAIN RELIEF BK709021 TERMINAL POSITION NO COLOR POSITION NO TERMINAL BK709365 PINS 1 cs GREEN 12 BK709018 SOCKET 2 BLACK 18 22 3 WHITE 21 4 BLACK 15 5 RED 2 6 ta Si 1 BK709018 SOCKET 23 7 YELLOW XX 8 BLACK XX 9 cis BLUE XX 10 BLACK XX 24 11 BROWN xX BK709365 PINS 12 BLACK xx JUMPER 22 BK709018 SOCKET BK711005 28 BK709018 SOCKET This information is subject to the controls of the Export Administration Regulations EAR This information shall no
76. Spirit II User s Manual Gas Supply Microprocessor DSP BK300301 Quadrant 1 Ll R E z awe T PCB Quadrant Map E This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 22 Spirit II User s Manual Section 7 Parts List Gas Supply Microprocessor DSP BK300301 Quadrant 2 PCB Quadrant Map r OTs OR a ce R253 L Rear TP50 Ta a2 o a E R248 C cs WOU NC CANL CANH TP47 C44 R4 RS R269 pas FF koo PLU kioo RAT pigs RSL i a is C ro 0 s n sO LILI ILI A oo ES oe oe TET HCRECERGE u42 C155 R277 R276 R282 R281 R158 R106 R159 R109 R160 R112 R162 R110 R161 R114 R163 a 2 9 z L R278 R283 R192 et na OH R196 DH R279 R284 R207 R208 2 2 T oe R206 LH on a a R210 35 LHe Z gt 0 amp J a Lo FS r z i Sje G i E fo l 2 C188 C189 C171 C172 C175 C176
77. TP33 R221 8 EMi4 Q cot FT i H R220 C110 L5 uaa R21 arr SRR IN GG U E u3 R20 o 5 ao of OO AA aaa p 00an og soaa bo S45 ron ND NNI EMI2 R171 C159 D N oO a sel N c28 R5 8 mm 3 ot TP11 TP10 CUCL TT 1 3 c63 cet 1 u10 L34 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 24 Spirit II User s Manual Section 7 Parts List Gas Supply Microprocessor DSP BK300301 Quadrant 4 Pae eee PCB Quadrant Map is a ae U nN S l A Q g sl Li az Be 4 D D JNF D2 PVP R103 R157 R100 R156 Laa N a E N E a o E a D5 EMI PV MP amp o a no a pi 1 E Ct LINCOLN ELECTRIC J18 FD3 BLANK PCB P N 300300 REV C H J18 ASSEMBLY P N 300301 I M so H O2 EN H17 EN N2 M SHL N2 M OUT 02 MIX N2 MIX AIR SHL This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to t
78. age Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 125 140 300 500 139 Nl 165 5 8 105 135 325 600 3 4 138 90 120 350 800 170 1 144 65 160 400 1000 185 1 25 150 45 175 500 20 81 70 79 1 50 163 25 235 1 75 170 20 290 350 190 1l 1 1500 2 00 180 15 350 2 25 185 13 375 375 260 2 50 190 9 385 385 275 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 139 3290 3 6 7 4 500 43 16 138 2650 3 3 8 3 800 i 20 2190 3 1 9 0 4 3 1000 25 143 1690 4 0 10 1 A 32 150 1120 4 4 12 8 f 20 81 70 79 38 162 645 5 9 45 170 495 7 5 8 9 4 8 1500 50 178 395 8 7 5517 183 345 9 2 9 2 6 6 60 187 285 9 6 9 6 6 9 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 108 250 6350 100 25 100 2 5 0 Argon Air N A 50 25 N A 54 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on sys
79. ainless Steel 150 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 S cm 7 J j iH Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK277139 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 150 160 250 400 125 3 8 150 115 180 275 500 i 1 2 20 71 70 69 155 85 210 300 600 130 5 8 160 60 220 325 800 3 4 168 45 240 350 1200 135 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 144 3910 4 0 6 3 400 3 2 10 150 2805 4 7 7 0 600 12 20 71 70 69 153 2330 5 1 7 4 33 16 160 1510 5 6 8 3 800 i 20 170 1030 6 2 9 0 1200 3 4 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitr
80. alth Support EQUIDING Mixed sites iieii iiai a a aieea a a ai Aaa 1 4 Safety Standards Booklet IndeX sc s ecetn seetienGueneonenw aie 1 5 Section 2 Specifications System Description seciet Fal eedioisteeeproeks teen bite pease atone beie as wtaoehnee reminders aed 2 1 System COMP NA S r aia tat aiietel aldiat titel E A 2 2 Power Supply Specifications cccccceeeeeeceeceneeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeneeeeeeeeees 2 3 Cooling System Specifications cccccccceeeeeeeseeeecceeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeeesaeees 2 4 Porch GoOolanit Specification Sissi i 2 5 Manual Gas Console MGC Specifications ceceeeeeeeeneeeeeeeeeeeeeeeeetteeeeeeeees 2 6 Gas Supply Requirement cccccceeeeeeeeeeeneceeeeeeeeeeeeeeeeaaeaeeeeeeeeeeeeensaaeees 2 7 Impulse Start Console ISC Specifications cceeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeee 2 8 Torch and 2 Gang Manifold Specifications ccccceceeeeeeeeeeeeeeeenteeeeeeeeeeeeeees 2 9 5 Gang Manifold SOSCHICAUOMS sities sts cscs acess dude cend tucedvedcotsauas Oucedwestvdeceaddudtass 2 10 Airborne Noise Emissions ino cee ake a oh the aE he aie enn 2 11 Section 3 Installation Initial MISS CUOM irnn ra coccaasevesnces a presecnsa success EEan pE 3 1 Component Placementizsccn ctu set ctssteei oa e a a a aaa a 3 1 System Interconnection 0 eeeeeeeeececee cece eeeeeeeeaaeeeeeeeeeeeeeeeeaaaeeeeeeeeeeeeeeenaeees 3 2 Power Supply Primary Power Connection
81. any location outside the United States contrary to the requirements of the EAR 5 52 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 200 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277274 BK279489 BK279440 yellow o ring ji y Ai fa D sg Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK279443 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 150 190 135 250 300 150 3 8 155 145 140 275 400 l 1 2 110 300 500 20 74 58 72 t 135 N L155 5 8 160 95 350 600 3 4 65 150 400 800 160 1 0 175 35 200 f 1000 170 Metric Material 7 Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 149 4955 3 3 6 3 300 38 10 3545 3 5 7 0 i 155 N 500 12 2995 7 4 20 74 58 72 3 4 3 9 16 160 2380 8 9 800 20 162 1575 3 9 4 1 10 2 1000 25 174 940 5 0 4 3 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height
82. ared for some coolant to escape from the fitting on the cooling system and from the supply hose Blow compressed air 100 psi maximum into the coolant supply hose This will force the remaining coolant from the torch torch leads and supply hose into the reservoir and out of the drain petcock Continue until coolant stops flowing into the bucket Tighten the drain petcock and remove the hose and bucket 10 Unscrew the coolant filter housing and remove the coolant filter deionization cartridge Install a new coolant filter deionization cartridge and replace the coolant filter housing Dry any leaked coolant 11 Reconnect the coolant supply hose on the rear of the cooling system 12 Follow all of the steps in Filling the Cooling System in Section 3 of this manual to complete this procedure This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 4 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting Microprocessor DSP Status Indicators The microprocessor DSP board controls all of the functions of the Spirit power supply It contains diagnostic LEDs and OPTO LEDs which aid in troubleshooting the system These indicators illuminate when a particular event occurs Illuminated LEDs indicate the foll
83. ary to the requirements of the EAR 7 9 Section 7 Parts List Spirit II Users Manual Gas Hose Package with MGC Part Number Length BK300085 20 20 ft 6 1m BK300085 30 30 ft 9 1m BK300085 40 40 ft 12 2m BK300085 50 50 ft 15 2m BK300085 60 60 ft 18 3m Custom lengths are available Contact factory PREFLOW HOSE MGC 5 GANG MANIFOLD SHIELD HOSE MGC 5 GANG MANIFOLD PLASMA HOSE i MGC RED 2 GANG MANIFOLD POSTFLOW HOSE MGC 3_ 5 GANG MANIFOLD MARKING HOSE MGC 5 GANG MANIFOLD 7 5 FOOT SHIELD HOSE 5 GANG MANIFOLD BLUE TORCH 6 FOOT PREFLOW POSTFLOW MARKING HOSE GREEN ae 2 GANG MANIFOLD 5 GANG MANIFOLD an Cooling System Control Cable Part Number Length BK300276 10 10 ft 3 0 m COOLING SYSTEM POWER SUPPLY This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 10 Spirit II User s Manual Section 7 Parts List Coolant and Power Leads
84. as Hose 3 Connect one end of the marking shield gas hose to the marking shield outlet on the rear of the MGC 2 Connect the other end of the marking shield gas hose to the marking shield inlet on the 5 gang manifold This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 14 Spirit II User s Manual Section 3 Installation Postflow Gas Hose 25 1 Connect one end of the postflow hose to the postflow outlet on the rear of the MGC Note that the postflow hose fittings have left hand threads 2 Connect the other end of the postflow hose to the postflow inlet on the 5 gang manifold Plasma Gas Hose 1 Connect on end of the plasma hose to the plasma outlet on the rear of the MGC 2 Connect the other end of the plasma hose to the plasma inlet on the 2 gang manifold Shield Gas Hose 7 1 Connect one end of the shield hose to the shield outlet on the rear of the MGC 2 Connect the other end of the shield hose to the shield inlet on the 5 gang manifold Preflow Gas Hose 1 Connect one end of the preflow hose to the preflow outlet on the rear of the MGC Note that the preflow hose fittings have left hand threads 2 Connect the other end of the preflow hose to the preflow inlet on the 5 gang manifold 5 Gang Manifo
85. at to return to the main menu Adjusting the Screen Contrast The contrast of the display on the MGC can be adjusted as described below On the main menu move the pointer to Configure Press SELECT Setup On Errors Input Gaz Version Configure Move the pointer to Contrast Press SELECT to cycle through the list of PCortast 20 contrast settings Languages Move the pointer to Return and press SELECT to return to the main menu This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 8 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Section 5 Torch Consumables and Cutting Charts Installing Removing the Torch Head A WARNING Remove primary power from the Spirit system 1 Each time the torch head is connected to the torch base use a cotton swab to apply a small amount of o ring lubricant on each of the seven o rings on the top of the torch head Reminder do not use an excessive amount of o ring lubricant 2 Align the indicator on the torch head circle with the one on the torch base slot 3 Apply enough upward force to engage the threads while tightening the attachment ring Turn the attachment ring to the RIGHT to tighten K
86. ation shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 31 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 275 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277263 BK277276 BK277270 R 9 C y Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277258 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 143 120 125 300 600 165 5 8 148 90 140 350 800 i 3 4 152 80 180 400 1200 20 73 70 75 170 1 0 165 55 210 450 1 25 175 35 250 350 1500 180 1 50 185 25 300 350 i Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 141 3220 3 1 7 3 600 a 16 148 2275 3 6 8 9 800 i 20 153 1940 4 7 10 3 20 73 70 75 4 3 25 164 1435 5 2 11 3 1500 32 175 880 6 4 8 9
87. ations Note Refer to the supplier s most current Material Safety Data Sheet for information regarding safety handling and storage of torch coolant The Spirit system is shipped without torch coolant in the reservoir Coolant must be added before applying power to the system Only use Kaliburn approved torch coolant solution for optimal system performance as commercially available antifreeze contains corrosion inhibitors that will damage the cooling system The standard coolant solution consists of 25 industrial grade propylene glycol and provides freezing protection down to 13 C 9 F The standard solution can be ordered in one gallon containers PN 500695 For operating temperatures below 13 C a 50 solution of industrial grade propylene glycol can be ordered in one gallon containers PN 500895 providing protection down to 36 C 33 F Failure to use the proper propylene glycol solution may result in cooling system and or torch damage The torch coolant should be flushed out of the Spirit system every six months and replaced with new coolant The coolant filter deionization cartridge should also be changed at the same time See Section 6 for details This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 5 S
88. ble The star ground point is generally referred to as the common ground point on the cutting table where all subsystems of the machine are grounded This point is then connected to a driven earth ground rod that should be as close as possible to the star ground The ground rod should have no other wires connected to it The ground rod should be at least 3 4 inches in diameter and should be driven into the earth s permanent moisture layer The length of the ground rod varies from installation to installation and should be installed according to local and national codes Refer to the National Electrical Code Article 250 Section H Ground Electrode System for additional information This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 7 Section 3 Installation Spirit II User s Manual EN Strain Relief Figure 4 Power Supply Output Connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 8 Spirit II User s Manual Section 3 Installation ISC
89. ch and arc current cutting level acceptable noise levels may be exceeded Proper ear protection should be used as defined by local or national codes The following chart gives the noise levels generated by the system when operating at 400 amps 205 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound Pressure Level C Weighted Sound Pressure Level 1 meter horizontal 1 6 meters above the workpiece 120 dB 115 dB The maximum noise level is 131 dB at a distance of 3 inches 76 2 mm from the torch while cutting at 400 amps 205 arc volts This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 11 Section 2 Specifications Spirit II User s Manual BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 12 Spirit II User s Manual Section 3 Installation Section 3 Installation Initial Inspection All systems undergo full testing before being shipped from Kaliburn In the unlikely event that one of the components is defectiv
