User`s Manual

Add to my manuals
136 Pages

advertisement

User`s Manual | Manualzz

User's Manual

Spirit II 150

High Current Density Plasma Cutting System with Manual Gas Console (MGC)

BK718114 Rev F

This information is subject to the controls of the Export Administration Regulations [EAR].

This information shall not be provided to non-U.S. persons or transferred 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

A

B

C

D

E

F

-

LAD0202

LAD0217

LAD0228

LAD0223

LADC0260

LAD0264

CAD

CAD

CAD

CAD

CAD

CAD

Description of Change

02/04/2013 Initial Release

06/07/2013

08/06/2013

08/28/2013

03/18/2014

03/31/2014

Added 100A/150A silver electrodes, replaced RHF with

ISC, corrected system interconnect diagrams, changed rated inlet gas pressure to 115 psi, added 100 psi minimum to inlet gas pressure.

Deionization filter cartridge (500510) replaced sediment filter (300152). Parts list updated.

Expanded notes on System Interconnection diagrams to clarify cabling requirements for various configurations.

Corrected contact ratings on page 3-19.

Added pinouts to CII, FII, JII cables in Parts List.

Corrected part numbers for coolant/power leads and work ground in Parts List.

Inductor (707150) replaced by (707155). 10” fan (500516) replaced by (284031). Added notes about torch handle vent hole. Updated Chopper Test Procedure.

Added “BK” prefix to all part numbers. Added PCB Outline

Dwgs and corrected electrode tool in Part List. Corrected

Remote On/Off info in Installation section.

This documentation may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine-readable format without explicit written permission from Kaliburn.

FASTON is a trademark of the TE Connectivity Ltd family of companies.

Other logos, products and company names mentioned herein may be trademarks of their respective owners.

© Copyright 2013-2014 Lincoln Global, Inc.

Kaliburn Inc. a Lincoln Electric Company

4130 Carolina Commerce Parkway

Ladson, SC 29456 USA

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. ii

Spirit II User’s Manual

Table of Contents

Section 1: Safety

General Precautions ......................................................................................... 1-1

Ultraviolet Radiation Protection ......................................................................... 1-1

Noise Protection ................................................................................................ 1-1

Toxic Fume Prevention ..................................................................................... 1-2

Electric Shock Prevention ................................................................................. 1-2

Fire Prevention .................................................................................................. 1-3

Explosion Prevention......................................................................................... 1-3

Health Support Equipment ................................................................................ 1-4

Safety Standards Booklet Index ........................................................................ 1-5

Section 2: Specifications

System Description ........................................................................................... 2-1

System Components ......................................................................................... 2-2

Power Supply Specifications ............................................................................. 2-3

Torch Coolant Specifications ............................................................................. 2-4

Manual Gas Console (MGC) Specifications ...................................................... 2-5

Gas Supply Requirements ................................................................................ 2-6

Impulse Start Console (ISC) Specifications ....................................................... 2-7

Torch and 2-Gang Manifold Specifications ........................................................ 2-8

5-Gang Manifold Specifications ......................................................................... 2-9

Airborne Noise Emissions ................................................................................. 2-10

Section 3: Installation

Initial Inspection ................................................................................................ 3-1

Component Placement ...................................................................................... 3-1

System Interconnection ..................................................................................... 3-2

Power Supply Primary Power Connections ....................................................... 3-5

Power Supply Output Connections ................................................................... 3-7

ISC Control Cable and ISC Ground Connections .............................................. 3-9

Cooling System Connections ............................................................................ 3-9

Torch Leads to Impulse Start Console Connections ......................................... 3-11

Torch Leads to Torch Base Connections .......................................................... 3-13

Torch Gas Connections ..................................................................................... 3-14

Gas Supply Connections ................................................................................... 3-17

CAN Communication Connections .................................................................... 3-18

CNC Machine Interface Connections ................................................................ 3-19

Filling the Cooling System ................................................................................. 3-20

Prologue

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. iii

Prologue Spirit II User’s Manual

Section 4: Operation

Operating the Manual Gas Console (MGC) ...................................................... 4-1

Setting up to Cut ............................................................................................... 4-2

Setting up to Mark (Overrides Cut) .................................................................... 4-3

Verifying Input Gas Pressures ........................................................................... 4-3

Making a Cut or Mark ........................................................................................ 4-4

Piercing Thick Materials .................................................................................... 4-5

Moving Pierces and Edge Starts ....................................................................... 4-5

Cut Quality ........................................................................................................ 4-6

Checking Errors ................................................................................................ 4-7

Checking the Version and Serial Number ......................................................... 4-7

Changing the Language .................................................................................... 4-8

Adjusting the Screen Contrast ........................................................................... 4-8

Section 5: Torch Consumables and Cut Charts

Installing / Removing the Torch Head ............................................................... 5-1

Installing / Replacing Consumables .................................................................. 5-2

Maximizing Consumable Life ............................................................................ 5-3

Inspecting for Damage ...................................................................................... 5-4

Selecting Consumables ..................................................................................... 5-5

Cutting Charts ................................................................................................... 5-12

Section 6: Maintenance and Troubleshooting

Routine Maintenance ........................................................................................ 6-1

Replacing the Torch Coolant and Filter ............................................................. 6-4

