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718117 Spirit II 400 AGC

1. This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 BK300234 BK300239 Top View Item Part Number Quantity Description 1 BK501163 1 Light Housing 2 BK501164 1 Bulb 3 BK501162 1 White Lens 5 BK500557 2 T2 T3 Control Transformer 208 220 240 460 V 60 Hz BK706410 T2 T3 Control Transformer 600 V 60 Hz 7 BK709359 1 F3 Fuse 5A Slow Blow 8 BK709358 1 F4 Fuse 5A Medium Blow 9 BK709358 1 F5 Fuse 5A Medium Blow 10 BK709360 1 F6 Fuse 6 3A 11 BK709360 1 F7 Fuse 6 3A 13 BK709061 4 F1A F1B and F2A F2B Fuse Holder 14 BK709128 4 F1A F1B and F2A F2B Fuse FNM 6 25A 38 BK300250 3 CA1 CA2 CA3 Chopper Assembly 41 BK708103 1 Fan Relay 42 BK708104 1 Relay Socket
2. Part Number Part Number Length Non CSA Systems CSA Systems g BK284306 XX BK288406 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments E ASC CONSOLE CONTROL CABLE a POWER SUPPLY FE g p I ASC CONSOLE 5 5 PONN POWER SUPPLY ELECTRODE LEAD POWER SUPPLY ASC CONSOLE POWER SUPPLY NOZZLE LEAD POWER SUPPLY ASC CONSOLE POWER SUPPLY CTP SENSOR LEAD POWER SUPPLY S ASC CONSOLE POWER SUPPLY COOLANT RETURN HOSE POWER SUPPLY Ct ASC CONSOLE POWER SUPPLY COOLANT SUPPLY HOSE POWER SUPPLY Gi RHF CONSOLE Work Ground Lead Part Number Part Number Lenath Non CSA Systems CSA Systems g BK284318 XX BK288418 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 increments POWER SUPPLY STAR GROUND This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 14 Spirit II User s Manual Section 7 Parts List
3. s d a L AL Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK279439 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 145 130 250 400 405 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 Postfow 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 39 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 All Material Thicknesses f Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 69 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on sy
4. aa a oo a Q Zn ama 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 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 o
5. Outer Cap Retaining Cap Swirl Ring BK284150 BK284156 BK284122 BK279100 Imperial Material i Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 105 190 300 600 165 5 8 165 90 180 350 800 175 3 4 75 170 400 1200 1 170 50 185 500 1500 200 30 80 82 96 1 25 175 40 210 700 2000 1 5 185 30 270 800 2500 225 ELIT 193 23 300 235 350 1500 2 00 200 18 350 250 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 2750 4 8 7 3 600 4 2 16 165 2270 4 5 8 9 800 4 4 20 1810 4 3 10 5 1500 25 169 1310 4 6 12 5 5 1 30 80 82 96 32 175 1005 5 3 18 0 2000 38 184 765 6 8 20 2 2500 5 7 45 193 570 7 6 7 8 6 0 1500 50 199 470 8 7 8 9 6 4 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 100 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 68 100 2540 160 4 1 100 2 5 0 Use an arc transfer height ignition height of 3
6. oO Item Part Number Quantity Description 1 BK200092 1 Coolant Reservoir without Fittings or Cap 2 BK500518 1 Coolant Reservoir Cap Level Gauge 3 BK300135 1 Coolant Level Switch 4 BK505024 1 Coolant Temperature Switch 5 BK284033 1 Pump Motor 1 2hp 230V 50 60 Hz 6 BK500513 1 V band Clamp 7 BK300193 1 Coolant Pump 125 gph 8 BK708061 1 Solenoid Valve 220 240VAC 9 BK715118 1 Check Valve Coolant Return 10 BK708068 1 CR5 Relay 11 BK300134 1 Coolant Flow Sensor 12 BK284031 2 Fan 10 Aluminum 13 BK500514 2 Heat Exchanger 14 BK500509 1 Coolant Filter Housing 15 BK500510 1 Coolant Filter Deionization Cartridge 16 BK715052 1 Drain Petcock 17 BK709086 1 TB3 Terminal Block Marker 14 Position 18 BK709007 1 TB3 Terminal Block 14 position 19 BK709262 1 P1 16 Pin Receptacle 20 BK500526 2 Fan Guard 10 2 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 4 Spirit II User s Manual Section 7 Parts List Automatic Gas Console BK300418 Front View Item Part Number Quantity Description 1 BK300412 1 Power Supply 24VDC 8 3A 2 BK300301 AGC 1 Printed Circuit Board PCB Gas Console DSP 3 BK280030 1 Fan 24VDC 4 BK260109 1 Nit
7. 275 Amps 4 K This button also indicates three gp par eset ee different system conditions IOF eee Pree i Process Setup ste Material Parameters Status Purge Config The system is ON cooling fans and coolant pump are running The system is OFF Press to turn the system ON The system is OFF but enabled OFF Button has been released Press to turn the system ON This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Automatic Gas Console Spirit Il User s Manual Important Messages and Icons Messages and icons at the top of the screen provide additional important information Material Stainless Steel H17 Disabled Thickness 3 000 4 3 000 inches 78 Air Current Amps View Torch Parts 275 amps N Shield 63 a Nitrogen A Display Process Gases e Cut SE Mark Ge Process Setup System Material Parameters Status Purge Config Diagnostics Warning message see Error Log The system is cutting The system is marking a Gas pressures are adjusting Setup Optimum Current pressures and gasses are set to the cutting chart defaults for the sel
8. Shield Cap Nozzle Electrode BK277263 BK277269 BK277270 SNS 9 OMD gt D ps i ie 7 Zt C Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277258 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 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 jez 1 25 150 45 175 500 1500 i 20 81 70 79 1 50 163 25 235 750 2500 15S 170 20 290 190 350 2 00 180 15 350 _____ _ oo oT 1500 H F 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 49 16 436 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 89 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 s 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
9. Network TA Enabled Process Setup System Material Parameters Status Purge Config Diagnostics This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 15 Section 4 Operation with Automatic Gas Console Spirit II User s Manual Software Updates Tab Press the Config navigation button followed by the Software Updates tab to update the Spirit system software Configuration Advanced Config Network Settings Software Updates System Info Tools pie Selected Update Package Install Process Setup System Material Parameters Status Purge Cong Diagnostics See the next page for details on updating the software This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 16 Spirit II User s Manual Section 4 Operation with Automatic Gas Console Updating the Software 1 Copy the file Installer exe onto a USB thumbdrive This file will be emailed or an ftp address will be provided for download 2 Turn the Plasma Console off 3 Insert the
10. ccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 13 Section 3 Installation Talitce a tslo ells a terrae eeerenmeernreemenrec seereeer E ermre a a ranean nr reat aAA 3 1 Component Placement eere rences essa eE EE ee Ee Eee Ee Ete ret 3 1 System Interconnection scenkne neko ttrt rrtt ttrt ttrt ttt EErEE EEEEEEEEEEEEEEEEEEE EEEE 3 2 Power Supply Primary Power Connections c cccccccceeeeeeeeeeeeeeeeeeeeeeeeees 3 5 Power Supply Output Connections ccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 3 7 ASC Control Cable and ASC Ground Connections ccceccceeeeeeeeeeeeeeeeeeeeees 3 9 Cooling System Connections scsccos des cescceeevectcenc cevecdui cent cepiceticeplsentcepicedidenlcentcext 3 9 Torch Leads to Arc Starting Console Connections cccccceeeeeeeeeeeeeeeeeeeees 3 11 Torch Leads to Torch Base Connections ccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaes 3 13 TORCH GAS Connections ps ce pcs d sec he Sch oh Scns eS xt ced oud Gud a nba das axotaeelun be 3 14 Gas Supply CONMECHONS sesen 3 17 Plasma Console Connections ccccceceeeeeeeeeeeeeeeeeeceeeeaeeeeeeeeeeeeeeeeaaeeneeees 3 18 CAN Communication Connections cccceeeceeeeeeeeeeeeeeeeeeeeeaaeeeeeeeeeeeeeeeaaes 3 19 CNC Machine Interface Connections ccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaes 3 20 Initial Filling of the Cooling System 26 ccecd feccceed dvsdceed euaccecd
11. RS422 Tab Press the Diagnostics navigation button followed by the RS422 tab to access the screen described below Note that incoming data is appended to show an R before the data and outgoing transmissions are appended to show a T before the data Pressures Coolant RS422 Electrical Cut Info Power Supply Error Log Messages i Messages Sent Received enee Desc rona C Dee Protocol Type Time Queue Message MSG NetID Data LSB MSB Enable Clear Supress Telemetry System Material Parameters Status Purge Contig Electrical Tab Press the Diagnostics navigation button followed by the Electrical tab to access the screen described below This diagnostic screen displays important parameters for the Power Supply and Gas Console that may be useful during troubleshooting Pressures Coolant RS422 Electrical Cut Info Power Supply Error Log Messages Power Supply Parameters Gas Console Parameters Plasma Valve Output Voltage 1 Volts Oxygen Valve Output Current 1 Amps E ee litrogen Valve 4 Preflow Valve Phase 1 Volts Shield Valve Phase 2 1 Volts Marking Shield Valve Phase 3 1 vons Marking Plasma Valve Process Setup System Material Parameters Status Purge Config This information is subject to the controls of the Export Administration Regulations EAR Th
12. 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 Consumables and Cutting Charts Selecting Consumables Mild Steel Copper Electrode Outer Shield Inner Nozzle Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 wA N 4 D BK277140 Q BK284150 BK277122 BK277142 BK277131 BK279100 AN NI SNE Q 2 D ONB D Ey BK277142 BK284150 BK277125 BK277131 Q 70A 9 OD pp sa eel eS ee 100A SD BK277151 BK284150 BK277117 BK277152 BK277293 BK277139 BK277292 BK279100 Q S D 150A BK284150 BK277289 BK277143 BK277291 D D BK277269 BK277258 BK284150 BK277270 BK2791 f la AN Ny ia Q 49 D cw a S 5 4 ae BK284150 BK284123 BK284121 BK284125 BK284122 BK284124 BK279100 400A oy OWD D ry j j This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to n
13. 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 22 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 30 Amps Air Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277144 BK277121 BK277137 e X Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277110 BK277138 BK279100 Imperial Material F 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 Postfow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 71 4855 0 6 100 35 81 30 85 1 3 1 7 1 5 73 3260 0 9 200 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Vol
14. Gas Console Code Short Description Long Description 20100 Plasma Adjust Could not adjust Plasma Gas 20110 Shield Adjust Could not adjust Shield Gas 20120 Preflow Adjust Could not adjust Preflow Gas 20130 Postflow Adjust Could not adjust Postflow Gas 20140 Marking Adjust Could not adjust Marking Gas Automatic Gas Console 20160 N2 Mix Adjust Could not adjust N2 Mix Gas 20170 O2 Mix Adjust Could not adjust O2 Mix Gas 20200 O2 Low O2 Input Pressure is low 20210 N2 Low N2 Input Pressure is low 20220 Argon Low Argon Input Pressure is low 20230 O2N2 Low Air Input Pressure is low 20240 H17 Low H17 Input Pressure is low 20250 O2 High O2 Input Pressure is high 20260 N2 High N2 Input Pressure is high 20270 Argon High Argon Input Pressure is high 20280 O2N2 High Air Input Pressure is high 20290 H17 High H17 Input Pressure is high 20300 PS Quiet Lost CAN communication with Power Supply 20310 PC Quiet Lost CAN communication with Plasma Controller This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 troublesho
15. 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 20 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 location outside the United States contrary to the requirements of the EAR 7 21 Section 7
16. Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 25 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 70 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 N NE 9 pp A 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 ga in psi psi psi psi volts ipm in in msec in 10 135 132 120 060 150 200 Gas 3 16 134 100 070 200 300 25 76 25 76 1 4 140 75 090 225 400 090 3 8 148 50 120 250 500 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 3 131 3210 1 4 3 3 200 99 5
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 contrary to the requirements of the EAR 1 3 Section 1 Safety Spirit II User s Manual Health Support Equipment Compressed gas cylinders should be maintained properly Never attempt to use a cylinder that is leaking cracked or has other signs of physical damage All gas cylinders should be secured to a wall or rack to prevent accidental knock over If a compressed gas cylinder is not being used replace the protective valve cover Never attempt to repair compressed gas cylinders Keep compressed gas cylinders away from intense heat sparks or flames Clear the compressed gas cylinder connection point by opening the valve momentarily prior to installing a regulator Never lubricate compressed gas cylinder valves or pressure regulators with any type of oil or grease Never use a compressed gas cylinder or pressure regulator for any purpose other than which it is intended Never use a pressure regulator for any gas other than which it is intended Never use a pressure regulator that is leaking or has other signs of physical damage Never use oxygen hoses and pressure regulators for any gas other than oxygen Never use any gas hose that is leaking or has other signs of physical damage M The Spirit s
18. 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 10 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 Torch Handle BK278001 9 46 240 BK278018 7 06 179 1 99 51 A err Alignment Indicator ye Slot 5 Attachment Ring Sa Alignment Indicator Torch Head Circle 5 08 129 T This information is subject to t
19. in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 108 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 54 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 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 Mild Steel 400 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK284123 BK284125 BK284124 R SS 2 opp 6 Z Wy 4 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK284121 BK284122 BK279100 Imperial Material P Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfiow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 140 160 140 300 500 150 5 8 135 350 600 155 3 4 123 110 A30 400 800 160 1 150 85 160 5
20. Nitrogen Shield This gas combination Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen Shield Cap BK277150 Nozzle BK277124 Electrode BK277132 ives the best cut quality and minimum dross levels Torch Head Retaining Cap Swirl Ring BK284150 BK277113 BK277140 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 A 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 5 35 65 30 60 135 2030 2 5 5 1 300 2 3 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 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 Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking
21. Retaining Cap BK277151 1 4 118 165 105 200 300 495 3 8 20 71 30 69 123 125 135 250 400 j 1 2 125 90 140 300 500 130 Retaining Cap BK277152 5 8 127 70 440 325 600 130 3 4 130 55 350 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 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 39 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 36 8 3 1000 3 3 20 130 1340 i 9 0 3 4 1500 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 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 09 01 2015 This informat
22. This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 x Y S A 9 o eam 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 4 145 150 160 250 400 408 3 8 150 115 180 275 500 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 3 10 150 2805 4 7 7 0 B00 l 12 20 71 70 69 153 2330 5 1 7 4 48 16 160 1510 5 6 8 3 800 20 170 1030 6 2 9 0 1200 3 4 Marking For All Material Thicknesses A 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
23. With the RS422 Parameter Control set to Automatic the Inova is automatically updated with the correct arc voltage pierce initial height and cutting marking height any time a new condition is loaded the process cutting or marking is changed or when the arc voltage pierce initial height or cutting marking height is changed on the Parameters Screen With the value set to Manual the parameters are transmitted using the Manual Transmit button on the Parameters Screen Choose Disable to prevent the system from sending RS422 communications Cut Mark Control The Spirit system has the capability of plasma cutting and plasma marking with the same set of consumables The process cutting or marking can be set by the RS 422 serial interface COMM by a hard signal Hard Wire on the CNC interface plug or locally Local through the plasma console Hydrogen Cutting H17 When hydrogen cutting is enabled the H17 hydrogen mixture will automatically be selected as the plasma gas for certain material types and thicknesses To prevent the use of H17 hydrogen cutting must be disabled Units of Measure The Spirit system will display Imperial units or Metric units Press to select Language Press to select the desired language This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the U
24. ccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess 5 3 Maximizing Consumable Lifes i2 c ccescceseeenccanctenecexehebecevetenesevehedecevetenecevehedeeenetene 5 5 Inspecting for Damage rsenisnneniseni nen seeded shecded heeded hed Re 5 6 Selecting GOmSumia bles 2 z ce ce t te clasts let lentbantbendbantlentbantledbertlestbasthesblahesds 5 7 Cutting Chans arere ed piles adie piled adlnk piled ouias A phen odio 5 14 Section 6 Maintenance and Troubleshooting ROLLING Maintenance snesen E omelette 6 1 Replacing the Torch Coolant and Filter 6 4 Power Supply Microprocessor DSP Status Indicators ccceeeeeeeeeeeeeeeeeeees 6 5 Power Supply Microprocessor DSP Sequence of Operation 0668 6 5 EOF COU SS aee ee o ereere btvndheves subienercnbtexesuncdeuss a E 6 7 General Troubleshooting fo ad oie loa lea a lea aie i fi ad fo as 6 9 Chopper Test Procedure ax cesscihs cca cca dcsscatnduandalss Avducaaaguundaasdadscuensaancaasdudsacenaaseanne 6 11 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR iv Spirit II User s Manual Prologue Section 7 Parts List Power Supply BK300234 BK300239 eccccccceeceeeeeeeeeeeeceeeeeeeeeeeeeeeneeeeeeeeees 7 1 Cooling System BK3002 5 lt s scsnsnnneneneneken
25. 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 Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 145 250 6350 147 3 7 100 2 5 0 Argon Air N A 50 25 N A 71 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 135 3 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 16 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 70 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode
26. A WARNING Falling equipment can cause injury e Lift only with equipment of adequate lifting id a a PU gy ne capacity i mM i e Be sure power Sling j a supply is stable Hole when lifting 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 have a grade of no greater than 10 to eliminate the risk of toppling over This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 1 Section 3 Installation Spirit II User s Manual The power supply must be cleaned as often as necessary to prevent the accumulation of metallic dust inside the unit See Section 2 for unit dimensions Automatic Gas Console AGC The AGC is usually mounted on the gantry of the cutting machine See Section 2 for mounting dimensions Plasma Console The plasma console should be mounted near the CNC controller so that it is easy
27. EAR This information shall not be provided 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 Aluminum 275 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277263 BK277276 BK277270 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277258 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 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 60 240 400 170 1 25 185 45 260 1000 1 50 190 25 270 180 Metric Material S 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 25 179 1565 6 0 10 2 4 3 32 185 1120 6 6 1000 38 189 645 6 8
28. Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 175 150 170 300 600 200 5 8 180 125 190 400 700 205 3 4 185 100 205 500 800 30 85 63 96 210 1 190 75 215 600 1200 1 25 200 55 220 700 1500 225 1 5 205 35 225 800 2000 240 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 173 3950 4 1 7 0 600 5 1 16 180 3150 4 8 10 3 800 5 2 20 185 2445 5 2 13 0 30 85 63 96 1200 5 3 25 189 1945 5 4 15 0 32 200 1375 5 6 17 9 1500 5 7 38 204 895 5 6 20 2 2000 6 1 Marking For All Material Thicknesses 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 106 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 75 100 2540 140 3 6 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any m