90. chopper PCB c Leave the OFF Button pushed in d With a digital voltmeter measure the following voltages on the J1 plug J1 5 ground to J1 1 15vdc Supply J1 5 ground to J1 2 5vdc Supply J1 5 ground to J1 3 5vdc PWM Signal If ALL of the voltages are present replace chopper If any of the voltages are not present go to step 13 13 Remove primary power from the Spirit system Check cable continuity between the chopper PCB and DSP PCB Use a digital voltmeter set up to read resistance ohms and make the following measurements Chopper 1 J1 1 to DSP J7 1 Chopper 1 J1 2 to DSP J7 2 Chopper 1 J1 3 to DSP J7 3 Chopper 1 J1 5 to DSP J7 4 Chopper 2 J1 1 to DSP J8 1 Chopper 2 J1 2 to DSP J8 2 Chopper 2 J1 3 to DSP J8 3 Chopper 2 J1 5 to DSP J8 4 Chopper 3 J1 1 to DSP J9 1 Chopper 3 J1 2 to DSP J9 2 Chopper 3 J1 3 to DSP J9 3 Chopper 3 J1 5 to DSP J9 4 If ALL of the continuity readings are good replace DSP PCB This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 13 Section 6 Maintenance amp Troubleshooting Spirit II User s Manual BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S
91. ck for the proper DC voltage refer to TABLE 1 at the output terminal block between Electrode and Work which is located on the left side of the unit If the proper DC voltage is present the chopper is working properly TABLE 1 Chopper 1 Chopper 2 Chopper 3 3 Phase OCV 3 Phase OCV 3 Phase OCV AC DC AC DC AC DC Spirit Il 400 Am 255 370 255 370 255 370 Spirit Il 275 Amp 225 325 225 325 N A N A Spirit Il 150 Amp 208 300 N A N A N A N A This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 12 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting 10 If the proper DC voltage is not present at the output terminal block check the 200 amp fuse F9 chopper 1 fuse F10 chopper 2 or fuse F11 chopper 3 located on the bottom right of the output bus bars If the fuse is open replace chopper and fuse 11 If the fuse s is good check if the chopper PWM LED illuminates when a start signal is applied a check D24 on the DSP PCB If D24 doesn t illuminate replace DSP PCB b check D2 on the chopper PCB If D2 doesn t illuminate green go to step 12 12 Check PCB power to the chopper from the DSP a Push the OFF Button b Disconnect the J1 plug from the
92. consumables installed in torch properly 2 Loose pressure transducer cable on PC board in the MGC 3 Check connectors on the MGC valve associated Low pressure error Pressure error during cut Liquid or torch coolant leaking from drain hole in torch handle 1 with the malfunction Supply gas pressure s less than 120 psi Supply gas pressure s fluctuating during cut Infrequent dripping from the drain hole may be condensation no action is required Noticeable flow from the drain hole indicates a problem with the torch leads and or connections 1 Check for damaged or loose torch lead connections within the torch handle This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 10 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting Chopper Test Procedure WARNING Only qualified maintenance personnel should perform the chopper test procedure The system utilizes potentially fatal A C and D C voltages All maintenance should be performed with safety in mind Use extreme caution when working near the power conversion module i e chopper The large electrolytic capacitors store large amounts of energy even after power has been removed from the system Wait at least five minutes after tu
93. d States contrary to the requirements of the EAR 1 5 Section 1 Safety Spirit II User s Manual 12 17 18 19 NFPA Standard 51 Oxygen Fuel Gas Systems for Welding Cutting and Allied Processes obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 NFPA Standard 70 National Electrical Code obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 CGA booklet P 1 Safe Handling of Compressed Gases in Containers obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 CGA booklet P 14 Accident Prevention in Oxygen Rich and Oxygen Deficient Atmospheres obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 CGA booklet TB 3 Hose Line Flashback Arrestors obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 CSA Standard W117 2 Safety in Welding Cutting and Allied Processes obtainable from Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario M9W IR3 Canada Canadian Electrical Code Part 1 Safety Standard for Electrical Installations obtainable from the Canadian Standards Associa
94. e EAR 5 54 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting Section 6 Maintenance amp Troubleshooting WARNING Only qualified maintenance personnel should perform maintenance on the Spirit system The system utilizes potentially fatal A C and D C voltages All maintenance should be performed with safety in mind Use extreme caution when working near the power conversion module i e chopper The large electrolytic capacitors store large amounts of energy even after power has been removed from the system Wait at least five minutes after turning off power and then use a voltmeter to verify that the capacitors are fully discharged before touching the power conversion module Capacitor failure can injure and or cause property damage If troubleshooting requires the system to be powered with the enclosure panels removed remain clear of the capacitors Failure of a capacitor can result in a sudden release of stored energy causing rupture of the capacitor case Routine Maintenance Note At minimum these checks should be performed on a monthly basis In excessively dirty environments or in heavy usage situations the checks should be performed more frequently jab Supply 2 OO a ae Remove the left right and top covers on the power supply Weng clean dry compressed air blow out all accumulated dust including dust on PC boards and fans In an excessively dirty environment blow out the
95. e EAR 7 11 Section 7 Parts List Spirit Il User s Manual Oxygen Supply Gas Hose Optional Part Number Length BK200362 25 25 ft 7 6 m BK200362 50 50 ft 15 2 m r BLUE Nitrogen Supply Gas Hose Optional miile Air Supply Gas Hose Optional we H17 Supply Gas Hose Optional Part Number Length BK200365 25 25 ft 7 6 m BK200365 50 50 ft 15 2 m 5 BLACK lp Part Number BK200364 25 Length 25 ft 7 6 m BK200364 50 50 ft 15 2 m 3 BLACK HWT Part Number Length BK200363 25 BK200363 50 25 ft 7 6 m 50 ft 15 2 m S Te CL J9 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 12 Spirit II User s Manual Section 7 Parts List CII Cable for Optional External Inova Part Number Length BK300902 XX Where XX is the length in feet Available in 10 foot increments INOVA CONSOLE SPIRIT II POWER SUPPLY PS 9 POS STRAIN RELIEF BK709015 28 POS CABLE BK711001 PLUG BK709016 STRAIN RELIEF BK709025 ra PLUG BK709364 TERMINAL POSITION NO COLOR PO
96. e Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 1 Section 7 Parts List Spirit Il User s Manual Torch and Manifold Assemblies Item Part Number Quantity Description 1 BK284214 1 2 Gang Manifold includes Bracket 2 BK277195 1 2 Gang Manifold Bracket 3 BK278001 1 Torch Handle Standard BK278018 Torch Handle Short 4 BK279000 1 Torch Base 5 BK279100 1 Torch Head Copper Electrode BK279060 Torch Head Silver Electrode 6 BK820209 1 O ring red 7 BK500024 1 O ring blue 8 BK500018 1 O ring red 9 BK279013 1 O ring red indicator only not a seal 10 BK279112 1 O ring red 11 BK279113 6 O ring red 12 BK284039 1 17 Torch Solenoid Plasma Hose 13 BK280022 1 5 Gang Manifold for Manual Gas Console Not shown BK716012 1 O ring Lubricant Not shown BK277056 1 Nozzle Removal Tool Not shown BK277086 1 Electrode Removal Tool Driver Not shown BK284052 1 Copper Electrode Removal Tool 400 Amp BK277087 Copper Electrode Removal Tool All others Not shown BK279061 1 Silver Electrode Removal Tool l Tip CH ree f l
97. e or missing please contact Kaliburn so a replacement item can be sent Also Kaliburn has taken special care in packaging the system If the system was damaged during shipment file a claim with the shipping company and then contact Kaliburn to order replacement parts Component Placement Plasma Power Supply The power supply should be lifted by a forklift pallet jack or crane In order to prevent damaging the power supply when lifting with a forklift or pallet jack the forks should be of adequate length to protrude on the far side of the power supply If lifting with a sling lifting straps ensure the following e Sling and material handling equipment must comply with local and national laws and regulations The personnel involved in the move must be properly trained and qualified to use such equipment e All power supply covers must be securely installed e Two slings are required Each sling should pass through all three 3 structural members on the bottom of the power supply See sling access holes below e Lift slowly not more than 8 in 203 mm high to ensure even weight distribution e Move slowly to prevent uncontrollable acceleration deceleration A WARNING Falling equipment Te a vs Ty Coa es ao aae ae can cause injury e Lift only with equipment of HMA i a A Lg th M a e Be sure power supply is stable when lifting The proper loca
98. e requirements of the EAR 5 47 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 100 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 brown o ring Outer Cap Retaining Cap 2 Swirl Ring Torch Head BK284150 BK277151 BK279483 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 141 100 135 225 400 092 3 8 25 80 35 80 147 80 170 250 500 095 1 2 154 55 210 300 600 j Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 140 2595 3 2 5 6 400 2 3 10 25 80 35 80 148 1935 4 4 6 5 600 2 4 12 152 1540 5 0 7 3 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 68 100 2540 100 2 5 100 2 5 0
99. eans to any location outside the United States contrary to the requirements of the EAR 5 44 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 200 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277274 BK279489 BK279440 yellow o ring 4 d amp Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK279443 BK279060 Imperial Thickness Prefow Plasma Shield Postiow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 230 040 200 300 3 8 130 140 090 250 400 150 1 2 133 120 115 300 500 5 8 137 100 130 350 600 152 3 4 140 75 150 400 800 153 20 74 58 72 MM 1 147 50 175 450 1000 4155 1 25 155 25 240 500 1 50 165 17 300 350 1500 158 1 75 175 12 350 2 00 185 7 500 500 160 Metric Material pretow plasma shit Posttow AR Qiavel Cutng Perce Farce Ker mm psi psi psi psi volts mm m mm mm msec mm 6 124 6100 8 4 9 300 10 130 3480 2 3 6 5 500 3 8 12 132 3160 2 7 7 3 16 137 2515 3 3 8 9 800 20 141 1810 3 8 10 3 20 74 58 72 1000 3 9 25 146 1310 4 3 11 3 32 155 610 6 1 12 7 38 164 435 7 5 8 9 1l t 1500 4 0 45 175 295 9 2 9 2 50 183 195
100. eats tote tient earan ete e teat Aen teat Ae haut Aan d 4 2 Setting up to Mark Overrides Cut eeeeeeceesececeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeeenaaeees 4 3 Verifying Input Gas PreSSUres ccccceeeeeeeeeeeeneceeeeeeeeeeeseeaaaaeeeeeeeeeeeeeeenaaaees 4 3 MaKING GC UT or Malk assi jd toes a a tater nest ieee he nents aches 4 4 Piercing Thick Materials cx nike ee ek ea ek CN eas ek ee ee 4 5 Moving Pierces and Edge Starts oosiciss cesses toes renee el aie ete 4 5 CUP QUALI sae Seaicte feist cani teeta tui ost io heal a sea bat soa h oat iach let Sie Rat A 4 6 CHECKING ErrOrS wens cats aaa a a aa laedidebiaediaeasen 4 7 Checking the Version and Serial Number ccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaeees 4 7 Ghanging the LANGUAGE css e iesiri a aea e a aiai ii 4 8 Adjusting the Screen Cont ast 4vsnaeiinn eee aaa 4 8 Section 5 Torch Consumables and Cutting Charts Installing Removing the Torch Head ccccesseeceesessseeceesesseeeeeseesseeseeeeeseees 5 1 Installing Replacing Consumables cis c iscestaccicteietiintstatcicteiehdigtiaiteatatetdiginlaliice 5 2 Maximizing Consumable Life ccccceececeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeennneeeeeeeees 5 3 Inspecting for Damage 8a Ane aaa Ne na eae a Ane a eae 5 4 Selecting COMSUMADICS ss cea aaaea Loca coed susdeuns EAE e ia AAN EAE TAEDE E 5 5 Cutting GNAMS orses a a a a aa Eaa 5 12 Section 6 Maintenance and Troubleshooting Routine Maintenance
101. ection 2 Specifications Spirit II User s Manual Manual Gas Console MGC Specifications Part Number o ccc ceeeeeccecceeececcecececcecceceeeeeeens BK300600 Weights tartan hvele aarti E 50 Ib 23 kg Se i BS pict V o o e Q QO F 12 4 315 z J y ien y o Q QO F O e o e ED lo 12 0 305 Js 13 7 348 Si 4 300 7 6 10 9 277 al Oo oO eas SPOT This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 6 Spirit II User s Manual Section 2 Specifications Gas Supply Requirements Plasma gas types Mild Steele cccadscciece cs cndicnescteensscnddchonendermdnandee Oxygen Stainless Steel a e Air Nitrogen or H17 Aluminum e eer
