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1. Olo Diode Bridge Terminals 6 o O hy O N iB ii O Oi fo Chopper PCB gt gt s J1 Plug _ D2 Green LED is under J1 Plug Top View of Chopper 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 9 With a start signal applied check 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 Amp 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 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
2. Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 brown o ring _ a OD I D a Z Z f 7 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 Postfow 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 gt 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 SANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height
3. 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 BK300221 BK300229 Top View Item Part Number Quantity Description 1 BK501163 1 Light Housing 2 BK501164 1 Bulb 3 BK501162 1 White Lens 5 BK706409 1 T2 Control Transformer 200 480 V 60 Hz BK706410 T2 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 13 BK709061 2 F1A F1B Fuse Holder 14 BK709128 2 F1A F1B Fuse FNM 6 25A 18 BK500518 1 Coolant Reservoir Cap Level Gauge 38 BK300250 2 Chopper Assembly 41 BK708103 2 Fan CR5 Relay 42 BK708104 2 Relay Socket 43 BK708105 4 Relay Hold Down Clip 1 213 38 38 O A342 41 7X8 X9 X10 A1 42Y43 F3 F4 F5 F6 pos 1 pos 4 pos 12 pos 17 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 con
4. 30A BK284150 BK277149 BK277110 BK277123 BK277142 BK277137 BK279100 50A a Op BK284150 BK277150 BK277153 BK277125 _BK277142 BK277131 BK279100 70A 2 g Y BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100 100A 9 O e 5K284150 BK277117 BK277152 BK277293 BK277139 BK277292 BK279100 150A 2 D ps m E o a a a a Sala Data ae a a BK284150 BK277289 BK277143 BK277291 BK279100 T Q D BK284150 BK277263 BK277266 BK277276 BK277258 BK277270 BK279100 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 10 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 BK284150 BK277286 BK277151 BK279484 BK279483 a BK279060 100A OD val jt BK284150 eae BK279060_ OD Q BK284150 Q BK277266 BK279489 BK279443 PR 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 req
5. L 7 9 178 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 Section 2 Specifications Spirit II User s Manual Gas Supply Requirements Plasma gas types Mild SSt Clive toc osetenctt dette ieii eieaa Oxygen Stainless Steel 2 2 sccccee eee Air or H17 AIUMINUM eeaeee reneis Air Shield gas types Mild Steel Oxygen or Air Stainless Steel nnnnnnnnnnneeneeneeeeereeeeen Air or Nitrogen AlUMINUM 54 Pees cece tees aed tees cave teee caus tees cceeteeecd Nitrogen Preflow gas type cceccccnececeeeneceneeenecenenenenenene Oxygen and Nitrogen Marking gas type cccccecceeeeeeeeeeeeeeeeeeeeeeeeetees Nitrogen Plasma gas flow rate maximum ORVOEM ON PIE ces cccst ee Secs tise er enrica roerei eerst 67 scfh 1897 liters hour UU Los ted ed tial AE oho a eo 75 scfh 2124 liters hour Shield gas flow rate maximum YOGA sae cesecesecentrencecncpeaccentceuccesecesecentcesecent 19 scfh 538 liters hour Air or Nitrogen n 225 scfh 6371 liters hour Preflow gas flow rate maximum 60 scfh 1699 liters hour Marking gas flow rate maximum 79 scfh 2237 liters hour Rated Inlet gas PreSSUre ccec
6. Retaining Cap Swirl Ring 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 Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 WGN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Revised 04 26 2013 This information is subject to the controls of the Export Administration
7. Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 A X 9 yp 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 4 125 150 090 200 300 3 8 430 100 130 250 400 090 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 4 7 1000 2 4 20 145 800 9 0 Marking For All Material Thicknesses i 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 2 5 100 2 5 0 NANNE Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition h
8. Item Part Number Length 2 Gang Manifold BK280312 XX Where XX is the length in feet 5 Gang Manifold BK280321 XX 10 150 ft lengths available in 10 ft increments 2 GANG MANIFOLD CONTROL CABLE POWER SUPPLY 2 GANG MANIFOLD 5 GANG MANIFOLD CONTROL CABLE 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 contrary to the requirements of the EAR 7 10 Spirit II User s Manual Section 7 Parts List Gas Hose Package with MGC Part Number Length BK300086 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Custom lengths are available Contact factory PREFLOW HOSE MGC 5 GANG MANIFOLD SHIELD HOSE MGC 5 GANG MANIFOLD PLASMA HOSE MGC RED 2 GANG MANIFOLD POSTFLOW HOSE MGC 1_ 5 GANG MANIFOLD 7 5 FOOT SHIELD HOSE 5 GANG MANIFOLD BLUE TORCH 6 FOOT PREFLOW POSTFLOW ot 5 GANG MANIFOLD aye GREEN age 2 GANG MANIFOLD This information is subject to the controls of the Export Adm
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 6 Spirit II User s Manual Section 7 Parts List Arc Starting Console BK300510 with Remote High Frequency RHF Item Part Number Quantity Description 1 BK715051 2 Coolant return fitting left hand 2 BK715050 1 Coolant supply fitting right hand 3 BK709227 1 Strain relief 5 BK709001 1 4 pin receptacle 6 BK707001 1 Line filter 7 BK706109 1 Transformer 5000V 20 mA 8 BK702069 1 Capacitor 15 kV 9 BK708057 1 Door interlock switch 10 BK500014 1 Spark gap assembly 11 BK740039 3 Spark gap electrode 12 BK505043 1 High frequency inductor 13 BK740072 2 Standoff 14 BK800041 1 Busbar 15 BK500505 1 Printed Circuit Board PCB ASC 16 BK715021 1 Coolant supply fitting right hand 17 BK500503 1 Cathode manifold 18 BK205010 1 CTP sensor lead filter assembly 19 BK200287 1 Transformer insulating plate 22 BK500098 1 Ground cable 14 13 6 7 8 9 10 11 12 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
10. 3 16 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 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 Manifold 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 suppl
11. Incorrect gas pressure settings Pilot arc transistor PAT is not 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 N gt 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 the manual gas console screen is blank The manual gas console screen is on but the screen doesn t work Gas pressures will not adjust properly Low pressure error Pressure error during cut Liquid or torch coolant leaking from drain hole in torch handle Consistently receiving error code 10320 Possible Cause 1 Check power communications CAN cable connection on back of manual gas console 2 Check for blown DIN rail fuse 3 Che
12. 11 Check for coolant leaks at all hose connections the arc starting 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 power supply covers 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 22 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 II system It includes a display to access all settings as well as the adjustment regulator knobs used to manually adjust the gas pressures necessary for cutting and marking OFF Button Display Push in to disable the Spirit II The display turns on automatically system Release turn to the right when AC power is applied to the to enable the system Spirit II system It displays the menu tree which is navigated using the Up Down Select buttons Up Down Select Buttons Press the up A or down V button to move the pointer accordingly on the display Pr
13. 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 i 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 WYN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 275 7 0 mm for cutting and 100 2 5 mm for marking 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 40 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 100 Amps Silver Electrode Oxygen Plasma Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 brown o ring _ 2 D Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK27
14. Goods will be free of defects in workmanship and material subject to the terms of this Limited Warranty WARRANTY REMEDY Purchaser must promptly report any defect or failure of the Goods to Kaliburn an authorized service center or an authorized OEM integrator distributor Such notice must be in writing and received within the warranty periods set forth herein Upon receiving such written notice and if Kaliburn or Kaliburn s authorized service facility confirms the existence of a defect covered by this warranty Kaliburn will at its sole option repair or replace the defective Goods At Kaliburn s request the purchaser must return to Kaliburn or its authorized service facility any Goods claimed to be defective Kaliburn reserves the right to refuse to perform the warranty remedies set forth herein if the Goods are not received by Kaliburn within sixty 60 days of the return request date The purchaser is solely responsible for shipment of any defective Goods to and from Kaliburn s facility or that of its authorized service facility and all related freight costs WARRANTY PERIODS All warranty periods start from the date of shipment from Kaliburn PARTS FOR All Plasma Power Supplies Gas Consoles Cooling Tower Plasma Controllers for the Spirit Il series as applicable Spirit series as applicable ProLine series as applicable Dagger 100 and other legacy plasma cutters Three 3 years Integr
15. ccccceeeececeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 3 Torch Coolant Specifications cccccceeeeseeeeeeeceeeeeeeesseeeeeeeeeeeeeees 2 4 Manual Gas Console MGC Specifications c ccccceeeeseeeeeeees 2 5 Gas Supply Requirements sccivscarncreriinteraiavecientn cg chesercokeeareasesnvecaunsts 2 6 Arc Starting Console ASC Specifications with RHF 006 2 7 Arc Starting Console ASC Specifications with CleanStrike 2 8 Torch and 2 Gang Manifold Specifications cccceeeeeeeeeeeeeeeeeeeees 2 9 5 Gang Manifold Specifications cc ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 10 Airborne Noise EMISSIONS eseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaeeeees 2 11 Electromagnetic Compatibility EMC 0 0 eeeeeeeeeeeeeeeeeeeeeeeeeeeee 2 11 Section 3 Installation Initial APIS DECOR 4 des cine dene dent cate ded ovadand dune lsh eona e e dom oe miata 3 1 Component Placement ccccccccecceeeeeseeeeeeeeeeeeeeaesseeeeeeeeeeeeeees 3 1 System InterconnectiOn c2 2 aiee et eee eee aeons 3 2 Power Supply Primary Power Connections seeeeeeeeeeeeeeeeeeeee 3 5 Power Supply Output Connections ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 3 7 ASC Control Cable and ASC Ground Connections cccceeeee 3 9 Cooling System Connections 3 9 Torch Leads to Arc Starting Console Connections 066 3 11 Torch Leads to Torch Base Conne
16. 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 SNN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 150 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 A i a OD D Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK277139 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width in
17. 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 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 ri Oxygen or Air Use an arc transfer height ignition height of 050 1 3 mm for cutting and 100 2 5 mm for marking Revised 04 26 2013 Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as 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 User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 50 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277149 BK277123 BK277137 9 OND D Outer Cap Retai
18. 200 1500 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 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 NANNE Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking 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 Chart
19. 6 BK820209 1 O ring red T7 BK500024 1 O ring blue 8 BK500018 1 O ring red 9 BK279013 1 O ring red indicator only not a seal 10 BK279112 2 O ring red 11 BK279113 6 O ring red 12 BK284039 1 17 Torch Solenoid Plasma Hose 13 BK300075 1 5 Gang Manifold Not shown BK716012 1 O ring Lubricant Not shown BK277056 1 Nozzle Removal Tool Not shown BK260105 1 Swirl Ring Removal Tool Not shown BK277086 1 Copper Electrode Installation Removal Driver Not shown BK277087 1 Copper Electrode Installation Removal Socket Not shown BK279061 1 Silver Electrode Installation Removal Tool 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 9 Section 7 Parts List Spirit II Users Manual Shielded Torch Leads Part Number Length BK284304 XX Where XX is the length in feet 4 10 ft lengths available in 1 ft increments 15 150 ft lengths available in 5 ft increments O CAN Communication Cable and Termination Plug Item Part Number Length CAN Cable BK300177 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Manifold Control Cables