29. Maximum Time Delay Fuse 2 Output amps Size amps 380 VAC 50 60Hz 400 VAC 50 60Hz 440 VAC 50 60Hz 480 VAC 60Hz 600 VAC 60Hz 415 VAC 50 60Hz Connection to the supply circuit can be by means of flexible supply cables or supply cables through conduit to a permanent installation The supply cables should have a 600 volt minimum rating and should be sized according to local and national codes Route flexible supply cables through the strain relief on the back of the power supply and connect to the input terminal block TB5 as shown For supply cables through conduit install the conduit in place of the strain relief and connect the associated supply cables to the input terminal block TB5 See Figure 3 on the next page TB5 is located on the rear of the power supply and is accessible with the right side cover removed Be sure to connect the primary ground cable to the ground stud on the input terminal block This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 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 Sc
30. Postfow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 145 85 160 250 500 iod 1 2 142 80 140 300 600 5 8 145 65 185 350 800 40 63 64 63 195 3 4 150 55 225 400 1200 1 0 160 33 250 450 200 1500 1 25 7 170 26 280 350 205 Metric Material A 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 f Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 108 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 75 100 2540 160 4 1 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shal
31. Press the Thickness Selection button to choose from a list of predefined Thickness Selection spon a gauges and thicknesses or press the E ts data entry button to manually enter a thickness Current Amps 3 8 View Torch Parts IWP o rary AD Cancel 8 Process Setup System Material Parameters tus Purge Config Diagnostics oO Matra Select Cut or Mark Process Stainless Steel SS er Press Cut or Mark to select the i i desired process and the default gases pa E a will be displayed 3 000 3 000 inches in 78 a a Air ee Current Amps _ gt Shield 275 amps 2 Nitrogen 4 The selected process will have a light blue background y ore Note The X Y controller can i si automatically override the selected process unless the cut mark cut configuration is set to Local Process Setup System Material Parameters Status Purge Config Diagnostics This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Automatic Gas Console Spirit II User s Manual Verifying Important Parameters Prior to
32. This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 46 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 200 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277274 BK279489 BK279440 yellow o ring l 3 d 2 pi bia A 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 TTT TooToo 1 147 50 175 450 1000 45 1 25 155 25 240 500 f 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 Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 6100 8 4 9 300 10 130 3480 2 3 6 5 500 3 8 12 132 3160
33. XX is the length in feet 10 150 ft lengths available in 10 ft increments Custom lengths are available Contact factory e PREFLOW HOSE 2s AGC 5 GANG MANIFOLD SHIELD HOSE AGC 5 GANG MANIFOLD PLASMA HOSE PE AGC RED 2 GANG MANIFOLD POSTFLOW HOSE AGC 1_ 5 GANG MANIFOLD MARKING PLASMA HOSE AGC BLACK BLACK 5 GANG MANIFOLD MARKING SHIELD HOSE AGC 5 GANG MANIFOLD 7 5 FOOT SHIELD HOSE 5 GANG MANIFOLD BLUE TORCH 6 FOOT PREFLOW POSTFLOW MARKING HOSE 5 GANG MANIFOLD z GREEN 2 GANG MANIFOLD Cooling System Control Cable Part Number Length BK300276 10 10 ft 3 0m POWER SUPPLY COOLING 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 7 13 Section 7 Parts List Spirit II User s Manual Coolant and Power Leads
34. lt ET 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 KET BK7110051 005 28 BK709018 SOCKET KET This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 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 25 STRAIN RELIEF BK709021 1 PLUG BK709364 4 PLUG BK709020 9 CABLE BK711049 49 TERMINAL POSITION NO COLOR POSITION NO TERMINAL BK709018 SOCKET T 5 oz am RED 5 BK709365 PIN 6 BLACK 6 amp 6 22 15 wWTE 15 16 BLACK _ 16 13 i BROWN 13 14 BLACK _ 14 23 1 GREEN 2 BLACK 2 7 YELLOW 7 8 BLACK 8 24 9 BLUE 9 10 BLACK 10 aane aE 4 BLACK 4 BK709365 PIN 19 20 C RED xx 20 WHT x 20 JI 21 RED x 21 GRN Xxx BK709018 SOCKET T 21 BK709019 KEY This information is subject to the controls of the
35. transmitted to switch the material type to stainless steel for a Spirit system on node 1 AA 01 FA 01 00 01 OD To send a parameter the parameter value needs to be sent as part of the command For example to send a desired cutting pierce time of 1000 milliseconds to the 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 B 1 Appendix B Serial Communication Spirit II User s Manual look up the Set Cutting Pierce Time command in the command table You will see the following table entry Command Hex String Additional Information Set Pierce Time 4 AAnnFA04 0D Time in mS seconds 1000 Valid range 0 to 5000 Once again AA hex signifies the start of the command nn is the net node of the power supply and FA hex is the Spirit identifier The value 04 hex signifies the Set Pierce Time command and OD hex signifies the end of the command The in the hex string is the MSB followed by the LSB of a type int The integer is the value used in the additional information column Thus the is sometimes referred to as the additional information value In the example we wanted to transmit a pierce time of 1000 mS 1 second This value in hexadecimal would be 03E8 msb 03 Isb E8 In this examp
36. 1 0 170 35 240 450 1500 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 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 s Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 120 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 72 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 31 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 200 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium
37. 2 Connect the other end of the marking plasma hose to the marking plasma inlet on the 5 gang manifold Postflow Gas Hose 25 1 Connect one end of the postflow hose to the postflow outlet on the rear of the AGC 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 AGC 2 Connect the other end of the plasma hose to the plasma inlet on the 2 gang manifold Shield Gas Hose 27 1 Connect one end of the shield hose to the shield outlet on the rear of the AGC 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 AGC 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 connect
38. 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 2534 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 25 100 2 5 0 Argon Air N A 50 25 N A 71 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 55 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 275 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277263 BK279469 BK279450 red o ring 3 d Outer Cap Retaining Cap Swirl Ring BK284150 BK277266 BK279458 BK279060 Imperial Material Arc Travel Cutting Pier
39. 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 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 Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm Retaining Cap BK277151 6 117 4305 2 6 4 9 300 32 10 20 71 30 69 123 3040 3 4 6 5 500 i 12 124 2485 3 5 7 3 3 3 Retaining Cap BK277152 16 127 1760 56 8 3 1000 3 3 20 130 1340 9 0 iso 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 k 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 25 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 09 01 2015 This information is subject to the controls of the Export Administration Regulations EAR
40. 43 BK708105 2 Relay Hold Down Clip z H e a 5 OCEEE JOCO ma g CA1 2 O o o o o COn sem Ve AoA 4 il B E T2 T3 38 OOrEIs Las OO a CA3 ge 4342X41 CXe Xe KA F3 F4 F5 F6 F7 pos 1 pos 4 pos 12 pos 17 pos 19 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 3 Section 7 Parts List Spirit Il User s Manual Cooling System BK300275
41. 51 Stainless Steel 200 Amps H17 Nitrogen Page 5 31 Stainless Steel 200 Amps Air Nitrogen Page 5 32 Page 5 52 Stainless Steel 260 Amps H17 Nitrogen Page 5 33 Stainless Steel 275 Amps Air Nitrogen Page 5 34 Stainless Steel 400 Amps H17 Nitrogen Page 5 35 Stainless Steel 400 Amps Nitrogen Air Page 5 36 Aluminum 30 Amps Air Nitrogen Page 5 37 Aluminum 50 Amps Air Nitrogen Page 5 38 Aluminum 70 Amps Air Nitrogen Page 5 39 Aluminum 100 Amps Air Nitrogen Page 5 40 Page 5 53 Aluminum 150 Amps Air Nitrogen Page 5 41 Page 5 54 Aluminum 200 Amps Air Nitrogen Page 5 42 Page 5 55 Aluminum 275 Amps Air Nitrogen Page 5 43 Page 5 56 Aluminum 400 Amps Nitrogen Air Page 5 44 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Oxygen Plasma Oxygen Shield Copper Electrode Shield Cap Nozzle Electrode BK277145 BK277120 BK277130 n _ YN A YA a OMD D Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK279100 Imperial Material F Arc Trave
42. 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 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 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 20 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 275 Amps Oxygen Plasma Air Shield Copper Electrode
43. 9 46 38 184 640 7 5 8 9 j 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 55 100 2540 130 3 3 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 34 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 400 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode BK284158 BK284159 BK284155 Lf Torch Head
44. Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 176 3415 5 5 7 3 600 42 16 169 2775 4 2 8 9 800 20 165 2190 10 5 3 8 1500 25 169 1690 12 5 5 1 30 85 63 96 32 175 1120 4 1 18 0 2000 38 179 895 4 2 20 2 2500 45 190 610 4 8 7 8 5 2 1500 50 203 410 5 2 8 9 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 107 250 6350 100 25 100 2 5 0 Argon Nitrogen N A 50 25 N A 71 100 2540 160 4 1 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 36 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 30 Amps Air Plasma Nitrogen Shiel
45. BK300234 BK300239 Right Side View Item Part Number Quantity Description 4 BK707155 3 L1 L2 L3 Inductor 5 BK500557 2 T2 T3 Control Transformer 208 220 240 460 V 60 Hz BK706410 T2 T3 Control Transformer 600 V 60 Hz 6 BK706406 1 T1 Main Transformer 208 220 240 460 V 60 Hz 30 BK706503 T1 Main Transformer 600 V 60 Hz 30 15 BK709296 1 Strain Relief 30 BK708120 1 CON 1 Main Contactor 31 BK702076 1 EMI Filter 380 415 V units only 35 BK709251 2 TB5 3 Phase Input Power Terminal Block 38 BK300250 3 Chopper Assembly 44 BK200204 3 Fan 4 7 59 BK284031 2 Fan 10 60 BK500526 2 Fan Guard Mounted Outside 59 60 pal
46. Controller Remote A Cable 2 Gan Manifold 5 Gang Manifold 17 Inch Plasma Hose 7 5 Foot Shield Hose Gang Manifold Cabl Gang Manifold Cable Cooling System Control Cable To Star i __ Ground Cooling System SC Control Cable Torch Handle Arc Starting Console Positioner Work Ground Lead Torch Base Internal Inova Fe Se eo Ground Cable ep ee mtd oe Saye Torch Head Siar Ground Work Piece Figure 1a Spirit Il System AGC 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 User s Manual Legend Supplied Optional Customer Supplied p AN Cable To Star Ground z 1 Cable Remote at A Cabley Termination pean Plug j 1 To Star CNC Controller Positioner p Ground F Cable B Cable 4 Notes 1 If only the Inova Remote is used to set Inova parameters then follow the configuration shown E Cable anova 2 If only the CNC Controller is used to set To Star onsole Inova parameters no Inova Remote then Ground e add the K Cable from the Inova Console P5 to the Plasma Console and ad
47. Cooling System in Section 3 of this manual to complete this procedure This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 4 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting 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 c
48. 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 4 150 190 135 250 300 480 3 8 J58 145 140 275 400 i 1 2 110 300 500 20 74 58 72 135 155 5 8 460 95 350 600 3 4 65 150 460 800 160 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 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations
49. 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 Use an arc transfer height ignition height of 100 2 5 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 38 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 70 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 lt SON a Z y ZL Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 080 130 250 050 150 100 080 1 8 135 160 070 175 3 16 145 80 100 200 200 25 76 25 76 0
50. 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 contrary to the requirements of the EAR 7 9 Section 7 Parts List Spirit Il User s Manual Arc Starting Console BK300505 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
51. 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 Tl 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 e EA 54 as LAL Argon 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 ma 55 pac TJD This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 CII Cable for Optional External Inova Part Number Length BK300902 XX Where XX is the length in feet 5 150 ft lengths available
52. 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 22 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 23 Section 7 Parts List Spirit II Users Manual Power Supply A C Detect BK300112 N 8 ta m lt a cal Fi vn lt KALIBURN NC This information is subject to the c
53. 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 D zA pas Ultraviolet Radiation Protection Plasma cutting produces ultraviolet radiation similar to a welding arc This ultraviolet radiation can cause skin and eye burns For this reason it is essential that proper protection be worn The eyes are best protected by using safety glasses or a welding helmet with an AWS No 12 shade or ISO 4850 No 13 shade which provides protection up to 400 amperes All exposed skin areas should be covered with flame retardant clothing The cutting area should also be prepared in such a way that ultraviolet light does not reflect Walls and other surfaces should be painted with dark colors to reduce reflected light
54. 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 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 decompose and form harmful gases when exposed to ultraviolet radiation These solvents should be removed from the area prior to cutting Galvanized metal can produce harmful gases during the cutting process Ensure proper ventilation and use breathing equipment when cutting these materials Certain metals coated with or containing lead cadmium zinc beryllium and mercury produce harmful toxins Do not cut these metals unless all people subjected to t
55. 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 26 Spirit II User s Manual Section 7 Parts List Gas Console Microprocessor DSP BK300301 AGC Quadrant 3 J20 I J19 I I i J21 l Bg c67 gt o boo C86 o o vo A fo N o Q N o o Q cor tT OR D O o N Hga ORG Nw l Swe 8 A e SRO MRR EEE Sgro LI Orro 8 BR I X 30 C84 L cow D17 C75 I Fa a 10 Q u12 pg 7 O t a 0 2 A N Buse 3 2 Dre OMT re 6 BEER ht io U14 ooo 2 BRD E EEDD S67 kG c18 ok eek amp amp EED gm DEER oO KOK C
56. USB thumbdrive into either port on the back of the Plasma Console 4 Turn the Plasma Console on 5 Allow the system to boot to the normal main screen and select Config from the Navigation Menu 6 Select the Software Updates tab 7 Using the arrows navigate to the software package to be installed Note that the system will overwrite the file without warning if steps aren t taken to rename the default Installer exe file If you wish to maintain older software updates you may wish to rename the file to something like Installer mm dd yy_Installer exe 8 Select the Install button 9 At this point the Plasma Console will shut itself down and run the installer package 10 To complete the install follow the onscreen instructions 11 Follow the on screen instructions a Kaliburn Software Update Program rex a gt Update Pack Components To Be Updated Installation Component GasConsole PowerSupply HeightControl v PlasmaConsole None Cancel Install Update Status Installation files unpacked This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 17 Section 4 Operation with Automatic Gas Console Spirit II User s Manual System Info Tab Press the Co
57. 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 2 Gang Manifold The 2 gang manifold assembly must be mounted to the torch See Section 2 for mounting dimensions Torch The torch must be installed on the positioner of an arc voltage control height control capable of maintaining the cutting arc voltage within 1 arc volt The arc voltage must be adjustable in 1 arc volt increments The positioner must be rigid to ensure cut quality and a torch collision sensor is highly recommended See Section 2 for mounting dimensions Cooling System The cooling system must be located within 8 feet 2 4 meters of the plasma power supply The surface on which the cooling system is located should have a grade of no greater than 10 to eliminate the risk of toppling over See Section 2 for unit dimensions System Interconn
58. according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed plasma cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the plasma power source so that good electrical contact is maintained between the conduit and the plasma power source enclosure Maintenance of the Plasma Cutting Equipment The plasma cutting equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the plasma cutting equipment is in operation The plasma cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer 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 tr
59. current set point from the default setting press the Current Amps button on the Material Screen and choose from the list of available a values 275 ams E N Note When marking is the selected process the current cannot be changed Material Stainless Steel H17 Disabled Current Selection Thickness 3 000 3 000 rees e nano Current Amps View Torch Parts Elod rar la Cancel Process Setup Parameters I Altering Gas Types On the Material Screen press the Plasma or Shield button and select the desired gas type So The plasma gas can be changed to Air Oxygen Nitrogen or H17 Shield gas can be changed to Air Oxygen or Nitrogen Prev Next Bea System Material Parameters Status Purge Config Diagnostics Material Stainless Steel Cancel 8 Cancel Preflow gas cannot be changed Altering Gas Pressures Normally the preflow gas and plasma gas pressures should not be changed The shield gas can be adjusted in small increments to fine tune a cut Use the ones data entry button to enter a desired trogen pie pressure Note that all of the gases have minimum and maximum limits A LI JE and cannot be programmed beyond m R 9 z these limits System Material Parameters Status Purge Config Diagnostics Thickness 3 00
60. depending upon the connection scheme See CAN Communication Connections for more details RS 422 Communications e Insert an RS 422 cable if necessary to connect to other devices RS 422 Communications e Insert an RS 422 cable if necessary to connect to other devices USB e Either USB port can be used to update the Spirit II software Ethernet e Noconnection For future development RS 422 Pinout This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 CAN Communication Connections Choose one of the schemes below to connect the Spirit system for CAN communications Both schemes require two CAN cables and a CAN termination plug Plasma Power Supply ix Automatic Gas Console 3 Plasma Console o9 CAN 2 e Termination Plasma Power Supply f ia e 8AN Cab Automatic Gas Console ese CAN Cbe A e 8 Plasma age r A 5 Console CAN j r Termination Cre X sd o o o 89 0 s o o A gt se of This information is subject to the controls of the Export Administration Regulations EAR This inform
61. hand threads Cooling System Control Cable 1 Connect the cooling system control cable plug labeled P14 to the connector labeled P14 on the rear of the power supply 2 Connect the cooling system control cable plug labeled P1 to the connector labeled P1 on the cooling system Cooling System Ground Connection Customer Supplied The Cooling System must be connected to protective earth ground in accordance with national or local codes The Cooling System receives its power from the plasma power supply and as such must be connected to the same protective ground as the plasma power supply Use a minimum of 8AWG 10 mm wire connected from the cooling system grounding stud to the plasma power supply protective earth ground Note the customer must supply grounding wire This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 11 Section 3 Installation Spirit Il User s Manual ASC with RHF ASC with CleanStrike Technolo G o o a A P q E E E E R fo