102. eep tightening the attachment ring until it stops There should be no gap between the attachment ring and the o ring on the torch base During this process a small amount of coolant will collect in the torch head It is normal for this coolant to discharge between the o ring on the torch base and the attachment ring while the system is being pressurized If coolant continues to discharge after the system is pressurized turn off the plasma power supply remove the torch head and inspect the o rings for damage YES NO FA N O ring O ring sil J DS D Torch Base Q lt Torch Head There is no Gap is visible P SS gap between between E o ring and o ring and attachment attachment ring ring To remove the torch head turn the attachment ring to the LEFT This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 1 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Installing Replacing Consumables A WARNING Remove primary power from the Spirit system Note When installing the consumables do not use an excessive amount of o ring lubricant Al
103. eflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 120 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 70 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 30 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 260 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277211 BK277118 BK277135 4 3 S IY Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277280 BK277139 BK279100 Imperial Material Arc Travel Cutting Pierce Pie
104. el Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 176 3415 5 5 7 3 600 1a 16 169 2775 4 2 8 9 800 20 165 2190 10 5 3 8 1500 25 169 1690 12 5 5 1 30 85 63 96 32 175 1120 4 1 18 0 2000 38 179 895 4 2 20 2 2500 45 190 610 4 8 7 8 5 2 1500 50 203 410 5 2 8 9 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 107 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 71 100 2540 160 4 1 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 34 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 30 Amps Air Plasma Nitrogen Shield Copper Electr
105. ements of the EAR 5 9 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum Copper Electrode Outer Shield Inner Nozzle Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 Brera 30A Q 9 6 BK2841 50 BK277122 BK277142 si Q D KEEA 50 BK277125 BK277142 a Q 5 BKB 50 BK277284 BK277283 100A Q 9 O BKB 50 BK277293 BK277139 150A Q 9 BK 50 BK277289 BK277143 200A Q 9 9 BKOSA 50 BK277276 BK277258 275A 9 Brea 50 BK284158 BK284122 400A Q 9 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 10 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum Silver Electrode Outer Shield Inner Nozzle Swirl Silver Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK27941 BK284150 BK277286 BK277151 BK279484 BK279483 ay BK279060 pN Y lt N 100A o 9 D EL BK284150 BK279493 BK279439 getting BK279060 N i 150A 9 D J BK279440 BK284150 BK279489 BK279443 yellow o ring BK279060 lt lt f N i 200A i a D il BK279450 BK279469 BK279458 red o
106. ents of the EAR 3 4 Spirit II User s Manual Section 3 Installation Power Supply Primary Power Connections Before connecting primary power check the data plate on the power supply to verify the voltage required A primary disconnect switch switching all ungrounded supply conductors should be provided for each Spirit system The disconnect switch should be located as close as possible to the power supply so it can be turned off quickly in case of an emergency The disconnect switch should be equipped with time delay fuses only The magnetic inrush current of the power supply will cause fast acting fuses to blow The disconnect switch should be sized according to local and national codes The rating must meet or exceed the continuous rating of the fuses used See the following chart for recommended fuse sizes 3 Phase Input Current Recommended at Maximum Time Delay Fuse TIS EET SS Output amps Size amps 220 VAC 60Hz 240 VAC 60Hz 380 VAC 50 60Hz Connection to the supply circuit can be by means of flexible supply cables or supply cables through conduit to a permanent installation The supply cables should have a 600 volt minimum rating and should be sized according to local and national codes Route flexible supply cables through the strain relief on the back of the power supply and connect to the input terminal block TB5 as shown For supply cables through conduit install the conduit in place of the strain rel
107. er height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 17 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 200 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277274 BK277289 BK277291 I Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277143 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow otage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 230 040 200 300 3 8 130 140 090 250 400 150 1 2 133 120 115 300 500 5 8 137 100 130 350 600 152 3 4 140 75 150 400 800 153 20 74 58 72 1 147 50 175 450 1000 155 1 25 155 25 240 500 f 1 50 165 17 300 l l 350 1500 158 1 75 175 12 350 2 00 185 7 500 500 160 Metric Material Arc T
108. essure is too high A convex cut face usually indicates that the torch standoff distance is too high or the shield gas pressure is too low 7 Note that different material compositions have an effect on dross formation 8 If the material is not being completely severed the likely causes are that the cutting current is too low the travel speed is too high the gas pressures are incorrect the incorrect gas types are selected the incorrect consumables are installed in the torch or the consumables are worn This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 6 Spirit II User s Manual Section 4 Operation with Manual Gas Console Checking Errors The last ten 10 system errors are available through the MGC as described below nput Gas Version onfigure On the main menu move the pointer to Errors Press SELECT Press SELECT to cycle through the last ten 10 error codes See Section 6 in this manual for details on the error codes Simultaneously pressing DOWN and SELECT will erase all ten error codes Move the pointer to Return and press SELECT to return to the main menu Checking the Version and Serial Number The hardware version software
109. fety Spirit II Users Manual Health Support Equipment Compressed gas cylinders should be maintained properly Never attempt to use a cylinder that is leaking cracked or has other signs of physical damage All gas cylinders should be secured to a wall or rack to prevent accidental knock over If a compressed gas cylinder is not being used replace the protective valve cover Never attempt to repair compressed gas cylinders Keep compressed gas cylinders away from intense heat sparks or flames Clear the compressed gas cylinder connection point by opening the valve momentarily prior to installing a regulator Never lubricate compressed gas cylinder valves or pressure regulators with any type of oil or grease Never use a compressed gas cylinder or pressure regulator for any purpose other than which it is intended Never use a pressure regulator for any gas other than which it is intended Never use a pressure regulator that is leaking or has other signs of physical damage Never use oxygen hoses and pressure regulators for any gas other than oxygen Never use any gas hose that is leaking or has other signs of physical damage am The Spirit system creates electric and magnetic fields that may interfere with certain types of health support equipment such as pacemakers Any person who uses a pacemaker or similar item should consult a doctor before operating observing maintaining or servicing the system Observe the following guide
110. for damage If using the copper electrode the torch head uses cooling tube P N BK277007 If replacement is required use tool P N BK200109 If using the silver electrode the torch head uses cooling tube holder assembly P N BK279216 Remove this using the tool socket P N BK277087 amp driver P N BK277086 and inspect the o rings for damage Apply a small amount of o ring lubricant before re installing in the torch head Wipe any excess o ring lubricant off of the torch base and head This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 2 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting Impulse Start Console ISC 1 Open the cover door of the impulse start console and verify that all leads and hoses are tightened securely Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened Work Ground 1 Verify that the work ground lead is securely fastened to the star ground on the cutting table and that the connection point is free from corrosion Use a wire brush to clean the connection point if necessary This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U
111. g Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 108 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 56 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 275 7 0 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 41 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 400 Amps Nitrogen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK284155 BK284157 BK284159 A g lt 5 lt x V 1 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK284156 BK284122 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 175
112. ghout the cutting range Each enclosure in the system is rated for IP21S sealing which is intended for indoor use only The system is not suitable for use in rain or snow This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 1 Section 2 Specifications Spirit II User s Manual System Components The Spirit II 400 System consists of the following components Standard Components Power Supply Cooling System includes torch coolant Cooling System Control Cable Manual Gas Console CAN Cable CAN Termination Plug Impulse Start Console ISC ISC Control Cable ISC Ground Cable Torch and Handle Assembly Torch Lead Set 5 gang Manifold Assembly 5 gang Manifold Control Cable 2 gang Manifold Assembly 2 gang Manifold Control Cable 17 Inch Plasma Hose Coolant and Power Leads Gas Hose Package Work Ground Lead Spirit II Users Manual Optional Components Supply Gas Hoses Internal Inova Console This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 2 Spirit II User s Manual Section 2 Specifications
113. ght Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 144 3910 4 0 6 3 400 3 2 10 150 2805 4 7 7 0 600 12 20 71 70 69 153 2330 5 1 7 4 y 16 160 1510 5 6 8 3 800 20 170 1030 6 2 9 0 1200 3 4 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 65 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 49 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 200 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277274
114. gnment Indicator Torch Head Circle 5 08 129 il This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 9 Section 2 Specifications Spirit II User s Manual 5 Gang Manifold Specifications Part Number o ccc ceeeeeccecceeececcecececcecceeeceeeeeens BK280022 WEIN asirica 6 Ib 2 7 kg 6 18 157 0 327 8 3 eke 0 25 6 4 1 os So 4 0 187 4 8 Mounting Holes j f 1 18 30 3 80 97 4 20 107 Cop Re RE A i Bi 3 035 77 L A 8 35 212 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 10 Spirit II User s Manual Section 2 Specifications Airborne Noise Emissions The system generates high noise levels while cutting Depending on the size of the cutting area distance from the cutting tor
115. h the menu as described below pb Setup Push the OFF Button on the MGC to disable ors Input ae the system On the main menu move the Merion pointer to Setup Press SELECT Configure Be rocess Cuting Press SELECT to cycle through the list until Current 150 Cutting is displayed select Sas Adjust Gaz Rebii Cutting Move the pointer to Current b Current 450 Press SELECT to cycle through the list until Select Gas the desired amperage is displayed Adjust Gas Retum Move the pointer to Select Gas Press SELECT Cutting Curent Select Gas Adjust Gaz Press SELECT to choose the Plasma gas Move the pointer to Shield and press SELECT to choose the shield gas Move the pointer to Return and press SELECT Move the pointer to Adjust Gas Press SELECT Cutting Current 158 Select Gas Adjust Gas Move the pointer to a gas and then press SELECT to start the flow of that gas Turn the corresponding regulator knob on the MGC to adjust the displayed pressure to match the value in the cutting chart Repeat for all other gases Move the pointer to Return and press SELECT Repeat to return to the main menu PostFiowm O Petm Pre Flow I Plasma Shield 0 0 0 The system is now setup to cut This information is subject to the controls of the Export Administration Regula
116. he requirements of the EAR 7 25 Section 7 Parts List Spirit II User s Manual Chopper Gate Driver BK300106 1 0000000 KALIBURN INC ASSEMBLY P N 300106 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 26 Spirit II User s Manual Section 8 Internal Inova Console Option Section 8 Internal Inova Console Option Overview This optional Inova system is designed to provide arc voltage control to any plasma cutting system however combining it with the Spirit Il provides the added convenience of having Inova console built directly into the plasma power supply This section only covers topics unique to the Spirit II system with the internally installed Inova console See the standard Inova manual for all other Inova information Plug Identification Connections for the internal Inova console option are distinguished from other connections on the back of the power supply by the addition of the letter I before the plug number The function of each plug e g IP1 is the same as the corresponding plug found on the external Inova console e g P1 o AIN j IP1 IP1 Be P4 POSITIONER POSITIONER wT IP8 IPs CONSOLE 2