Microprocessor (DSP) Status Indicators ........................................................... 6-5

Microprocessor (DSP) Sequence of Operation ................................................. 6-5

Error Codes ....................................................................................................... 6-7

General Troubleshooting ................................................................................... 6-9

Chopper Test Procedure ................................................................................... 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

Section 7: Parts List

Power Supply (BK300211 - BK300219) ............................................................ 7-1

Manual Gas Console (BK300600) ..................................................................... 7-5

Impulse Start Console (BK300500) ................................................................... 7-7

Torch and Manifold Assemblies ........................................................................ 7-8

Shielded Torch Leads ....................................................................................... 7-9

CAN Communication Cable and Termination Plug ........................................... 7-9

Manifold Control Cables .................................................................................... 7-9

Gas Hose Package with MGC ........................................................................... 7-10

Coolant and Power Leads ................................................................................. 7-11

Work Ground Lead ............................................................................................ 7-11

Oxygen Supply Gas Hose (Optional) ................................................................ 7-12

Nitrogen Supply Gas Hose (Optional) ............................................................... 7-12

Air Supply Gas Hose (Optional) ........................................................................ 7-12

H17 Supply Gas Hose (Optional) ...................................................................... 7-12

"CII" Cable (for Optional External Inova) ........................................................... 7-13

"FII" Cable (for Optional Internal Inova) ............................................................. 7-14

"JII" Cable (for Optional Internal Inova) ............................................................. 7-15

PCB Assemblies – Component Reference Locations ....................................... 7-16

Section 8: Internal Inova Console Option

Overview ........................................................................................................... 8-1

Plug Identification .............................................................................................. 8-1

Unique Interconnect Cables .............................................................................. 8-1

Grounding ......................................................................................................... 8-2

Parts List ........................................................................................................... 8-3

Appendix A: Electromagnetic Compatibility (EMC)

Background ....................................................................................................... A-1

Installation and Use ........................................................................................... A-1

Assessment of Area .......................................................................................... A-2

Methods of Reducing Emissions ....................................................................... A-2

Prologue

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. v

Prologue Spirit II User’s Manual

Limited Warranty

KALIBURN expressly warrants that this product shall be free from defects in materials and workmanship, under proper and normal use for the intended function of such product, for a period of three (3) years for the Spirit II plasma power supply (includes the cooling system and internally installed Inova option) and one (1) year for all other Spirit

II system component. This warranty does not apply to torch consumable parts.

The warranty period starts three (3) months after the product ships from the factory.

This product is intended for commercial use and is not intended for personal, family, or household purposes. There are no warranties that extend beyond the express limited warranty set forth immediately above. All other warranties, whether expressed, implied, statutory or made herein or in any other communication, including any implied warranty of merchantability, fitness for any particular purpose or non-infringement, are expressly excluded.

This warranty will be considered void if the Spirit II system is operated with non-genuine

KALIBURN torch consumables, or if the equipment has been subjected to improper installation, improper care or abnormal operation.

If this product or any component thereof is determined to be defective in materials or workmanship, KALIBURN will repair or replace the defective component or product.

The buyer’s remedies are limited to the return of the product for repair or replacement of any defective product or part at the sole discretion of KALIBURN. No freight charges of any kind are covered under this warranty. All returned goods shall be at the buyer’s risk and expense. In no event will KALIBURN be responsible for any special, incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any equipment sold hereunder.

Returned Goods Procedure

KALIBURN utilizes a returned goods procedure that must be followed before returning any items for repair, replacement, or restocking. This means that a returned goods authorization number must be obtained prior to shipment to KALIBURN. It will be necessary for the customer to provide a description, along with the part number and serial number, if applicable, of the item to be returned. In no case will KALIBURN accept a returned shipment without the proper returned goods authorization number.

For shipments inside the U.S., parts must be returned to KALIBURN within 30 days of the invoice date to be considered for credit. For shipments outside the U.S., parts must be returned within 60 days of the invoice date to be considered for credit.

Electromagnetic Compatibility (EMC)

The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit 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. vi

Spirit II User’s Manual Section 1: Safety

Section 1: Safety

General Precautions

Whereas plasma cutting has been used safely for years, it does 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.

Installation, operation, and repairs made to the Spirit system should only be performed by qualified personnel. The system makes use of both A.C. and D.C. circuitry for operation.

Fatal shock hazard does exist. Exercise extreme caution while working

on the system.

Ultraviolet Radiation Protection

Plasma cutting produces ultraviolet radiation similar to a welding arc. This ultraviolet radiation can cause skin and eye burns. For this reason, it is essential that proper protection be worn. The eyes are best protected by using safety glasses or a welding helmet with an AWS No. 12 shade or ISO 4850 No. 13 shade, which provides protection up to 400 amperes. All exposed skin areas should be covered with flame-retardant clothing. The cutting area should also be prepared in such a way that ultraviolet light does not reflect. Walls and other surfaces should be painted with dark colors to reduce reflected light. Protective screens or curtains should be installed to protect additional workers in the area from ultraviolet radiation.

Noise Protection

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 II User’s Manual

Toxic Fume Prevention

Care should be taken to ensure adequate ventilation in the cutting area. Some materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the cutting area. Also, some solvents decompose and form harmful gases when exposed to ultraviolet radiation. These solvents should be removed from the area prior to cutting.