62. in 5 ft increments INOVA CONSOLE SPIRIT Il POWER SUPPLY P8 28 POS PS 9 POS STRAIN RELIEF BK709015 315 i a CABLE BK711001 01 O PLUG BK709016 16 STRAIN RELIEF BK709025 025 PLUG BK709364 i4 TERMINAL POSITION NO COLOR POSITION NO TERMINAL BK709018 SOCKET lt ET 1 ER RED 3 BK709365 PIN y 2 BLACK 4 7 3 WHITE _ 12 4 BLACK 14 5 TOD GREEN 10 6 BLACK 11 BK709365 PIN 1 BK709018 SOCKET ET 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 16 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 02 Note Add Label S Wired for Phantom Controller PLUG BK709364 oe STRAIN RELIEF BK709025 025 ie BK709095 45 STRAIN RELIEF BK709021 021 TERMINAL POSITION NO COLOR POSITION NO TERMINAL BK709365 PINS 1 a GREEN 12 BK709018 SOCKET ET 2 BLACK __ 18 22 3 WHITE 21 4 BLACK 15 5 RED 2 6 an ina 1 BK709018 SOCKET
63. 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 400 System consists of the following components Standard Components Power Supply Cooling System includes torch coolant Cooling System Control Cable Automatic Gas Console Plasma Console Touch Screen CAN Cables CAN Termination Plug 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 e Supply Gas Hoses e 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 outsi
64. making a cut or mark with the system the torch height control and the X Y controller must be configured properly To view the recommended cutting data press the Parameters navigation button See RS422 Parameter Control for more information on how to adjust these settings Cutting Parameters Cut Pierce Time Cutting Height Pierce Height Arc Voltage Kerf Width Transfer Height Travel Speed 1500 ms 0 290 inches 0 350 inches 215 0 vots 0 205 inches 0 300 inches 5 iPM Marking Parameters Mark Pierce Time Marking Height Initial Height Arc Voltage Travel Speed 0 100 inches 0 100 inches 107 0 vots 250 Pm Manual Transmit Manage Custom Setups Process Setup System Status Purge Config Diagnostics Viewing the Required Torch Parts Once the material and thickness have been selected the torch parts are determined automatically To see which consumables need to be built up in the torch head press the View Torch Parts button on the Material screen Press Cancel to return to the Material screen Torch Parts 1 _BK277154 Ja 5 BK279483 BK277151 BK279060 Cancel This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S pers
65. 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 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 45 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 150 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 green o ring s d Outer Cap Retaining Cap Swirl Ring BK284150 BK277151 BK 277152 BK279439 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in Retaining Cap BK277151 1 4 118 165 105 200 300 195 3 8 20 71
66. s Manual Automatic Gas Console AGC Specifications Part Number c cccecceececceceeceecesceeeececeeeeees BK300418 Weight Sane ee ne ee ee eee eee 53 Ibs 24 kg 12 4 315 EA o l 12 0 305 13 7 348 4 300 7 6 10 9 277 7 0 178 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 6 Spirit II User s Manual Section 2 Specifications Gas Supply Requirements Plasma gas types Mill Stee e e cect itt ret encanta a iai Oxygen Stainless Steelin rererere nt ee ed hale ede Air Nitrogen or H17 AlUMINUM e e eE Air or Nitrogen Shield gas types Mild Steel Oxygen or Air Stainless Steel 2 4 s0seeeeedeeeeeeeeees Air or Nitrogen AMINU cade Seces tees ced ees ceee tees cand te voccebteeece Air or Nitrogen Preflow gas type 0 ce ceececeecteccceeeecenene Oxygen and Nitrogen Marking gaS tyPe ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees Nitrogen or Argon Plasma gas flow rate maxi
67. s Manual Stainless Steel 200 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277274 BK279489 BK279440 yellow o ring D d Outer Cap Retaining Cap Swirl Ring 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 l 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 l N 600 12 138 3020 2 6 7 3 16 146 1890 3 8 8 9 800 3 9 20 74 58 72 oo r a 20 153 1450 4 8 10 3 25 157 1050 5 2 11 3 4 1 N 1500 Ieee 327 170 495 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
68. subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 56 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 Suppl
69. 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 zy cutting especially with high amperages and long cut times e Allow cooling period before working on the torch Each time the torch head is connected to the torch base use a cotton swab to apply a small amount of o ring lubricant on each of the seven o rings on the top of the torch head Reminder do not use an excessive amount of o ring lubricant 1 2 3 Align the indicator on the torch head circle with the one on the torch base slot Apply enough upward force to engage the threads while tightening the attachment ring Turn the attachment ring to the RIGHT to tighten 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 transfe
70. 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 Phillips 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 3 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 4 0AWG work ground lead through the bottom strain relief on the rear of the power supply and connect it to the work terminal 2 Connect the other end of the work ground lead to the star ground point on the cutting 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 i
71. transferred by any means to any location outside the United States contrary to the requirements of the EAR B 2 Spirit II User s Manual Appendix B Serial Communication Default Cutting Parameters In order to initialize parameters on a Spirit system an external device must communicate in sequence the material type material thickness process cutting or marking and the cutting current Once the Spirit system receives the cutting current all other parameters will be set to their default values Whenever the material type material thickness process or cutting current is changed new default values will be retrieved for all other parameters If a changed is desired cutting current must be sent last for the updated to occur To use non standard parameters first set the material type material thickness process and cutting current in sequence and then set the remaining parameters i e Pierce time to the desired values Troubleshooting Serial Communication When troubleshooting serial communication with the Spirit system switch to the View Serial Communication Screen to view incoming and outgoing data See Section 4 for information on the RS 422 Tab This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR B 3 Appendix
72. 0 Current Amps View Torch Parts This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 4 Operation with Automatic Gas Console Altering Important Parameters Eon basi nce With the RS422 Parameter Control set ut Pierce Time Mark Pierce Time P to Manual certain values on the ma Manna a De eee Parameters Screen can be changed Perca nsont 0 0000 A Kaua ome manually Press the corresponding me votage 0 000 amp Axe Vottage 0 000 4 data entry button and enter the desired Kerf Width 0 000 inches Travel Speed 00000 Pm value asetan OOOO me fe Once a value has been changed press Manual a valu 5 7 im sao the Manual Transmit button to send the aaa Fame es Page Soe toro value to the X Y machine or torch height control Saving Customized Settings If one of the default cutting or marking parameters was altered the new configuration can be saved for later use an A Press the Manage Custom Setups Beige Sa button on the Parameters Screen Cut Pierce Time 1500 ms Mark Pierce Time Cutting Height 0 290 inches Marking Height 0 100 inches P
73. 0 260 800 3000 200 2 00 165 33 270 1 00 4500 210 2 25 170 20 280 350 1000 235 2 50 182 15 300 350 1300 245 215 185 12 325 350 1500 245 3 00 195 8 350 350 2000 250 Metric Material 3 Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfiow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 138 4205 3 6 7 3 500 3 8 16 4145 3405 3 3 8 9 800 3 9 20 2700 3 4 10 5 1000 4 1 25 149 2200 4 0 12 5 4 6 32 155 1500 4 4 15 3 1500 48 38 159 1275 5 6 17 7 2000 45 30 79 70 76 162 995 6 6 20 5 3000 5 1 50 164 860 6 8 25 4 4500 5 3 55 168 620 6 9 11 9 1000 6 0 60 175 450 7 2 1300 62 65 182 365 7 7 8 9 1500 70 185 300 8 3 TOE 193 220 8 7 2090 Sa Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 112 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 53 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the control
74. 00 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 35 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 400 Amps Nitrogen Plasma Air Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK284155 BK284157 BK284159 Outer Cap Torch Head Retaining Cap Swirl Ring BK284150 BK284156 BK284122 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 175 130 210 300 600 465 5 8 170 110 170 350 800 i 3 4 165 90 150 400 1200 1 170 65 150 500 1500 200 30 85 63 96 1 25 175 45 160 700 2000 1 5 180 35 170 800 2500 TZINE 190 25 190 350 205 1500 2 00 205 15 210 350 Metric Material
75. 00 1000 180 1 25 155 60 175 600 1500 190 1 5 30 79 70 76 160 50 225 700 2000 1 75 162 40 260 800 3000 200 2 00 165 33 270 1 00 4500 210 2 25 170 20 280 350 1000 235 2 50 182 15 300 350 1300 245 2 75 185 12 325 350 1500 245 3 00 195 8 350 350 2000 250 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfiow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 138 4205 3 6 7 3 500 3 8 16 4145 3405 3 3 8 9 800 3 9 20 2700 3 4 10 5 4000 4 1 25 149 2200 4 0 12 5 4 6 32 155 1500 4 4 15 3 1500 48 38 159 1275 5 6 17 7 2000 i 45 30 79 70 76 162 995 6 6 20 5 3000 5 1 50 164 860 6 8 25 4 4500 5 3 55 168 620 6 9 11 9 1000 6 0 60 175 450 7 2 1300 62 65 182 365 7 7 8 9 1500 j 70 185 300 8 3 i 752 193 220 8 7 2009 S4 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 112 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 53 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console
76. 1 2 154 55 210 300 600 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 6 140 2595 3 2 5 6 400 2 3 10 25 80 35 80 148 1935 4 4 6 5 600 2 4 12 152 1540 5 0 7 3 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 68 100 2540 100 2 5 100 2 5 0 5 50 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 150 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 green o ring S W AY w OD YW J Z LL J Ly F j a aer Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK279439 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in
77. 1 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 Chopper 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
78. 1 4 145 150 160 250 400 408 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 30 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 j 20 170 1030 6 2 9 0 1200 3 4 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 Nitrogen N A 50 25 N A 65 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 51 Section 5 Torch Consumables and Cutting Charts Spirit II User
79. 108 R50 R120 Q e a L C104 L38 C325 i R4 R3 R2 R219 R218 R217 Al N N D28 L34 Q LJ R180 R179 J LO R43 C163 I J21 u10 EMI1 gel J n N N 2a cio TP33 8 5 c16 N g P E c M z EMI4 Q 8 a 25 cit x peu ooo C110 m L2 u11 x C26 x R310 caed l z R309 g C162 5 ina R175 R177 ROR L_ C25 R176 R178 i R330 L11 c56 R307 c3 c60 3 oof R331 c8 c53 TP5 C17 u9 m MEN D6 NOS TP12 B i i O K 5 c31 R Ri T54 iat o c18 C28 RS a 2 FICE TT 3 a a g R4 rf i T i ces cei g Jez R171 R17 ree R223 R169 R171 C96 E c95 L_ c140 C158 C159 R137 S gt a 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 27 Section 7 Parts List Spirit II User s Manual Gas Console Microprocessor DSP BK300301 AGC Quadrant 4 ee PCB Quadrant Map is a ae U nN S l A Q g sl Li az Be 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
80. 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 o gt 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 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 2 5 100 2 5 0 Argon Air N A 50 25 N A 62 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 47 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 275 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277263
81. 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 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 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 70 100 2540 100 2 5 100 2 5 0 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 32 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 260 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277211 BK277118 BK277135 x WON a j p Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277280 BK277139 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield
82. 20 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 Use an arc transfer height ignition height of 070 1 8 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 24 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Outer Cap Stainless Steel 70 Amps H17 Plasma
83. 25 76 25 76 134 2445 1 8 5 1 400 i 6 138 2050 2 1 5 5 2 3 Marking For All Material Thicknesses 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 096 2 4 100 2 5 0 Argon Nitrogen N A 50 25 N A 65 100 2540 100 25 100 2 5 0 Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 26 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 100 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277146 BK277126 BK277133 oe 9 OND D j LA Z_f 7 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277113
84. 277135 BK279100 150A 9 o BK284150 BK277274 BK277266 BK277287 BK277259 BK277135 BK279100 200A Q a D BK24150 BK277211 BK277280 BK277118 BK277139 BK277135 BK279100 E z XNA 260A a p BK284150 BK284155 BK284156 BK284158 BK284122 BK284159 BK 279100 400A Q 9 j This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 User s 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 30A Q 9 BK284150 BK377149 BKSV7T10 BROT TID BK277142 BKGTTA7 BK279100 m S a r r ora a BRETTON ooo 70A 9 9 L J BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100 a 100A Q 9 D lt ee er e a aaa a rao D 150A 9 BK284150 BK277274 BK277266 BK277289 BK277143 BK277291 BK279100 200A 9 6 BK284150 BK277263 BK277266 BK277276 BK277258 BK277270 BK279100 275A 9 BK284150 BK284155 BK284156 BK284157 BK284122 BK284159 BK279100 400A Q 9 This information is subject to the controls of the Export A
85. 2D 0D AA nn FA 2E 00 01 OD Additional Information If requested in command 30 the system will transmit the cutting chart version x 10 If requested in command 30 the system will transmit the number of pierces Range 0 to 9999 If requested in command 30 the system will transmit the number of pierce errors Range 0 to 9999 Resets number of pierces and errors to 0 Energizes power supply torch coolant pump and cooling fans If torch coolant flow switch not satisfied within 8 seconds unit will power down Deenergizes power supply torch coolant pump and cooling fans System status can only be requested after a Power On command 38 is transmitted The status is returned in the following form All bits O fault 1 ok LSB Bit 0 ASC Door LSB Bit 1 AC Power LSB Bit 2 Coolant Flow LSB Bit 3 Coolant Level LSB Bit 4 Coolant Temp LSB Bit 5 AGC status LSB Bit 6 Inlet Gas Pressures LSB Bit 7 Not used MSB Bit 0 Not used MSB Bit 1 Hydrogen Cutting Enabled Purges gas lines Sets cutting arc voltage in Volts x 100 Valid Range 5000 to 20000 Sets cutting height in mils inches 1000 Valid Range 0 to 999 Sets cutting pierce height in mils inches 1000 Valid Range 0 to 999 Sets cutting travel speed inches min displayed on the voltage screen Valid Range 0 to 999 Saves the present cutting conditions as a user file This information is subject to the controls of the Export Adm
86. 4 10 Saving Customized Settings a e o es cence eecechcvenetcherexetenerenetcherevetenerenetcderenetenereneeete 4 11 Restoring or Deleting Customized SettingS ccccccccceeeeeceeeeeeeeeeeeeeeeeeeeeeeeeees 4 12 Gontig ration Tabee aree e ea falas Selah E Ea Sella the ellos Sella ead 4 13 Advanced Contig TAD saccuster cccstordecestorsccedtoedecvstevsenescendecvsdendeudecendecnstencennetereenede 4 14 Network Settings Tabicis cx aoe sto ition tien ties 4 15 Software Updates Tab nc cccike te cas deeadatadetaeaaa ds cicaeadasnenasadacatalananastaantaaalaaaeads 4 16 System IMO Weal ass oats ash aa EEA sh 10 Sh 10 eho ete AAAA EERE 4 18 Tools Tab Restart Plasma Console cccceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeerees 4 18 RECSSUPSS GOOAME I AD cect ested ts Races deck e e eei caeetemheaeitewherese 4 19 RS422 ADe clea ad dash ad e kd ati hd reid ath td P at td eit R 4 20 Electrical Tab cacmcennvione neta a eee tet 4 21 CUO AD yo ce Cok ec Penk eat oaks en Cenk cee enh ant Cok cee lal cull Col cee al cont Sal ce eal cant et 4 21 Power Supply Tab Wate eee renee Soa Pere teen irre vee Bye tote irre ion Pere en treet oly Nore vene vere vote loro rene 4 23 e i LOG TaD EAEE AEAEE AATA TAATA TA ETE 4 23 Messages tabis encendia a eaae 4 24 Section 5 Torch Consumables and Cutting Charts Installing Removing the Torch Head ccccccecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 5 1 Installing Replacing Consumables
87. 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 Use an arc transfer height ignition height of 275 7 0 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 43 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 400 Amps Nitrogen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK284155 BK284157 BK284159 D j lt ZF 7 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK284156 BK284122 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height
88. 5 BK277142 BK277131 BK279100 1 eae roa 34 D BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100 100A a D cD BK284150 BK277117 BK277152 BK277293 BK277139 BK277292 BK279100 150A 2 p BK284150 BK277274 BK277266 BK277289 BK277143 BK277291 BK279100 p i dea ENTA 200A Q 9 O BK284150 BK277263 BK277266 BK277276 BK277258 BK277270 BK279100 275A S BK284150 BK284155 BK284156 BK284158 BK284122 BK284159 BK279100 400A Q 9 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 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 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to
89. 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 40 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 150 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK277139 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 145 130 250 400 435 3 8 155 115 185 275 500 i 1 2 20 71 50 69 165 90 230 300 600 130 5 8 65 325 800 135 170 250 3 4 45 350 1200 140 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 143 3770 3 1 6 3 400 3
90. 666 6 PPTI EEN aloille i ei L1 U Wl e meee L3 W Ground L1 L2 L3 Gnd TB5 Connections Strain Relief Disconnect Box Connections Figure 3 Power Supply Primary Connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 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 4 0AWG power supply electrode lead through the upper strain relief on the rear of the power supply and connect it to the electrode terminal 2 Route the other end of the power supply electrode lead through the strain relief on the arc starting console and connect it to the cathode manifold Power Supply Nozzle Lead 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
91. 7 ISO 3821 hose color black e Air must be supplied to the unit at all times regardless of the cutting current or material type Oxygen Inlet 62 ISO 3821 hose color blue e Oxygen must be supplied to the unit at all times unless stainless steel is being cut with H17 plasma Nitrogen Inlet 3 ISO 3821 hose color black e Nitrogen must be supplied to the unit at all times regardless of the cutting current or material type H17 Inlet ISO 3821 hose color red e H17 must be supplied to the unit when stainless steel is being cut with H17 as the plasma gas See cutting charts in Section 5 for more information Argon Inlet 65 e Argon is optional and provides improved marking capabilities If not used this inlet should be capped This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 19 Section 3 Installation Spirit II User s Manual Plasma Console Connections Perform the following steps to connect the plasma console to the Spirit system CAN Communications e Insert the male end of the CAN communication cable See CAN Communication Connections for more details CAN Communications 7 e Insert the female end of the CAN communication cable or the CAN termination plug