117. hey are not available for the chosen gases and pressures to prevent a possible fire from propagating back to the gas supplies Ensure that oxygen lines remain free from contaminants such as oil and grease The mixture of such contaminants with oxygen presents an additional fire hazard Compressed air must be clean dry and oil free and may be supplied from compressed cylinders or from an air compressor Be aware that shop air systems are prone to oil and moisture contamination If shop air is used it must be cleaned to ISO 8573 1 Class 1 4 1 Specify dry air when using compressed cylinders Breathing quality air contains moisture and must not be used 3 8 inside diameter hoses are required for all inlet gas connections Mating connectors are supplied with the unit Quick connect fittings must not be used This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 7 Section 2 Specifications Spirit II User s Manual Impulse Start Console ISC Specifications Part NUM 0 0 0 2 ccc ceceeeccecceeccecceecceececceeeeeecesens BK300500 WeigN i aa a eee r rear sen tenrrsen enn rae n a 22 lb 10 kg _ 8 00 2039 ES 4 312 8 p 12 75 324 12 00
118. ief and connect the associated supply cables to the input terminal block TB5 See Figure 3 on the next page TB5 is located on the rear of the power supply and is accessible with the right side cover removed Be sure to connect the primary ground cable to the ground stud on the input terminal block Under no circumstances are the supply cables to be routed through the opening in the power supply cabinet without conduit or an appropriate strain relief as per local and national codes This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 5 Section 3 Installation Spirit II User s Manual S SSB fF WY A MA WS L1 U L2 V L3 W Ground L1 L2 L3 Gnd Strain Relief Disconnect Box TB5 Connections Connections Figure 3 Power Supply Primary Connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 6 Spirit II User s Manual Section 3 Installation Power Supply Output Connections Perform the following steps to connect the outpu
119. ield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277274 BK277289 BK277291 S cm y j Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277143 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Votage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 130 200 200 400 070 150 3 8 133 150 250 500 1 2 140 110 115 300 600 152 5 8 146 75 150 350 800 20 74 58 72 155 3 4 153 60 190 400 1200 1 0 158 40 210 450 160 1 25 170 20 250 350 1500 165 1 50 180 10 275 350 175 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voitage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 129 5220 1 8 4 9 400 3 8 10 134 3655 1 9 6 5 600 12 138 3020 2 6 7 3 16 146 1890 3 8 8 9 800 3 9 20 74 58 72 20 153 1450 4 8 10 3 25 157 1050 5 2 11 3 4 1 1500 32 170 495 6 4 8 9 4 2 38 179 260 6 9 8 9 4 4 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Pr
120. ielded Torch Leads sirsenis eters 7 9 CAN Communication Cable and Termination Plug eceeeeeeeeeeeeeeeeteees 7 9 Manifold Control Cables cncxc325 ii tac endedet a deceeccndecechendadesdaadincd adedesl edi ancl ndedede 7 9 Gas Hose Package with MGC cccceceeeeeeeeeeceeeeeeeeeeeeeeaaaeeeeeeeeeeeeeeeeeaeees 7 10 Cooling System Control Cable aie ied tard ctie deel triat tals tle dt deened Uedettad Ualesved eedatues tie 7 10 Coolant and Power LeddScca eset he ees ee Ne le Ak Ne A ke Nhe 7 11 Work Ground Lead i cccssedrcicsss ccc ceccceaneeticuscnsbeecennesatyssnee Gd eanebiteennpedeesngeedpeaneentees 7 11 Oxygen Supply Gas Hose Optional ecceeceeccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeees 7 12 Nitrogen Supply Gas Hose Optional ccccceeeeeeeeeeeeeneeeeeeeeeeeseeeennneeeeeeees 7 12 Air Supply Gas Hose Optional ccceeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeeneneeeeeeeeeeeeees 7 12 H17 Supply Gas Hose Optional saccvccesi oii ce coe ee eile ue ae teiie cc haredue oe adel 7 12 Cll Cable for Optional External Inova cc ccccceeeeeeeessenecceeeeeeeeeeeeseneeeeeeeees 7 13 Fil Cable for Optional Internal INOVa cceceeeeeeseseceeeeeeeeeeeeesseneneeeeeeees 7 14 JII Cable for Optional Internal Inova c cecceceeeeeseeeeeeeeeeeeeeeeeeeeeeeteeeeeeees 7 15 PCB Assemblies Component Reference Locations cccccceeeseteeeeeeeees 7 16 Section 8 Inte
121. ight Height Time Width ga in psi psi psi psi volts ipm in in msec in 14 075 87 105 100 12 105 88 75 105 035 070 11 120 89 65 25 66 40 67 200 10 135 90 55 110 3 16 94 50 040 080 300 1 4 100 40 060 125 400 115 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 2 2 87 565 100 2 5 2080 9 1 8 2 7 3 25 66 40 67 88 1685 200 5 94 1235 1 0 2 1 2 8 400 6 98 1075 1 3 2 9 2 9 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 145 250 6350 147 3 7 100 2 5 0 Argon Nitrogen N A 50 25 N A 65 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 070 1 8 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 22 Spirit II
122. ight of 150 3 8 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 15 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 100 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 L DoD i oO j j Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277283 BK279100 Imperial Material 5 Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 150 090 200 300 3 8 130 100 130 250 400 090 1 2 25 83 26 81 65 155 300 500 5 8 143 47 325 800 185 095 3 4 145 35 350 1000 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m m
123. ing mode Opening the contacts puts the system in cutting mode The operating mode should be selected prior to applying a start signal The contacts should be rated for 24VDC 7 3mA Arc Hold Input The power supply requires a contact closure between P8 pins 10 and 11 to inhibit arc starting even though a plasma start signal has been applied to the unit When the contacts are opened the arc is initiated This feature is used to decrease cycle time by allowing pre cut gas and contact sequencing to occur simultaneously with initial torch height positioning The contacts should be rated for 24VDC 7 3mA Motion Output The power supply provides a maintained contact closure output between P8 pins 12 and 14 as long as an arc is maintained between the torch and the workpiece The motion contacts are rated for 24VDC 10mA Remote On Off Input The power supply requires a maintained contact closure between P8 pins 5 and 6 to energize the system from a remote location provided that the OFF Button on the manual gas console is released The contacts should be rated for 24VAC 10mA Opening the contacts deenergizes the system If the remote on off feature is to be used remove the jumper between positions 1 and 2 on the J17 connector on the microprocessor DSP board Power Supply Ready Output The power supply provides a maintained contact closure output between P8 pins 7 and 8 when the system is ready to cut or mark The contacts are open during ga
124. irements Mating hose barbs and connectors are supplied with the system and are sized for 3 8 inch inside diameter hose Do not change the inlet gas supply fittings to quick connect fittings Using quick connect fittings to connect and disconnect pressurized hoses may cause damage to the system Note When making hose connections only tighten the brass fittings enough to make gas seals The fittings are subject to damage if over tightened Air Inlet G ISO 3821 hose color black e Air must be supplied to the unit at all times regardless of the cutting current or material type Oxygen Inlet 2 ISO 3821 hose color blue e Oxygen must be supplied to the unit at all times unless stainless steel is being cut with H17 plasma Nitrogen Inlet 3 ISO 3821 hose color black e Nitrogen must be supplied to the unit at all times regardless of the cutting current or material type H17 Inlet ISO 3821 hose color red e H17 must be supplied to the unit when stainless steel is being cut with H17 as the plasma gas See cutting charts in Section 5 for more information n This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 17 Section 3 Installation Spirit II User s Manual CAN Communicati
125. is information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 35 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 50 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277122 BK277131 lt g 9 cap v Ji AM i Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 050 135 180 050 100 100 080 063 25 66 19 67 138 140 065 i 150 082 080 143 90 075 150 200 085 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 5 137 3870 1 5 2 5 150 2 1 25 66 19 67 2 0 142 2360 1 8 3 7 200 2 2 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height
126. it may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel plasma cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC 974 13 Arc welding equipment Installation and use This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 1 Appendix A Electromagnetic Compatibility EMC Spirit II User s Manual Assessment of Area Before installing plasma cutting equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the plasma cutting equipment b radio and television transmitters and receivers c computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment the user shall ensure that
127. ject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 4 Spirit II User s Manual Section 4 Operation with Manual Gas Console Piercing Thick Materials Care must be taken when piercing thick materials in order to prevent damage to the shield cap and nozzle As with all thicknesses the pierce height must be set high enough so the metal ejected while piercing does not come into contact with the shield cap Also some of the material ejected during the pierce may adhere to the top side of the plate and form a ring of solidified material around the pierce point Action must be taken so the torch does not move from the pierce height down to the cutting height and come into contact with this solidified metal The torch should not move from the pierce height down to the cutting height until the X Y controller has moved the torch away from the pierce point One way to accomplish this may be to program the pierce time on the torch height control system to a value that is longer than the X Y controller motion delay time Moving Pierces and Edge Starts On very thick materials an edge start or moving pierce may be required to prevent damage to the torch consumables With a moving pierce the X Y machine should begin moving at approximately 5 10 inches minute 125
128. ject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 8 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting General Troubleshooting The following contains general troubleshooting guidelines for the Spirit system Please contact KALIBURN technical support for any issues not covered in this section Before any tests are performed make sure that all system fuses are good remove top cover of power supply to check these fuses Problem Power supply indicator white light will not illuminate Power Supply will not energize after choosing ON and then SELECT on the MGC Power supply will not stay on after choosing ON and then SELECT on the MGC No arc at the torch The arc will not transfer to the workpiece Possible Cause Primary disconnect fuse blown Internal power supply fuse is blown F1A F1B Power supply indicator light is burned out or the associated wiring is bad Control Transformer or associated wiring bad ISC door open Low coolant level Fuse is blown F1 F6 Faulty Off Button or associated wiring Off Relay faulty Faulty DSP board Off Relay faulty Incorrect torch consumables installed Incorrect gas pressure settings Pilot arc transistor PAT is n
129. ld Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 150 190 135 250 300 150 3 8 155 145 140 275 400 1 2 110 300 500 20 74 58 72 135 155 5 8 160 95 350 600 3 4 65 150 400 800 160 1 0 175 35 200 1000 170 Metric Material 7 Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 149 4955 3 3 6 3 300 38 10 3545 3 5 7 0 12 139 2995 7 4 eve 20 74 58 72 3 4 3 9 16 160 2380 8 9 800 20 162 1575 3 9 4 1 10 2 1000 25 174 940 5 0 4 3 Marking For All Material Thicknesses P Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 120 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 71 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or tran
130. ld Control Cable 1 Connect the 5 gang manifold control cable plug marked P15 to the 5 gang manifold as shown 2 Connect the 5 gang manifold control cable plug labeled P12 to the connector labeled P12 on the rear of the power supply 2 Gang Manifold Control Cable 1 Connect the 2 gang manifold control cable plug marked P18 to the 2 gang manifold as shown 2 Connect the 2 gang manifold control cable plug labeled P13 to the connector labeled P13 on the rear of the power supply This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 15 Section 3 Installation Spirit II User s Manual Manual Gas Console GREEN CF E D EE adf mp m I DU 21 GREEN RED REAR PORT Figure 8 Torch Gas Connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 16 Spirit II User s Manual Section 3 Installation Gas Supply Connections Perform the following steps to connect the gas supply lines to the MGC See Section 2 for gas supply requ