Galvanized metal can produce harmful gases during the cutting process. Ensure proper ventilation and use breathing equipment when cutting these materials.

Certain metals coated with or containing lead, cadmium, zinc, beryllium, and mercury produce harmful toxins. Do not cut these metals unless all people subjected to the fumes wear proper air breathing equipment.

Electric Shock Prevention

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:

• 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.

• 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.

• 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.

• 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.

• Inspect the torch leads frequently. Never use the system if the leads are damaged in any way.

• Do not stand in wet, damp areas when operating or performing maintenance on the system.

• Wear insulated gloves and shoes while operating or performing maintenance on the system.

• 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

• Never change torch consumable parts unless the system is switched off at the wall disconnect.

• 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.

• Never bypass the safety interlock devices.

• 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.

• Never operate the system without all of the covers in place. See Section 6 for additional safety precautions.

• Preventive maintenance should be performed daily to avoid possible safety hazards.

Fire Prevention

When using the Spirit system, it is necessary to exercise good judgment. While cutting, the arc produces sparks that could cause a fire if they fall on flammable materials.

Make sure that all flammable materials are a suitable distance away from the cutting area. All flammable liquids should be at least 40 feet away from the cutting area, preferably stored in a metal cabinet. Plasma cutting should never be attempted on containers that contain flammable materials. Make sure that fire extinguishers are readily accessible in the cutting area.

Make sure that the cutting area is properly ventilated when using oxygen as a cutting gas.

Explosion Prevention

The Spirit system uses compressed gases. Use proper techniques when handling compressed gas cylinders and other compressed gas equipment. Observe the following guidelines to protect against explosion:

• Never operate the system in the presence of explosive gases or other explosive materials.

• Never cut pressurized cylinders or any closed container.

• When using a water table and cutting aluminum under water or with water touching the underside of the aluminum plate, hydrogen gas is produced. This hydrogen gas may collect under the plate and explode during the cutting process. Make sure the water table is properly aerated to help prevent the accumulation of hydrogen gas.

• Handle all gas cylinders in accordance with safety standards published by the U.S.

Compressed Gas Association (CGA), American Welding Society (AWS), Canadian

Standards Association (CSA), or other local or national codes.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

• 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.

Health Support Equipment

The Spirit system creates electric and magnetic fields that may interfere with certain types of health support equipment, such as pacemakers. Any person who uses a pacemaker or similar item should consult a doctor before operating, observing, maintaining, or servicing the system. Observe the following guidelines to minimize exposure to these electric and magnetic fields:

• Stay as far away from the power supply, torch, torch leads, and impulse start console as possible.

• Route the torch leads as close as possible to the work ground cable.

• Never place your body between the torch leads and work ground cable. Keep the work ground cable and the torch leads on the same side of your body.

• Never stand in the center of a coiled up set of torch leads or work ground cable.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

1-4

Spirit II User’s Manual Section 1: Safety

Safety Standards Booklet Index

For further information concerning safety practices to be exercised with plasma arc cutting equipment, please refer to the following publications:

1. AWS Standard AWN, Arc Welding and Cutting Noise, obtainable from the American

Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

2. AWS Standard C5.2, Recommended Practices for Plasma Arc Cutting, obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

3. AWS Standard FSW, Fire Safety in Welding and Cutting, obtainable from the

American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

4. 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.

5. AWS Standard ULR, Ultraviolet Reflectance of Paint, obtainable from the American

Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

6. 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.

7. 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.

8. ANSI Standard Z49.2, 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.

9. ANSI Standard Z87.1, 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.

10. ANSI Standard Z88.2, Respiratory Protection, obtainable from the American

National Standards Institute, 11 West 42nd Street, New York, NY 10036.

11. OSHA Standard 29CFR 1910.252, Safety and Health Standards, obtainable from the U.S. Government Printing Office, Washington, D.C. 20402.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

1-5

Section 1: Safety Spirit II User’s Manual

12. 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.

13. NFPA Standard 51B, Cutting and Welding Processes, obtainable from the National

Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

14. NFPA Standard 70, National Electrical Code, obtainable from the National Fire

Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

15. 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.

16. 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.

17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the

Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004,

Arlington, VA 22202.

18. CSA Standard W117.2, Safety in Welding, Cutting, and Allied Processes, obtainable from Canadian Standards Association, 178 Rexdale Boulevard, Toronto,

Ontario M9W lR3, Canada.

19. 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 150 is a 150 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 1-1/2" thick and stainless steel up to 1” thick.

The system contains a manually controlled gas console, which also provides the primary interface to the entire Spirit system.

For cutting mild steel, the system uses oxygen for the plasma gas and either oxygen or air for the shielding gas. When cutting stainless steel or other non-ferrous materials, air or H17 (17.5% hydrogen, 32.5% argon, 50% nitrogen) is used for the plasma gas and either air or nitrogen is used for the shielding gas. Oxygen and nitrogen are used for the preflow and postflow gases.