92. 75 400 098 1 2 165 70 195 300 500 100 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 158 2710 3 8 6 3 300 2 4 10 25 80 26 80 162 2210 4 6 7 0 500 2 5 12 165 1890 4 9 7 4 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 71 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 53 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 150 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 green o ring
93. 75 500 f 1 2 25 77 75 81 165 60 165 300 600 0 5 8 50 185 325 800 3 4 40 250 350 1200 145 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 81 100 2540 140 3 6 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 29 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 150 Amps Air Plasma Nitrogen Shield Copper Electrode
94. 85 1 4 150 50 060 250 300 3 8 155 40 075 275 400 090 1 2 162 30 115 300 500 f Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 2 129 6400 1 2 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 Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 39 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 100 Amps Air Plasma Nitrogen Shiel
95. 9 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 All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 135 250 6350 100 2 5 100 2 5 0 Argon Air N A 50 25 N A 69 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 41 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 200 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap BK277274 Nozzle BK277289 Electrode BK277291 gt lt AL LL Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277143 BK279100 Imperial Material F Arc Travel
96. 9 14 28 AM 3 End 2 7 2012 9 22 45 AM Process Setup System Material Parameters Status Purge Config This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 23 Section 4 Operation with Automatic Gas Console Spirit II User s Manual Messages Tab Press the Diagnostics navigation button followed by the Messages tab to access the screen described below This screen displays all power supply and gas console messages sequencing and errors The message screen should be the initial starting point when troubleshooting the system Pressures Coolant RS422 Electrical Cut Info Power Supply Error Log Messages Process Setup System Material Parameters Status Purge Config This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 24 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
97. ASTON 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 electronic 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 ccccceeeeeseeeeeeceeeeeeesseeeeeeeeeeeeeeeaaseeeeeeeeeeseeeasseeeeeees 1 1 Ultraviolet Radiation Protection cccccccccccceeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeeeeaeeees 1 1 Noise Protection isnan eni a a a E dele 1 1 TOXIC FUMES Prevention 2 fo cos pit oaks eer eee e Er ee a A Eea aeee Erie EEE execenas ents 1 2 Electric Shock Prevention sfic sndcsvcd cad teccendervad tad eahecsed vaaderderved tad edeadeadavned ad teedieds 1 2 Fire PREVeniONsscavi dire csiceees i tichisalaa dieu ale iaae iiaiemiaeialaee eet aie dia taas enka hias 1 3 Explosion Prevention vcs case cisegacesneecniessveahassneecaerensteneeseeieaceaet phecenveemeeesseeheusaeeaae 1 3 Health Support Equipment wcrais coocks pccnneiaicep ths pee resesplacereapecoak idae even eee 1 4 Safety St
98. Argon Nitrogen N A 50 25 N A 65 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 30 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 200 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the good cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277274 BK277287 BK277135 e 4 D 9 O j p Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277259 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 156 80 195 250 500 450 1 2 148 75 130 300 600 5 8 37 72 79 68 155 60 190 350 800 155 3 4 160 50 200 400 1200 i
99. B Serial Communication Spirit II User s Manual RS 422 Serial Commands Note In the following commands nn represents the net node of the power supply that is to receive the command To send a global command to all power supplies in a network configuration nn should be set to C8 hex 200 decimal The in the hex string is the MSB followed by the LSB of a type int The integer is the value found in the additional information column Command Hex String Additional Information Set Material Type 1 AAnnFA01 00 0D 00 Mild Steel Hot Rolled 01 Stainless Steel 02 Aluminum 03 Other 04 Mild Steel Cold Rolled Set Thickness 2 AA nn FA 02 OD Thickness in mils inches x 1000 Valid Range 0 to 2000 Set Operating 3 AA nn FA 03 00 OD 01 30A Current 02 50A 03 70A 04 100A 05 150A 06 200A OA 260A OB 275A OC 400A Set Cutting Pierce 4 AAnnFA 04 OD Cutting pierce time in ms Time Valid Range 0 to 9999 Set Preflow 6 AAnnFA 06 0D Preflow psi x 10 Pressure Valid Range 0 to 1200 Set Plasma Gas 7 AAnn FA 07 00 OD 00 Oxygen Type 02 Air 04 H17 Set Plasma 8 AAnnFA 08 0D Plasma psi x 10 Pressure Valid Range 0 to 1200 Set Shield Gas Type 9 AAnnFA09 00 0D 00 Oxygen 01 Nitrogen 02 Air Set Shield Pressure 10 AA nn FA OA OD Shield psi x 10 Valid Range 0 to 1200 Cutting Travel 15 AA nn FA OF 0D If requested in command 30 the system will S
100. BK277141 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 16 138 115 105 200 300 100 1 4 28 72 40 67 140 100 125 225 400 105 3 8 152 65 180 250 500 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 5 138 2865 2 7 5 1 2 5 28 72 40 67 400 6 139 2625 3 0 5 5 2 7 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in mm msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 25 100 2 5 0 Argon Nitrogen N A 50 25 N A 80 100 2540 110 28 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary t
101. BK277150 BK277125 BK277131 WON x 9 OMD D Z Y Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial Material 3 Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 Bus 3 8 122 75 140 250 400 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 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 Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administra
102. BK279469 BK279450 red o ring D 2 Outer Cap Retaining Cap Swirl Ring 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 1 2 125 140 300 500 139 l 165 5 8 105 135 325 600 3 4 138 90 120 350 800 170 1 144 65 160 400 1000 4185 1 25 150 45 175 500 1500 J l 20 81 70 79 1 50 163 25 235 750 2500 POE 170 20 290 190 l l 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 Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 139 3290 3 6 7 4 500 49 16 438 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 i 20 81 70 79 38 162 645 5 9 19 1 2500 45 170 495 7 5 89 4 8 50 178 395 8 7 i 1l l 1500 col 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 Ar
103. Export Administration Regulations EAR This information shall not be provided 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 PCB Assemblies Component Reference Locations Power Supply Microprocessor DSP BK300101 Quadrant 1 Oa PCB Quadrant Map FD1 J20 g 7 g se i 2 i 5 5 z A a 8 x 2 E 3 5 Ed 3 J2 7 Q a 5 Dy wn gt n E no GSV_GND GSV_GND GSV_24V g q 5 Gsv 1 7 Ce a U36 Impulse Start 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 19 Section 7 Parts List Spirit II User s Manual Power Supply Microprocessor DSP BK300101 Quadrant 2 i 8 8 amp Dido U28 Plasma U27 Preflow u27 d u19 N SOL R20 C12 C54 oD DA ae g 8 Ese cw oe
104. F 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 Coolant Supply Lead e Connect the torch electrode coolant supply lead to the torch base as shown Torch Coolant Return Lead D 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 Co
105. Hose Optional cccceccecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 15 CII Cable for Optional External Inova 2222 2 2222 cccececeeeeeceeeeeeeceeteceece ones 7 16 FII Cable for Optional Internal INOVA eect eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 7 17 JII Cable for Optional Internal Inova 2 002 eceeceeeeeeeeeeeeeeeeeeeeeeenee enone 7 18 PCB Assemblies Component Reference Locations ccccceceeseeeeeeeeeeees 7 19 Section 8 Internal Inova Console Option OVGIVICW ctl eenaa nella a eset oot i ads Sh Ie CIN Lad 8 1 Plug Identification coche ee eet lat leila elle e ila onllar lente wentuaat santas sats 8 1 Unique Interconnect Cablesssc ctovsrcvotersssvetevecovateressveteravenetersuuvetenisnaterseaverc canes 8 1 Grounding ereed eat t ats ae aaa etait tabs ae tabi ad abs At tabs sie 8 2 Pearse iS bt os cats ets eels hts ih tls he ts Jha As dhe ds dh ds es dh des olde ae 8 3 Appendix A Electromagnetic Compatibility EMC Backgro nd sae eee gece eee cenec ccecentevsccescecdeeceseceeeesteceee cee cuecdees cuted e eeaeee A 1 Installation and Se ston 8 oc occ eS ech alt hee tae nenene ennnen A 1 ASSESSMENLOL AeA e E E a E E E E a E EA sats Ea EEE alot A 2 Methods of Reducing Emissions ccf ccesd sectcend febtcesd Sebtcecd cebtcend ebtdent ebtoeel Ghee ek A 2 Appendix B Serial Communication initializing THE Spirit Syste M aeree stecedcettendtacedeebcdeddevbcceddertadesdevbacedd
106. I cables in Parts List Inductor 707150 replaced by 707155 ISC Console 300500 replaced by 300505 AGC 300400 replaced by E LADO260 CAD 03 18 2014 300418 Added argon purity specification Added notes about torch handle vent hole Updated Chopper Test Procedure Clarified RS422 Parameter Control description Added BK prefix to all part numbers Added PCB Outline F LADO0264 CAD 03 31 2014 Dwgs and corrected electrode tool in Part List Corrected Remote On Off info in Installation section Clarified fuse breaker types in Installation section updated Parts List with second o ring in Q D Head on cathode B LADO202 CAD 06 07 2013 C LAD0217 CAD 08 06 2013 D LAD0228 CAD 08 28 2013 LAD0276 G PADOT CAD 09 18 2014 adapter corrected several parts numbers in the Parts List LAD0284 a updated interior drawings of ISC console throughout added LAD0288 hot parts warning Changed ISC to ASC Updated branding throughout j peel CAD VARAS Combined RHF and CleanStrike Technology throughout LAD0234 Updated part numbers for terminal blocks Updated manifold LAD0317 part numbers Updated coolant pump part number Updated LAD0323 CAD 09 01 2015 warranty Added pierce capability for 1 25 32mm MS at LAD0330 150A and 1 5 38mm MS at 275A Removed 220VAC and LADO296 240VAC PS models Trademark Notice Spirit is a registered trademark of Lincoln Global Inc F
107. LINCOLN amp Technical Manual SPIRIT 11400 i riren nigh betintion Technology Register your equipment LINCOLN http www burny com warranty PARTS Save for future reference Date Purchased Model Number Serial Number THE LINCOLN ELECTRIC COMPANY BK718117 Rev I 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 wwwincolnelectric 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 02 04 2013 Initial Release Added 100A 150A silver electrodes replaced RHF with ISC added argon marking corrected system interconnect diagrams changed rated inlet gas pressure to 115 psi added 100 psi minimum to inlet gas pressure Deionization filter cartridge 500510 replaced sediment filter 300152 Parts list updated Corrected Plasma Console icon description from hardware error to warning message Expanded notes on System Interconnection diagrams to clarify cabling requirements for various configurations Corrected contact ratings on page 3 20 Added pinouts to CII FII JI
108. 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 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 r
109. ON 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 STRICT 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
110. P4 to the X Y Machine CNC controller The JII cable is used to connect multiple Spirit II internal Inova consoles IP8 See the parts list in Section 7 for more details on these cables This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 1 Section 8 Internal Inova Console Option Spirit 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 Descri
111. 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 plasma 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 RS 422 Serial Communication Link An RS 422 serial communication link can be connected between the plug on the rear of the plasma console and a CNC machine or automatic height control system All process parameters can be controlled via the RS 422 communication link Also cutting or marking information such as initial height cutting or marking height recommended arc voltage and recommended travel speed can be transmitted from the plasma console to the CNC machine or height control See Appendix B for additional serial communication information This information is subject to the controls of the Export Administra
112. R 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 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 J
113. Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 5 Section 8 Internal Inova Console Option Spirit II User s Manual Location in Spirit 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
114. Send cutting pierce height 48 Send cutting condition type 51 Send arc off delay time 52 Send machine type 53 Send marking arc voltage 54 Send marking height 55 Send marking start height 56 Send marking travel speed 57 Send marking pierce time 59 Send cut mark cut configuration Set Process 32 AA mn FA 20 00 0D 00 Cutting 01 Marking Software Version 33 AA mn FA 21 00 OD If requested in command 30 the system will transmit the software version x 10 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR B 6 Spirit II User s Manual Appendix B Serial Communication Command Cutting Chart Version Number of Pierces Number of Pierce Errors Reset Pierce Counter Power On Power Off Request System Status Purge Gases Set Cutting Arc Voltage Set Cutting Height Set Cutting Pierce Height Set Cutting Travel Speed Save as User File 35 36 37 38 39 40 41 42 43 44 45 46 Hex String AA nn FA 22 00 0D AA nn FA 23 00 OD AA nn FA 24 00 0D AA nn FA 25 00 01 OD AA nn FA 26 00 01 OD AA nn FA 27 00 01 OD AA nn FA 28 00 01 OD AA nn FA 29 00 01 OD AA nn FA 2A OD AA nn FA 2B OD AA nn FA 2C 0D AA nn FA
115. 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 28 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 29 Section 7 Parts List Spirit Il User s Manual Plasma Console RS422 Isolation BK300701 Oo 3 1 n2 10 9g 4 o 1 o G o O o 8 o KALIBURN A BLANK PCB P N 500700 REV A 0O ASSEMBLY P M 32070 oO o 3 oooo 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 Un
116. _Lzlz This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 1 Section 7 Parts List Spirit Il User s Manual Power Supply BK300234 BK300239 Left Side View Item Part Number Quantity Description 4 BK707150 3 L1 L2 L3 Inductor 12 BK300101 1 Printed Circuit Board PCB Microprocessor DSP 16 BK300112 1 Printed Circuit Board PCB A C Detect 32 BK708118 2 CR3 PAR Relay 33 BK705011 1 PAT IGBT 34 BK702075 2 PAT IGBT Filter Capacitor 36 BK300108 1 Printed Circuit Board PCB I O 37 BK301200 1 Optional Printed Circuit Board PCB Voltage Divider 39 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 I O Terminal Block large 47 BK709253 2 Strain Relief 50 BK284029 4 Current Sensor 51 BK300130 3 F9 F10 F11 Fuse 200A 52 BK300129 3 F9 F10 F11 Fuse Holder 53 BK300153 1 Off Relay 54 BK300156 1 Off Relay Socket 55 BK701165 2 R1 R2 Resistor 300W 3 Ohm 56 BK701141 1 R3 Resistor 300W 2 Ohm 57 BK701083 3 Resistor Mounting Hardware C G0 Go
117. ace 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 cover from the cooling system Connect a 3 8 ID hose and bucket to the drain petcock on the bottom of the reservoir Unscrew the petcock to drain the reservoir Leave the hose and bucket in place after the coolant drains out Remove the coolant supply hose coolant out from the rear of the cooling system Note that the coolant supply hose has right hand threads Be prepared for some coolant to escape from the fitting on the cooling system and from the supply hose Blow compressed air 100 psi maximum into the coolant supply hose This will force the remaining coolant from the torch torch leads and supply hose into the reservoir and out of the drain petcock Continue until coolant stops flowing into the bucket Tighten the drain petcock and remove the hose and bucket 10 Unscrew the coolant filter housing and remove the coolant filter deionization cartridge Install a new coolant filter deionization cartridge and replace the coolant filter housing Dry any leaked coolant 11 Reconnect the coolant supply hose on the rear of the cooling system 12 Follow all of the steps in Filling the
118. andards Booklet Index 22 22 22 2cccseeeeeeeeeteeeeeeeeceeeeeeeeeeeeeeeceeeeeeeeees 1 5 Section 2 Specifications System Description 2 2 ceecusce Scot tates deste setae ate atesehate a teate se elate a teates tants 2 1 System Xa a 86 9 lt om eeeeen ee P MRS RRP RRNT AER TMRT REM DMRNT RENT REN AEMTMEN ENTRIES REMNANT RENTARNT REND ERSTE 2 2 Power Supply Specifications siinchocectoteve scented pate dipeeA nn deteleed oath Aoties 2 3 Cooling System SPSCihiCAllOMS see 0 2 825 cose cone Cope ceui desi cens Cesicesicepicenecenicesicesicentceu 2 4 Torch GOOlMU SPSCiiCAlOns xix icsdslicacsden saauinlesbenladen hela hcelaien beniodon neendgunenolede 2 5 Automatic Gas Console AGC Specifications ccccccceeeeeeeeeeeeeeeeeeeeeeeeees 2 6 Gas Supply ReguirementS oe setie eoeta setae on Coad seated cht Eedi Einde 2 7 Plasma Console Specifications ccccccccccsseeeeeeeeeeeeeeeeeaceeseseeeeeeeeeeeeeeeeeeess 2 8 Arc Starting Console ASC Specifications with RHF cccccccecceeeeeeeeeeeeeeeees 2 9 Arc Starting Console ASC Specifications with CleanStrike oo ee 2 10 Torch and 2 Gang Manifold Specifications ccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 11 5 Gang Manifold SPeCiiCAtlOnS esi 5e 05k Seceid ab ous ob iets cous eb ould ables ah ed ed 2 12 Airborne Noise EMISSIONS ssseeeeeeecececeeeeeeeeeeeeeeeeeeeeeesseeeeeeeeeeeeeaaeeees 2 13 Electromagnetic Compatibility EMC
119. ansferred by any means to any location outside the United States contrary to the requirements of the EAR A 2 Spirit II User s Manual Appendix A Electromagnetic Compatibility EMC Equipotential Bonding Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to 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 ent
120. 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 wears in order to maintain the correct cutting height Cutting Chart Index Also remember that the arc voltage must be increased as the electrode Copper Silver Mild Steel 30 Amps Oxygen Oxygen Page 5 15 Mild Steel 50 Amps Oxygen Oxygen or Air Page 5 16 Mild Steel 70 Amps Oxygen Air Page 5 17 Mild Steel 100 Amps Oxygen Air Page 5 18 Page 5 45 Mild Steel 150 Amps Oxygen Air Page 5 19 Page 5 46 Mild Steel 200 Amps Oxygen Air Page 5 20 Page 5 47 Mild Steel 275 Amps Oxygen Air Page 5 21 Page 5 48 Mild Steel 400 Amps Oxygen Air Page 5 22 Page 5 49 Stainless Steel 30 Amps Air Air Page 5 23 Stainless Steel 50 Amps Air Nitrogen Page 5 24 Stainless Steel 70 Amps H17 Nitrogen Page 5 25 Stainless Steel 70 Amps Air Nitrogen Page 5 26 Stainless Steel 100 Amps H17 Nitrogen Page 5 27 Stainless Steel 100 Amps Air Nitrogen Page 5 28 Page 5 50 Stainless Steel 150 Amps H17 Nitrogen Page 5 29 Stainless Steel 150 Amps Air Nitrogen Page 5 30 Page 5
121. 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 Oxygen Plasma Oxygen or Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277115 BK277122 BK277131 4 yp eh Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK277142 BK279100 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow 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 i 225 400 087 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m
122. 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 Never operate the system in the presence of explosive gases or other explosive materials e Never cut pressurized cylinders or any closed container e When using a water table and cutting aluminum under water or with water touching the underside of the aluminum plate hydrogen gas is produced This hydrogen gas may collect under the plate and explode during the cutting process Make sure the water table is properly aerated to help prevent the accumulation of hydrogen gas e Handle all gas cylinders in accordance with safety standards published by the U S Compressed Gas Association CGA American Welding Society AWS Canadian Standards Association CSA or other local or national codes
123. ard 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 means to any location outside the United States contrary to the requirements of the EAR 1 6 Spirit II User s Manual Section 2 Specifications Section 2 Specifications System Description The Spirit II 400 is a 400 amp microprocessor controlled 100 duty cycle high current density plasma cutting and marking system It utilizes a precision dual gas torch that is capable of cutting mild steel up to 3 thick and stainless steel up to 1 1 2 thick The system contains a computer controlled automatic gas console with a touch screen interface plasma console All cutting parameters are controlled through the plasma console Setting up a cut is as simple as selecting the material type material thickness and process cutting or marking All gas types and pressures are set automatically The operator can easily view pictures and part numbers of the torch consumables Another screen shows the recommended cutting spee