20. Cull Quality ssas crai soba coarse s ohanate Gane Gia aia a a oot oxi oa 4 7 Checking EOTS ipa atlas the lea e e E e A Enit 4 8 Checking the Version Number 4 8 Changing the Language 4 9 Adjusting the Screen Contrast cccccccccseeecceeeeeeetenereeeeeseneeetenereeees 4 9 Section 5 Torch Consumables and Cutting Charts Installing Removing the Torch Head 5 1 Installing Replacing Consumables ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 5 3 Maximizing Consumable Life cece eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeea 5 5 Inspecting for DAMAaGEe ccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeetess 5 6 Selecting Consumables seicassiscv ccs selescn see eee Seen sede 5 7 LUI SS AS gs ha EEE aed a dad ed a sa ed ca es 5 14 Section 6 Maintenance and Troubleshooting Routine Maintenance so oc 25h cc cc eteeceenst acmersee cake tedd tec esved cone eed eeteseeues 6 1 Replacing the Torch Coolant and Filter 6 4 Power Supply Microprocessor DSP Status Indicators 6 5 Power Supply Microprocessor DSP Sequence of Operation 6 6 Eror OOS 52235 e 2 Blo Farad 2 the toh eof 6 7 General Troubleshooting 2 2 2 2 c c 0 sce ceeeeseeceeeeeeeceeeeneeceeeeneeceeees 6 9 Chopper Test PEG CS I stad Sess oe bed Sess Stead Gees Seas Eae 6 11 Section 7 Parts List Power Supply BK300221 BK300229 ccccceeeteeeeeeeeeeeeeeeeeeeees 7 1 Manual Gas Console BK300610 cece eeeeeeee
21. Legend E Cable Inova j Console Shield Supplied zo Star Hose paranana Optional Customer Supplied Voltage Divider Notes D Cable Pe Foot 1 2 Gang 1 If only the Inova Remote is used to set Inova PostFlow Manifold parameters then follow the configuration shown Power See Hose le 2 If only the CNC Controller is used to set Inova parameters no Inova Remote then e add the G Cable from the Inova Console 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 Cll Cab 5 Gang Manifold 7 5 Foot Shield H Gang Manifold Control Cabl Gang Manifold Control Cabl SC Control Cable Arc Starting Console Positioner oolant Return Ho lant Supply Hoses gg _ _ A L Star Ground Figure 1b Spirit II System MGC External Inova ASC with RHF Work Piece 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 4 Spirit II User s Manual Section 3 Installation ic noneeeenenne Shield GaS HOSC 002eeeeeeeeeeeeeeees oe Remote tc O T L Pla
22. Oxygen Plasma Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277274 BK279489 BK279440 yellow o ring Op am a tf 7 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 4 125 230 040 200 300 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 TO Toot 1 147 50 175 450 1000 455 1 25 155 25 240 500 i 1 50 165 17 300 350 1500 158 1 75 175 12 350 2 00 185 7 500 500 160 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 oo oo __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
23. 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 5 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 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 EARE PUL gt IARE or i 6 Use the swirl ring removal tool P N BK260105 to remove the swirl ring from the nozzle 7 Remove the electrode from the torch head using the appropriate tool e All copper electrodes use socket P N BK277087 amp driver P N BK277086 e All silver electrodes use P N BK279061 8 Inspect all consumables and o rings for damage and excess wear Replace with new consumables as necessary 9 Inspect the cooling tube in the torch head for damage See Section 6 Maintenance and Troubleshooting if replacement is necessary This information is subject to the controls of the Expo
24. 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 Power Supply Specifications ae Input Current at Power Supply Description Part Number Maximum Output 208 VAC 30 60Hz BK300221 163 amps 220 VAC 30 60Hz BK300222 153 amps 240 VAC 30 60Hz BK300223 140 amps 380 VAC 3G 50 60Hz BK300224 88 amps 400 VAC 3G 50 60Hz BK300225 84 amps 415 VAC 3 50 60Hz BK300226 81 amps 440 VAC 3G 50 60Hz BK300227 76 amps 480 VAC 30 60Hz BK300228 70 amps 600 VAC 30 60Hz BK300229 56 amps Open Circuit VOMGGCs 5 50 220252ssvasesartedstedeteaentene 325 VDC Output Current drooping characteristic 10 275 amps Maximum Output Voltage 0 0 0 0 eeeeeeeeeeeeeeeeeee 180 VDC D t Cycle Sine eee enone Pernt E 100 44 kw Maximum Ambient Temperature Coolant Discharge Pressure Coolant Flow Rate ee Coolant FlUIC ceeeeeeeeeeeeeees Coolant Tank Capacity Weight without coolant rere rarer 104 F 40 C E 1
25. 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 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 Also remember that the arc voltage must be increased as the electrode wears in order to maintain the correct cutting height Current Preflow amp Plasma Copper Silver Postflow Gas Gas Electrode Electrode Mild Steel 30 Amps Air Oxygen Oxygen Page 5 15 Mild Steel 50 Amps Air Oxygen Oxygen or Air Page 5 16 Mild Steel 70 Amps Air Oxygen Air Page 5 17 Mild Steel 100 Amps Air Oxygen Air Page 5 18 Page 5 41 Mild Steel 150 Amps Air Oxygen Air Page 5 19 Page 5 42 Mild Steel 200 Amps Air Oxygen Air Page 5 20 Page 5 43 Mild Steel 275 Amps Air Oxygen Air Page 5 21 Page 5 44 Stainless Steel 30 Amps Air Air Air Page 5 22 Stainless Steel 50 Amps Air Air Nitrogen Page 5 23 Stainless Steel 70 Amps Nitrogen H17 Nitrogen Page 5 24 Stainless Steel 70 Amps Air Air Nitrogen Pa
26. o I Fa a 10 Q u12 pg 7 O t a 0 2 A N Buse 2 epee Of Ss IEL SEL LFO u14 Vivo 2 QRL oe 22 50 S RG cna 5 HES E EEEO FED Drga EOY P Sto a RI swi Aas Le ee o S g uo gegen LJ Z Fr rans oy 3 3 E 7 oarre re C R183_ Rao ii PTS H RI82_ R42 B R24 E l g 7 we N LJ R43 C163 ws E 2 pi R 6 a c g Hp g tio e a E D 5 EMi4 Q ray ie em cin x l lt R311 t 5 ciio R220 m L2 u11 x R310 C26 R309 g caen cTe2 i a B303 hd R175 R177 L C25 R176 R178 i R330 L11 c56 R307 c3 c60 o 3 of R331 c53 TP5 C17 u9 m ase De cai O rrr a g R sE a Foy Clee et C28_ RS 3 ot TP11 TP10 s I I S g Bi g R4 R39 B a l g j ia c63 cei 5 E E R223 R169 R171 E c95 L_ c140 C158 C159 c51 AUUT Dor C 8 iS O t MH3 J17 J17 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 25 Section 7 Parts List Spirit II User s Manual Gas Console Microprocessor DSP BK300301 PMGC Quadrant 4 ee PCB Quadrant Map is a ae U nN S l A Q g sl Li az B
27. of 250 6 4 mm for cutting and 100 2 5 mm for marking 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 Aluminum 150 Amps Silver Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 green o ring _ a i J 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 4 145 145 130 250 400 498 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 95 10
28. 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 SZN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 100 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 N A 9 OMD D Z J 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 Heigh
29. taal Review the necessary information EDIT 4 Hardware 55 camare G5 Press the select button to return to the previous screen Move the pointer to Return and press the select button 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 4 Operation with Manual Gas Console 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 the select button Setup OF Errors Input Gas Version Configure Press the select button on Languages aE Move the pointer to the desired language and espa ol cate then press the select button The display eo hilar changes immediately to the selected language Deutech Retum Move the pointer to Return and press the select button to return to the previous screen Repeat 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 Setup Or Configure Press the select button Errors Input Gas Version orfiqure Move the pointer to Contrast Pr
30. 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 2 5 100 2 5 0 NANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 275 Amps Copper Electrode Oxygen Plasma Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277263 BK277269 BK277270 A gt y 9 AD 6 i j f f 7 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK2772
31. 3 7 100 2 0 3 134 4420 1 7 4 3 5 145 1920 2 3 5 2 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 NANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking 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 100 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Outer Cap Shield Cap BK277286 Nozzle BK277284 2 D Electrode BK277282 Torch Head 7
32. Airborne Noise Emissions The system generates high noise levels while cutting Depending on the size of the cutting area distance from the cutting torch 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 275 amps 145 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 110 dB 107 dB The maximum noise level is 127 dB at a distance of 3 inches 76 2 mm from the torch while cutting at 275 amps 145 arc volts Electromagnetic Compatibility EMC The 380V 50 60Hz and 415V 50 60Hz CE marked Spirit II 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 2 11 Section 2 Specifications Spirit II User s Manua BLANK
33. 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 16 Spirit II User s Manual Section 7 Parts List PCB Assemblies Component Reference Locations Power Supply Microprocessor DSP BK300101 Quadrant 1 Oa PCB Quadrant Map N J20 AUX 03 RHF AUX 02 Ns AUX 01 MOV5 ja nas Q a Dy wn gt n E PA GSV_GND GSV_GND GSV _24V a 5 Gsv 1 7 U 8 C U37 RHF O U36 Arc Starting u37 N NI Es n7 13 REMOTE ON OFF CORNER MARK HOLD STRT oe Bo To iit E g z R186 EMI2 R127 R128 cia ca 5 g PA E 8 a 2 R269 R272 ou 5 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 2 i 8 8 amp Dido U28 Plasma U2
34. CleanStrike Technology are only recommended for use with downdraft cutting tables a 8 00 203 aa 4 312 8 12 75 324 12 00 305 13 50 343 G2 T j e ae 10 00 254 Hm l 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 BK284214 Torch Handle Standard ccccccccceeeeeeeeeceeeeeeeeeeeeeeeeeeeeees BK278001 Torch Handle SHON eeaeee eee BK278018 LOr BaSe ea aan er vane ere ene RA RAE RA EEEE rere BK279000 Torch Head Copper Electrode ccceeceeeeeeeeeeeeeeeeees BK279100 Torch Head Silver ElectrOd ccccccccceeeeeeeceeeeeeeeeeeeeeeeeeees BK279060 Max Weight Manifold Bracket Handle BK278001 Base and Head 8 3 Ibs 3 8 kg Manifold 3 38 86 E5 HN To
35. Control Cable 1 Connect the ASC control cable plug labeled P16 to the connector labeled P16 on the rear of the power supply 2 Connect the ASC control cable plug labeled P1 to the connector labeled P1 on the arc starting console ASC Ground Cable 6 1 Connect one end of the ASC ground cable to the ground stud on the arc starting console 2 Connect the other end of the ASC 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 arc starting 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 power supply 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 arc starting 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 power supply 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 arc starting console Note that the coolant out fitting has left hand threads This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided
36. 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 2 5 100 2 5 0 NANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 43 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 275 Amps Silver Electrode Oxygen Plasma Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277263 BK279469 BK279450 red o ring WTA N OD l Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK279458 BK279060 Imperial Material Arc Travel Cutting Pierce Pierc
37. Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 10 135 132 120 060 150 200 OBE 3 16 134 100 070 200 300 l 25 76 25 76 1 4 140 75 090 225 400 090 3 8 148 50 120 250 500 l 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 3 131 3210 1 4 3 3 200 29 5 25 76 25 76 134 2445 1 8 5 1 400 l 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 0096 2 4 100 2 5 0 Argon Nitrogen N A 50 25 N A 65 100 2540 100 2 5 100 2 5 0 Wile Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking 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 l
38. USAGE can cause explosion and or fire e The combination of Preflow Postflow Plasma and Shield input gases should always adhere to the types specified in the cut charts for a given material type e When changing to a different type of gas oxidizing or oxygen containing to combustible or vice versa a purge of the gas lines 30 second minimum must be completed to reduce the risk of fire or explosion e Do not connect H17 combustible gas to the gas inputs Pre Postflow Plasma or Shield at the same time as Oxygen or Air Shield Gas Inlet e Connect the proper shield gas to the Shield In port See the cutting charts in Section 4 for proper gas types Plasma Gas Inlet 2 e Connect the proper plasma gas to the Plasma In port See the cutting charts in Section 4 for proper gas types PreFlow PostFlow Gas Inlet 3 e Connect the proper preflow gas to the Preflow In port See the cutting charts in Section 4 for proper gas types Ea 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 Il User s Manual CAN Communication Connections Perform the following steps to connect the plasma power supply to the MGC CAN Cable e Connect t
39. 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 4 Keep 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 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 O ring O ring ji iS ji lt Torch Base Torch Head There is
40. contrary to the requirements of the EAR 1 7 Section 7 Parts List Spirit Il User s Manual Arc Starting Console BK300500 with CleanStrike Technology 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 7 BK300506 1 Printed Circuit Board PCB ASC 8 BK980201 1 ASC Manifold 9 BK707300 1 Inductor 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 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