The torch is water-cooled and consumables are machined to exacting dimensions and checked with the latest computerized measuring systems. Five nozzle sizes (30, 50,

70, 100, and 150 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 is not suitable for use in rain or snow.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

2-1

Section 2: Specifications

System Components

The Spirit II 150 System consists of the following components:

Standard Components

• Power Supply

• Manual Gas Console

• CAN Cable

• CAN Termination Plug

• Impulse Start Console (ISC)

• ISC Control Cable

• ISC Ground Cable

• Torch and Handle Assembly

• Torch Lead Set

• 5-gang Manifold Assembly

• 5-gang Manifold Control Cable

• 2-gang Manifold Assembly

• 2-gang Manifold Control Cable

• 17 Inch Plasma Hose

• Coolant and Power Leads

• Gas Hose Package

• Work Ground Lead

• Spirit II User’s Manual

Optional Components

• Supply Gas Hoses

• Internal Inova Console

Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

2-2

Spirit II User’s Manual Section 2: Specifications

Power Supply Specifications

Power Supply Description

208 VAC, 3Ø, 60Hz

220 VAC, 3Ø, 60Hz

240 VAC, 3Ø, 60Hz

380 VAC, 3Ø, 50/60Hz

400 VAC, 3Ø, 50/60Hz

415 VAC, 3Ø, 50/60Hz

440 VAC, 3Ø, 50/60Hz

Part Number

BK300211

BK300212

BK300213

BK300214

BK300215

BK300216

BK300217

Input Current at

Maximum Output

99 amps

94 amps

86 amps

54 amps

52 amps

50 amps

47 amps

480 VAC, 3Ø, 60Hz

600 VAC, 3Ø, 60Hz

BK300218

BK300219

43 amps

34 amps

Open Circuit Voltage ......................................... 300 VDC

Output Current (drooping characteristic) ........... 10 - 150 amps

Maximum Output Voltage ................................. 170 VDC

Duty Cycle ........................................................ 100% @ 25.5 kW

Maximum Ambient Temperature ....................... 104° F (40° C)

Coolant Discharge Pressure ............................. 150 psi (10.2 bar)

Coolant Flow Rate ............................................ 1 gal/min (3.8 liters/min)

Coolant Fluid ..................................................... Propylene glycol solution

Coolant Tank Capacity ...................................... 3.2 gal (12 liters)

Weight (without coolant) ................................... 953 lb (432 kg)

150

38.4"

[975]

29.0" [737] 43.2" [1097]

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

2-3

Section 2: Specifications Spirit II User’s Manual

Torch Coolant Specifications

Note: Refer to the supplier’s most current Material Safety Data Sheet for information regarding safety, handling, and storage of torch coolant.

The Spirit system is shipped without torch coolant in the reservoir. Coolant

must be added before applying power to the system. Only use Kaliburn approved torch coolant solution for optimal system performance as commercially available antifreeze contains corrosion inhibitors that will damage the cooling system. The standard coolant solution consists of 25% industrial grade propylene glycol and provides freezing protection down to -13º C (9º F). The standard solution can be ordered in one-gallon containers, PN BK500695. For operating temperatures below -13º C, a 50% solution of industrial grade propylene glycol can be ordered in one-gallon containers, PN BK500895, providing protection down to -36º C (-33º F).

Failure to use the proper propylene glycol solution may result in cooling

system and/or torch damage.

The torch coolant should be flushed out of the Spirit system every six months and replaced with new coolant. The coolant filter / deionization cartridge should also be changed at the same time. See Section 6 for details.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

2-4

Spirit II User’s Manual

Manual Gas Console (MGC) Specifications

Part Number .................................................... BK300600

Weight .............................................................. 50 lb (23 kg)

Section 2: Specifications

12.4" [315]

12.0" [305]

10.9" [277]

13.7" [348]

(4) Ø .300 [7.6]

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.

2-5

Section 2: Specifications Spirit II User’s Manual

Gas Supply Requirements

Plasma gas types:

Mild Steel ..................................................... Oxygen

Stainless Steel ............................................ Air or H17

Aluminum .................................................... Air

Shield gas types:

Mild Steel ..................................................... Oxygen or Air

Stainless Steel ............................................. Air or Nitrogen

Aluminum .................................................... Nitrogen

Preflow gas type ............................................... Oxygen and Nitrogen

Marking gas type............................................... Nitrogen

Plasma gas flow rate (maximum):

Oxygen or Air ............................................... 67 scfh (1897 liters/hour)

H17 .............................................................. 75 scfh (2124 liters/hour)

Shield gas flow rate (maximum):

Oxygen ........................................................ 19 scfh (538 liters/hour)

Air or Nitrogen ............................................. 225 scfh (6371 liters/hour)

Preflow gas flow rate (maximum) ...................... 60 scfh (1699 liters/hour)

Marking gas flow rate (maximum) ..................... 67 scfh (1897 liters/hour)

Rated Inlet gas pressure ................................... 115 psi (7.9 bar)

Minimum Inlet gas pressure .............................. 110 psi (7.6 bar)

Maximum Inlet gas pressure ............................. 145 psi (10.0 bar)

Oxygen and nitrogen should be supplied with a purity of at least 99.5%.

H17 should be supplied with a purity of at least 99.995%.

A potential fire hazard exists when cutting with oxygen. KALIBURN recommends that an exhaust ventilation system be used when cutting with oxygen. Flashback arrestors must be supplied (unless they are not available for the chosen gases and pressures) to prevent a possible fire from propagating back to the gas

supplies.