124. ates contrary to the requirements of the EAR 49 5 1257 2 3 Section 2 Specifications Spirit Il User s Manual Cooling System Specifications Part NUMDEr eno tery actbenteansctarsseiesnmsencterssenetennsenn BK300275 Discharge pressure cccciecesesencceeecceenteeeteens 150 psi 10 2 bar FIOW TATE ee R 2 1 gal min 7 9 liters min Gool nt MUNG sceecceccececssecrteesscetceesecceseceseeteeceeceeuer Propylene glycol solution Coolant tank Capacity 0 0 0 0 eee eeeeeeeeeeeeeeeeeeeee 3 2 gal 12 liters Weight sssrin eea aeee E EE EEEE 141 Ibs 64 kg without coolant aN Paw i Se S al A 8 o 4 N 4 A 4 4 A 4 4 A A 36 0 914 e e R h 4 4 h 4 5 7 4 N 4 Heo a 23 0 584 e 15 8 401 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 4 Spirit II User s Manual Section 2 Specifications Torch Coolant Specifications Note Refer to the supplie
125. ation Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 6 Spirit II User s Manual Section 6 Maintenance amp Troubleshooting Error Codes The following is a comprehensive list of error codes for the Spirit system When the system uses a Manual Gas Console only the numeric error code is displayed When an Automatic Gas Console is used the text description is also displayed Power Supply Code Short Description Long Description 10121 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
126. ation Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 1 Section 7 Parts List Spirit II User s Manual Plasma Console BK300800 Item Part Number Quantity Description 1 BK300712 1 Power Supply 12VDC 2 BK300701 1 Printed Circuit Board PCB RS422 Isolation 3 BK300706 1 PCB Assembly Computer 4 BK300707 1 10 4 LCD Touchscreen 5 BK708111 1 Switch Pushbutton OFF Button This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Arc Starting Console BK284500 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 BK709253 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
127. ation 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 3 24 Spirit II User s Manual Section 4 Operation with Automatic Gas Console Section 4 Operation Operating the Plasma Console The Plasma Console is the touch screen interface to the entire Spirit system when the Automatic Gas Console AGC is used instead of the Manual Gas Console MGC eee oe OFF Button p aa Push to disable the Spirit system sts Sl Cji 2da fee Release turn to the right to enable zm E Fie sM iter the system which can then be or energized using the ON Button 215 ve G E f Touch Screen Turns on automatically when AC power is applied to the Spirit system Press the screen to operate as described below e Navigation and ON Button Press the navigation buttons to access the various screens described in this section Change settings by simply pressing that part of the screen a gt Navigation Buttons Stainless Steel SS ea Press to access the desired screen H17 Disabled 3 000 inches ON Button Press to energize the system the i gt OFF Button must be released first
128. ation shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 21 Section 3 Installation Spirit II User s Manual CNC Machine Interface Connections Perform the following steps to properly interface the Spirit system with a CNC cutting machine See the system schematic for additional information Plasma Start Input The power supply requires a contact closure between P8 pins 3 and 4 to commence the cutting or marking sequence The sequence is terminated when the contacts are opened The contacts should be rated for 24VDC 7 3mA Plasma Cut Mark Input The power supply requires a contact closure between P8 pins 1 and 2 to put the system in plasma marking mode Opening the contacts puts the system in cutting mode The operating mode should be selected prior to applying a start signal The contacts should be rated for 24VDC 7 3mA Arc Hold Input The power supply requires a contact closure between P8 pins 10 and 11 to inhibit arc starting even though a plasma start signal has been applied to the unit When the contacts are opened the arc is initiated This feature is used to decrease cycle time by allowing pre cut gas and contact sequencing to occur simultaneously with initial torch height positioning The contacts should be rated for 24VDC 7 3mA Motion Output The power supply provides a maintained contact closure output between
129. ations with Remote High Frequency RHF Part Number ctsscctareoctetarbosebarsotebatboccbarsosedeeede BK284500 Weigh het 24 Ibs 10 9 kg Spark gap distance eeeeeeeeeeeeeeeeeees 0 015 in 0 381 mm Note The Spirit II system requires either an ASC with RHF or an ASC with CleanStrike Technology but not both m 8 00 203 A A i 4 312 8 12 75 324 12 00 305 13 50 343 8 j 3 i a 10 00 254 5 35 136 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 Arc Starting Console ASC Specifications with CleanStrike Technology Part Number 2Ascnetondcnnecandacaneces BK300505 Wagh serae caren enenarmemananeecen 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 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
130. ce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 160 160 160 275 400 160 1 2 165 125 180 300 500 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 1l N 400 170 1 25 44 185 45 260 1000 1 50 190 25 270 180 Metric Material gt 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 NNA 500 4 1 12 163 3375 4 4 7 4 16 168 2645 4 8 8 9 A 800 4 2 20 20 73 65 75 173 2055 5 3 25 179 1565 6 0 N 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 Use an arc transfer height ignition height of 275 7 0 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is
131. contrary to 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 2
132. cut quality and minimum dross levels Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 Shield Cap Nozzle Electrode BK277274 BK277289 BK277291 S A 9 opp am LT Z f 7 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 4 130 200 200 400 070 150 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 1257 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 i 600 12 138 3020 2 6 7 3 16 146 1890 3 8 8 9 800 3 9 20 74 58 72
133. d Copper Electrode Shield Cap Nozzle Electrode BK277145 BK277120 BK277130 z IIIA I D JB 2 Z Z J Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 040 150 100 100 065 050 35 81 20 85 135 120 030 063 90 150 200 070 Metric Material gt 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 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 177 45 100 2 5 0 Argon Air N A 50 25 N A 75 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 100 2 5 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Co
134. d Copper Electrode Shield Cap Nozzle BK277286 BK277284 Electrode BK277282 OD gt lt AL LL Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277283 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 158 105 155 250 300 095 3 8 25 80 26 80 162 90 180 275 400 098 1 2 165 70 195 300 500 100 Metric Material gt 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 Use an arc transfer height ignition height of 250 6 4 mm for cutting and 100 2
135. d and torch height for making the cut These parameters can be transmitted to an X Y machine controller or an arc voltage control system via RS 422 serial communication The RS 422 port also allows for full control of the cutting parameters from an x y machine controller The system keeps a detailed record of errors that may have occurred during the cutting sequence Additionally systems utilizing the automatic gas console can use argon for marking which produces improved mark quality The Spirit Il 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 Nine nozzle sizes 30 50 70 100 150 200 260 275 and 400 amps are available to produce excellent cut quality throughout the cutting range Each enclosure in the system is rated for IP21S sealing which is intended for indoor use only The system
136. d the G Cable from the Inova Console P6 to the CNC Controller Voltage Divider D Cable e remove the Cable and A Cable from the k Gan configuration shown anifold Power Supply 3 If both the CNC Controller and Inova Remote CII Cable are used to set Inova parameters then e add the G Cable to the configuration shown from the Inova Console P6 to the 5 Gang Manifold 17 Inch CNC Controller 7 5 Foot Shield Hose Fiasma AEN piy Gang Manifold Cabl To Star Gang Manifold Cabl s i Ground Cooling System SC Control Cable Torch Handle Arc Starting Console Positioner Work Ground Lead Torch Base Torch Head Star Ground Work Piece Figure 1b Spirit II System AGC External 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 4 Spirit II User s Manual Section 3 Installation Legend Supplied Optional Customer Supplied p AN Cable To Star 1 Ground Pi i om Eas Termination Aet p ug Positioner B Cable f To Star CNC Controller _ Ground Fil Cable iy Notes 1 If only the Inova Remote is used to set Inova parameters th
137. de and the Nozzle lead to the large brass body of the torch Loose work ground connection Pierce height too high This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 plasma console screen is blank The plasma console screen is on but the touch 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 plasma console 2 Check for blown DIN rail fuse 3 Check for 120v on pins of power communications CAN cable at back of the plasma console 1 Cycle primary power to the Spirit system 1 Wrong consumables installed in torch 2 Loose pressure transducer cable on PC board in the AGC 3 Check connectors on the AGC 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
138. de the United States contrary to the requirements of the EAR 2 2 Spirit II User s Manual Section 2 Specifications Power Supply Specifications R Input Current at Power Supply Description Part Number Maximum Output 380 VAC 3G 50 60Hz BK300234 152 amps 400 VAC 3G 50 60Hz BK300235 144 amps 415 VAC 3G 50 60Hz BK300236 140 amps 440 VAC 3G 50 60Hz BK300237 131 amps 480 VAC 30 60Hz BK300238 120 amps 600 VAC 30 60Hz BK300239 96 amps Open Circuit Voltage 2 0 ceeeeceeeee eee 370 VDC Output Current drooping characteristic 10 400 amps Maximum Output Voltage eeeeeeeeeeeeeeee 200 VDC Duty Cycle cots cscs seated Maximum Ambient Temperature MV GIO reenit a E Cs Cs Cs SS OS AA ABA AA ABA AAR ABA o A BRB RA 39 9 1013 100 80 kW 104 F 40 C 1922 Ibs 872 kg Ow z z z z o o SS SS 34 2 869 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United St
139. dministration Regulations EAR This information shall not be provided 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 Nose Swirl Silver Torch Retaining Cap Cap Retaining Cap Ring Electrode Head BK284150 BK277286 BK277151 BK279484 BK279483 pecan BK279060 Q en A ane NN y a VW OD 8 BK279420 BK284150 BK279493 BK279439 green rin BK279060_ Q S 9 BK279489 BK279443 SA E aa BK284150 Q This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements 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 A ae soa Q s BK984150 BK277150 BK277153 BK277122 BK277142 BK277131 BK279100 50A 9 o NS J BK 384150 BK277150 BK277153 BK27712
140. ds 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 from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 NFPA Standard 70 National Electrical Code obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 CGA booklet P 1 Safe Handling of Compressed Gases in Containers obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 CGA booklet P 14 Accident Prevention in Oxygen Rich and Oxygen Deficient Atmospheres obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 CGA booklet TB 3 Hose Line Flashback Arrestors obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 CSA Stand
141. dvaddeed dusccetd cuaddusd deaceesdeete 3 21 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Plasma Console 220 2 ccecceeceeeeeeeceeeeceeeeneneeeneneneeeneneneees 4 1 Setting up to Cut or Mark a25 22 28 created cee teadadee aad deuteadadtet onde tetondhde saab deet scab 4 3 Verifying Important Parameters 2 2 c cccedececccedeceeneedetecetedeneeenedetecetedeneentedeneeeee 4 4 Viewing the Required Torch Pants vcciccced ced dceed ouad cect ned cved duadencd onadeetd cuadeesdenddeustcete 4 4 Checking System Status 4 J 2Jin2 od nd lodind ei ledlodiad piled loiind piled odin 4 5 Purging Pressure Regulators cccccccceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess 4 6 Makin va uk OF Malk cecccdiecacccaectadee epee evetancuavetenes evetancs auetanes ELELEE t EDLE LEDen En eEG 4 7 Piercing Thick Materials 22 nncnenesene sone ene sees ones enesenenene 4 8 Moving Pierces and Edge Starts 2 c ccceccceccceecceeeceeeeeeeeeeeeeeeseeeeeeeseeeteeeteeeeees 4 8 C tQUAlY Sennen Ne eNO a w RRP OR SOAP T RAT NOT EE EO EATE E TO AOE SY UREA ON 4 9 Customizing Cutting or Marking Settings 2 0 0 0 eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee
142. e 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 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 52 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 100 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 brown o ring 5 O oD i Dig fa K 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 2
143. e 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 edge start required icon H will appear at the top of the screen the torch should be positioned at the edge of the material prior to starting the arc This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 8 Spirit II User s Manual Section 4 Operation with Automatic 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 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 paramet
144. eans to any location outside the United States contrary to the requirements of the EAR 5 44 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 100 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 brown o ring s d X 4 4 YY e y Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 150 090 200 300 3 8 130 100 130 250 400 090 1 2 25 83 26 81 65 155 300 500 5 8 143 47 325 800 185 095 3 4 145 35 350 1000 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 3950 2 1 4 9 300 10 2405 3 3 6 5 2 3 130 N 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
145. ected material and thickness Setup Custom Not Saved Changes to cutting chart defaults have been made but not yet saved Setup Custom Saved Changes to cutting chart defaults have been saved as a custom setup This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Automatic Gas Console Setting up to Cut or Mark Press the Material navigation button to setup a cut or mark Material type material thickness and process cut or mark are the only parameters that must be selected All other parameters are adjusted automatically however these parameters can be customized See Customizing Cutting or Marking Settings for more information Select Material Type Press the Material Selection button 72 oO pata Material Selection Stainless Steel i eae AEE RE and select the desired material from posa J the list Choose cancel to return to xl 3 000 3 000 inches nie the previously selected material 275 s PEB Aumin ewecoe ee bee es oro Process Setup _ System Material Parameters Status Purge Config Diagnostics Material Stainless Steel A H17 Disabled Current Amps Select Material Thickness
146. ection 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 Legend Supplied Optional Customer Supplied rn To Star Ground AN Cable n C A Termination Plug ae Positioner B Cable To Star CNC Controller in e Ground FII Cable Notes 1 If only the Inova Remote is used to set Inova parameters then follow the configuration shown 2 If only the CNC Controller is used to set Inova parameters no Inova Remote then e add the K Cable from the Power Supply IP5 to the Plasma Console and add the G Cable from the Power Supply IP6 to the CNC Controller e remove the Cable and 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 to the configuration shown from the Power Supply IP6 to the CNC
147. eeen ee CAN RXD Dim Flashing gt DIZ raana a CAN TXD Dim Flashing The following DSP Indicators should illuminate when the OFF Button is released gt TAO o koncni OFF Button The following DSP Indicators should illuminate when the ON Button is activated X Opto U2 ninri Motor Solenoid gt Opto U19 stances ce cee Solenoid not used gt Opto U26 vniiscemisicicestences Fan gt X D42 vnia Plasma Ready The following DSP Indicators should illuminate when a START signal is applied begin cut cycle X SG vce cnsecanesecccenevecccecst Start gt Opto U2 annaa Preflow gt Opto U29 itech edtarndcedarths Shield A OPO 2A iara estseer ergin Surge only over 100 amps X OPO U23 aoirean Contactor X D24 oanp PWM Chopper ON gt Opto U22 x theless Pilot Arc Relay ON gt Df Cnet er Oe en ee Na ete PAT ON Blinks during a START gt Opto US6 UST nnan Impulse RHF Blinks during a START The following DSP Indicators should illuminate with an arc transfer E 01101 Pe i ESEAS E ar Postflow gt Opto U28 a wsereiceteteottetecs Plasma Pin DAN E E E Motion The following LEDs should turn OFF after the Motion Indicator turns ON gt Opto U36 U3T7 s c52cerceccconss Impulse RHF gt Opto U27 nested Preflow gt WAS errea aniani 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 Administr
148. eflow Regulator Valve 13 BK300415 1 Preflow Regulator Valve Amplifier Programmed 14 BK260109 1 Plasma Regulator Valve 15 BK300415 1 Plasma Regulator Valve Amplifier Programmed 16 BK260109 1 Marking Shield Regulator Valve 17 BK300415 1 Marking Shield Regulator Valve Amplifier Programmed 19 BK300420 1 Manifold Block Gas Outputs Lt This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Automatic Gas Console BK300418 Left Side View Item Part Number Quantity Description 1 BK300412 1 Power Supply 24VDC 8 3A 2 BK300301 AGC 1 Printed Circuit Board PCB Gas Console DSP 3 BK280030 1 Fan 24VDC 4 BK260109 1 Nitrogen Regulator Valve 5 BK300415 1 Nitrogen Regulator Valve Amplifier Programmed 6 BK260109 1 Oxygen Regulator Valve T BK300415 1 Oxygen Regulator Valve Amplifier Programmed 8 BK260109 1 Marking Plasma Regulator Valve 9 BK300415 1 Marking Plasma Regulator Valve Amplifier Programmed 10 BK260109 1 Shield Regulator Valve 11 BK300415 1 Shield Regulator Valve Amplifier Programmed 18 BK300419 1 Manifold Block Gas Inputs This information is subject to the controls of the Export Administr
149. emote om A Cable Termination Plug j d To Star CNC Controller Positioner S _ Ground F Cable B Cable ae Notes 1 If only the Inova Remote is used to set Inova parameters then follow the configuration shown E Cable g be 2 If only the CNC Controller is used to set o Star onsole Inova parameters no Inova Remote then Ground e add the K Cable from the Inova Console P5 to the Plasma Console and add the G Cable from the Inova Console P6 to the CNC Controller e remove the I Cable and A Cable from the Jon configuration shown o anifold Power Supply 3 If both the CNC Controller and Inova Remote CII Cable are used to set Inova parameters then 5 Gang Manifold e add the G Cable to the configuration shown from the Inova Console P6 to the Voltage Divider D Cable 17 Inch ONC Control 7 5 Foot Shield Hose Plasma Soin g som Gang Manifold Cabl To Star Gang Manifold Cable Ground Cooling i System SC Control Cable Torch Handle Arc Starting Console Positioner Work Ground Lead Torch Base Torch Head Star Ground Work Piece Figure 1d Spirit Il System AGC 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
150. en follow the configuration shown 2 If only the CNC Controller is used to set Inova parameters no Inova Remote then e add the K Cable from the Power Supply IP5 to the Plasma Console and add the G Cable from the Power Supply IP6 to the CNC Controller e remove the Cable and 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 to the configuration shown from the Power Supply IP6 to the CNC Controller Remote A Cable 2 Gan Manifold 5 Gang Manifold Plasma Hose 7 5 Foot Shield Hose Gang Manifold Cabl Gang Manifold Cable Cooling System Control Cable To Star __ Ground Cooling System l Torch Handle Arc Starting Console Positioner Torch Base he Se cere Internal Inova oR dl Ground Cable Torch Head Star Gro nd Work Piece Figure 1c Spirit Il System AGC 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 Legend Supplied Optional Customer Supplied rn To Star Ground AN Cable Cable R