41. h__ 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 4 145 150 160 250 400 495 3 8 150 115 180 275 500 i 1 2 20 71 70 69 155 85 210 300 600 430 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 Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 144 3910 4 0 6 3 400 39 10 150 2805 4 7 7 0 600 l 12 20 71 70 69 153 2330 5 1 7 4 a8 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 2 5 100 2 5 0 SNN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm f
42. have a grade of no greater than 10 to eliminate the risk of toppling over 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 Arc Starting Console ASC The ASC should be mounted in a convenient location that is away from other electronic control devices The ASC with CleanStrike Technology offers significantly reduced emissions compared to ASC with RHF however the high voltage pulse generated inside the unit may interfere with the operation of sensitive control electronics The ASC 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 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 Il User s Manual 2 Gang Manifold The 2 gang manifold assembly must be mounted to the torch See Section 2 for mounting dimensions Torch T
43. 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 7 Section 4 Operation with Manual Gas Console Spirit II User s Manual Checking Errors The last ten 10 system errors are available through the MGC as described below On the main menu move the pointer to Errors Press the select button nput Gas Version Configure Press the select button to cycle through the 40290 last ten 10 error codes See Section 6 in this manual for details on the error codes Simultaneously pressing the down V button and the select button will erase all ten error codes Move the pointer to Return and press the select button to return to the main menu Checking the Version Number The hardware version and software version for the Power Supply and Gas Console can be displayed as described below On the main menu move the pointer to Sep 4 Version Press the select button Errors Version Configure Move the pointer to either Power Supply or Pomer EER b y Gas Console Press the select button Supply Congole Fehr
44. 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 circuit 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 lo
45. 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 Outer Cap Stainless Steel 70 Amps Copper Electrode H17 Plasma Nitrogen Shield Nitrogen Preflow amp Postflow H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination Shield Cap BK277150 Nozzle BK277124 2 Electrode BK277132 ives the best cut quality and minimum dross levels 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 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 35 65 30 60 135 2030 2 5 5 1 300 2 3 Marking For All Material Thicknesses Arc Travel M
46. no Gap is visible gap between between o ring and o ring and O attachment attachment O 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 2 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Installing Replacing Consumables Electric Shock Can Kill e Remove primary power from the Spirit system before installing or removing the torch head Hot Parts Can Burn Skin e Do not touch hot parts bare handed e Always use gloves when handling the torch as it can be hot after 24 cutting especially with high amperages and long cut times e Allow cooling period before working on the torch Note When installing the consumables do not use an excessive amount of o ring lubricant Also 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 Remove the outer retaining cap from the torch head
47. of the EAR 7 13 Section 7 Parts List Spirit Il User s Manual CII Cable for Optional External Inova Part Number Length BK300902 XX Where XX is the length in feet 5 150 ft lengths available in 5 ft 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 POSITION 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 14 Spirit II User s Manual Section 7 Parts List FII Cable for Optional Internal Inova Part Number Length BK300903 XX Where XX is the length in feet 5 150 ft lengths available in 5 ft increments INOVA CONSOLE BURNY PHANTOM IP4 28 POS 11 RECP PLASMA CONTROL 37 POS CABLE BK711002 Note Add Label k O Wired for Phantom Controller PLUG BK709364 STRAIN RELIEF BK709025 PLUG BK709095 STRAIN RELIEF BK709021 TERMINAL POSITION NO COLOR POSITION NO TERMINAL BK
48. 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 Cutting Charts Mild Steel 30 Amps Copper Electrode Oxygen Plasma Oxygen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277145 BK277120 BK277130 a OMD D 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 20 036 120 105 080 100 062 18 048 121 97 090 16 060 125 78 110 065 14 075 35 77 6 75 126 65 105 200 i 12 105 127 55 11 120 129 50 070 l N 120 125 300 10 135 131 40 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 1 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 Al
49. 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 current 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 pann 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 Il 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 decom
50. psi psi psi psi volts ipm in in msec in 1 4 145 150 160 250 400 425 3 8 150 115 180 275 500 i 1 2 20 71 70 69 155 85 210 300 600 430 5 8 160 60 220 325 800 3 4 168 45 240 350 1200 135 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 6 144 3910 4 0 6 3 400 39 10 150 2805 4 7 7 0 600 l 12 20 71 70 69 153 2330 5 1 7 4 aa 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 2 5 100 2 5 0 SANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 St
51. psi psi psi volts mm m mm mm msec mm 6 129 5220 1 8 4 9 400 38 10 134 3655 1 9 6 5 l t 600 12 138 3020 2 6 7 3 16 146 1890 3 8 8 9 800 3 9 20 74 58 72 So om 20 153 1450 4 8 10 3 25 157 1050 5 2 11 3 4 1 N 1500 Ieee 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 Tim 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 2 5 100 2 5 0 NANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 47 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 100 Amps Silver Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow
52. 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 users 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 in
53. s Manual Stainless Steel 150 Amps Copper Electrode H17 Plasma Nitrogen Shield Nitrogen Preflow amp Postflow 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 9 pp A f 4 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 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 95 250 250 400 sae 3 8 75 150 275 500 1 2 25 77 75 81 165 60 165 300 600 440 5 8 50 185 325 800 f 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 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
54. 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 ar 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 guidelines to minimize exposure to these electric and magnetic fields Stay as far away from the power supply torch torch leads and arc starting console as possible Route the torch leads as close as possible to the work ground cable
55. 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 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 N WARNING Do not touch the fans inside the power supply 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 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 Oh ON ce ee Sh aa 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 top left and right covers from the power supply Connect a 3 8 ID hose and bucket to the dr
56. 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 22 Spirit II User s Manual Section 7 Parts List Gas Console Microprocessor DSP BK300301 PMGC Quadrant 1 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 23 Section 7 Parts List Spirit II User s Manual Gas Console Microprocessor DSP BK300301 PMGC 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 pera C Rus reo C ors PAL eeo E rio PE rios PSL r L ru C kios L n sO n anA LIL o
57. 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 ASC with RHF ASC with CleanStrike Technolo e o o al a P N OLL o fo 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 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 Arc Starting Console Connections Perform the following steps to connect the torch leads to the arc starting 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 11 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 arc
58. to the requirements of the EAR 5 52 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 Power Supply 1 2 NO TO fF W Remove the left right and top covers on the power supply Using clean dry compressed air blow out all accumulated dust including dust on PC boards and fans Be sure to bl
59. 0 100 25 100 2 5 0 WYSE Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 135 3 4 mm for cutting and 100 2 5 mm for marking 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 70 Amps Copper Electrode Oxygen Plasma Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 9 OND D 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 ene 3 8 122 75 140 250 400 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Sh
60. 156 2825 4 8 7 0 600 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 i 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 FYI Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking 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 Aluminum 200 Amps Silver Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277274 BK279489 BK279440 yellow o ring ae O 4 D a E Oute
61. 277140 BK277142 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage 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 16 113 105 440 200 300 085 1 4 117 75 225 400 087 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 5 113 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 71 100 254
62. 5 200 195 260 175 275 175 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 3 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 5 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 Inspect all parts for dirt debris and excess o ring lubricant and clean as necessary Part Inspect For Corrective
63. 50 psi 10 2 bar ET 1 gal min 3 8 liters min PEE S Propylene glycol solution eee cere 3 2 gal 12 liters EEE 1270 Ibs 576 kg i ee Tn MU i Ti 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 3 Section 2 Specifications Spirit Il Users Manual Torch Coolant Specifications 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 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 BK500695 For operating temperatures below 13 C a 50 solution of industrial grade propylene glycol can be ordered i
64. 58 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 495 1 25 150 45 175 500 1500 20 81 70 79 1 50 163 25 235 750 2500 1 75 170 20 290 190 350 2 00 180 15 350 1500 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 Postfow 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 42 16 496 2650 3 3 8 3 800 20 2190 3 1 9 0 4 3 1000 25 143 1690 4 0 10 1 47 32 150 1120 4 4 12 8 1500 20 81 70 79 38 162 645 5 9 19 1 2500 45 170 495 7 5 a 4 8 50 178 395 8 7 i 1500 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 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 NANN Do not connect H17 combustib
65. 7 Preflow u27 d u19 N SOL R20 C12 C54 oD DA ae g 8 Ese cw oe 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 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 18 Spirit II User s Manual Section 7 Parts List 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 locati
66. 709365 PINS 1 TRE 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 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 JIP Cable for Optional Internal Inova Part Number Length BK300904 XX Where XX is the length in feet 5 50 ft lengths available in 5 ft increments CONSOLE 1 CONSOLE 2 IP8 24 POS IP4 24 POS STRAIN RELIEF BK709025 STRAIN RELIEF BK709021 PLUG BK709364 PLUG BK709020 CABLE BK711049 TERMINAL POSITION NO COLOR POSITION NO TERMINAL BK709018 SOCKET 5 a RED mm 5 BK709365 PIN 6 BLACK __ 6 22 15 WHITE 15 16 BLACK 16 13 TOR BROWN 13 14 BLACK 14 23 1 GREEN 2 BLACK 2 7 YELLOW 7 8 BLACK 8 24 9 BLUE 9 10 BLACK 10 3 ORN 3 C BACK a BK709365 PIN 19 20 ay ee RED Xx 20 WHT XX 20 I 21 zA RED x 21 GRN Xxx
67. 930 4 1 7 1 NNA 500 4 1 12 163 3375 4 4 7 4 16 168 2645 4 8 8 9 SSCS 4 2 20 20 73 65 75 173 2055 5 3 25 179 1565 6 0 N 10 2 4 3 32 185 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 SANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 275 7 0 mm for cutting and 100 2 5 mm for marking 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 51 Section 5 Torch Consumables and Cutting Charts 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
68. 9483 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 m 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 Argon Air N A 50 25 N A 60 100 2540 100 2 5 100 2 5 0 NANNE Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Revised 04 26 2013 This information is subj