Ensure that oxygen lines remain free from contaminants such as oil and grease. The mixture of such contaminants with oxygen presents an additional fire hazard.

Compressed air must be clean, dry, and oil-free and may be supplied from compressed cylinders or from an air compressor. Be aware that shop air systems are prone to oil and moisture contamination. If shop air is used, it must be cleaned to ISO 8573.1:

Class 1.4.1. Specify dry air when using compressed cylinders. Breathing quality air contains moisture and must not be used.

3/8” (inside diameter) hoses are required for all inlet gas connections. Mating connectors are supplied with the unit. Quick-connect fittings must not be used.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.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

Impulse Start Console (ISC) Specifications

Part Number ..................................................... BK300500

Weight .............................................................. 22 lb (10 kg)

Section 2: Specifications

 

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Torch and 2-Gang Manifold Specifications

Part Number:

2-Gang Manifold Assembly .................................................. BK284214

Torch Handle (standard) ...................................................... BK278001

Torch Handle (short) ............................................................ BK278018

Torch Base........................................................................... BK279000

Torch Head (Copper Electrode) ........................................... BK279100

Torch Head (Silver Electrode) .............................................. BK279060

Max Weight:

Manifold/Bracket, Handle (BK278001), Base and Head ...... 8.3 lbs (3.8 kg)

Manifold

3.38" [86]

Torch Handle

BK278001 = 9.46" [240]

BK278018 = 7.06" [179]

Torch Base

1.87" [47]

1.99"



[51]

Alignment Indicator

(Slot)

Attachment Ring

Alignment Indicator

(Circle)

Torch Head

5.08" [129]

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

5-Gang Manifold Specifications

Part Number .................................................... BK280022

Weight .............................................................. 6 lb (2.7 kg)

Section 2: Specifications

4.20"

[107]

3.80"

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

2-9

Section 2: Specifications Spirit II User’s Manual

Airborne Noise Emissions

The system generates high noise levels while cutting. Depending on the size of the cutting area, distance from the cutting torch, and arc current cutting level, acceptable noise levels may be exceeded. Proper ear protection should be used as defined by local or national codes. The following chart gives the noise levels generated by the system when operating at 150 amps, 130 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

97 dB 94 dB

The maximum noise level is 121 dB at a distance of 3 inches (76.2 mm) from the torch while cutting at 150 amps, 130 arc volts.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

2-10

Spirit II User’s Manual Section 3: Installation

Section 3: Installation

Initial Inspection

All systems undergo full testing before being shipped from Kaliburn. In the unlikely event that one of the components is defective or missing, please contact Kaliburn so a replacement item can be sent. Also, Kaliburn has taken special care in packaging the system. If the system was damaged during shipment, file a claim with the shipping company, and then contact Kaliburn to order replacement parts.

Component Placement

Plasma Power Supply

The power supply should be lifted by a forklift or pallet jack. In order to prevent damaging the power supply, the forks should be of adequate length to protrude on the far side of the power supply. The proper location of the power supply will provide dependable service and reduce periodic maintenance time. Choose a location that will provide unrestricted air movement into and out of the power supply. Maintain at least

24 inches of space on all sides of the unit. The location should subject the power supply to the least amount of dust, dirt, moisture, and corrosive vapors. The surface on which the power supply is located should have a grade of no greater than 10º to eliminate the risk of toppling over. The power supply must be cleaned as often as necessary to prevent the accumulation of metallic dust inside the unit. See Section 2 for unit dimensions.

Manual Gas Console (MGC)

The MGC should be mounted near the CNC controller so that it is easy accessible by the operator. See Section 2 for mounting dimensions.

Impulse Start Console (ISC)

The ISC should be mounted in a convenient location that is away from other electronic control devices. The ISC offers significantly reduced emissions compared to traditional high frequency, however, the high voltage pulse generated inside the unit may interfere with the operation of sensitive control electronics. The ISC is usually mounted on the gantry of the cutting machine or on the cutting table. See Section 2 for mounting dimensions.

5-Gang Manifold

The 5-gang manifold assembly must be mounted within 6 feet (1.8 m) of the torch. See

Section 2 for mounting dimensions.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

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.

System Interconnection

The Spirit II 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

Figure 1: Spirit II System with Manual Gas Console and Internal Inova System

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. 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

Figure 2: Spirit II System with Manual Gas Console and External Inova System

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-4

Spirit II User’s Manual Section 3: Installation

Power Supply Primary Power Connections

** Before connecting primary power, check the data plate

on the power supply to verify the voltage required **

A primary disconnect switch, switching all ungrounded supply conductors, should be provided for each Spirit system. The disconnect switch should be located as close as possible to the power supply so it can be turned off quickly in case of an emergency.