151. enesekenenenenenene 7 4 Automatic Gas Console BK300418 cccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneees 7 5 Plasma Gonsole BKS00600 GxwaiesscnnSuotlei ane nt lee needa ee ee lainds 7 8 Arc Starting Console BK300505 with RHPF ccccceeeeeeeeeeeeeeeeeeeeeeeeeeees 7 9 Arc Starting Console BK300505 with CleanStrike cccccceeeeeeeeeeseeeees 7 10 Torch and Manifold Assemblies ee cecceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 11 shielded Torch Leads xcs loietastle fae ect see ites athe neee Meni at lends 7 12 CAN Communication Cable and Terminator Plug cece eeeeeeeeeeeeeeeeeeeeeeeeee 7 12 Manifold Control Cabl es c ccncsces sete sensectotcnetetotcnn seo 7 12 Gas Hose Package with AGC eenen nenene nennen 7 13 Cooling System Control Cable 22 22 0200c2 ceeceteeeeeeeteeeeeeeceeeeeeeceeeeeeeceeeneneceeeeenes 7 13 Coolant and Power Leads sncseceseneueee ene eee eee meee eee 7 14 Work Ground Lead maemeerre nee nne Merman Tenten Te NtenTeNTen te NTenTeNTen Te ereat entry ter 7 14 Oxygen Supply Gas Hose Optional 22 000 2202 ecceeeeeeeeeteeeeeeeneeeeeeeteeeece ene 7 15 Nitrogen Supply Gas Hose Optional cccceccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 15 Air Supply Gas Hose Optional ca cosccen peeteenceevteieeeeeteenceeuceeeeeeteesceeeeresepeeteenecest 7 15 H17 Supply Gas Hose Optional i cccc cent ceed eee 7 15 Argon Supply Gas
152. er 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 piece larger than the bottom dimension usually occurs when the torch standoff distance is too low or when the cutting speed is too slow 3 Top dross usually occurs when the torch standoff distance is too high 4 Bottom dross usually occurs when the cutting speed is either too slow slow speed dross or too fast high speed dross Low speed dross is easily removed while high speed dross usually requires grinding or chipping off When using oxygen as the shielding gas bottom dross can sometimes be removed by increasing the shield gas pressure However increasing the shield pressure too much can cause cut face irregularities see below Bottom dross also occurs more frequently as the metal heats up As more pieces are cut out of a particular plate the mo
153. erred 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 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
154. ers or from an air compressor Be aware that shop air systems are prone to oil and moisture contamination If shop air is used it must be cleaned to ISO 8573 1 Class 1 4 1 Specify dry air when using compressed cylinders Breathing quality air contains moisture and must not be used 3 8 inside diameter hoses are required for all inlet gas connections Mating connectors are supplied with the unit Quick connect fittings must not be used This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 7 Section 2 Specifications Spirit II User s Manual Plasma Console Specifications Part NUMDE ccssecssessseeseesseesseeseveseesseeeseeseess BK300800 IN CINE EEE ERONEN 10 Ibs 4 5 kg ii iii Os 9 2 234 13 4 340 7 3 6 91 3 2 81 10 1 257 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Arc Starting Console ASC Specific
155. es Coolant Tab Press the Diagnostics navigation button followed by the Pressures Coolant tab to access the screen described below Pressing any of the Output Pressure buttons will cause the corresponding valve to open or close Note that the preflow valve and the plasma valve cannot be on at the same time During a cutting or marking sequence the status of all valves will display N A See the Installation Section to initially fill the system with coolant See the Maintenance Section for the procedure to refill or flush coolant Pressures Coolant RS422 Electrical Cut Info Power Supply Error Log Messages Output Pressure Plasma shie Actual PSI 000 0 000 0 000 0 000 0 000 0 000 0 000 0 000 0 Setpoint PSI Input Pressure Oxygen Inlet Nitrogen Inlet Air Inlet H17 Inlet Argon Inlet 000 0 psi 000 0 psi 000 0 psi 000 0 psi 000 0 psi Coolant Temp 25 Flow 0 0 GPM Fill Flush Process Setup Material Parameters System Status Purge Config Diagnostics This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 19 Section 4 Operation with Automatic Gas Console Spirit Il User s Manual
156. ession Press Enable to allow error suppression Press Disable to stop error suppression Arc Off Delay In some instances such as when cutting thicker stainless steel materials it may be desirable to delay the extinction of the cutting arc after a stop signal is received To program an arc off delay press the data entry button f and enter the desired delay time in milliseconds The delay can be set from 0 to 2000 mS This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 14 Spirit II User s Manual Section 4 Operation with Automatic Gas Console Network Settings Tab Press the Config navigation button followed by the Network Settings tab to access the screen described below To enable networking press the red exclamation graphic next to Network Disabled The graphic will change to a green check mark Enter the appropriate IP Address Subnet Mask and Gateway If DHCP is necessary press the red exclamation graphic next to DHCP Disabled The graphic will change to a green check mark Enter the required information Configuration Advanced Config Network Settings Software Updates System Info Tools IP Address A 168 lh Subent Mask A 255 fe Gateway 192 4 168 y E om
157. et P N BK284052 amp driver P N BK277086 e All other copper electrodes use socket P N BK277087 amp driver P N BK277086 e All silver electrodes use P N BK279061 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 Export Administration Regulations EAR This information shall not be provided 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 cut
158. ets marking height in mils inches 1000 Valid Range 0 to 999 Set Marking Start 55 AA nn FA 37 0D Sets marking start height in mils inches 1000 Height Valid Range 0 to 999 Set Marking Travel 56 AA nn FA 38 OD Sets marking travel speed inches min Speed Valid Range 0 to 999 Set Marking Pierce 57 AA nn FA 39 OD Sets marking pierce time in ms Time Valid Range 0 to 9999 Configure 59 AA nn FA 3B 00 OD 0 Local at power supply Cut Mark Cut 1 Hard signal via interface plug 2 RS 422 Node Focus 254 AA C8 FAFE 00nn0D Sends a global command to all systems and sets the node focus to system nn This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR B 8
159. eves are positioned to properly cover the brass torch fittings at the torch base Inspect the outer sleeve on the torch base s electrode coolant supply lead If nicks cuts or holes are found replace the torch base Remove the torch consumables from the torch head and inspect all o rings Replace any o rings with cuts nicks abrasions or any other signs of wear Faulty o rings may cause gas or water leaks which will affect cut quality This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 8 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 9 Wipe any excess o ring lubricant off of the torch base and head Arc Starting Console ASC 1 Open the cover door of the arc starting console and verify that al
160. evtadedtectecest B 1 Transmitting Parameters to the Spirit System sseeeeseeeeereererrrrrrrrrrrrrrrrren B 1 Communication Error Checking 2 2 2 s ccseecseececeeeeeceeeeeeeceeeeeeeceenenes B 2 Default Cutting Parameters 2 h2c c ccdcteeehnceecedannnebneedebneneeebenehends B 3 Troubleshooting Serial Communication eee cece eee eeeeeeeeeeeeeeeteeeeeeeeeeeees B 3 RS 422 Seral Commands sens ccek tet ccete eset e e cancer ee ease B 4 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 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 author
161. gized Check the troubleshooting section if any indicators in this procedure fail to change from red to green after 10 seconds Note The DC Power indicator will only turn green while cutting This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Automatic Gas Console Spirit Il User s Manual Piercing Thick Materials Care must be taken when piercing thick materials in order to prevent damage to the shield cap and nozzle As with all thicknesses the pierce height must be set high enough so the metal ejected while piercing does not come into contact with the shield cap Also some of the material ejected during the pierce may adhere to the top side of the plate and form a ring of solidified material around the pierce point Action must be taken so the torch does not move from the pierce height down to the cutting height and come into contact with this solidified metal The torch should not move from the pierce height down to the cutting height until the X Y controller has moved the torch away from the pierce point One way to accomplish this may be to program the pierce time on the torch height control system to a value that is longer than the X Y controller motion delay time Moving Pierces and Edg
162. gon Air N A 50 25 N A 54 100 2540 120 3 0 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Edge start recommended Revised 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 48 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 400 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode BK284123 BK284125 BK279460 black o ring D d Outer Cap Retaining Cap Swirl Ring BK284150 BK284121 BK279422 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfiow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 140 160 140 300 500 150 5 8 135 350 600 155 3 4 193 110 ee 400 800 160 1 150 85 160 500 1000 180 1 25 155 60 175 600 1500 190 1 5 30 79 70 76 160 50 225 700 2000 1 75 162 4
163. h 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 Marking Gas Hose 22 1 Connect one end of the 6 foot 1 8 m preflow postflow marking gas hose to the preflow postflow marking outlet on the 5 gang manifold 2 Connect the other end of the 6 foot 1 8 m preflow postflow marking gas hose to the preflow postflow marking inlet on the 2 gang manifold Marking Shield Gas Hose 23 1 Connect one end of the marking shield gas hose to the marking shield outlet on the rear of the AGC 2 Connect the other end of the marking shield gas hose to the marking shield inlet on the 5 gang manifold This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 16 Spirit II User s Manual Section 3 Installation Marking Plasma Gas Hose 1 Connect one end of the marking plasma gas hose to the marking plasma outlet on the rear of the AGC
164. he fumes wear proper air breathing equipment Electric Shock Prevention A PA The Spirit system uses high open circuit voltages that can be fatal Extreme care should be used when operating or performing maintenance on the system Only qualified personnel should service the system Observe the following guidelines to protect against electric shock e A wall mounted disconnect switch should be installed and fused according to local and national electrical codes The disconnect switch should be located as close as possible to the power supply so it can be turned off in case of an emergency e The primary power cord should have a 600 volt minimum rating in order to protect the operator In addition it should be sized according to local and national electrical codes Inspect the primary power cord frequently Never operate the system if the power cord is damaged in any way e Make sure the primary power ground wire is connected to the input power ground stud on the power supply Make sure the connection is securely tightened e Make sure the positive output work ground of the power supply is connected to a bare metal area on the cutting table A driven ground rod should be placed no further than five feet from this connection Make sure this ground point on the cutting table is used as the star ground point for all other ground connections e Inspect the torch leads frequently Never use the system if the leads are damaged in any way e Do no
165. 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 2 11 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 12 Spirit II User s Manual Section 2 Specifications Airborne Noise Emissions The system generates high noise levels while cutting Depending on the size of the cutting area distance from the cutting torch and arc current cutting level acceptable noise levels may be exceeded Proper ear pro
166. ierce Height 0 350 inches Initial Height 0 100 inches Arc Voltage 215 0 vots Arc Voltage 107 0 vots Kerf Width 0 205 inches Travel Speed 250 Pm Transfer Height 0 300 inches Manual Travel Speed 5 iPM Transmit Press the Save button and enter a Soup tame name using the on screen keyboard CurrentSetup F Materia Stainless Steel This name is added to the list of EEE existing custom setup files and can be Cuting Heth 0 290 tehas accessed again by scrolling through j mo a the list using the left Prev or right ms E E o E Next arrow buttons Arc Voltage 107 0 volts Marking Height 0 100 Inches Nitrogen Plasma Pressure 25 psi Initial Height 0 100 Inches as Nitrogen Shield Pressure 25 psi Travel Speed 250 IPM Cancel This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 11 Section 4 Operation with Automatic Gas Console Spirit Il User s Manual Restoring or Deleting Customized Settings If anew setup configuration was saved for later use it can be restored at any time or deleted permanently from the list Cutting Parameters Cut Pierce Time Cutting Height Pierce Height Arc Voltage Kerf Width Transfe
167. 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 B 7 Appendix B Serial Communication Spirit Il User s Manual Command Hex String Additional Information Restore Factory 47 AAnnFA2F00010D Restores the factory cutting condition for the Condition present material type and thickness Cutting Condition 48 AA nmn FA 30 00 0D If requested in command 30 the system will Type transmit whether the present cutting condition is a factory default setting or a custom user setting Note This is only valid when initially loading material type thickness and process 0 factory 1 custom Configure H17 49 AA nn FA 31 00 OD 0 Disable H17 cutting Cutting 1 Enable H17 cutting Reload Cutting 50 AAnnFA3200010D Reloads the cutting conditions for the present Condition material type and thickness Set Arc Off Delay 51 AA nn FA 33 OD Sets the delay time in mS between the reception Time of a stop signal and the extinction of the arc Valid Range 0 to 2000 mS Machine Type 52 AA nn FA 34 0D If requested in command 30 the system will transmit the machine type 153 Spirit150a 203 Spirit200a 273 Spirit275a 403 Spirit400a Set Marking Arc 53 AA nn FA 35 0D Sets marking arc voltage in Volts x 100 Voltage Valid Range 5000 to 20000 Set Marking Height 54 AA nn FA 36 OD S
168. ion is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 19 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Mild Steel 200 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277274 BK277289 BK277291 gt pe Z J H Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277143 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 230 040 200 300 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 ies 1 25 155 25 240 500 1 50 165 17 300 tt a 350 1500 158 HFIS 175 12 350 2 00 185 7 500 500 160 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
169. ire welding installation may be considered for special applications This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 3 Appendix A Electromagnetic Compatibility EMC Spirit II User s Manual BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 4 Spirit II User s Manual Appendix B Serial Communication Appendix B Serial Communication Initializing the Spirit System The Spirit system uses an RS 422 serial communication port located on the rear of the plasma console to receive and respond to commands that are transmitted from an x y controller The communications ground is isolated to prevent ground loops System initialization is simple Apply power wait until the plasma console has finished booting then transmit the desired material type material thickness and optionally the process cutting or marking and the system will be ready for operation All other parameters will be set to their default values and may be changed at any time Transmitting Parameters to the Spirit System To transmit pa
170. is information shall not be provided 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 20 Spirit II User s Manual Section 4 Operation with Automatic Gas Console Cut Info Tab Press the Diagnostics navigation button followed by the Cut Info tab to access the screen described below Press the Save to History button to add the Present Cut Errors to the History list for future reference This should be done each time consumables are changed Pressures Coolant RS422 Electrical Cut Info Power Supply Error Log Messages Present Cut Errors Save To History Pierces 0 Error 0 History i 9 14 2011 2 Pierces Pa 3 Pierces Process Setup Material Parameters Cut Errors Detailed Cut Error Information Current Statistics Pierces 0 Errors 0 Details No Transfer Arc Detected Transfer Arc Lost Before Upslope Transfer Arc Lost During Upslope Transfer Arc Lost During Cut Transfer Arc Lost During Downslope This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 21 Section 4 Operation with Automatic Gas Co
171. ited States contrary to the requirements of the EAR 7 30 Spirit II User s Manual Section 8 Internal Inova Console Option Section 8 Internal Inova Console Option Overview This optional Inova system is designed to provide arc voltage control to any plasma cutting system however combining it with the Spirit Il provides the added convenience of having Inova console built directly into the plasma power supply This section only covers topics unique to the Spirit II system with the internally installed Inova console See the standard Inova manual for all other Inova information Plug Identification Connections for the internal Inova console option are distinguished from other connections on the back of the power supply by the addition of the letter I before the plug number The function of each plug e g IP1 is the same as the corresponding plug found on the external Inova console e g P1 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 I
172. ized 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 Integrated 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 cu
173. l 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 50 070 120 125 300 10 135 131 40 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 120 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 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 45 100 2 5 0 Argon Air N A 50 25 N A 66 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 100 2 5 mm for cutting and marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by
174. l 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 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 7 WARNING Do not touch the fans inside the cooling system Important Never turn on the system when the coolant reservoir is empty Important When handling coolant wear nitrile gloves and safety glasses Important Only use 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 Repl
175. l not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 33 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 275 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277263 BK277276 BK277270 2 YN 5 B ae LZ LF 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 55 210 450 125 175 35 250 350 1500 480 1 50 185 25 300 350 i Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 141 3220 3 1 7 3 600 49 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
176. le the following string would be transmitted in order to set the pierce time to 1000mS for a power supply on net node 1 AA 01 FA 04 03 E8 0D For multiple power supply installations commands can be sent to all power supplies at the same time This is referred to as a global command To send a global command set the net node value to C8 hex 200 decimal In the example above the following string would be transmitted to set the pierce time to 1000mS for all power supplies connected on the network AA C8 FA 04 03 E8 0D Communication Error Checking With a single torch system all commands and parameters transmitted to the Spirit will be back transmitted in exactly the same form for error checking With a multiple torch system only the system with node focus will back transmit the commands The purpose of the node focus command 254 is to allow one Spirit system to use the transmission lines at a time If no node focus is set on initialization the first system to receive a command will receive node focus automatically Commands may be transmitted to systems without node focus but there will be no back transmission from those systems Also all parameters can be read at any time by transmitting a Send Parameter command 30 to the Spirit followed by the appropriate parameter to be read This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or