131. lines to minimize exposure to these electric and magnetic fields Stay as far away from the power supply torch torch leads and impulse start console as possible Route the torch leads as close as possible to the work ground cable Never place your body between the torch leads and work ground cable Keep the work ground cable and the torch leads on the same side of your body Never stand in the center of a coiled up set of torch leads or work ground cable This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 4 Spirit II User s Manual Section 1 Safety Safety Standards Booklet Index For further information concerning safety practices to be exercised with plasma arc cutting equipment please refer to the following publications 1 10 11 AWS Standard AWN Arc Welding and Cutting Noise obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 AWS Standard C5 2 Recommended Practices for Plasma Arc Cutting obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 AWS Standard FSW Fire Safety in Welding and Cutting obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 AWS Standard F4 1 Recommended Safe Practices for Preparation
132. m mm msec mm 6 124 3950 2 1 4 9 300 10 2405 3 3 6 5 2 3 130 500 12 25 83 26 81 1850 3 7 7 3 16 143 1180 8 3 4 7 1000 2 4 20 145 800 9 0 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 60 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 16 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 150 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 D D Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277152 BK
133. n msec in 1 2 140 160 140 300 500 150 5 8 135 350 600 155 3 4 148 110 da 400 800 160 1 150 85 160 500 1000 180 1 25 155 60 175 600 1500 190 1 5 30 79 70 76 160 50 225 700 2000 f 1 75 162 40 260 800 3000 200 2 00 165 33 270 1 00 4500 210 2 25 170 20 280 350 1000 235 2 50 182 15 300 350 1300 245 2 754 185 12 325 350 1500 245 3 00 195 8 350 350 2000 250 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 138 4205 3 6 7 3 500 3 8 16 145 3405 3 3 8 9 800 3 9 20 2700 3 4 10 5 4000 4 1 25 149 2200 4 0 12 5 4 6 32 155 1500 4 4 15 3 1500 4 8 38 159 1275 5 6 17 7 2000 f 45 30 79 70 76 162 995 6 6 20 5 3000 5 1 50 164 860 6 8 25 4 4500 5 3 55 168 620 6 9 11 9 1000 6 0 60 175 450 7 2 1300 62 65 182 365 7 7 8 9 1500 i 70 185 300 8 3 75 193 220 8 7 2008 ad Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 112 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 53 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of
134. n 1 BK300412 1 Power Supply 24VDC 8 3A 2 BK300301 1 Printed Circuit Board PCB Gas Console DSP 3 BK280030 1 Fan 24VDC 4 BK300602 1 Keypad 5 BK300603 1 LCD Display 6 BK708111 1 Switch Pushbutton OFF Button 8 BK280032 1 Marking Regulator 0 60 PSI 145 PSI Max Input 9 BK500570 2 Plasma Shield Regulator 0 125 PSI 10 BK300605 1 Manifold Block Gas Outputs ji O 77 aE l Q Q HH This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 5 Section 7 Parts List Spirit Il User s Manual Manual Gas Console BK300615 Left Side View Item Part Number Quantity Description 1 BK300412 1 Power Supply 24VDC 8 3A 2 BK300301 1 Printed Circuit Board PCB Gas Console DSP 3 BK280030 1 Fan 24VDC 6 BK708111 1 Switch Pushbutton OFF Button 7 BK500562 1 Preflow Regulator 0 60 PSI 8 BK280032 1 Marking Regulator 0 60 PSI 145 PSI Max Input 9 BK50
135. nts of the EAR 7 3 Section 7 Parts List Spirit Il User s Manual Cooling System BK300275 oO Item Part Number Quantity Description 1 BK200092 1 Coolant Reservoir without Fittings or Cap 2 BK500518 1 Coolant Reservoir Cap Level Gauge 3 BK300135 1 Coolant Level Switch 4 BK505024 1 Coolant Temperature Switch 5 BK284033 1 Pump Motor 1 2hp 230V 50 60 Hz 6 BK500513 1 V Band Clamp 7 BK284032 1 Coolant Pump 125 gph 8 BK708061 1 Solenoid Valve 220 240VAC 9 BK715118 1 Check Valve Coolant Return 10 BK708068 1 CR5 Relay 11 BK300134 1 Coolant Flow Sensor 12 BK284031 2 Fan 10 Aluminum 13 BK500514 2 Heat Exchanger 14 BK500509 1 Coolant Filter Housing 15 BK500510 1 Coolant Filter Deionization Cartridge 16 BK715052 1 Drain Petcock 17 BK709086 1 TB3 Terminal Block Marker 14 Position 18 BK709007 1 TB3 Terminal Block 14 Position 19 BK709262 1 P1 16 Pin Receptacle 20 BK500526 2 Fan Guard 10 2 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 4 Spirit II User s Manual Section 7 Parts List Manual Gas Console BK300615 Right Side View Item Part Number Quantity Descriptio
136. ode Shield Cap Nozzle Electrode BK277120 BK277130 BK277145 a OD Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 040 150 100 100 065 050 35 81 20 85 135 120 030 063 90 150 200 070 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 3885 2 5 100 1 7 35 81 20 85 135 0 8 1 5 2520 3 4 200 1 8 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 145 250 6350 177 4 5 100 2 5 0 Argon Air N A 50 25 N A 75 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 100 2 5 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 Th
137. ode manifold Note that the torch coolant return lead has left hand threads Torch Nozzle Lead e Connect the torch nozzle lead to the angled bracket on the red standoff Note that the torch nozzle lead has right hand threads Torch CTP Sensor Lead 15 e Connect the 18AWG torch CTP sensor lead to the red standoff as shown This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 11 Section 3 Installation Spirit II User s Manual Ll ae 5 ABR gt X ss ste g 4 Figure 6 Torch Leads to Impulse Start Console Connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 12 Spirit II User s Manual Section 3 Installation Torch Leads to Torch Base Connections Perform the following steps to connect the torch leads to the torch base Note When making hose connections only tighten the brass fittings enough to make water or gas seals The fittings are subject to damage if over tightened Also use two wrenches when tightening the torch fittings
138. ogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 65 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 28 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 200 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the good cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277274 BK277287 BK277135 D 9 Typ st Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277259 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 156 80 195 250 500 150 1 2 148 75 130 300 600 i 5 8 37 72 79 68
139. omatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 38 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 150 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 A lt l e f q 9 cap v Ji A y i Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK277139 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 145 130 250 400 125 3 8 155 115 185 275 500 i 1 2 20 71 50 69 165 90 230 300 600 130 5 8 65 325 800 135 170 250 3 4 45 350 1200 140 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow oitage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 143 3770 3 1 6 3 400 3 2 10 156 2825 4 8 7 0 Ai 12 20 71 50
140. on Connections Perform the following steps to connect the plasma power supply to the MGC CAN Cable e Connect the male end of the CAN cable to the connector labeled P4 on the rear of the plasma power supply e Connect the female end of the CAN cable to the top connector on the rear of the MGC CAN Termination Plug e lf not already installed connect the CAN termination plug to the bottom connector on the rear of the MGC Plasma Power Supply o pre i Manual 223 2 Gas Console o o oo oo re o 2 gt o ar gt L oo o o This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 18 Spirit II User s Manual Section 3 Installation CNC Machine Interface Connections Perform the following steps to properly interface the Spirit system with a CNC cutting machine See the system schematic for additional information Plasma Start Input The power supply requires a contact closure between P8 pins 3 and 4 to commence the cutting or marking sequence The sequence is terminated when the contacts are opened The contacts should be rated for 24VDC 7 3mA Plasma Cut Mark Input The power supply requires a contact closure between P8 pins 1 and 2 to put the system in plasma mark
141. on Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 2 Spirit II User s Manual Section 3 Installation Legend Supplied Optional Customer Supplied rn To Star Ground CAN Termination Plug Positioner B Cable ro To Star Ground CNC Controller FII Cable Notes 1 If only the Inova Remote is used to set Inova parameters then follow the configuration shown 2 If only the CNC Controller is used to set Inova parameters no Inova Remote then e add the G Cable from the Power Supply IP6 to the CNC Controller e remove the A Cable from the configuration shown 3 If both the CNC Controller and Inova Remote are used to set Inova parameters then e add the G Cable from the Power Supply IP6 to the CNC Controller 2 Gang Manifold 5 Gang Manifold Cooling System Control Cable To Star Ground Cooling System Impulse Start Console Positioner ae Internal Inova Ground Cable l ts i 58 eL l poh Star Ground Work Piece Figure 1 Spirit II System with Manual Gas Console and Internal Inova System This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S person
142. onics The ISC is usually mounted on the gantry of the cutting machine or on the cutting table See Section 2 for mounting dimensions 5 Gang Manifold The 5 gang manifold assembly must be mounted within 6 feet 1 8 m of the torch See Section 2 for mounting dimensions 2 Gang Manifold The 2 gang manifold assembly must be mounted to the torch See Section 2 for mounting dimensions Torch The torch must be installed on the positioner of an arc voltage control height control capable of maintaining the cutting arc voltage within 1 arc volt The arc voltage must be adjustable in 1 arc volt increments The positioner must be rigid to ensure cut quality and a torch collision sensor is highly recommended See Section 2 for mounting dimensions Cooling System The cooling system must be located within 8 feet 2 4 meters of the plasma power supply The surface on which the cooling system is located should have a grade of no greater than 10 to eliminate the risk of toppling over See Section 2 for unit dimensions System Interconnection The Spirit Il system interconnection diagrams on the following pages will assist in the planning and installation of the system as well as identifying cables and hoses upon receipt The optional Inova torch height control is also shown to assist with its connections whether as an external console or internal to the plasma power supply This information is subject to the controls of the Export Administrati
143. ool in Part List Corrected Remote On Off info in Installation section C LAD0217 CAD 08 06 2013 E LAD0260 CAD 03 18 2014 This documentation may not be copied photocopied reproduced translated or reduced to any electronic medium or machine readable format without explicit written permission from Kaliburn FASTON is a trademark of the TE Connectivity Ltd family of companies Other logos products and company names mentioned herein may be trademarks of their respective owners Copyright 2013 2014 Lincoln Global Inc Kaliburn Inc a Lincoln Electric Company 4130 Carolina Commerce Parkway Ladson SC 29456 USA This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Spirit II User s Manual Prologue Table of Contents Section 1 Safety General Preca ti nS asuni ai bea aa aii ented ai ei 1 1 Ultraviolet Radiation Protection taxccaycacnnercaiccwriiied eaten hectenitcunneneenes 1 1 INGISE PrOle CuO Riveter E AE E EEEE E EEE EAE EE 1 1 Toxic F me Preve O a r a aa a a r a aa ra Pea UELAND 1 2 Electric Shock Prevention sesiccstvciscasdccdsvenhuniensadnckaueahacagucataeheavataciavenbialgacsiwebanendn 1 2 Fre Prevento a a E a R a 1 3 Explosion Preventi Men suea a E hth E a 1 3 He
144. ot be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 25 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 100 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 D J 7 J j iH Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277283 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 141 100 135 225 400 092 3 8 25 80 35 80 147 80 170 250 500 095 1 2 154 55 210 300 600 f Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 140 2595 3 2 5 6 400 2 3 10 25 80 35 80 148 1935 4 4 6 5 600 2 4 12 152 1540 5 0 7 3 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Pla