The disconnect switch should be equipped with time delay fuses only. The magnetic inrush current of the power supply will cause fast acting fuses to blow. The disconnect switch should be sized according to local and national codes. The rating must meet or exceed the continuous rating of the fuses used. See the following chart for recommended fuse sizes:

3 Phase

Input Voltage (VAC)

Input Current at

Maximum

Output (amps)

99

Recommended

Time-Delay Fuse

Size (amps)

125 208 VAC, 60Hz

220 VAC, 60Hz

240 VAC, 60Hz

380 VAC, 50/60Hz

400 VAC, 50/60Hz

415 VAC, 50/60Hz

440 VAC, 50/60Hz

94

86

54

52

50

47

125

110

65

65

60

60

480 VAC, 60Hz

600 VAC, 60Hz

43

34

60

45

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.

Under no circumstances are the supply cables to be routed through the opening in the power supply cabinet without conduit or an appropriate strain relief as per local and national codes.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-5

Section 3: Installation Spirit II User’s Manual

TB5

Strain Relief

L1 (U)

L2 (V)

L3 (W)

Ground

Disconnect Box

Connections

L1 L2 L3 Gnd

TB5 Connections

Figure 3: Power Supply Primary Connections

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-6

Spirit II User’s Manual Section 3: Installation

Power Supply Output Connections

Perform the following steps to connect the output of the power supply to the impulse start console and the work table. See Figure 4 on the next page.

Power Supply Electrode Lead

1

1. Route one end of the #1/0AWG power supply electrode lead through the upper strain relief on the rear of the power supply and connect it to the electrode terminal.

2. Route the other end of the power supply electrode lead through the strain relief on the impulse start console and connect it to the cathode manifold.

Power Supply Nozzle Lead 2

1. Route the larger ring terminal end of the #10AWG power supply nozzle lead through the bushing on the rear of the power supply and connect it to the nozzle terminal.

2. Route the smaller ring terminal end of the power supply nozzle lead through the strain relief on the impulse start console and connect it to the pilot terminal on the printed circuit board.

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 impulse start console and connect it to the CTP sensor lead with

FASTON connector.

Work Ground Lead

4

1. Route one end of the #1/0AWG work ground lead through the bottom strain relief on the rear of the power supply and connect it to the work terminal.

2. Connect the other end of the work ground lead to the star ground point on the cutting table.

The star ground point is generally referred to as the common ground point on the cutting table where all subsystems of the machine are grounded. This point is then connected to a driven earth ground rod that should be as close as possible to the star ground. The ground rod should have no other wires connected to it. The ground rod should be at least 3/4 inches in diameter and should be driven into the earth’s permanent moisture layer. The length of the ground rod varies from installation to installation and should be installed according to local and national codes. Refer to the National Electrical Code, Article 250, Section H, Ground

Electrode System for additional information.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-7

Section 3: Installation Spirit II User’s Manual

3

2

Strain Relief 4 1

1

2

3

Strain Relief

Figure 4: Power Supply Output Connections

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-8

Spirit II User’s Manual Section 3: Installation

ISC Control Cable and ISC Ground Connections

Perform the following steps to connect the ISC control cable and ISC ground. See

Figure 5 on the next page.

ISC Control Cable 5

1. Connect the ISC control cable plug labeled P16 to the connector labeled P16 on the rear of the power supply.

2. Connect the ISC control cable plug labeled P1 to the connector labeled P1 on the impulse start console.

ISC Ground Cable

6

1. Connect one end of the ISC ground cable to the ground stud on the impulse start console.

2. Connect the other end of the ISC ground cable to the star ground on the cutting table. Make sure that good metal-to-metal contact is made.

Cooling System Connections

Perform the following steps to connect the cooling system to the impulse start console.

See Figure 5 on the next page.

Coolant Supply Hose 7

1. Connect one end of the coolant supply hose to the coolant out fitting on the rear of the power supply. Note that the coolant out fitting has right hand threads.

2. Connect the other end of the coolant supply hose to the coolant in fitting on the impulse start console. Note that the coolant in fitting has right hand threads.

Coolant Return Hose

8

1. Connect one end of the coolant return hose to the coolant in fitting on the rear of the power supply. Note that the coolant in fitting has left hand threads.

2. Connect the other end of the coolant return hose to the coolant out fitting on the impulse start console. Note that the coolant out fitting has left hand threads.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

7 8

5

6

Spirit II User’s Manual

7 8

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.

3-10

Spirit II User’s Manual Section 3: Installation

Torch Leads to Impulse Start Console Connections

Perform the following steps to connect the torch leads to the impulse start console.

See Figure 6 on the next page.

Note: When making hose connections, only tighten the brass fittings enough to make water or gas seals. The fittings are subject to damage if over tightened.

Braided Shield 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 impulse start console and push the shield connector through the hole until it is seated against the side of the console.

2. Slide the threaded ring over the torch leads, thread it onto the brass shield connector, and tighten firmly. The shield connector should ground the braided shield to the case of the impulse start console in order to help reduce high frequency noise emission. Using an ohmmeter, measure for zero ohms between the braided shield and the ground stud located on the outside of the impulse start console.

Torch Electrode/Coolant Supply Lead

12

• 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

• Connect the torch coolant return lead to the brass cathode manifold. Note that the torch coolant return lead has left hand threads.

Torch Nozzle Lead

14

• Connect the torch nozzle lead to the angled bracket on the red standoff. Note that the torch nozzle lead has right hand threads.