69. Action Outer Cap Q Dents cracks Replace outer cap Shield Cap Center hole out of round Dents Scratches Dry o ring Damaged o ring Replace shield cap Replace shield cap Apply a thin film of o ring lubricant Replace shield cap Cap Center hole out of round Dents cracks Dry o ring Damage o ring Replace retaining cap Replace retaining cap Apply a thin film of o ring lubricant Replace retaining cap Center hole out of round Replace nozzle Dry o rings Damaged o rings 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 Apply a thin film of o ring lubricant Replace swirl ring Electrode HD or Pit depth Erosion or arcing Dry o rings Damaged o rings Replace electrode if center pit depth is greater than 0 040 1 mm for copper electrode or 0 098 2 5mm for silver Replace electrode Apply a thin film of o ring lubricant 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 the requirements of the EAR 5 6 Spirit II User s Manual Section 5 Torch Consumable
70. 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 SANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking 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 200 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277274 BK277289 BK277291 9 OMD D fo Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277143 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thicknes
71. L1 U iE 2 L3 W Ground Disconnect Box L1 L2 L3 Gnd Connections TB5 Connections Strain Relief 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 8 Spirit II User s Manual Section 3 Installation Power Supply Output Connections Perform the following steps to connect the output of the power supply to the arc starting console and the work table See Figure 4 on the next page Power Supply Electrode Lead O 1 Route one end of the 1 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 arc starting console and connect it to the cathode manifold Power Supply Nozzle Lead 2 1 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 arc starting console then e For systems that include ACS with RHF connect it to the angled bracket on the printed circuit board using the provided Phil
72. LINCOLN amp Technical Manual SPIRIT I 275 sinrinetine nign petnition technology ee i OE L m Register your equipment GENUINE www burny com warranty PARTS Save for future reference Date Purchased Model Number Serial Number THE LINCOLN ELECTRIC COMPANY BK8053 000094 Rev B Issue Date 01 SEP 2015 4130 Carolina Commerce Pkwy e Ladson SC 29456 e U S A Lincoln Global Inc All Rights Reserved Phone 1 843 695 4000 e wwwiincolnelectric com 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 Revision History Rev ECO Author Date Description of Change A CAD 19 MAR 2015 Initial Release Updated part numbers for terminal LAD0234 blocks Updated coolant pump part B LAD0323 CAD 01 SEP 2015 number Added pierce capability for LAD0330 1 25 32mm MS at 150A and 1 5 38mm MS at 275A Trademark Notice Spirit is a registered trademark of Lincoln Global Inc FASTON is a trademark of the TE Connectivity Ltd family of companies All other trademarks are property of their respective owners This documentation may not be copied photocopied reproduced translated or reduced to any el
73. 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 288 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 United 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 fr
74. 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 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
75. O 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 U36 IMPULSE Impulse circuit energized OPTO U37 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 Power Supply Microprocessor DSP Sequence of Operation The following DSP Indicators should illuminate after primary power is applied X WLS geena ninaa 3 3V Supply P DIO ee etd el ed seblekile 1 8V Supply WR DSO cia2rnuinadeund odin gious ASC Door Z DSS tiiiea iea Coolant Level X OY Ge eee Orn Arc Hold if INOVA is being used gt DIO crnscousevescoenex RS232 T1 Out Blinking F DN e ects ctlactlentdedttentiedte CAN RXD Dim Flashing X DAZ e ain ing nein ass CAN TXD Dim Flashing The following DSP Indicators should illuminate when the OFF Button is released gt DAO sos ine aio aeh OFF Button The followin
76. Parts List Spirit Il User s Manual Power Supply BK300221 BK300229 Left Side View Item Part Number Quantity Description 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 Power Supply Output I O 37 BK301200 1 Optional Printed Circuit Board PCB Voltage Divider 39 BK709378 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 BK709379 1 O Terminal Block large 47 BK709227 2 Strain Relief 50 BK284029 2 Current Sensor 51 BK300130 2 F9 F 10 Fuse 200A 52 BK300129 2 F9 F10 Fuse Holder 53 BK300153 1 Off Relay 54 BK300156 1 Off Relay Socket 58 BK701165 2 R1 R2 Resistor 300W 3 Ohm 59 BK701141 1 R3 Resistor 300W 2 Ohm 60 BK701083 3 Resistor Mounting Hardware ee ee ee
77. 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 150 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 _ _ N 9 OMD D fo 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 4 145 145 130 250 400 498 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 Y 10 156 2825 4 8 7 0 600 i 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
78. S eeeeeeeeeeeeeeeeee w0 Remote nnnnnnntennnnnnnnn anne Plasma Gas Hose 4 a To Star A Cable LD Ground a L PreFlow PostFlow a gt Gas Hose rn To Star CNC Controller Positioner Ground F Cable B Cable Legend E Cable mova Supplied To Star Console ry sneessees Optional Ground Customer Supplied Voltage Divider Notes D Cable 6 Foot 2 Gang 1 If only the Inova Remote is used to set Inova Pret iow Manifold parameters then follow the configuration shown Per ste Hose 2 If only the CNC Controller is used to set Inova parameters no Inova Remote then e add the G Cable from the Inova Console P6 to 5 Gang Manifold the CNC Controller 7 5 Foot Shield H e remove the A Cable from the configuration shown 3 If both the CNC Controller and Inova Remote are Gang Manifold Control Cabl used to set Inova parameters then e add the G Cable from the Inova Console P6 to the CNC Controller Gang Manifold Control Cabl Arc Starting Console Positioner Star Ground Work Piece Figure 1d Spirit Il System MGC External Inova ASC with CleanStrike Technology 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
79. 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 Arc Starting Console ASC Specifications with Remote High Frequency RHF Part Number a sasotint cn ect cttocect oreo tebathoceebareesteeentes BK300510 Weight aati eee 24 Ibs 10 9 kg Spark gap distance eeeeeeeeeeeeeeeeees 0 015 in 0 381 mm Note The Spirit Il system requires either an ASC with RHF or an ASC with CleanStrike Technology but not both m 8 00 203 F al a 4 312 8 l 12 75 324 12 00 305 13 50 343 e 1 e 10 00 254 Ml 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 7 Section 2 Specifications Spirit Il User s Manual Arc Starting Console ASC Specifications with CleanStrike Technology Part Number 2Ascnetondcnnncanda canes BK300500 WN eighitas tussieranie scones ence nears penne seisscces 22 Ibs 10 kg Note The Spirit Il system requires either an ASC with RHF or an ASC with CleanStrike Technology but not both Systems containing an ASC with
80. T LIABILITY IN TORT WILL KALIBURN BE LIABLE FOR INDIRECT EXEMPLARY PUNITIVE SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF BUSINESS OR LOST PROFITS EVEN IF KALIBURN HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES IN ADVANCE AND EVEN IF A REMEDY SET FORTH HEREIN IS FOUND TO HAVE FAILED OF ITS ESSENTIAL PURPOSE LINCOLN ELECTRIC The Lincoln Electric Company 4130 Carolina Commerce Parkway Ladson SC 29456 Phone 1 843 695 4000 www lincolnelectric com Spirit II User s Manual Section 1 Safety Section 1 Safety General Precautions Whereas plasma cutting has been used safely for years it does require 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 Always wear appropriate personal protective equipment PPE 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 A 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
81. 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 the factory In the unlikely event that one of the components is defective or missing please contact customer service so that a replacement can be sent Also special care has been taken in the packaging of the system If the system was damaged during shipment file a claim with the shipping company and then contact customer service to order the necessary parts Component Placement Plasma Power Supply The power supply should be lifted by a forklift or pallet jack In order to prevent damaging the power supply the forks should be of adequate length to protrude on the far side of the power supply The proper location 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
82. Wire igs 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 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 Manual Gas Console to enable the system Move the pointer to ON and then press the select button to energize the system After the gases set prepare to apply a start signal to the unit 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 oll O
83. ain 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 power supply Note that the coolant supply hose has right hand threads Be prepared for some coolant to escape from the fitting on the power supply 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 Protect the area beneath the coolant filter housing as coolant will leak during this step Unscrew the coolant filter housing and remove it from the power supply Use caution as the housing will be full of coolant Install a new coolant filter deionization cartridge and replace the coolant filter housing Remove the protective material and dry any leaked coolant 11 Reconnect the coolant supply hose on the rear of the power supply 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 ou
84. al Inova 0 0 0 0 eee eeeeeeeeeeeeeeeeeeeeee 7 15 JI Cable for Optional Internal INOVA cece eeeeeeeeeeeeeeeeeeeeeeeee 7 16 PCB Assemblies Component Reference Locations 0 7 17 Section 8 Internal Inova Console Option OETA E E AEE cea canta E 8 1 Plug ldentificatiONs e Eee 8 1 Unique Interconnect Cables ccccccccccceeeeeeeeeeeeeeeeeeeeessseeeeeeess 8 1 Ekolu lare G P E EEA EAEE EEEE AEEA AEA AEAEE AE 8 2 Pars LIS ices euineond on meno e Ribbed remade 8 3 Appendix A Electromagnetic Compatibility EMC BACK QROUNG so oi ror tet aee eet AEn eat ered Seat eater Net ta ath ate A 1 I stallation and WSC xcct ccccest nee ceetevecccetenseceeteveccreteneeceecevecaeeteneeceetenee A 1 Assessment Of ALO iicsescecsececccccedesenctedetencnedeneneteceneceneceneneteceneneneceneds A 2 Methods of Reducing EMiSSIONS eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 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 LIMITED WARRANTY Burny Kaliburn A Lincoln Electric Company Kaliburn warrants that all new Kaliburn manufactured controllers and plasma cutting equipment torch height control systems plasma torches consumables expendables and accessories collectively
85. ans 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 275 is a 275 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 2 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 The Spirit II system is available with an Arc Starting Console ASC that utilizes CleanStrike technology which results in reduced EMI and thereby minimizes interference with sensitive electronic equipment 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 Eight nozzle sizes 30 50 70 100 150 200 260 and 275 amps are available to produce excellent cut quality throughout the cutting range The sa
86. arking 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 0096 2 4 100 2 5 0 Argon Nitrogen N A 50 25 N A 80 100 2540 130 3 3 100 2 5 0 Ate Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking 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 70 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 N A 9 OND D Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf
87. ated INOVA electronics within the power supply for Spirit Il and ProLine series products PARTS FOR a All Burny shape cutting controllers such as product models for Phantom Phantom Il hantom ST Phantom ST Il Burny 10LCD Plus and agger NC and others as applicable chassis and front panel upgrades as applicable agger 100 torch and leads plasma cutting torches and torch leads for pirit Il Spirit ProLine and other plasma cutters other plasma cutting system components such Arc Starting Consoles vP NDP OU BOY 2h torch height control systems and collision nsors Ww mD purchased non expendable replacement parts gt D torch valve assemblies LABOR warranty labor for Plasma power supplies gas consoles cooling tower and plasma controllers for Spirit series as applicable Spirit II and INOVA electronics within the power supply for Spirit II applicable in U S only One 1 year SPARE PARTS all repair parts Ninety 90 days WARRANTY LIMITATIONS The Goods are intended for commercial use only and are not intended for personal family or household purposes Kaliburn is not responsible for cable or torch leads wear or any damage resulting from cable wear due to flexing and abrasion Purchaser is solely responsible for routine inspection of cables Kaliburn is not responsible for repair or replacement of any part or Goods due to normal wear and tear Parts and
88. ates 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 Copper Electrode H17 Plasma Nitrogen Shield Nitrogen Preflow amp Postflow 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 9 pp Z f 4 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 i50 1 2 148 75 130 300 600 i 5 8 37 72 79 68 155 60 190 350 800 155 3 4 160 50 200 400 1200 i 1 0 170 35 240 450 1500 160 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 10 154 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 39 20 161 1215 5 2 10 3 i 1500 25 169 915 6 0 11 3 4 1 Marking For All Material Thicknesses Arc Travel Marking I