145. ot operating properly Check the PAT LED D43 on the DSP microprocessor board Damaged or loose torch lead connections Shorted torch or torch leads Check the continuity between the Electrode lead and the Nozzle lead to make sure they are not shorted Open torch or torch leads Check the continuity from the Electrode lead to the torch electrode and the Nozzle lead to the large brass body of the torch Loose work ground connection Pierce height too high Incorrect damaged or worn consumables This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 9 Section 6 Maintenance amp Troubleshooting Spirit II User s Manual Problem Primary power has been applied to the system but Possible Cause Check power communications CAN cable connection on back of manual gas console the manual gas console 2 Check for blown DIN rail fuse screen is blank 3 Check for 120v on pins of power communications CAN cable at back of the manual gas console The manual gas console 1 Cycle primary power to the Spirit system screen is on but the screen 2 Check the connection of the ribbon cable that doesn t work connects the keypad to the DSP PCB in the manual gas console Gas pressures will not adjust 1 Wrong
146. ow Arc Shutdown Times Current A Time ms 30 490 50 390 70 300 100 300 150 175 200 195 260 175 275 175 400 375 Use the recommended pierce height given in the cutting charts A pierce height that is too low will allow molten metal that is ejected during the piercing process to damage the shield cap and nozzle A pierce height that is too high will cause the pilot arc time to be excessively long and will cause nozzle damage See Piercing Thick Materials in Section 4 Never fire the torch in the air Nozzle damage will occur 4 Make sure the torch does not touch the plate while cutting Shield cap and nozzle damage will result Use a chain cut when possible Starting and stopping the torch is more detrimental to the consumables than making a continuous cut Always use error tracking on the plasma console to keep track of cut errors See Section 4 for information on error tracking This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 3 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Inspecting for Damage When the cut quality is not satisfactory use the following guidelines for determining which consumable parts need to be changed Ins
147. owing LED Indication D7 RS232 OUT Isolated Serial transmission D10 RS232 T1 OUT Serial transmission D11 CAN RXD CAN transmission D12 CAN TXD CAN transmission D24 PWM Chopper s energized D33 COOLANT LEVEL Coolant reservoir level is sufficient D36 PLASMA START Plasma start signal applied to Spirit D37 ARC HOLD Arc hold input enabled D38 MARKING Marking input enabled D39 CORNER Corner current input enabled D40 EOFF Off button disengaged D41 MOTION Motion output signal activated D42 PLASMA READY Power supply ready output signal activated D43 PAT Pilot arc transistor energized D48 RMT ON OFF Remote On Off input enabled D50 ISC DOOR ISC door is closed D77 3 3V uP PWR 3 3V Microprocessor power D78 1 8V uP PWR 1 8V Microprocessor power OPTO U21 MTR SOL Coolant pump relay CR5 energized Pump On OPTO U22 PAR Pilot arc relay energized OPTO U23 CON DC power output main contactor energized OPTO U24 SURGE CR3 and K1 I O PCB relays energized OPTO U26 FAN Fans energized OPTO U27 PREFLOW Preflow gas valve 1 energized OPTO U28 PLASMA Plasma gas valve 2 energized OPTO U29 SHIELD Shield gas valve 3 energized OPTO U30 VENT Vent gas valve 4 energized OPTO U31 POSTFLOW Postflow gas valve 5 energized OPTO U32 MARKING Marking gas valves 6 and 7 energized OPTO U34 IMPULSE START Impulse start circuit energized OPTO U37
148. pect all parts for dirt debris and excess o ring lubricant and clean as necessary Part Inspect For Corrective Action Outer Cap Q Dents cracks Replace outer cap Center hole out of round Replace shield cap Shield Ca Nea Dents Scratches Replace shield cap Dry o ring Apply a thin film of o ring lubricant Damaged o ring Replace shield cap Center hole out of round Replace retaining cap Retaining Cap Dents cracks Replace retaining cap Dry o ring Apply a thin film of o ring lubricant Damage o ring Replace retaining cap Center hole out of round Replace nozzle Nozzle Erosion or arcing Replace nozzle Dry o rings Apply a thin film of o ring lubricant Damaged o rings Replace nozzle Damage Replace swirl ring Clogged holes Blow out with compressed air Replace Swirl Ring swirl ring if clogs can t be removed Dry o rings Apply a thin film of o ring lubricant Damaged o rings Replace swirl ring Pit depth Replace electrode if center pit depth is greater than 0 040 1 mm for copper electrode or 0 098 2 5mm for silver Electrode Erosion or arcing Replace electrode D Dry o rings Apply a thin film of o ring lubricant Damaged o rings Replace electrode This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to
149. r 3 maximum operating temperature exceeded This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 7 Section 6 Maintenance amp Troubleshooting Spirit II User s Manual Gas Console Code Short Description Long Description 20100 Plasma Adjust Could not adjust Plasma Gas 20110 Shield Adjust Could not adjust Shield Gas 20120 Preflow Adjust Could not adjust Preflow Gas 20130 Postflow Adjust Could not adjust Postflow Gas 20140 Marking Adjust Could not adjust Marking Gas Automatic Gas Console 20160 N2 Mix Adjust Could not adjust N2 Mix Gas 20170 O2 Mix Adjust Could not adjust O2 Mix Gas 20200 O2 Low O2 Input Pressure is low 20210 N2 Low N2 Input Pressure is low 20220 Argon Low Argon Input Pressure is low 20230 O2N2 Low Air Input Pressure is low 20240 H17 Low H17 Input Pressure is low 20250 O2 High O2 Input Pressure is high 20260 N2 High N2 Input Pressure is high 20270 Argon High Argon Input Pressure is high 20280 O2N2 High Air Input Pressure is high 20290 H17 High H17 Input Pressure is high 20300 PS Quiet Lost CAN communication with Power Supply 20310 PC Quiet Lost CAN communication with Plasma Controller This information is sub
150. r transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 10 Spirit II User s Manual Section 3 Installation Torch Leads to Impulse Start Console Connections Perform the following steps to connect the torch leads to the impulse start console See Figure 6 on the next page Note When making hose connections only tighten the brass fittings enough to make water or gas seals The fittings are subject to damage if over tightened Braided Shield 71 1 Remove the threaded ring from the brass shield connector on the end of the braided shield Route the torch leads through the opening in the impulse start console and push the shield connector through the hole until it is seated against the side of the console 2 Slide the threaded ring over the torch leads thread it onto the brass shield connector and tighten firmly The shield connector should ground the braided shield to the case of the impulse start console in order to help reduce high frequency noise emission Using an ohmmeter measure for zero ohms between the braided shield and the ground stud located on the outside of the impulse start console Torch Electrode Coolant Supply Lead e Connect the torch electrode coolant supply lead to the brass cathode manifold Note that the torch electrode coolant supply lead has right hand threads Torch Coolant Return Lead 13 e Connect the torch coolant return lead to the brass cath
151. ravel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 6100 8 4 9 300 10 130 3480 2 3 6 5 500 3 8 12 132 3160 2 7 7 3 16 137 2515 3 3 8 9 800 20 141 1810 3 8 10 3 20 74 58 72 1000 3 9 25 146 1310 4 3 11 3 32 155 610 6 1 12 7 38 164 435 7 5 8 9 1500 4 0 45 175 295 9 2 9 2 50 183 195 12 2 12 2 4 1 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 120 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 62 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 18 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 275
152. rce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 145 85 160 250 500 490 1 2 142 80 140 300 600 f 5 8 145 65 185 350 800 40 63 64 63 195 3 4 150 55 225 400 1200 1 0 160 33 250 450 1500 200 1 25 170 26 280 350 205 Metric Material i Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 144 2140 4 0 6 5 600 4 8 12 142 2060 3 7 7 3 16 145 1640 4 7 8 9 800 40 63 64 63 5 0 20 151 1315 5 8 10 3 25 159 875 6 3 11 3 1500 5 1 32 170 650 7 1 8 7 5 2 Marking For All Material Thicknesses r Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 108 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 75 100 2540 160 4 1 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This inform
153. rce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 145 130 250 400 125 3 8 155 115 185 275 500 i 1 2 20 71 50 69 165 90 230 300 600 130 5 8 65 325 800 135 170 250 3 4 45 350 1200 140 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 143 3770 3 1 6 3 400 3 2 10 156 2825 4 8 7 0 300 12 20 71 50 69 162 2430 5 5 7 4 3 3 16 170 1630 8 3 3 4 6 4 1200 20 170 990 9 0 3 6 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 69 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to
154. re certain precautions to ensure the safety of the operator and other people around the equipment The following safety information must be provided to each person who will operate observe perform maintenance or work in close proximity to this piece of equipment Installation operation and repairs made to the Spirit system should only be performed by qualified personnel The system makes use of both A C and D C circuitry for operation Fatal shock hazard does exist Exercise extreme caution while working on the system Ultraviolet Radiation Protection Plasma cutting produces ultraviolet radiation similar to a welding arc This ultraviolet radiation can cause skin and eye burns For this reason it is essential that proper protection be worn The eyes are best protected by using safety glasses or a welding helmet with an AWS No 12 shade or ISO 4850 No 13 shade which provides protection up to 400 amperes All exposed skin areas should be covered with flame retardant clothing The cutting area should also be prepared in such a way that ultraviolet light does not reflect Walls and other surfaces should be painted with dark colors to reduce reflected light Protective screens or curtains should be installed to protect additional workers in the area from ultraviolet radiation Noise Protection O The system generates high noise levels while cutting Depending on the size of the cutting area distance from the cutting torch and arc curren
155. ring BK279060 BK284150 Q 4 D 275A This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 11 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Cutting Charts The cutting charts shown on the following pages are intended to give the operator the best starting point to use when making a cut on a particular material type and thickness Small adjustments may have to be made to achieve the best cut wears in order to maintain the correct cutting height Cutting Chart Index Also remember that the arc voltage must be increased as the electrode Copper Silver Mild Steel 30 Amps Oxygen Oxygen Page 5 13 Mild Steel 50 Amps Oxygen Oxygen or Air Page 5 14 Mild Steel 70 Amps Oxygen Air Page 5 15 Mild Steel 100 Amps Oxygen Air Page 5 16 Page 5 43 Mild Steel 150 Amps Oxygen Air Page 5 17 Page 5 44 Mild Steel 200 Amps Oxygen Air Page 5 18 Page 5 45 Mild Steel 275 Amps Oxygen Air Page 5 19 Page 5 46 Mild Steel 400 Amps Oxygen Air Page 5 20 Page 5 47 Stainless Steel 30 Amps Air Air Page 5 21 Stainless Steel 50 Amps Air Nitrogen Page 5 22 Stainless Steel 70 Amps H17 Nitrogen Page 5 23 Stainless Steel 7
156. rnal Inova Console Option OV EIVIC WN adaa NAE E N A N DS 8 1 Plug ld ntificati n eiei eteeni eae one Mie ae Inte a ann ater sie NE ESEA ana aE 8 1 Unique Interconnect Cables cinuknnakineainnnnnamaniiamedaenieiinens 8 1 Ekolu nte aO seis2e ticicen tude T 8 2 Parts LIST nuodai inadai anaa aiaiai eiad 8 3 Appendix A Electromagnetic Compatibility EMC FBI citi ah sei ca hea nh nk Cai ek eth Se el bl cee A 1 Installation and WIS Oi orca vores iactt esa ances banc nei dca aetde anos dnd aes ined amc aanet amen ened eaciauwidmcaunct ous A 1 Assessment Of AMC aicdcc dees eee a dal ced ie lt del tote A 2 Methods of Reducing Emissions ccceeececeeeeeeeeeeeeeneeeeeeeeeeeeseeeeneeeeeeeeees A 2 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR V Prologue Spirit II User s Manual Limited Warranty KALIBURN expressly warrants that this product shall be free from defects in materials and workmanship under proper and normal use for the intended function of such product for a period of three 3 years for the Spirit Il plasma power supply includes the cooling system and internally installed Inova option and one 1 year for all other Spirit Il system component This warranty does not apply to torch consumable parts
157. rning off power and then use a voltmeter to verify that the capacitors are fully discharged before touching the power conversion module Capacitor failure can injure and or cause property damage If troubleshooting requires the system to be powered with the enclosure panels removed remain clear of the capacitors Failure of a capacitor can result in a sudden release of stored energy causing rupture of the capacitor case IMPORTANT Depending upon the system there are one two or three chopper assemblies in the power supply The following steps must be performed on each chopper with the other chopper s disabled To disable a chopper remove the plug from J1 on the chopper PCB see drawing on next page 1 Remove primary power from the Spirit system 2 Open the impulse start console door and disconnect the Green P1 Plug from the impulse start PCB Close the impulse start console door to activate the door interlock switch 3 Remove the top left right and front covers from the power supply to expose the DSP PCB input and output terminal blocks and chopper s 4 Remove the Electrode Work and Nozzle leads from the output terminal block which is located on the left side of the unit 5 Ensure the torch head with a full set of consumables is properly installed onto the torch base 6 Apply primary power to the Spirit system 7 Release the OFF Button on the Plasma Controller or Manual Gas Console to enable the system Press or