Torch CTP Sensor Lead

15

• Connect the #18AWG torch CTP sensor lead to the red standoff as shown.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-11

Section 3: Installation

11 14

12

15

13

Spirit II User’s Manual

Figure 6: Torch Leads to Impulse Start Console Connections

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-12

Spirit II User’s Manual Section 3: Installation

Torch Leads to Torch Base Connections

Perform the following steps to connect the torch leads to the torch base.

Note: When making hose connections, only tighten the brass fittings enough to make water or gas seals. The fittings are subject to damage if over tightened. Also, use two wrenches when tightening the torch fittings to avoid damaging the torch base.

Torch Lead through Torch Handle Installation

• 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

16

• Connect the torch electrode/coolant supply lead to the torch base as shown.

Torch Coolant Return Lead

17

• 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

18

• Connect the torch nozzle lead to the torch base as shown.

Torch CTP Sensor Lead

19

• Connect the torch CTP sensor lead to the torch base as shown.

18 19

18

19

17 16 17 16

Figure 7: Torch Leads to Torch Base Connections

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-13

Section 3: Installation Spirit II User’s Manual

Torch Gas Connections

Perform the following steps to connect the torch gas hoses to the manual gas console, torch base, and manifold assemblies. See figure 8.

Note: When making hose connections, only tighten the brass fittings enough to make gas seals. The fittings are subject to damage if over tightened.

7.5 Foot Shield Gas Hose 20

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 ¼" diameter pin).

4. Attach the 2-gang manifold assembly to the torch handle. The top of the manifold bracket should be flush with the top of the torch handle.

5. Connect the other end of the 14 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 Gas Hose

23

1. Connect one end of the marking shield gas hose to the marking shield outlet on the rear of the MGC.

2. Connect the other end of the marking shield gas hose to the marking shield inlet on the 5-gang manifold.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-14

Spirit II User’s Manual Section 3: Installation

Postflow Gas Hose

25

1. Connect one end of the postflow hose to the postflow outlet on the rear of the

MGC. Note that the postflow hose fittings have left hand threads.

2. Connect the other end of the postflow hose to the postflow inlet on the 5-gang manifold.

Plasma Gas Hose 26

1. Connect on end of the plasma hose to the plasma outlet on the rear of the

MGC.

2. Connect the other end of the plasma hose to the plasma inlet on the 2-gang manifold.

Shield Gas Hose 27

1. Connect one end of the shield hose to the shield outlet on the rear of the

MGC.

2. Connect the other end of the shield hose to the shield inlet on the 5-gang manifold.

Preflow Gas Hose 28

1. Connect one end of the preflow hose to the preflow outlet on the rear of the

MGC. Note that the preflow hose fittings have left hand threads.

2. Connect the other end of the preflow hose to the preflow inlet on the 5-gang manifold.

5-Gang Manifold Control Cable

29

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

30

1. Connect the 2-gang manifold control cable plug marked P18 to the 2-gang manifold as shown.

2. Connect the 2-gang manifold control cable plug labeled P13 to the connector labeled P13 on the rear of the power supply.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-15

Section 3: Installation Spirit II User’s Manual

28

26

25

Manual Gas

Console

27

23

BLUE

20

BLUE

27 23 28 29 25

22

REAR

PORT

GREEN

22

RED

26

30

GREEN RED

21

REAR

PORT

21 20

Figure 8: Torch Gas Connections

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-16

Spirit II User’s Manual Section 3: Installation

Gas Supply Connections

Perform the following steps to connect the gas supply lines to the MGC. See Section 2 for gas supply requirements. Mating hose barbs and connectors are supplied with the system and are sized for 3/8 inch inside diameter hose. Do not change the inlet gas

supply fittings to quick-connect fittings. Using quick-connect fittings to connect

and disconnect pressurized hoses may cause damage to the system.

Note: When making hose connections, only tighten the brass fittings enough to make gas seals. The fittings are subject to damage if over tightened.

Air Inlet (ISO 3821 hose color - black)

• Air must be supplied to the unit at all times, regardless of the cutting current or material type.

Oxygen Inlet (ISO 3821 hose color - blue)

• Oxygen must be supplied to the unit at all times, unless stainless steel is being cut with H17 plasma.

Nitrogen Inlet (ISO 3821 hose color - black)

• 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)

• 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.

32

34

31

33

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-17

Section 3: Installation Spirit II User’s Manual

CAN Communication Connections

Perform the following steps to connect the plasma power supply to the MGC.

CAN Cable

• Connect the male end of the CAN cable to the connector labeled P4 on the rear of the plasma power supply.

• Connect the female end of the CAN cable to the top connector on the rear of the

MGC.

CAN Termination Plug

• If not already installed, connect the CAN termination plug to the bottom connector on the rear of the MGC.

35

35

36

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-18

Spirit II User’s Manual Section 3: Installation

CNC Machine Interface Connections

Perform the following steps to properly interface the Spirit system with a CNC cutting machine. See the system schematic for additional information.

Plasma Start Input

The power supply requires a contact closure between P8 pins 3 and 4 to commence the cutting or marking sequence. The sequence is terminated when the contacts are opened. The contacts should be rated for 24VDC - 7.3mA.

Plasma Cut/Mark Input

The power supply requires a contact closure between P8 pins 1 and 2 to put the system in plasma 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 P8 pins 12 and 14 as long as an arc is maintained between the torch and the workpiece. The motion contacts are rated for 24VDC – 10mA.