177. ll transmit the least significant word of the torch body part number If requested in command 30 the system will transmit the most significant word of the electrode part number If requested in command 30 the system will transmit the least significant word of the electrode part number If requested in command 30 the system will transmit the most significant word of the swirl ring part number If requested in command 30 the system will transmit the least significant word of the swirl ring part number If requested in command 30 the system will transmit the most significant word of the nozzle part number If requested in command 30 the system will transmit the least significant word of the nozzle part number If requested in command 30 the system will transmit the most significant word of the retaining cap part number If requested in command 30 the system will transmit the least significant word of the retaining cap part number If requested in command 30 the system will transmit the most significant word of the shield cap part number If requested in command 30 the system will transmit the least significant word of the shield cap part number If requested in command 30 the system will transmit the most significant word of the outer cap part number This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S perso
178. losed D77 3 3V uP PWR 3 3V Microprocessor power D78 1 8V uP PWR 1 8V Microprocessor power OPTO U21 MTR SOL Coolant pump relay CR5 energized Pump On OPTO U22 PAR Pilot arc relay energized OPTO U23 CON DC power output main contactor energized OPTO U24 SURGE CR3 and K1 I O PCB relays energized OPTO U26 FAN Fans energized OPTO U27 PREFLOW Preflow gas valve 1 energized OPTO U28 PLASMA Plasma gas valve 2 energized OPTO U29 SHIELD Shield gas valve 3 energized OPTO U30 VENT Vent gas valve 4 energized OPTO U31 POSTFLOW Postflow gas valve 5 energized OPTO U32 MARKING Marking gas valves 6 and 7 energized OPTO 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 Dlo ed ead dadh 1 8V Supply wi DOr eani neinei ne ned ASC Door Xo DIZ raai ta Coolant Level pclae DI Taea a Re Arc Hold if INOVA is being used gt DIO N RS232 T1 Out Blinking F DI b
179. low Indicator Green when the coolant flow through the system is satisfactory Red when the coolant flow is restricted This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Automatic Gas Console Spirit Il User s Manual Purging Pressure Regulators Press the Purge navigation button to access the screen described below The background color of the actual pressure reading will change e Green for pressures at the set point e Yellow for pressures not at the setpoint Press the Adjust button to automatically adjust the gas pressures A message at the top of the screen 7 Cutting Gases indicates the status of the regulators Preflow Plasma Shield Postflow Set Point Set Point Set Point Set Point in the automatic gas console 25 80 80 psi si psi Actual Actual Pressure Regulators Adjusted Actual reading equals the Set Point psi r Marking Gasses Pasma The background color of the Actual Set Point reading will be Green Actual amp M Regulators Need Adjusted Tae a E me pa Actual pressures do not equal the Set 1 HAE Point the background color of the Actual reading will be Yellow Press the Adjust button Pres
180. m j msec Nitrogen Nitrogen N A 25 25 N A 130 250 6350 100 2 5 100 2 5 0 Argon Nitrogen N A 50 25 N A 68 100 2540 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 28 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Stainless Steel 150 Amps H17 Plasma Nitrogen Shield Copper Electrode H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277298 BK277297 BK277135 WON r_ 9 O j p Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK277139 BK279100 Imperial Material i Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 95 250 250 400 she 3 8 75 150 2
181. ma 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 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 18 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Mild Steel 150 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 R N S gt pe J H Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277152 BK277139 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in
182. mum MAY GON Seer E E Gace A 78 scfh 2209 liters hour PU tah as cs lash Sani ed aa a oss eee tad 67 scfh 1897 liters hour H17 or Nitrogen e 106 scfh 3002 liters hour Shield gas flow rate maximum OXVOEN i a E a i 19 scfh 538 liters hour AN e AEAEE EEEE EAEE EEE EAEE 258 scfh 7306 liters hour NItrogeN ei a lath a pani deh 326 scfh 9231 liters hour Preflow gas flow rate Maximum 60 scfh 1699 liters hour Marking gas flow rate maximum 008 89 scfh 2520 liters hour Rated Inlet gas PpreSSUre seeeeeeeeeeeeeees 115 psi 7 9 bar Minimum Inlet gas pressure 110 psi 7 6 bar Maximum Inlet gas preSSUre cceeeeeeeee 145 psi 10 0 bar Oxygen and nitrogen should be supplied with a purity of at least 99 5 H17 purity should be at least 99 995 Argon purity should be at least 99 99 All should be clean dry and oil free 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 cylind
183. n 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 nozzle 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 Il User s Manual ASC with RH
184. nfig navigation button followed by the System Info tab to access the screen described below This screen displays the hardware software and serial number for each of the components in the Spirit system Configuration Advanced Config Network Settings Software Updates System Info Tools Plasma Power Gas Console Supply Console Hardware A Software A Serial Number XXXXXX Process Setup system Material Parameters Purge consa Diagnostics Tools Tab Restart Plasma Console Press the Config navigation button followed by the Tools tab to access the screen described below This screen provides an on screen calculator and buttons to restart the plasma console Restart Computer and to Close Program Configuration Advanced Config Network Settings Software Updates System Info Tools Restart Computer 0 Oller Ddec O0a OBin Degres ORadians Grads fa GI bs I Gell Goa EE Calli Ca a Cd ee emf ref ee et Laal Gia alad a Process Setup System Material Parameters Status Purge Diagnostics This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 18 Spirit II User s Manual Section 4 Operation with Automatic Gas Console Pressur
185. nited States contrary to the requirements of the EAR 4 13 Section 4 Operation with Automatic Gas Console Spirit II User s Manual Advanced Config Tab Press the Config navigation button followed by the Advanced Config tab to access the screen described below Configuration Advanced Config Network Settings Software Updates System Info Tools SET RS422 NODE dal kaa ig 4 s5 Ls 7 8 Disabiea SET CAN DOMAIN gt ja all 0 E 2 3 4 5 6 vs TORCH SELECTION Silver Head Copper Head ALLOW ERROR SUPPRESSION enes ott 0 Was Process Setup ster Material Parameters Status Purge Diagnostics L J Set RS422 Node When multiple Spirit systems are being used together on an RS 422 serial communication link each system must have a unique identification number node number to identify itself to the network To set the communication node number simply choose from node 1 through 8 ARC OFF DELAY When using an Inova torch height control system with the Spirit the communication node feature must be disabled To disable the communication node press the Disabled button Set CAN Domain Make sure the CAN domain is set to 1 All other selections are for future use Torch Selection Choose which type of Quick Disconnect head is being used The type of head corresponds to the type of electrodes being used either copper or silver Allow Error Suppr
186. nnections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 automatic 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 inch 432 mm plasma gas hose through the torch handle and connect to the plasma gas fitting on the torch base 2 Thread the torch handle onto the torch base being careful not to twist the torch leads and gas hoses when tightening the torch handle 3 Tighten the base to the handle using a pin style adjustable spanner wrench fits 2 diameter with 74 diameter pin 4 Attach the 2 gang manifold assembly to the torch handle The top of the manifold bracket should be flus
187. ns or transferred by any means to any location outside the United States contrary to the requirements of the EAR B 5 Appendix B Serial Communication Spirit II User s Manual Command Hex String Additional Information Torch Outer Cap 29 AAnnFA 1D OD If requested in command 30 the system will Part Number Isw transmit the least significant word of the outer cap part number Send Parameter 30 AAnnFA1E OD 01 Send material type 02 Send material thickness 03 Send current set point 04 Send cutting pierce time 05 Send preflow gas type 06 Send preflow pressure 07 Send plasma gas type 08 Send plasma gas pressure 09 Send shield gas type 10 Send shield gas pressure 15 Send cutting travel speed 16 Send torch body part number msw 17 Send torch body part number Isw 18 Send electrode part number msw 19 Send electrode part number Isw 20 Send swirl ring part number msw 21 Send swirl ring part number Isw 22 Send nozzle part number msw 23 Send nozzle part number Isw 24 Send retaining cap part number msw 25 Send retaining cap part number Isw 26 Send shield cap part number msw 27 Send shield cap part number Isw 28 Send outer cap part number msw 29 Send outer cap part number Isw 32 Send process select 33 Send software version 34 Send cutting chart version 35 Send number of pierces 36 Send number of pierce errors 42 Send cutting arc voltage 43 Send cutting height 44
188. nsferred 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 Users Manual Shielded Torch Leads Part Number BK284304 XX Length 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 Termination Plug BK300408 N A CAN Cable BK300177 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Manifold Control Cables Item Part Number Length 2 Gang Manifold BK280312 XX Where XX is the length in feet 5 Gang Manifold BK280321 XX 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 12 Spirit II User s Manual Section 7 Parts List Gas Hose Package with AGC Part Number Length BK300080 XX Where
189. nsole Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 37 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Aluminum 50 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277122 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 050 135 180 050 400 100 080 063 25 66 19 67 138 140 065 f 150 082 080 143 90 075 150 200 085 Metric Material gt 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 Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height
190. nsole Spirit II Users Manual When any of the following errors occur measures should be taken to avoid further errors The following is a description of the errors and possible causes Transferred arc not established This error occurs when the arc fails to transfer to the workpiece It primarily causes nozzle damage and is typically due to a pierce height that is too high Transferred arc lost before upslope This error occurs when the arc transfers to the workpiece but is lost immediately It primarily causes nozzle damage and is typically due to a pierce height that is too high Transferred arc lost during upslope This error occurs when the arc transfers to the workpiece but is lost before steady state operation It primarily causes electrode damage and is typically due to a pierce time that is too long or when cutting a given thickness with excessive current Transferred arc lost during cut This error occurs when the arc is lost during steady state operation It substantially shortens the electrode life and is typically due to a torch standoff distance that is too high or a travel speed that is to slow Transferred arc lost during downslope This error occurs when the arc is lost after a stop signal is received but before the current downslope completes It substantially shortens the electrode life and is typically due to an incorrect lead out or when cutting a given material thickness with excessive current When cutting small pieces
191. nstallation and should be installed according to local and national codes Refer to the National Electrical Code Article 250 Section H Ground Electrode System for additional information This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 9 Section 3 Installation Spirit Il User s Manual T BJ ASC with RHF ASC with CleanStrike Technology I a 1 ots HSS lt 3 E AN Vie 7 p Hi Le ol a Strain Relief E 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 Connection
192. nts of the EAR 2 14 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 pallet jack or crane In order to prevent damaging the power supply when lifting with a forklift or pallet jack the forks should be of adequate length to protrude on the far side of the power supply If lifting with a sling lifting straps ensure the following e Sling and material handling equipment must comply with local and national laws and regulations The personnel involved in the move must be properly trained and qualified to use such equipment e All power supply covers must be securely installed e Two slings are required Each sling should pass through all three 3 structural members on the bottom of the power supply See sling access holes below e Lift slowly not more than 8 in 203 mm high to ensure even weight distribution e Move slowly to prevent uncontrollable acceleration deceleration
193. o the requirements of the EAR 5 27 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 100 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 S Sd x Y S A 9 D eam 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 4 141 100 135 225 400 092 3 8 25 80 35 80 147 80 170 250 500 695 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 volts mm m mm mm msec mm 6 140 2595 3 2 5 6 400 2 3 10 25 80 35 80 148 1935 4 4 6 5 600 2 4 12 152 1540 5 0 7 3 Marking For All Material Thicknesses Arc Travel Marking Initial Pierce Type of Gas Preflow Plasma Shield Postflow Voltage Speed Height Height Time Plasma Shield psi psi psi psi volts ipm mm min in mm in m
194. ogen Shield Gas Nitrogen Arc Voltage 135 0 volts 25 psi Plasma Pressure Shield Pressure 25 psi Marking Height 0 096 Inches Initial Height 0 100 Inches Travel Speed 250 IPM Cancel Press the Manage Custom Setups button on the Parameters Screen Press the left Prev or right Next arrow button to scroll through the list of existing custom setups The name of the selected setup will appear under Setup Name When the desired setup is displayed press the Restore or Delete button This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 12 Spirit II User s Manual Section 4 Operation with Automatic Gas Console Configuration Tab Press the Config navigation button followed by the Configuration tab to access the screen described below Configuration Advanced Config Network Settings Software Updates System Info Tools RS422 PARAMETER CONTROL CUT MARK CONTROL HYDROGEN CUTTING H17 UNITS OF MEASURE LANGUAGE Process Setup System Material Parameters Status Purge Cong Diagnostics RS422 Parameter Control Controls how the Spirit communicates with the X Y controller and height control system
195. on 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 a BK279060 ie an _ A t S NE x A iy QO O s ey BK279420 green o ring BK279493 BK284150 Q BK284150 Q BK284150 Q BK284150 Q 150A BK279489 BK279443 ea D D S BK279469 BK279458 pene OP OD BK284125 BK279422 ich ite S This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 f m D 5 i AZT BK284150 BK277146 BK277113 BK277126 _BK277141 BK277133 BK279100 A w C 3 BK284150 BK277298 BK277266 BK277297 BK277139 BK
196. only on the o rings Excess lubricant can interfere with gas flow which can cause starting problems poor cut quality and short consumable life 1 Unthread the torch head from the torch base by turning the attachment ring to the LEFT Verify the torch base doesn t unthread from the torch handle 2 Remove the outer retaining cap from the torch head 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 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual R 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 400A copper electrodes use sock
197. ons 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 Automatic Gas Console Checking System Status To view the system status indicators press the Status navigation button Each indicator will be either Green or Red DC Power Indicator DC Power Green when the main contactor has been energized and D C current is flowing through the torch Red when no D C current is flowing 3 Phase Power QO Gas Console O ASC Door Coolant Temperature 3 Phase Power Indicator O Coolant Level Green when 3 phase power is O Coolant Flow satisfactory Red when there is a problem with main 3 phase power Process Setup System Material Parameters Purge Config Diagnostics Gas Console Indicator Green when the automatic gas console is operational Red when there is a problem with the gas system Check the message screen for errors ASC Door Indicator Green when the arc starting console door is closed Red when the arc starting console door is open Coolant Temperature Indicator Green when the torch coolant temperature is satisfactory Red when the coolant temperature is too hot If this indicator turns Red leave the system on until it turns Green again Coolant Level Indicator Green when the coolant level inside the reservoir is satisfactory Red when coolant must be added Coolant F
198. ontrols of the Export Administration Regulations EAR This information shall not be provided 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 AGC 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 25 Section 7 Parts List Spirit II User s Manual Gas Console Microprocessor DSP BK300301 AGC 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 oo JEN oe oe IE HCRECERGE u42 C155 R277 R276 R282 R281 R158 R106 R159 R109
199. or labeled P13 on the rear of the power supply This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 17 Section 3 Installation Spirit Il User s Manual Automatic Gas Console 25 mma B BLACK Lee o G RED G 60 g 5 DEEE af Hiki D U GREEN RED G1 PORT Wi WD BLACK Figure 8 Torch Gas Connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 18 Spirit II User s Manual Section 3 Installation Gas Supply Connections Perform the following steps to connect the gas supply lines to the AGC See Section 2 for gas supply requirements Connectors are sized for 3 8 inch inside diameter hose Do not change the inlet gas supply fittings to quick connect fittings Using quick connect fittings to connect and disconnect pressurized hoses may cause damage to the system Note When making hose connections only tighten the brass fittings enough to make gas seals The fittings are subject to damage if over tightened Air Inlet
200. oting 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 Power supply indicator 1 white light will not 2 illuminate 3 4 Power Supply will not 1 energize when ON Button is 2 pressed 3 4 5 Power supply will not stay on 1 2 Off Relay faulty when the ON Button is pressed No arc at the torch The arc will not transfer to 1 the workpiece 2 Incorrect damaged or worn consumables Possible Cause Primary disconnect fuse blown Internal power supply fuse is blown F1A F1B Power supply indicator light is burned out or the associated wiring is bad Control Transformer or associated wiring bad ASC door open Low coolant level Fuse is blown F1 F6 Faulty OFF Button or associated wiring Off Relay faulty Faulty DSP board Incorrect torch consumables installed 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 electro
201. peed transmit the cutting travel speed in inches per minute Range 0 to 999 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR B 4 Spirit II User s Manual Appendix B Serial Communication Command Torch Body Part Number msw Torch Body Part Number Isw Torch Electrode Part Number msw Torch Electrode Part Number Isw Torch Swirl Ring Part Number msw Torch Swirl Ring Part Number Isw Torch Nozzle Part Number msw Torch Nozzle Part Number Isw Torch Retaining Cap Part Number msw Torch Retaining Cap Part Number Isw Torch Shield Cap Part Number msw Torch Shield Cap Part Number Isw Torch Outer Cap Part Number msw oF 17 18 19 20 21 22 23 24 25 28 Hex String AA nn FA 10 OD AA nn FA 11 OD AA nn FA 12 OD AA nn FA 13 OD AA nn FA 14 OD AA nn FA 15 OD AA nn FA 16 OD AA nn FA 17 OD AA nn FA 18 OD AA nn FA 19 OD AA nn FA 1A OD AA nn FA 1B OD AA nn FA 1C 0D Additional Information If requested in command 30 the system will transmit the most significant word of the torch body part number If requested in command 30 the system wi