158. rols of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 3 Section 4 Operation with Manual Gas Console Spirit II User s Manual Making a Cut or Mark Once the process type gas types and gas pressures have been set in the MGC the correct torch parts consumables installed and the X Y controller and torch height control are properly configured the system is ready to cut or mark B setup on 4 Release the OFF Button turn to the right on SH the MGC On the main menu move the pointer to On Press SELECT Errors Input Gaz Version Configure The MGC will purge the gas hoses The purge Suing et a a E 150 icon is displayed during this process Voltage Adjust Gas ee Once purging is complete the ready icon if l is displayed The system is now ready to cut or mark Culling Current 150 ro When the system receives a start signal from the X Y controller the following sequence is initiated e Two second gas preflow e Impulse start circuit energized e Pilot arc initiation e Transferred arc cutting or marking arc established e Motion output relay energized Adjust Gas ie When the start signal is removed the arc is extinguished and the motion output relay is deenergized This information is sub
159. round lead Spirit Il 150 275 Spirit Il 400 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 2 Spirit II User s Manual Section 8 Internal Inova Console Option Parts List Item Part Number Quantity Description 1 BK110200 1 Printed Circuit Board PCB Microprocessor 2 BK110705 1 Printed Circuit Board PCB Power Distribution 3 BK110900 1 Printed Circuit Board PCB H Bridge 4 BK706003 1 Transformer 5 BK709360 1 F7 Fuse 6 3A 6 BK709370 1 F8 Fuse 3A 7 BK301200 1 Printed Circuit Board PCB Voltage Divider 8 BK709276 1 Power Distribution Block 1 Pole Location in Spirit Il 150 amp 275 SE QRS 5 6 F7 F8 pos A pos B This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 3 Section 8 Internal Inova Console Option Spirit II User s Manual Location in Spirit Il 150 amp 275 Continued This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U
160. rs or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 3 Appendix A Electromagnetic Compatibility EMC Spirit II User s Manual BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 4
161. s ceceeeeeeeeceeeeeeeeeeeeeeeneneeeeeeeees 3 5 Power Supply Output Connections ccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeennneeeeeeeeees 3 7 ISC Control Cable and ISC Ground Connections cccceeeceeeeeeeeeeeeeeeeeeeee 3 9 Cooling System Connections ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeeeeeeeseeseaaeees 3 9 Torch Leads to Impulse Start Console Connections ccccceeeeeeeeeeeeeeeeeeeees 3 11 Torch Leads to Torch Base Connections ccceeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeees 3 13 Forch Gas COMME CHOMS aa aa e a en ccages enc aces wee taudenes ise caceived aan Eia 3 14 Gas Supply COMNECHONG sui G cette ete etka eh te hese hehe tke heh 3 17 CAN Communication Connections ccccccceceeeeeeeeeeeeeeeeeeeeenceeeeeeeeeeeeeeeeeeaaees 3 18 CNC Machine Interface Connections ccceecceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeees 3 19 Initial Filling of the Cooling System cccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeees 3 20 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Prologue Spirit II User s Manual Section 4 Operation Operating the Manual Gas Console MGC cccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaees 4 1 Setting up to Cut s
162. s Also check the parts for any dents or distortions Irregularities in the torch parts can cause cut quality problems 1 A positive cut angle top dimension of piece smaller than the bottom dimension usually occurs when the torch standoff distance is too high when cutting too fast or when excessive power is used to cut a given plate thickness 2 Anegative cut angle top dimension of piece larger than the bottom dimension usually occurs when the torch standoff distance is too low or when the cutting speed is too slow 3 Top dross usually occurs when the torch standoff distance is too high 4 Bottom dross usually occurs when the cutting speed is either too slow slow speed dross or too fast high speed dross Low speed dross is easily removed while high speed dross usually requires grinding or chipping off When using oxygen as the shielding gas bottom dross can sometimes be removed by increasing the shield gas pressure However increasing the shield pressure too much can cause cut face irregularities see below Bottom dross also occurs more frequently as the metal heats up As more pieces are cut out of a particular plate the more likely they are to form dross 5 When using oxygen as a shielding gas cut face irregularities usually indicate that the shield gas pressure is too high or the torch standoff distance is too low 6 A concave cut face usually indicates that the torch standoff distance is too low or the shield gas pr
163. s information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 2 Spirit II User s Manual Section 1 Safety Fire Prevention e Never change torch consumable parts unless the system is switched off at the wall disconnect e Do not attempt to remove any parts from beneath the torch when cutting Remember that the workpiece forms the current path back to the power supply e Never bypass the safety interlock devices e Before removing any of the covers switch the system off at the wall disconnect Wait at least five 5 minutes before removing any cover This will give the capacitors inside the unit time to discharge See Section 6 for additional safety precautions e Never operate the system without all of the covers in place See Section 6 for additional safety precautions e Preventive maintenance should be performed daily to avoid possible safety hazards Chi When using the Spirit system it is necessary to exercise good judgment While cutting the arc produces sparks that could cause a fire if they fall on flammable materials Make sure that all flammable materials are a suitable distance away from the cutting area All flammable liquids should be at least 40 feet away from the cutting area preferably stored in a metal cabinet Pla
164. s or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 3 Section 3 Installation Spirit II User s Manual Optional Customer Supplied ro CAN Termination To Star Plug Ground p To Star Ground CNC Controller Positioner F Cable B Cable Notes 1 If only the Inova Remote is used to set Inova parameters then follow the configuration shown E Cable Inova 2 If only the CNC Controller is used to set Inova To Star Console parameters no Inova Remote then Ground e add the G Cable from the Inova Console gt P6 to the CNC Controller e remove the A Cable from the configuration shown 3 If both the CNC Controller and Inova Remote are used to set Inova parameters then e add the G Cable from the Inova Console P6 to the CNC Controller Voltage Divider D Cable 2 Gang Manifold PRC Cabs 5 Gang Manifold Cooling System Control To Star Ground Cooling System Impulse Start Console Positioner Star Ground Work Piece Figure 2 Spirit II System with Manual Gas Console and External Inova System This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirem
165. s purge or when an error occurs The contacts are rated for 24VDC 10mA This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 19 Section 3 Installation Spirit II User s Manual Filling the Cooling System A WARNING Do not touch the fans inside the cooling system Important Never turn on the system when the coolant reservoir is empty Important When handling coolant wear nitrile gloves and safety glasses Important Only use Kaliburn approved coolant Commercially available antifreeze contains corrosion inhibitors that will damage the cooling system See Section 2 for more information Remove primary power from the Spirit system Ensure the torch base and torch head with consumables are properly installed Ensure the coolant supply in and out hoses are properly installed E OCN Remove the coolant reservoir cap level gauge and then remove the cover from the cooling system Ensure the coolant filter housing is tightened securely Ensure the drain petcock on the bottom of the reservoir is tightened securely Fill the reservoir with approximately 2 1 2 gallons of approved coolant Gon 2k OS LOT Apply primary power to the Spirit system and enable it by releasing turn right the OFF Button on the MGC 9
166. sferred by any means to any location outside the United States contrary to the requirements of the EAR 5 40 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 275 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277263 BK277276 BK277270 j Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277258 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 160 160 160 275 400 160 1 2 165 125 180 300 500 f 5 8 168 105 190 350 600 165 3 4 20 73 65 75 172 85 200 800 i 1 00 180 60 240 400 170 1 25 185 45 260 1000 1 50 190 25 270 180 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 160 3930 4 1 7 1 500 4 1 12 163 3375 4 4 7 4 16 168 2645 4 8 8 9 800 4 2 20 20 73 65 75 173 2055 5 3 25 179 1565 6 0 10 2 4 3 32 185 1120 6 6 1000 38 189 645 6 8 4 6 Marking For All Material Thicknesses Arc Travel Markin
167. sma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 68 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 26 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 150 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277298 BK277297 BK277135 f 9 I Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277139 BK279100 Imperial Material a Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts
168. sma cutting should never be attempted on containers that contain flammable materials Make sure that fire extinguishers are readily accessible in the cutting area Make sure that the cutting area is properly ventilated when using oxygen as a cutting gas Explosion Prevention The Spirit system uses compressed gases Use proper techniques when handling compressed gas cylinders and other compressed gas equipment Observe the following guidelines to protect against explosion e Never operate the system in the presence of explosive gases or other explosive materials e Never cut pressurized cylinders or any closed container e When using a water table and cutting aluminum under water or with water touching the underside of the aluminum plate hydrogen gas is produced This hydrogen gas may collect under the plate and explode during the cutting process Make sure the water table is properly aerated to help prevent the accumulation of hydrogen gas e Handle all gas cylinders in accordance with safety standards published by the U S Compressed Gas Association CGA American Welding Society AWS Canadian Standards Association CSA or other local or national codes This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 3 Section 1 Sa
169. so ensure that the lubricant is placed only on the o rings Excess lubricant can interfere with gas flow which can cause starting problems poor cut quality and short consumable life 1 Unthread the torch head from the torch base by turning the attachment ring to the LEFT Verify the torch base doesn t unthread from the torch handle 2 Remove the outer retaining cap from the torch head 3 Remove the inner retaining cap from the torch head 4 Separate the shield cap from either the inner retaining cap or the outer retaining cap Use the nozzle removal tool P N BK277056 to remove the nozzle from the torch head To do this insert the tool into the groove on the nozzle and hold the tool nozzle in the palm of your hand Pull both hands apart using a linear motion as shown in the left image below Do not use a prying or bending motion as shown in the right image below R Use the swirl ring removal tool P N BK260105 to remove the swirl ring from the nozzle Remove the electrode from the torch head using the appropriate tool e 400A copper electrodes use socket P N BK284052 amp driver P N BK277086 e All other copper electrodes use socket P N BK277087 amp driver P N BK277086 e All silver electrodes use P N BK279061 Inspect all consumables and o rings for damage and excess wear Replace with new consumables as necessary Inspect the cooling tube in the torch head for damage See Section 6
170. t be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 14 Spirit II User s Manual Section 7 Parts List JIP Cable for Optional Internal Inova Part Number Length BK300904 XX Where XX is the length in feet Available in 10 foot increments CONSOLE 1 CONSOLE 2 IP8 24 POS IP4 24 POS STRAIN RELIEF BK709025 STRAIN RELIEF BK709021 PLUG BK709020 CABLE BK711049 PLUGBK709364 TERMINAL POSITION NO COLOR POSITION NO TERMINAL BK709018 SOCKET 5 oz ame RED 5 BK709365 PIN 6 BLACK __ 6 22 15 WHITE 15 16 BLACK _ 16 13 BROWN 13 14 BLACK 14 23 1 GREEN 1 2 BLACK 2 7 YELLOW 7 8 BLACK 8 24 9 BLUE 9 10 BLACK 10 EE i 4 BLACK 4 BK709365 PIN 19 20 C RED XX 20 WHT x 20 I 21 RED x 21 GRN Xxx BK709018 SOCKET 21 BK709019 KEY This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 15 Section 7 Parts List Spirit Il User s Manual PCB Assemblies Component Reference Locations Power Supply Microprocessor DSP BK300101 Quadrant 1