89. cation 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 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 ma
90. ce 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 pressure 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
91. ch 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 17 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 6 Foot Preflow Postflow Gas Hose 22 1 Connect one end of the 6 foot 1 8 m preflow postflow gas hose to the preflow postflow outlet on the 5 gang manifold 2 Connect the other end of the 6 foot 1 8 m preflow postflow gas hose to the preflow postflow inlet on the 2 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
92. 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 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 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 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 Choppe
93. ck for 120v on pins of power communications CAN cable at back of the manual gas console 1 Cycle primary power to the Spirit system 2 Check the connection of the ribbon cable that connects the keypad to the DSP PCB in the manual gas console 1 Wrong consumables installed in torch 2 Loose pressure transducer cable on PC board in the MGC 3 Check connectors on the MGC valve associated with the malfunction 1 Supply gas pressure s less than 120 psi 1 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 1 Ensure start signal is removed from CNC 2 Cycle power to the Spirit Il 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 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
94. crements 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 the EAR 7 12 Spirit II User s Manual Section 7 Parts List Oxygen Supply Gas Hose Optional Part Number Length BK200362 XX Where XX is the length in feet 25 100 ft lengths available in 25 ft increments mi BLUE s BLUE H Nitrogen Supply Gas Hose Optional Part Number Length BK200365 XX Where XX is the length in feet 25 100 ft lengths available in 25 ft increments mia SS pee TIN Air Supply Gas Hose Optional Part Number Length BK200364 XX Where XX is the length in feet 25 100 ft lengths available in 25 ft increments COMM Pc OS pac TID H17 Supply Gas Hose Optional Part Number Length BK200363 XX Where XX is the length in feet 25 100 ft lengths available in 25 ft increments HES 55 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
95. ct cut quality With the electrode removed inspect the cooling tube in the torch head 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 Arc Starting Console ASC 1 Open the cover door of the arc starting 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 2 For systems that include ASC with RHF check the spark gap electrodes for signs of wear Replace electrodes that have rounded faces Use a clean feeler gauge and set the spark gap to 015 38 mm Work Ground 1 Verify that the work ground lead is securely fastened to the
96. ctions cceeeeeeeeeeeeeeeeees 3 13 Torch Gas Connections i cjccp coi ssdacsocand saeteseioncenshs gneeteklaaeunee noeeatlunes 3 14 Gas Supply COMMECHONS 2 As uies cia cSsecateniraceten Ssumasenivecoterseursteresenaterts 3 17 CAN Communication Connections ccceeeeeeeeeeeeeeeeeeeeeeeeeeeees 3 18 CNC Machine Interface Connections ccccccceceeeeeeeeeeeeeeeeeeeees 3 19 Filling the Cooling System sescedecco3icoicestceshcesncedccexecentceneceterevtcenecesecene 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 eee eeeeeeeeeeeeeeeeeeeeee 4 1 Setting up to Cubes tec os ens ec hes a a a a 4 2 Setting up to NN I 5 ss ss hl tO Tt gt ST tea 4 3 Verifying Input Gas Pressures cccccccceecereeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 4 4 Input Gas Pressure Error M SSQQ S 2 cccccccceeeceeeeeeeeeeeneeeeeeeeeeeeeee 4 4 Making a Cut or Mark 2 44 422 52 136 ip2louie2 onlen louis onlen onine lect 4 5 Piercing Thick Materials ceseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeea 4 6 Moving Pierces and Edge Starts 2 ceeceeeeeeeeeeeteeeeeeeteceeeeeee 4 6
97. e 4 D D JNF D2 PVP R155 R103 R157 R100 R156 u21 T E N ua E N N t N D T E N O IE W w i Ww O D5 EMI PYMP a C177 C164 C165 C166 C167 C168 C169 C170 i rE Fi Ti D62 D49 D51 CA _ CF Ce E I I I I I LINCOLN ELECTRIC J18 FDS BLANK PCB P N 300300 REV C aa ASSEMBLY P N 300301 I M so O2 EN H17 EN N2 M SHL N2M OUT O2 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 the requirements of the EAR 7 26 Spirit II User s Manual Section 7 Parts List 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 27 Section 7 Parts List 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 7 28 Spirit II Use
98. e 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 485 1 25 150 45 175 500 1500 i 20 81 70 79 1 50 163 25 235 750 2500 1 75 170 20 290 190 350 2 00 180 15 350 1500 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 Postfow 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 rc 16 i38 2650 3 3 8 3 800 i 20 2190 3 1 9 0 4 3 1000 25 143 1690 4 0 10 1 47 32 150 1120 4 4 12 8 1500 i 20 81 70 79 38 162 645 5 9 19 1 2500 45 170 495 7 5 39 4 8 50 178 395 8 7 i 1500 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 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 NANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the sa
99. ect 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 Mild Steel 150 Amps Silver Electrode Oxygen Plasma Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 green o ring _ D a Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 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 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 l 350 1000 135 1 20 71 45 69 134 40 150 400 1500 1 25 145 25 200 700 3000 140 1 50 155 15 225 350 1500 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Sp
100. ectronic medium or machine readable format without explicit written permission from Lincoln Electric 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 Precautions scrensdeudienererisercarudsenseeecierSacecsenGeeedcendcavcerveeendsevtees 1 1 Ultraviolet Radiation Protection ccccccccsseeeeseeeeeeeeeeeeeeeetseeeeeeees 1 1 Noise Pole Chlones secescses tus cua cia catadeea esas ts a cvbakeaacaaadaedsaabeeaiatsiedeisasiceeds 1 1 Toxic Fume Prevention s cc0cs0ssaccebenscccebcosecaebsssaccedeadassadincecaebeadersebenteds 1 2 Electric Shock Prevention wasssccosccnneieserosmcosksaneianhloieea eed onauanhiaaeenshlonben 1 2 Fire Prevention eee E E eetere eriei 1 3 Explosion Prevention coc scctvddescesnc cand dsnddvadeavc cand anacandessedvndasdsccedersacgueads 1 3 Health Support Equipment cccececceeceeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeees 1 4 Safety Standards Booklet Index 1 5 Section 2 Specifications System Description scan co8 eccestteas ed Gataes antec cansand Cars aaanaanends qaheauies 2 1 Syster Components fete scent ces eee etet erent eceseveces crest enecevecenecevecenccd 2 2 Power Supply Specifications
101. eed 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 oe 3 4 25 20 71 45 69 133 1040 3 7 10 1 32 145 625 5 1 17 8 3000 3 6 38 154 385 5 6 8 9 1500 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 61 100 2540 100 2 5 100 2 5 0 NEN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised 09 01 2015 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 II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 200 Amps Silver Electrode
102. eeeeeeeeeeeeeeeeeeeeeeeeeeeeee 7 5 Arc Starting Console BK300510 with RHF ccccceceeeeeeeeeeeeeeeeees 7 7 Arc Starting Console BK300500 with CleanStrike cceeeee 7 8 Torch and Manifold Assemblies ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 9 Shielded Torch Leads 2 2 4 44 ene eee 7 10 CAN Communication Cable and Termination Plug ee 7 10 Manifold Control Cablesieioc 0d neincini he tnd ini ted wad eed ea ee 7 10 Gas Hose Package with MGC 00 0 ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 7 11 Coolant and Power L adS icce ese cscpever epee even coccenet coer exee coerenet cverevencperene 7 12 Work Ground Lead 7 12 Oxygen Supply Gas Hose Optional cece eee eeeeeeeeeeeeeeeeeeeeeeeee 7 13 Nitrogen Supply Gas Hose Optional ccccccceceeeeeeeeeeeeeeeeeeeeeees 7 13 Air Supply Gas Hose Optional cccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 13 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 H17 Supply Gas Hose Optional cccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 13 CII Cable for Optional External INOVa cee eeeeeeeeeeeeeeeeeeeeeeeee 7 14 FII Cable for Optional Intern
103. eeeeeeeeeeeeeees 115 psi 7 9 bar Minimum Inlet gas PreSSUre ccccceeeeeeeeeeees 105 psi 7 2 bar Maximum Inlet gas preSSUre eeeees 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 It is recommended that an exhaust ventilation system be used when cutting with oxygen Flashback arrestors must be supplied unless they 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
104. eight of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 150 Amps Copper Electrode Oxygen Plasma Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 a y x 2 9 e Z SS jf Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 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 Retaining Cap BK277151 1 4 118 165 105 200 300 495 3 8 20 71 30 69 123 125 135 250 400 1 2 125 90 140 300 500 130 Retaining Cap BK277152 5 8 127 70 440 325 600 130 3 4 130 55 i 350 1000 135 1 20 71 45 69 134 40 150 400 1500 1 25 145 25 200 700 3000 140 1 50 155 15 225 350 1500 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness P
105. em 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 9 Section 3 Installation Spirit II User s Manual e e e e e 8 ga 3 2 e ap f mpoo o Strain Relief 4 1 ASC with RHF ASC with CleanStrike Technolo o o al 1 E I N 9 3 z P Me ae gt Strain Relief 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 10 Spirit II User s Manual Section 3 Installation ASC Control Cable and ASC Ground Connections Perform the following steps to connect the ASC control cable and ASC ground See Figure 5 on the next page ASC
106. en follow the steps below NOTE When the Process is set to Marking the Current value is internally set to the proper value even though the cutting current is displayed Push the OFF Button on the MGC to disable the system On the main menu move the pointer to Setup Press the select button Setup a Errors input ars Version Configure Press the select button until Marking is tarkini ii displayed Current 150 Select Gas Adjust Gas Retum Move the pointer to Adjust Gas Process Cuttin Eo Press the select button Curent 150 Select Gas Adjust Gas Move the pointer to Plasma and then press the select button to start the flow of gas Turn Eea the corresponding regulator knob on the MGC Shield to adjust the displayed pressure to match the value in the cutting chart Repeat for the Shield gas Move the pointer to Return and press the select button Repeat to return to the main menu Fre Flor The system is now ready to mark 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 3 Section 4 Operation with Manual Gas Console Spirit II User s Manual Verifying Input Gas Pressures For the system to work properly the input gas pressures mus
107. equipment manufactured for Kaliburn is subject to the terms of the original manufacturer s warranty and Kaliburn has no warranty obligations for defect in such equipment THIS WARRANTY IS VOID IF A THE GOODS HAVE BEEN ABUSED ALTERED OR MISUSED B THE GOODS HAVE BEEN REPAIRED BY THE PURCHASER OR ANY THIRD PARTY WITHOUT THE AUTHORIZATION OR PRIOR WRITTEN APPROVAL OF KALIBURN THE SPIRIT Il SPIRIT OR PROLINE SYSTEM HAS BEEN OPERATED WITH NON GENUINE KALIBURN OR LINCOLN ELECTRIC TORCH CONSUMABLES KALIBURN SERIAL NUMBERS OR WARRANTY DECALS HAVE BEEN REMOVED OR ALTERED OR THE GOODS HAVE BEEN SUBJECTED TO IMPROPER INSTALLATION IMPROPER CARE UNAPPROVED PURPOSES OR ABNORMAL OPERATIONS SERVICE AND REPAIR SHOULD ONLY BE PERFORMED BY KALIBURN FACTORY TRAINED PERSONNEL UNAUTHORIZED REPAIRS PERFORMED ON THIS EQUIPMENT MAY RESULT IN DANGER TO THE TECHNICIAN AND MACHINE OPERATOR AND WILL INVALIDATE YOUR FACTORY WARRANTY THE EXPRESS LIMITED WARRANTIES SET FORTH HEREIN ARE THE SOLE AND EXCLUSIVE WARRANTIES FOR THE GOODS ALL OTHER WARRANTIES WHETHER EXPRESS IMPLIED OR STATUTORY INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR NON INFRINGEMENT ARE EXPRESSLY DISCLAIMED KALIBURN S LIABILITY UNDER THIS WARRANTY SHALL NOT EXCEED THE COST OF REPAIRING OR REPLACING THE DEFECTIVE GOODS IN NO EVENT WHETHER IN CONTRACT TORT OR OTHERWISE INCLUDING BREACH OF WARRANTY NEGLIGENCE AND STRIC
108. er tightened Inspect all gas hoses to ensure no damage exists Immediately replace any damaged gas hoses Torch Torch Leads and Gas Hoses T 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 arc starting console Also make sure the shield adapter is secured tightly to the arc starting console enclosure 3 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 affe