202. ption 1 BK110200 1 Printed Circuit Board PCB Microprocessor 2 BK110705 1 Printed Circuit Board PCB Power Distribution 3 BK110900 1 Printed Circuit Board PCB H Bridge 4 BK706003 1 Transformer 5 BK709360 1 F7 Fuse 6 3A 6 BK709370 1 F8 Fuse 3A 7 BK301200 1 Printed Circuit Board PCB Voltage Divider 8 BK709276 1 Power Distribution Block 1 Pole Location in Spirit 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
203. pump circulating coolant through the 11 system Note the Coolant Flow indicator press the Status navigation button will remain red until the coolant has filled the entire system and begins flowing back into the tank 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 If the Fill Flush button is not available grayed out release turn right the OFF Button With the coolant pump running locate the small red push button on top of the coolant filter housing Press and hold the red button until no air or bubbles are seen inside the filter housing Dry any coolant that leaks out 12 Check for coolant leaks at all hose connections the arc starting console and at the torch 13 Once the flow rate has stabilized see Diagnostics gt Pressures Coolant tab press the Fill Flush button again to stop the coolant pump 14 Remove primary power from the Spirit system 15 Fill the reservoir with coolant until the coolant gauge indicates full 16 Replace the cooling system cover and replace the coolant reservoir cap level gauge 17 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 23 Section 3 Install
204. r 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 in 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 5 Section 2 Specifications Spirit II User
205. r Height Travel Speed 1500 ms 0 290 inches 0 350 inches 215 0 vots 0 205 inches 0 300 inches 5 iPM Marking Height Initial Height Arc Voltage Travel Speed Manual Transmit Marking Parameters Mark Pierce Time 0 100 inches 0 100 inches 107 0 vots 250 Pm o Manage Custom Setups Aa Process Setup Material System Status Purge Config Diagnostics Setup Name Existing Custom Setup Files CurrentSetup Save Material Stainless Steel ent 260 Amps Thickness 3 000 Inches Pierce Time 1500 ms Cutting Plasma Gas Air Shield Gas Nitrogen e 96 Psi e 30 PSI 78 PSI e 63 PSI Arc Voltage 215 0 Volts Cutting Height 0 290 Inches Pierce Height 0 350 Inches Travel Speed 5 IPM Marking z Plasma Gas Nitrogen Shield Gas Nitrogen Arc Voltage 107 0 volts Plasma Pressure Shield Pressure 25 psi Marking Height 0 100 Inches initial Height 0 100 Inches Travel Speed 250 IPM Cancel Setup Name Existing Custom Setup Files MH_0_250_70 n Prev Restore Delete 0 kJ gt nnn ne Materia Stainless Steel Current 70 Amps Thickness 0 250 Inches 300 ms Pierce Time PSI PSI PSI PSI Arc Voltage 116 0 Volts Cutting Height 0 110 inches Pierce Height 0 225 Inches Travel Speed 120 IPM Plasma Gas Nitr
206. rameters to the Spirit convert the following hex strings to 8 bit binary arrays AA 10101010 and transmit them using a 9600 baud RS 422 serial communication port The port settings should have a start bit one stop bit and no parity A table can be found in this section that lists the RS 422 commands and their descriptions This table contains the necessary hex strings for sending different commands and parameters to the system For example to switch the material type from mild steel to stainless steel look up the command for setting material type in the table You will see the following table entry Command Hex String Additional Information Set Material Type 1 AAnnFA0100 0D 00 Mild Steel Hot Rolled 01 Stainless Steel 02 Aluminum 03 Other 04 Mild Steel Cold Rolled Note that spaces in the command string are shown for clarity only and should not be sent as part of the command A command string always begins with the value AA hex The nn is the net node communication node of the Spirit system that is to receive the command The net node value of a system is set via the Set Communication Node selection on the maintenance screen See Section 4 for detailed information on setting the net node The value FA hex is the Spirit identifier The value 01 hex is the value that signifies the Set Material Type command The value OD hex is the end of command character In the above example the following hex string would need to be
207. re 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 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 9 Section 4 Operation with Automatic Gas Console Spirit II User s Manual Customizing Cutting or Marking Settings Changes to any of these factory default settings will cause the Setup message at the top of the screen to change from Setup Optimum to Setup Custom Not Saved See the next section to save custom settings Altering the Current Set Point To alter the
208. rogen Regulator Valve 5 BK300415 1 Nitrogen Regulator Valve Amplifier Programmed 6 BK260109 1 Oxygen Regulator Valve T BK300415 1 Oxygen Regulator Valve Amplifier Programmed 8 BK260109 1 Marking Plasma Regulator Valve 9 BK300415 1 Marking Plasma Regulator Valve Amplifier Programmed 10 BK260109 1 Shield Regulator Valve 11 BK300415 1 Shield Regulator Valve Amplifier Programmed 12 BK260109 1 Preflow Regulator Valve 13 BK300415 1 Preflow Regulator Valve Amplifier Programmed 14 BK260109 1 Plasma Regulator Valve 15 BK300415 1 Plasma Regulator Valve Amplifier Programmed 16 BK260109 1 Marking Shield Regulator Valve 17 BK300415 1 Marking Shield Regulator Valve Amplifier Programmed 3 544 12113 7X6 14 15 9 8 16117 10111 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Automatic Gas Console BK300418 Right Side View Item Part Number Quantity Description 1 BK300412 1 Power Supply 24VDC 8 3A 2 BK300301 AGC 1 Printed Circuit Board PCB Gas Console DSP 3 BK280030 1 Fan 24VDC 10 BK260109 1 Shield Regulator Valve 11 BK300415 1 Shield Regulator Valve Amplifier Programmed 12 BK260109 1 Pr
209. rred 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 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 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 7 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
210. ry power to the Spirit system 7 Release the OFF Button on the Plasma Controller or Manual Gas Console to enable the system Press or SELECT the ON Button to energize the system After the gases set prepare to apply a start signal to the unit 8 With a start sinal applied check the three phase voltage input to each chopper at the diode bridge terminals three screws on the left side of each chopper Refer to TABLE 1 for the proper three phase AC voltage Note that the system will only energize for approximately two seconds each time a start signal is applied If the voltage is not present check for primary voltage on the main contactor CON 1 and on the primary side of the power transformer ole Olo Diode Bridge Terminals 7 Ole O l N D ii O One 1G oO Chopper PCB _ gt J1 Plug lt __ 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 EA
211. s Perform the following steps to connect the ASC control cable and ASC ground See Figure 5 on the next page ASC 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 power supply and 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 cooling system Note that the coolant out fitting has right hand threads 2 Connect the other end of the coolant supply hose to the coolant in fitting on the 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 cooling system Note that the coolant in fitting has left hand threads 2 Connect the other end of the coolant return hose to the coolant out fitting on the arc starting console Note that the coolant out fitting has left
212. s of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 49 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 100 Amps Air Plasma Nitrogen Shield Silver Electrode Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 brown o ring S W AY w O YW J Z LL J Ly AL Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow 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 80 170 250 500 605
213. shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 1 Appendix A Electromagnetic Compatibility EMC Spirit II User s Manual Assessment of Area Before installing plasma cutting equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the plasma cutting equipment b radio and television transmitters and receivers c computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment the user shall ensure that 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
214. stems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 54 Spirit II User s Manual Section 5 Torch Consumables and Cutting Charts Aluminum 200 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277274 BK279489 BK279440 yellow o ring I DD zi lt Ly A faa SF Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277266 BK279443 BK279060 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 150 190 135 250 300 iso 3 8 JEE 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 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 3 8 10 3545 3 5 7 0 i 155 500 12
215. sure Regulators Adjusting The system is in the process of adjusting the pressures to reach the Set Point This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Automatic Gas Console Making a Cut or Mark Once the material type material thickness and process have been selected the correct torch parts consumables installed and the X Y controller and torch height control are properly configured the system is ready to cut or mark 1 Release the OFF Button turn to the right and then press the ON Button on the Plasma Console The AGC will purge the gas hoses and set the correct gas pressures automatically After the pressures have been set the Gas Console indicator on the Status Screen will change from red to green Once the Gas Console indicator is green the system is ready for cutting or marking When the system receives a start signal from the X Y controller the following sequence is initiated Two second gas preflow RHF CleanStrike circuit energized Pilot arc initiation Transferred arc cutting or marking arc established Motion output relay energized When the start signal is removed the arc is extinguished and the motion output relay is deener
216. t all gas hose connectors are tight and that there are no leaks Only tighten the gas fittings enough to make a gas seal The fittings are subject to damage if over tightened Inspect all gas hoses to ensure no damage exists Immediately replace any damaged gas hoses Plasma Console 1 No maintenance is required on the inside of the plasma console 2 With primary power removed from the Spirit system clean the touch screen as necessary with a soft clean cloth and a cleaner approved for television or computer screens Torch Torch Leads and Gas Hoses 1 Verify that all torch lead and gas hose connections are tight and that there are no gas or water leaks Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened Verify that the braided shield of the torch leads is fastened securely to the brass shield adapter that connects to the 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 sle
217. t 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 Fire Prevention e Never change torch consumable parts unless the system is switched off at the wall disconnect e Do not attempt to remove any parts from beneath the torch when cutting Remember that the workpiece forms the current path back to the power supply e Never bypass the safety interlock devices e Before removing any of the covers switch the system off at the wall disconnect Wait at least five 5 minutes before removing any cover This will give the capacitors inside the unit time to discharge See Section 6 for additional safety precautions e Never operate the system without all of the covers in place See Section 6 for additional safety precautions e Preventive maintenance should be performed daily to avoid possible safety hazards Chi When using the Spirit system it is necessary to exercise good judgment While cutting the
218. tage 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 45 100 2 5 0 Argon Nitrogen N A 50 25 N A 55 100 2540 140 3 6 100 2 5 0 Use an arc transfer height ignition height of 050 1 3 mm for cutting and 100 2 5 mm for marking Only available on systems with the Automatic Gas Console Revised 04 26 2013 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 23 Section 5 Torch Consumables and Cutting Charts Spirit II User s Manual Stainless Steel 50 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277149 BK277123 BK277137 y s cB 5 Z Y Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277110 BK277142 BK279100 Imperial Material F 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 75 105 035 070 11 1
219. tection should be used as defined by local or national codes The following chart gives the noise levels generated by the system when operating at 400 amps 205 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound Pressure Level C Weighted Sound Pressure Level 1 meter horizontal 1 6 meters above the workpiece 120 dB 115 dB The maximum noise level is 131 dB at a distance of 3 inches 76 2 mm from the torch while cutting at 400 amps 205 arc volts 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 13 Section 2 Specifications Spirit II User s Manua 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 requireme
220. that tend to drop into the table after being cut there should be a very short lead out or none at all On thicker materials the arc is sometimes lost when crossing the kerf during the lead out It is critical that the lead outs be fine tuned so the arc is not lost before downslope is complete This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided 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 22 Spirit II User s Manual Section 4 Operation with Automatic Gas Console Power Supply Tab Press the Diagnostics navigation button followed by the Power Supply tab to access the screen described below Pressures Coolant RS422 Electrical Cut Info Power Supply Error Log Messages Chopper 1 Process Setup System Material Parameters Status Purge Config Error Log Tab Press the Diagnostics navigation button followed by the Error Log tab to access the screen described below Filters along the right side of the screen can be used to limit the data displayed based upon Error Date or Severity Press the Clear button to remove all filters Pressures Coolant RS422 Electrical Cut Info Power Supply Error Log Messages Date Time Severity Error Description Error Filter 0 Date Time Filter Statt 2 7 2012
221. the requirements of the EAR 7 10 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 6 BK820209 1 O ring red 7 BK500024 1 O ring blue 8 BK500018 1 O ring red g 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 for Automatic Gas Console 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 BK284052 1 Copper Electrode Inst Removal Socket 400 Amp BK277087 Copper Electrode Inst Removal Socket All others Not shown BK279061 1 Silver Electrode Installation Removal Tool WSO a Cee f ag This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or tra
222. timed out 10350 PAT Not Established Pilot Arc Current not established within 2 seconds 10360 TAC Not Established Transferred Arc Current not established within 2 seconds 10370 Current Unbalanced Current is not balanced between chopper assemblies 275A and 400A systems 10380 TAC Lost 1 Transferred Arc lost during TAC hold time 10390 TAC Lost 2 Transferred Arc lost during Upslope 10400 TAC Lost 3 Transferred Arc lost during Cutting 10410 TAC Lost 4 Transferred Arc lost during Downslope 10420 FCC Unreached Did not achieve final cut current 10430 Output Over Current Chopper has exceeded its maximum rated current 10432 Output Over Current TZ Instantaneous Over Current detected 10440 Output Over Voltage Maximum Cutting Voltage has been exceeded 10450 Start Premature Removal Start Signal removed prior to completion of upslope 10461 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
223. ting current are changed to optimum values for extinguishing the arc Ideally the x y machine controller should provide a plasma stop signal prior to the end of the cut path so the gases and current reach the shut off values at the same time that the part has been completely cut The shut down times are different for each current and are given below Arc Shutdown Times Current A Time ms 30 490 50 390 70 300 100 300 150 175 200 195 260 175 275 175 400 375 Use the recommended pierce height given in the cutting charts A pierce height that is too low will allow molten metal that is ejected during the piercing process to damage the shield cap and nozzle A pierce height that is too high will cause the pilot arc time to be excessively long and will cause nozzle damage See Piercing Thick Materials in Section 4 Never fire the torch in the air Nozzle damage will occur 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 transf
224. tion Regulations EAR This information shall not be provided 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 3 Installation Filling the Cooling System 7 WARNING Do not touch the fans inside the cooling system Important Never turn on the system when the coolant reservoir is empty Important When handling coolant wear nitrile gloves and safety glasses Important Only use approved coolant Commercially available antifreeze Pe eet a OND oO 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 Remove the coolant reservoir cap level gauge and then remove the cover from the cooling system Ensure the coolant filter housing is tightened securely Ensure the drain petcock on the bottom of the reservoir is tightened securely Fill the reservoir with approximately 2 gallons of approved coolant Apply primary power to the Spirit system and enable it by releasing turn right the OFF Button on the plasma console On the plasma console press the Diagnostics navigation button to access the Pressures Coolant tab 10 Press the Fill Flush button to start the coolant
225. tion Regulations EAR This information shall not be provided 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 Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 e 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 Postfow 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 Arc Travel Marking Initial Pierce Type of Gas Preflow Plas
226. to be achieved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installation and Use The user is responsible for installing and using the plasma cutting equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the plasma cutting equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the plasma cutting circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the plasma power source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer troublesome Note The plasma cutting 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
227. tters 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 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 N
228. tting 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 NW LeJeune Road Miami FL 33126 AWS ANSI Standard Z49 1 Safety in Welding Cutting and Allied Processes obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 ANSI Standard Z41 1 Standard For Men s Safety Toe Footwear obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 ANSI Standard 249 2 Fire Prevention in the Use of Cutting and Welding Processes obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 ANSI Standard 287 1 Safe Practices For Occupation and Educational Eye and Face Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 ANSI Standard Z88 2 Respiratory Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 OSHA Standard 29CFR 1910 252 Safety and Health Standar
229. upture 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 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 prima
230. y 1 2 OORA OQ 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 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 Cooling System 1 2 Remove the cover on the cooling system Check the torch coolant filter deionization cartridge and replace if dirty Flush the cooling system every six months and replace the coolant and coolant filter deionization cartridge This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 1 Section 6 Maintenance amp Troubleshooting Spirit II User s Manual Automatic Gas Console AGC 1 Remove the cover of the automatic 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 3 Verify tha
231. ystem 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 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 Cu

718117 Spirit II 400 AGC

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