171. t cutting level acceptable noise levels may be exceeded Proper ear protection should be used as defined by local or national codes See Section 2 for noise emission levels This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 1 Section 1 Safety Spirit II User s Manual Toxic Fume Prevention i Care should be taken to ensure adequate ventilation in the cutting area Some materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the cutting area Also some solvents decompose and form harmful gases when exposed to ultraviolet radiation These solvents should be removed from the area prior to cutting Galvanized metal can produce harmful gases during the cutting process Ensure proper ventilation and use breathing equipment when cutting these materials Certain metals coated with or containing lead cadmium zinc beryllium and mercury produce harmful toxins Do not cut these metals unless all people subjected to the fumes wear proper air breathing equipment Electric Shock Prevention A PA The Spirit system uses high open circuit voltages that can be fatal Extreme care should be used when operating or performing maintenance on the system Only qualified personnel should service the system
172. t of the power supply to the impulse start console and the work table See Figure 4 on the next page Power Supply Electrode Lead O 1 Route one end of the 4 0AWG power supply electrode lead through the upper strain relief on the rear of the power supply and connect it to the electrode terminal 2 Route the other end of the power supply electrode lead through the strain relief on the impulse start console and connect it to the cathode manifold ee Supply Nozzle Lead 2 Route the larger ring terminal end of the 10AWG power supply nozzle lead through the bushing on the rear of the power supply and connect it to the nozzle terminal 2 Route the smaller ring terminal end of the power supply nozzle lead through the strain relief on the impulse start console and connect it to the pilot terminal on the printed circuit board pte Supply CTP Sensor Lead 3 Route the ring terminal end of the 14AWG power supply CTP sensor lead through the bushing on the rear of the power supply and connect it to the CTP terminal 2 Route the FASTON end of the power supply CTP sensor lead through the strain relief on the impulse start console and connect it to the CTP sensor lead with FASTON connector Work Ground Lead 1 Route one end of the 4 0AWG work ground lead through the bottom strain relief on the rear of the power supply and connect it to the work terminal 2 Connect the other end of the work ground lead to the star ground point on the cutting ta
173. tem has been tested in accordance with CISPR 11 EMC classification Group 2 ISM Class A The limits used in this standard are based on practical experience However the ability of plasma cutting equipment to work in a compatible manner with other radio and electronic systems is greatly influenced by the manner in which it is installed and used For this reason it is important that the plasma cutting equipment be installed and used in accordance with the information below if electromagnetic compatibility is to be achieved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installation and Use The user is responsible for installing and using the plasma cutting equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the plasma cutting equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the plasma cutting circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the plasma power source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer troublesome Note The plasma cutting circu
174. tems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 46 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 400 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK284123 BK284125 BK279460 black o ring ay fa Sy Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK284121 BK279422 BK279060 Imperial Material p Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 140 160 140 300 500 150 5 8 135 350 600 155 3 4 S 110 alge 400 800 160 1 150 85 160 500 1000 180 1 25 155 60 175 600 1500 190 1 5 30 79 70 76 160 50 225 700 2000 1 75 162 40 260 800 3000 200 2 00 165 33 270 1 00 4500 210 2 25 170 20 280 350 1000 235 2 50 182 15 300 350 1300 245 2 75 185 12 325 350 1500 245 3 00 195 8 350 350 2000 2
175. the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 13 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 50 amps Oxygen Plasma Oxygen or Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277115 BK277122 BK277131 ZS lt a 5 9 D Ji Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK277142 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voitage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in Cold Rolled Steel Oxygen Shield Swirl Ring BK277140 12 105 123 70 120 100 075 11 120 25 74 12 72 126 60 125 135 200 078 10 135 128 50 135 Hot Rolled Steel Air Shield Swirl Ring BK277142 14 075 200 100 075 12 105 106 190 100 135 125 180 25 74 19 72 200 080 10 135 110 170 110 3 16 113 105 140 200 300 08
176. tion 178 Rexdale Boulevard Toronto Ontario M9W 1R3 Canada This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 6 Spirit II User s Manual Section 2 Specifications Section 2 Specifications System Description The Spirit II 400 is a 400 amp microprocessor controlled 100 duty cycle high current density plasma cutting and marking system It utilizes a precision dual gas torch that is capable of cutting mild steel up to 3 thick and stainless steel up to 1 1 2 thick The system contains a manually controlled gas console which also provides the primary interface to the entire Spirit system For cutting mild steel the system uses oxygen for the plasma gas and either oxygen or air for the shielding gas When cutting stainless steel or other non ferrous materials air or H17 17 5 hydrogen 32 5 argon 50 nitrogen is used for the plasma gas and either air or nitrogen is used for the shielding gas Oxygen and nitrogen are used for the preflow and postflow gases The torch is water cooled and consumables are machined to exacting dimensions and checked with the latest computerized measuring systems Nine nozzle sizes 30 50 70 100 150 200 260 275 and 400 amps are available to produce excellent cut quality throu
177. tion of the power supply will provide dependable service and reduce periodic maintenance time Choose a location that will provide unrestricted air movement into and out of the power supply Maintain at least 24 inches of space on all sides of the unit The location should subject the power supply to the least amount of dust dirt moisture and corrosive vapors The surface on which the power supply is located should have a grade of no greater than 10 to eliminate the risk of toppling over This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 1 Section 3 Installation Spirit II User s Manual The power supply must be cleaned as often as necessary to prevent the accumulation of metallic dust inside the unit See Section 2 for unit dimensions Manual Gas Console MGC The MGC should be mounted near the CNC controller so that it is easy accessible by the operator See Section 2 for mounting dimensions Impulse Start Console ISC The ISC should be mounted in a convenient location that is away from other electronic control devices The ISC offers significantly reduced emissions compared to traditional high frequency however the high voltage pulse generated inside the unit may interfere with the operation of sensitive control electr
178. tions EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 2 Spirit II User s Manual Section 4 Operation with Manual Gas Console Setting up to Mark Overrides Cut The system will automatically switch between cutting and marking based upon commands in the part program However all cutting commands in the part program can be overridden with marking commands by simply changing the Process to Marking Push the OFF Button on the MGC to disable the system On the main menu move the pointer to Setup Press SELECT b Setup mij Errors Input Gaz Version Configure tularkin Press SELECT to cycle through the list until warkhi i A A Eren 150 Marking is displayed Move the pointer to Select Gas Return and press SELECT Adjust Gas Rebum The system is now setup to mark instead of cut Verifying Input Gas Pressures For the system to work properly the input gas pressures must be within an acceptable range To check the input pressures follow the steps below On the main menu move the pointer to Input Gas Press SELECT Errors Version Configure Verify that all connected gas pressures are at least 120psi The maximum input gas pressure is 145psi Press SELECT to return to the main menu This information is subject to the cont
179. to avoid damaging the torch base Torch Lead through Torch Handle Installation e Route the torch leads through the torch handle Note that the threaded end of the torch handle mates with the torch base Torch Electrode Coolant Supply Lead e Connect the torch electrode coolant supply lead to the torch base as shown Torch Coolant Return Lead 7 e Connect the torch coolant return lead to the torch base as shown Note that the torch coolant return lead fitting has left hand threads Torch Nozzle Lead e Connect the torch nozzle lead to the torch base as shown Torch CTP Sensor Lead e Connect the torch CTP sensor lead to the torch base as shown Figure 7 Torch Leads to Torch Base Connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 13 Section 3 Installation Spirit II User s Manual Torch Gas Connections Perform the following steps to connect the torch gas hoses to the manual gas console torch base and manifold assemblies See figure 8 Note When making hose connections only tighten the brass fittings enough to make gas seals The fittings are subject to damage if over tightened 7 5 Foot Shield Gas Hose 1 Route one end of the 7 5 foot 2 3 m shield gas hose through the torch handle and connect
180. tting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 33 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 400 Amps Nitrogen Plasma Air Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK284155 BK284157 BK284159 9 D Ji Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK284156 BK284122 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 175 130 210 300 600 165 5 8 170 110 170 350 800 3 4 165 90 150 400 1200 1 170 65 150 500 1500 200 30 85 63 96 1 25 175 45 160 700 2000 1 5 180 35 170 800 2500 1 75 190 25 190 350 205 1500 2 00 205 15 210 350 Metric Material e Arc Trav
181. ure that must be followed before returning any items for repair replacement or restocking This means that a returned goods authorization number must be obtained prior to shipment to KALIBURN It will be necessary for the customer to provide a description along with the part number and serial number if applicable of the item to be returned In no case will KALIBURN accept a returned shipment without the proper returned goods authorization number For shipments inside the U S parts must be returned to KALIBURN within 30 days of the invoice date to be considered for credit For shipments outside the U S parts must be returned within 60 days of the invoice date to be considered for credit Electromagnetic Compatibility EMC The 380V 50 60Hz and 415V 50 60Hz CE marked Spirit Il plasma cutting systems are manufactured to comply with the European standard EN 60974 10 Electromagnetic compatibility EMC Product standard for arc welding equipment Information about the EMC standard EN 60974 10 can be found in Appendix A This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR vi Spirit II User s Manual Section 1 Safety Section 1 Safety General Precautions Whereas plasma cutting has been used safely for years it does requi
182. version and serial number for the Power Supply and Gas Console can be displayed as described below Setup Errors Version Configure E Supply Console Fetum Hardware 65 Software og Geral 01234567 014 On the main menu move the pointer to Version Press SELECT Move the pointer to either Power Supply or Gas Console Press SELECT Review the necessary information Press SELECT to return to the previous screen Move the pointer to Return and press SELECT to return to the main menu This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 7 Section 4 Operation with Manual Gas Console Spirit II User s Manual Changing the Language The language displayed on the MGC can be changed as described below On the main menu move the pointer to Configure Press SELECT Setup On 4 Errors Input Sag Version Configure Press SELECT on Languages Contrast Engish Move the pointer to the desired language and espa ol then press SELECT The display changes italiano immediately to the selected language Deutsch Move the pointer to Return and press SELECT to return to the previous screen Repe

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