109. ess the select button to cycle through the pconbast 20 list of contrast settings Languages Move the pointer to Return and press the select button 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 9 Section 4 Operation with Manual Gas Console 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 4 10 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Section 5 Torch Consumables and Cutting Charts Installing Removing the Torch Head Electric Shock Can Kill e Remove primary power from the Spirit system before installing or removing the torch head Hot Parts Can Burn Skin e Do not touch hot parts bare handed e Always use gloves when handling the torch as it can be hot after 74 cutting especially with high amperages and long cut times e Allow cooling period before working on the torch 1 Each time the torch head is connected to the torch base use a cotton swab to apply
110. ess the select button to access menu items or settings identified by the pointer Pressure Regulator Knobs Turn to the left or right to adjust the amount of output gas pressure for PreFlow Gas t A IN PostFlow Gas Nf W Plasma Gas W Shield Gas 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 Always verify the correct gases are connected to the proper input gas connections on the MGC in case marking was previously performed Push the OFF Button on the MGC to disable the system On the main menu move the pointer to Setup Press the select button Setup z Errors input ae Version Configure Press the select button until Cutting is Process Cutting Surrerit 150 displayed Select Gas Adjust Gas Feeturn Move the pointer to Current f Curent 150 Press the select button to cycle through the lect Gas i list until the required amperage from the Adjust Gas Return cutting chart is displayed Cutting Move the pointer to Select Gas Pr
111. formation 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
112. g DSP Indicators should illuminate when the ON Button is activated gt Opto U2 neee Motor Solenoid gt Opto U19 erent eee remnes Solenoid not used gt Opto U26 cnccnniaieiccs Fan DAD ara a a Plasma Ready The following DSP Indicators should illuminate when a START signal is applied begin cut cycle We E e e ETATE Start gt Opto U27 cesta attest Preflow gt Opto U29 aiaeaononoonnneeeeeeene Shield gt Opto U24 0 0 Surge only over 100 amps gt Opie U23 assesses none Contactor gt DDO his ereere end PWM Chopper ON gt Opto U22 ase nein pains Pilot Arc Relay ON X DII Re e a to eds PAT ON Blinks during a START gt Opto USG USF nnnm Impulse RHF Blinks during a START The following DSP Indicators should illuminate with an arc transfer Opt UST Aret eiretie Postflow gt Opto U28 cite eet Plasma Pe DTe reia Motion The following LEDs should turn OFF after the Motion Indicator turns ON gt Opto U36 U37 vencee tte ses Impulse RHF gt Opto U27 siete eles Preflow gt Dlg a 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 Sec
113. ge 5 25 Stainless Steel 100 Amps Nitrogen H17 Nitrogen Page 5 26 Stainless Steel 100 Amps Air Air Nitrogen Page 5 27 Page 5 45 Stainless Steel 150 Amps Nitrogen H17 Nitrogen Page 5 28 Stainless Steel 150 Amps Air Air Nitrogen Page 5 29 Page 5 46 Stainless Steel 200 Amps Nitrogen H17 Nitrogen Page 5 30 Stainless Steel 200 Amps Air Air Nitrogen Page 5 31 Page 5 47 Stainless Steel 260 Amps Nitrogen H17 Nitrogen Page 5 32 Stainless Steel 275 Amps Air Air Nitrogen Page 5 33 Aluminum 30 Amps Air Air Nitrogen Page 5 34 Aluminum 50 Amps Air Air Nitrogen Page 5 35 Aluminum 70 Amps Air Air Nitrogen Page 5 36 Aluminum 100 Amps Air Air Nitrogen Page 5 37 Page 5 48 Aluminum 150 Amps Air Air Nitrogen Page 5 38 Page 5 49 Aluminum 200 Amps Air Air Nitrogen Page 5 39 Page 5 50 Aluminum 275 Amps Air Air Nitrogen Page 5 40 Page 5 51 A WARNING IMPROPER GAS USAGE can cause explosion and or fire e The combination of Preflow Postflow Plasma and Shield input gases should always adhere to the types specified in the cut charts for a given material type e When changing to a different type of gas oxidizing or oxygen containing to combustible or vice versa a purge of the gas lines 30 second minimum must be completed to A reduce the risk of fire or explosion e Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air This information is subject to the controls
114. he 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 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 Possible Cause Power supply indicator 1 Primary disconnect fuse blown white light will not 2 Internal power supply fuse is blown F1A F1B illuminate Power supply indicator light is burned out or the associated wiring is bad 4 Control Transformer or associated wiring bad Power Supply will not 1 ASC door open energize after moving the 2 Low coolant level pointer to ON and then 3 Fuse is blown F1 F6 pressing the select button 4 Faulty OFF Button or associated wiring on the MGC 5 Off Relay faulty Power Supply will not stay 1 Faulty DSP board on after moving the pointer to ON and then pressing the select button on the MGC No arc at the torch The arc will not transfer to the workpiece 2 Off Relay faulty Incorrect torch consumables installed
115. he 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 Plasma Power Supply Manual Gas Console 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 20 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 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 positioni
116. he 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 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 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 2 Spirit II User s Manual Section 3 Installation ic noneeeenenne Shield GaS HOSC 002eeeeeeeeeeeeeeees oe Remote tc O T L Plasma Gas HOSe 2 r To Star A Cable z am Ground Rs O PreFlow PostFlow Gas Hose Gas Supply Positioner B Cable To Star CNC Controller Ground Fil Cable Legend Supplied aai Optional Customer Supplied Notes 2 Gang 1 If only the Inova Re
117. hield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277150 BK277122 BK277131 _ _ N 9 OMD D 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 voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 050 135 180 050 400 100 080 063 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 Postfow 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 i 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 77 100 2540 120 3 0 100 2 5 0 SEN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or A
118. ield Postflow voltage 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 2 5 100 2 5 0 WYSE Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking 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 100 Amps Copper Electrode Oxygen Plasma Air Shield Air Preflow amp Postflow
119. ield 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 NANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Edge start recomm Revised 04 26 2013 ended 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 Aluminum 30 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277145 BK277120 BK277130 SENN s a D S ye 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
120. ime Delay Fuse 2 Output amps Size amps 208 VAC 60Hz 220 VAC 60Hz 240 VAC 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 relief and connect the associated supply cables to the input terminal block TB5 See Figure 3 on the next page 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 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 eee Tt _ Ste GSS
121. inistration 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 11 Section 7 Parts List Spirit II User s Manual Coolant and Power Leads Part Number Part Number Length Non CSA Systems CSA Systems BK300306 XX BK388306 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Oe ASC CONSOLE CONTROL CABLE e POWER SUPPLY H 4 gt c ASC CONSOLE POWER SUPPLY ELECTRODE LEAD POWER SUPPLY O POWER SUPPLY NOZZLE LEAD POWER SUPPLY POWER SUPPLY CTP SENSOR LEAD ASC CONSOLE ASC CONSOLE POWER SUPPLY POWER SUPPLY COOLANT RETURN HOSE ASC CONSOLE POWER SUPPLY E ASC CONSOLE POWER SUPPLY COOLANT SUPPLY HOSE POWER SUPPLY Gi ASC CONSOLE Work Ground Lead Part Number Part Number pena Non CSA Systems CSA Systems g BK300318 XX BK388318 XX Where XX is the length in feet 10 100 ft lengths available in 5 ft increments 100 150 ft lengths available in 10 ft in
122. inted 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 11 150 amp 275 4 3 2 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 II 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 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 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 o
123. 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 Postfow 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 i 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 NEN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 100 2 5 mm for cutting and 100 2 5 mm for marking 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 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 50 Amps Copper Electrode Air Plasma Nitrogen S
124. ir Use an arc transfer height ignition height of 100 2 5 mm for cutting and 100 2 5 mm for marking 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 35 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 70 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277125 BK277131 Z 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 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 3 8 155 40 075 275 400 090 1 2 162 30 115 300 500 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 2 129 6400 1 2
125. ir Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 31 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 260 Amps Copper Electrode H17 Plasma Nitrogen Shield Nitrogen Preflow amp Postflow 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 2 A f j Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277280 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 3 8 145 85 160 250 500 isp 1 2 142 80 140 300 600 i 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
126. l 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 2 5 100 2 5 0 NANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 100 2 5 mm for cutting and marking 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 50 amps Copper Electrode Oxygen Plasma Oxygen or Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277115 BK277122 BK277131 a 9 C oy yf Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK
127. le gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised 09 01 2015 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 30 Amps Copper Electrode Air Plasma Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277144 BK277121 BK277137 A X fon 3 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 20 036 200 020 71 100 065 18 048 165 35 81 30 85 035 050 16 060 74 125 200 068 14 075 75 90 025 070 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width
128. le or vice versa a purge of the gas lines 30 second minimum must be completed to reduce the risk of fire or explosion e Do not connect H17 combustible gas to the gas inputs Pre Postflow Plasma or Shield at the same time as Oxygen or Air 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 Safety Spirit II User s Manual Health Support Equipment Never operate the system in the presence of explosive gases or other explosive materials Never cut pressurized cylinders or any closed container 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 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 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
129. lips head screw e For systems that include ACS with CleanStrike Technology connect it to the angled bracket on the red standoff using the provided Phillips head screw Power Supply CTP Sensor Lead 2 1 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 arc starting console and connect it to the CTP sensor lead with FASTON connector Work Ground Lead 1 Route one end of the 1 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 table 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 Syst
130. me consumable are used for cutting and marking which is determined by selecting the desired process in the Manual Gas Console Prior to marking the plasma gas and shield gas supply connections the back of the Manual Gas Console need to be connected to nitrogen 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 Systems containing an ASC with CleanStrike Technology are only recommended for use with downdraft cutting tables 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 Il User s Manual System Components The Spirit II 275 System consists of the following components Standard Components Power Supply Manual Gas Console CAN Cable Arc Starting Console ASC with Remote High Frequency RHF or Arc Starting Console ASC with CleanStrike Technology ASC Control Cable ASC 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 User s Manual Optional Components
131. me time as Oxygen or Air Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised 09 01 2015 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 44 Spirit II User s Man ual Section 5 Torch Consumables and Cutting Charts Stainless Steel 100 Amps Silver Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 brown o ring _ YEA Y Oo 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 4 141 100 135 225 400 092 3 8 25 80 35 80 147 80 170 250 500 095 1 2 154 55 210 300 600 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volt
132. mote is used to set Inova Manifold parameters then follow the configuration shown 2 If only the CNC Controller is used to set Inova parameters no Inova Remote then 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 5 Gang Manifold 7 5 Foot Shield Hos Gang Manifold Control Cabl Gang Manifold Control Cabl SC Control Cable Arc Starting Console Positioner fork Ground Lea Internal Inova yey tas Ground Cable T i Tae Torch Head L Star Ground Work Piece Figure 1a Spirit II System MGC Internal Inova ASC with RHF 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 3 Section 3 Installation Spirit II Users Manual ro r Remote To Star Ground rn To Star Ground CNC Controller F Cable Shield Gas HOSC seeeeeeeeeeee oor aeceeenennced Plasma Gas HOS 111 8 EEEE PreFlow PostFlow 29 Gas Hose iid Positioner B Cable
133. mpty Important When handling coolant wear nitrile gloves and safety glasses Important Only use 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 O INe a Remove the coolant reservoir cap level gauge and then remove the top left and right covers from the power supply 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 gallons of approved coolant Ot E Apply primary power to the Spirit system and enable it by releasing turn right the OFF Button on the MGC 9 On the MGC main menu move the pointer to On Press the select button 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 beneath the reservoir Press and hold the red button until no air or bubbles are seen inside the filter housing Dry any coolant that leaks out
134. n one gallon containers PN BK500895 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 4 Spirit II User s Manual Section 2 Specifications Manual Gas Console MGC Specifications Part NUMber ooo cece eee eeeceeeeeeceeeeeeceeeeeeeeeees BK300610 Megs 43 Ibs 19 5 kg a Alp ke 12 4 315 C C E q o a Q Q 12 0 305 13 6 348 A 4 300 7 6 10 9 277 Oyo yy
135. nection 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 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 2 Spirit II User s Manual Section 1 Safety 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 befo
136. ng 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 gas 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 21 Section 3 Installation Spirit Il User s Manual Filling the Cooling System AN WARNING Do not touch the fans inside the power supply Important Never turn on the system when the coolant reservoir is e
137. ning Cap Swirl Ring Torch Head BK284150 BK277110 BK277142 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 14 075 87 105 100 12 105 88 75 105 N 035 070 11 120 89 65 25 66 40 67 200 10 135 90 55 440 3 16 94 50 040 080 300 l 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 2565 87 100 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 2 5 100 2 5 0 NENN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 070 1 8 mm for cutting and 100 2 5 mm for marking Revised 04 26 2013 This
138. nistration 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 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 II 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 roundness 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 pie
139. nitial 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 WAGON Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 200 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277274 BK277289 BK277291 aN A a om D ay Outer Cap Retaining Cap S
140. nt Supply Lead e Connect the torch electrode coolant supply lead to the torch base as shown Torch Coolant Return Lead 17 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 15 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 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 21 1 Route one end of the 17 in
141. o JEN oe oe IE 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 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 24 Spirit II User s Manual Section 7 Parts List Gas Console Microprocessor DSP BK300301 PMGC Quadrant 3 J20 I J19 I I i J21 l L34 I J21 u10 Be C67 yo hoo C86 To t O THO oO ie A o Q N o O Q g gt TYT OR DogA Hga DOr A o l 8ef 28 46 BrO SEBS MOR BEES ORS Li Orro BERS l a N 1 a TL iS oe 30 C84 I C77 D17 C75 w i l
142. ocation 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 Copper Electrode H17 Plasma Nitrogen Shield Nitrogen Preflow amp Postflow 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 BK277146 BK277126 BK277133 A 5 zD 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 i05 3 8 152 65 180 250 500 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 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 Tim Plasma Shield psi psi
143. ocess Cutting Press the select button Current 150 Select Gas Adjust Gaz Press the select button until the proper Plasma gas is displayed Move the pointer and select the proper Shield gas Move the pointer to Return and press the select button Cult Move the pointer to Adjust Gas 150 5 Press the select button Gurrerit Select Gas Adjust Gas p PostFlaw Move the pointer to a gas and then press the Pre Flin 7 select button to start the flow that gas Turn the corresponding regulator knob on the MGC Shield 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 the select button Repeat to return to the main menu The system is now ready to cut 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 2 Spirit II User s Manual Section 4 Operation with Manual Gas Console Setting up to Mark The system can mark with the same consumables that are used to cut Refer to the cutting charts in Section 5 for the correct settings Connect nitrogen gas to the plasma and shield inputs on the MGC preflow and postflow inputs are not used for marking and th
144. om 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 Association 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 me
145. on outside the United States contrary to the requirements of the EAR 7 19 Section 7 Parts List Spirit Il User s Manual Power Supply Microprocessor DSP BK300101 Quadrant 4 IF i lee ore ig PCB Quadrant Map 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 20 Spirit II User s Manual Section 7 Parts List 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 21 Section 7 Parts List Spirit II Users Manual Power Supply A C Detect BK300112 N 8
146. or marking 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 Stainless Steel 200 Amps Silver Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277274 BK279489 BK279440 yellow o ring ae G 4I D a E 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 4 130 200 200 400 t 070 gt __ 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 Voltage Speed Height Height Time Width mm psi
147. ow out the fan and heat exchanger at the rear of the unit In an excessively dirty environment blow out the 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 Check the torch coolant filter deionization cartridge at the rear of the power supply 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 2 3 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 Verify that all PC board connectors are installed securely 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 ov
148. ozzle lead has right hand threads Torch CTP Sensor Lead 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 13 Section 3 Installation Spirit II User s Manual ASC with RHF ASC with CleanStrike Technology Figure 6 Torch Leads to Arc Starting 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 14 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 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 Coola
149. per 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 Chopper1 Temp Chopper 1 maximum operating temperature exceeded 10462 Chopper2 Temp Chopper 2 maximum operating temperature exceeded 10463 Chopper3 Temp Chopper 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 20200 Low Plasma Input Pressure is low 20210 Shield Low Input Pressure is low 20230 Low Pre Post Input Pressure is low This information is subject to t
150. ple 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 Il 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 Spirit II 150 275 Spirit II 400 Jumper to the work ground lead Spirit II 150 275 Spirit II 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 Pr
151. pose 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 aus N 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 Observe the following guidelines to protect against electric shock AS 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 con
152. r 2 J1 3 to DSP J8 3 Chopper 2 J1 5 to DSP J8 4 Chopper 3 J1 1 to DSP J9 1 3 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 14 Spirit II User s Manual Section 7 Parts List Section 7 Parts List Power Supply BK300221 BK300229 Right Side View Item Part Number Quantity Description 4 BK707155 2 L1 L2 Inductor 5 BK706409 1 T2 Control Transformer 200 480 V 60 Hz BK706410 T2 Control Transformer 600 V 60 Hz 6 BK706405 1 T1 Main Transformer 200 480 V 60 Hz 30 BK706502 T1 Main Transformer 600 V 60 Hz 30 15 BK709105 1 Strain Relief 30 BK708121 1 CON 1 Main Contactor 31 BK702076 1 EMI Filter 380 415 V units only 35 BK709376 1 TB5 3 Phase Input Power Terminal Block 38 BK300250 2 Chopper Assembly 44 BK200204 2 Fan 4 7 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
153. r 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 4 150 190 135 250 300 460 3 8 155 145 140 275 400 i 1 2 110 300 500 20 74 58 72 135 155 5 8 460 95 350 600 3 4 65 150 400 800 160 1 0 175 35 200 i 1000 170 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 155 500 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 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 120 250 6350 100 25 100 2 5 0 Argon Air N A 50 25 N A 71 100 2540 100 25 100 2 5 0 NANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 250 6 4 mm for cu
154. r s Manual Mild Steel 200 Amps Copper Electrode Oxygen Plasma Air Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277274 BK277289 BK277291 a y x 2 a e l Y Z lt f _ 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 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 1 147 50 175 450 1000 i55 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 Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 3 8 500 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
155. r 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 II IP1 IP1 POSITIONER POSITIONER IP8 IPs CONSOLE 2 CONSOLE 2 IPS IPS REMOTE REMOTE o o P4 Ce X Y MACHINE B ono n IP7 IP6 IP4 z RS 422 RS 422 X Y IPG RSs P7 RSAZZIN Sey d A OUT IN MACHINE O Ve e IP P16 RS 422 OUT AA Spirit II 150 275 Spirit II 400 Unique Interconnect Cables Two unique interconnect cables are required for this option with the Spirit Il 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 multi
156. r 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 II 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 system 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
157. rch Handle BK278001 9 46 240 BK278018 7 06 179 1 99 51 A are Alignment Indicator ye Slot 5 Attachment Ring Sa Alignment Indicator Torch Head Circle 5 08 129 T 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 Il User s Manual 5 Gang Manifold Specifications Part Number 5 catenstutencsuttdateiatenedcetaianents BK300075 CIE Gl AE AE Ea A REN ren PO nEOr iy rer 6 Ibs 2 7 kg 6 18 157 0 327 8 3 F 0 25 6 4 ry T Nc 4 0 187 4 8 Mounting Holes 1 18 30 pa t 3 80 4 20 97 107 i 2 0 Cl 3 035 77 TE U y 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
158. rder 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 125 250 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 Admi
159. re 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 Fire Prevention 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 Plasma 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 The combination of Preflow Postflow Plasma and Shield input gases should always adhere to the types specified in the cut charts for a given material type e When changing to a different type of gas oxidizing or oxygen containing to combustib
160. reflow 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 516 8 3 1000 3 3 20 130 1340 i 9 0 3 4 N 1500 Iel 25 20 71 45 69 133 1040 3 7 10 1 32 145 625 5 1 17 8 3000 3 6 38 154 385 5 6 8 9 1500 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 Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised 09 01 2015 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 Use
161. ring 150A 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 8 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 BK27910 j 70A Q ai LLL BK284150 BK277146 BK277113 BK277126 BK277141 BK277133 BK279100 lt N I D BK284150 BK277298 BK277266 BK277297 BK277139 I D BK284150 BK277274 BK277266 BK277287 BK277259 150A AiE BKI SK80 BKE BK BKA Bio seek S 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 5 9 Section 5 Torch Consumables and Cutting Charts Spirit II Users Manual Stainless Steel Air or Nitrogen Plasma Copper Electrode Outer Shield Inner Nozzle Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK284150 BK277144 BK277110 BK277121 BK277138 BK277137 Q
162. rt 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 4 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 shutdown times are different for each current and are given below Arc Shutdown Times Current A Time ms 30 490 50 390 70 300 100 300 150 17
163. s Stainless Steel 275 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277263 BK277276 BK277270 S N a OMD D j K f 7 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 2 143 120 125 300 600 465 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 480 1 50 185 25 300 350 i Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 42 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 if 38 184 640 7 5 8 9 i Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Sh
164. s 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 25 100 2 5 0 SZAN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 Stainless Steel 150 Amps Silver Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 green o ring _ YEA Y OD
165. s Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 150 190 135 250 300 480 3 8 155 145 140 275 400 i 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 i 1000 170 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 6 149 4955 3 3 6 3 300 38 10 3545 3 5 7 0 155 500 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 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 TMZ Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Expor
166. s 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 2 D J NY J BK277140 BK284150 BK277122 BK277142 BK277131 BK279100 7 CW Q 9 D BK277125 BK277142 BK277131 BK284150 70A Q a Q cD BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100 100A 2 BK277151 BK284150 BK277117 BK277152 BK277293 BK277139 BK277292 150A Q 59 D BK284150 BK277289 BK277143 BK277291 D D BK284150 BK277269 BK277258 BK277270 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 7 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 BK284150 BK277286 BK277151 BK279484 BK279483 Fenn BK279060_ Wy Op e Q BK284150 BK284150 BK277274 BK277266 BK279489 BK279443 yelow o ring BK284150 BK277263 BK277266 BK279469 BK279458 ted o ring BK279420 green o
167. 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 BK300610 Right Side View Item Part Number Quantity Description 1 BK300613 1 Power Supply 24VDC 1 04A 2 BK300301 PMGC 1 Printed Circuit Board PCB Gas Console DSP 3 BK300606 1 Keypad Membrane 4 BK300604 1 LCD Display Assembly 5 BK708111 1 Switch Pushbutton OFF Button 6 BK500570 3 Plasma Shield Regulator 0 125 PSI 7 BK500562 1 Preflow Regulator 0 60 PSI 8 BK300618 7 Manifold Block Gas Outputs 9 BK300614 7 Transducer 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 BK300610 Left Side View Item Part Number Quantity Description 1 BK300613 1 Power Supply 24VDC 1 04A 2 BK300301 PMGC 1 Printed Circuit Board PCB Gas Console DSP 5 BK708111 1 Switch Pushbutton OFF Button 6 BK500570 3 Postflow Regulator 0 125 PSI 7 BK500562 1 Preflow Regulator 0 60 PSI 8 BK300618 7 Manifold Block Gas Outputs 9 BK300614 7 Transducer
168. sma Gas HOSe 2 r To Star A Cable z am Ground Rs O PreFlow PostFlow Gas Hose Gas Supply Positioner B Cable To Star CNC Controller Ground Fil Cable Legend Supplied aai Optional Customer Supplied Notes 2 Gang 1 If only the Inova Remote is used to set Inova Manifold parameters then follow the configuration shown 2 If only the CNC Controller is used to set Inova parameters no Inova Remote then 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 5 Gang Manifold 7 5 Foot Shield Hos Gang Manifold Control Cabl Gang Manifold Control Cabl Arc Starting Console Positioner fork Ground Lead Internal Inova TUEZ Ground Cable a A e aed Torch Head T Star Gro nd Work Piece Figure 1c Spirit Il System MGC Internal Inova ASC with CleanStrike Technology 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 cae Shield Gas HO
169. starting 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 arc starting 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 arc starting console Torch Electrode Coolant Supply Lead 12 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 For systems that include ACS with RHF connect the torch coolant return lead to the brass cathode manifold Note that the torch coolant return lead has left hand threads e For systems that include ACS with CleanStrike Technology connect the torch coolant return lead to the brass elbow fitting on the ASC manifold Note that the torch coolant return lead has left hand threads Torch Nozzle Lead e For systems that include ACS with RHF connect the torch nozzle lead to the angled bracket on the red standoff Note that the torch nozzle lead has right hand threads e For systems that include ACS with CleanStrike Technology connect the torch nozzle lead to the fitting on the red standoff Note that the torch n
170. t 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 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 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 E 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 WYSE Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or Air Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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
171. t 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 275 Amps Copper Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277263 BK277276 BK277270 9 OMD D Z 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 8 160 160 160 275 400 460 1 2 165 125 180 300 500 5 8 168 105 190 350 600 4165 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 Plasma Shield Postfow 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
172. t be within an acceptable range To check the input pressures follow the steps below Setup on ill ee On the main menu move the pointer to Errors Input Gas Press the select button Version Configure Verify that all connected gas pressures are at Die aa least 115 psi 7 9 bar The maximum input PostFlom 137 gas pressure is 145 psi 10 0 bar Pre Flows Fetim d Press the select button to return to the main menu Input Gas Pressure Error Messages The following error messages are displayed when the associated input gas pressure drops below the minimum of 105 psi 7 2 bar To correct this error push in the Off Button and then restore the associated gas to the correct input pressure Once restored release the Off Button and then press the select button to return to the previous screen Plasma input gas pressure is too low PreFlow and or PostFlow input gas pressure is too low Shield input gas pressure is too low 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 4 Spirit II User s Manual Section 4 Operation with Manual Gas Console Making a Cut or Mark Once the process type gas types and gas pressures have been set in the MGC the correct torch par
173. the requirements of the EAR 3 6 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 must be equipped with time delay fuses only The magnetic inrush current of the power supply can be up to 30 times the steady state load current for 0 01 seconds and up to 12 times for 0 1 sec With non delay fuses the fuse will clear due to the inrush current The same applies for circuit breakers which have an instantaneous magnetic trip Use of a motor start circuit breaker or equivalent is recommended if time delay fuses are not used or allowed by local or national codes The main feed device breaker or fuse and any branch protection breaker or fuse upstream of the power supply must be sized to handle all branch loads for both steady state and inrush current 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 Input Voltage VAC 2tMaximum T
174. tion 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 ASC Door ASC 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 10180 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 Using default current remove start 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 chop
175. trary to the requirements of the EAR 7 3 Section 7 Parts List Spirit Il User s Manual Power Supply BK300221 BK300229 Cooling Section View Item Part Number Quantity Description 15 BK709105 1 Strain Relief 17 BK200092 1 Coolant Reservoir without Fittings or Cap 18 BK500518 1 Coolant Reservoir Cap Level Gauge 19 BK300135 1 Coolant Level Switch 20 BK505024 1 Coolant Temperature Switch 21 BK500052 1 Coolant Pump Motor 1 3hp 230V 50 60 Hz 22 BK500513 1 V Band Clamp 23 BK300192 1 Coolant Pump 70 gph 24 BK708061 1 Solenoid Valve 220 240VAC 25 BK715118 1 Check Valve Coolant Return 26 BK300134 1 Coolant Flow Sensor 27 BK260250 1 Heat Exchanger 28 BK500509 1 Coolant Filter Housing 29 BK500510 1 Coolant Filter Deionization Cartridge 45 BK500526 3 Fan Guard Mounted Outside 49 BK500525 2 Fan 6 61 BK284031 1 Fan 10 T 6 0 If i ome O 49 45 igoe O By 1 El p 27 0 gt se 49X45 26 eu 29X28 i 6145 24 15 25 9 less Oo E 21 w 23 22 This information is subject to the controls of the Export Administration Regulations EAR This information
176. ts consumables installed and the X Y controller and torch height control are properly configured the system is ready to cut or mark on Release the OFF Button turn to the right on i the MGC On the main menu move the pointer to On Press the select button Setup Errors Input Gaz Version Configure a N Cuttin The MGC starts to purge the gas hoses The OOBEE rik 1 4 a 7 En a purge icon 4 is displayed during this voltage i process Adjust Gas WJ Once purging is complete the ready icon is displayed The system is now ready to cut or mark Cutting Current 150 Voltage Adjust Gaz 15 When the system receives a start signal from the X Y controller CNC the following sequence is initiated e Two second gas preflow e RHF CleanStrike circuit energized e Pilot arc initiation e Transferred arc cutting or marking arc established e Motion output relay energized When the start signal is removed the arc is extinguished and the motion output relay is deenergized 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 Piercing Thick Materials Care must be taken when piercing thick materials in o
177. tside the United States contrary to the requirements of the EAR 6 4 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting Power Supply 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 following 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 ASC DOOR ASC 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 OPT
178. tting and 100 2 5 mm for marking 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 275 Amps Silver Electrode Air Plasma Nitrogen Shield Air Preflow amp Postflow Shield Cap Nozzle Electrode BK277263 BK279469 BK279450 red o ring 3 d 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 voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 160 160 160 275 400 460 1 2 165 125 180 300 500 i 5 8 168 105 190 350 600 465 3 4 20 73 65 75 172 85 200 800 i 1 00 180 60 240 l N 400 170 1 25 185 45 260 1000 1 50 190 25 270 180 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 10 160 3
179. uirements of the EAR 5 11 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 BK279100 30A 9 QD cp BK277122 BK277131 50A 9 Basas BKa77i80 BKA77183 BRATZ BRAVIA BKZTTIS BK279100 70A 9 O BIE BREPTOBS BROTTIET BRATTOBA BROTTIES BKT BK279100 100A 9 D BK277293 BK277139 BK277292 S D 150A BK277289 BK277143 BK277291 S 200A BK277276 BK277270 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 12 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 BK284150 BK277286 BK277151 BK279484 BK279483 hoe fhe BK279060 S NN 6 y B penne BK279493 BK279439 BK2 9420 BK279060 Q 9 D BK279440 BK284150 BK277266 BK279489 BK279443 yellow o ring BK279060 BK279450 BK284150 BK277263 BK277266 BK279469 BK279458 red o ring 275A
180. 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 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 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 3 Remove the HF ISC wire connected to TB2 side 2 right side from position 2 or 3 Make sure to isolate the connector so that it doesn t come in contact with anything metal during this test Return the jumper wire to the original position at the end of this test oe C i TB2 Side 2 Position 2 a TB2 Side 2 Position 3 HF ISC
181. wirl Ring Torch Head BK284150 BK277266 BK277143 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 4 130 200 200 400 070 150 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 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 38 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 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 70 100 2540 100 2 5 100 2 5 0 NANN Do not connect H17 combustible gas as an input gas Pre Postflow Plasma or Shield at the same time as Oxygen or A
182. y 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 Il User s Manual 2997 9 Manual Gas A Console D ill oe BLUE Figure 8 Torch Gas Connections f iai H Zi m ZA ZZ CLLALLLLLLLLLMMAA AMMAR MME LALLA 28 G G5 REAR PORT 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 Gas Supply Connections Perform the following steps to connect the gas supply lines to the MGC See Section 2 for gas supply requirements Mating hose barbs should be 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 A WARNING IMPROPER GAS
183. y 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 s instructions In particular the spark gaps if the system includes ACS with RHF 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

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