Remote On/Off Input

The power supply requires a maintained contact closure between P8 pins 5 and 6 to energize the system from a remote location, provided that the OFF Button on the manual gas console is released. The contacts should be rated for 24VAC – 10mA.

Opening the contacts deenergizes the system. If the remote on/off feature is to be used, remove the jumper between positions 1 and 2 on the J17 connector on the microprocessor DSP board.

Power Supply Ready Output

The power supply provides a maintained contact closure output between P8 pins 7 and

8 when the system is ready to cut or mark. The contacts are open during gas purge or when an error occurs. The contacts are rated for 24VDC – 10mA.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-19

Section 3: Installation Spirit II User’s Manual

Filling the Cooling System

WARNING: Do not touch the fans inside the power supply.

Important: Never turn on the system when the coolant reservoir is empty.

Important: When handling coolant, wear nitrile gloves and safety glasses.

Important: Only use Kaliburn approved coolant. Commercially available antifreeze contains corrosion inhibitors that will damage the cooling system. See Section 2 for more information.

1. Remove primary power from the Spirit system.

2. Ensure the torch base and torch head (with consumables) are properly installed.

3. Ensure the coolant supply (in and out) hoses are properly installed.

4. Remove the coolant reservoir cap/level gauge and then remove the top, left and right covers from the power supply.

5. Ensure the coolant filter housing is tightened securely.

6. Ensure the drain petcock on the bottom of the reservoir is tightened securely.

7. Fill the reservoir with approximately 2 ½ gallons of approved coolant.

8. Apply primary power to the Spirit system and enable it by releasing (turn right) the

OFF Button on the MGC.

9. On the MGC main menu, move the pointer to On. Press SELECT to start the coolant pump circulating coolant through the system. Note: The coolant pump will turn off automatically if the coolant level drops below the minimum level inside the reservoir. If this happens, add more coolant.

10. With the coolant pump running, locate the small red push-button on top of the coolant filter housing (beneath the reservoir). Press and hold the red button until no air or bubbles are seen inside the filter housing. Dry any coolant that leaks out.

11. Check for coolant leaks at all hose connections, the impulse start console, and at the torch.

12. Push the OFF Button on the MGC to stop the coolant pump.

13. Remove primary power from the Spirit system.

14. Fill the reservoir with coolant until the coolant gauge indicates full.

15. Replace the power supply covers and replace the coolant reservoir cap/level gauge.

16. End of procedure.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

3-20

Spirit II User’s Manual Section 4: Operation with Manual Gas Console

Section 4: Operation

Operating the Manual Gas Console (MGC)

The Manual Gas Console (MGC) is the interface to the entire Spirit system when the

MGC is used instead of the Automatic Gas Console (AGC).

OFF Button

Push to disable the Spirit system.

Release (turn to the right) to enable the system, which can then be energized by choosing ON and then

SELECT.

Up/Down/Select Buttons

Press the up or down button to move the pointer ( ) accordingly on the display. These buttons are represented as UP and DOWN throughout this manual.

Press the select button to access menu items or settings identified by the pointer. This button is shown as

SELECT throughout this manual.

Display

The display turns on automatically when AC power is applied to the

Spirit system. It displays the menu tree, which is navigated using the

Up/Down/Select buttons and is used to control the entire Spirit system.

Pressure Regulator Knobs

Turn to the left or right to adjust the amount of output gas pressure for

PreFlow, PostFlow, Plasma and

Shield gases.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

4-1

Section 4: Operation with Manual Gas Console Spirit II User’s Manual

Setting up to Cut

The following procedure uses the information from the cutting charts in Section 5 to prepare the system to cut. Press the UP or DOWN button on the MGC to move the pointer through the menu as described below.

Push the OFF Button on the MGC to disable the system. On the main menu, move the pointer to Setup. Press SELECT.

Press SELECT to cycle through the list until

Cutting is displayed.

Move the pointer to

Current.

Press SELECT to cycle through the list until the desired amperage is displayed.

Move the pointer to Select Gas.

Press SELECT.

Press SELECT to choose the Plasma gas.

Move the pointer to Shield and press SELECT to choose the shield gas. Move the pointer to

Return and press SELECT.

Move the pointer to Adjust Gas.

Press SELECT.

Move the pointer to a gas and then press

SELECT to start the flow of that gas. Turn the corresponding regulator knob on the MGC to adjust the displayed pressure to match the value in the cutting chart. Repeat for all other gases. Move the pointer to Return and press

SELECT. Repeat to return to the main menu.

The system is now setup to cut.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

4-2

Spirit II User’s Manual Section 4: Operation with Manual Gas Console

Setting up to Mark (Overrides Cut)

The system will automatically switch between cutting and marking based upon commands in the part program. However, all cutting commands in the part program can be overridden with marking commands by simply changing the Process to Marking.

Push the OFF Button on the MGC to disable the system. On the main menu, move the pointer to

Setup. Press SELECT.

Verifying Input Gas Pressures

Press SELECT to cycle through the list until

Marking is displayed. Move the pointer to

Return and press SELECT.

The system is now setup to mark instead of

cut.

For the system to work properly the input gas pressures must be within an acceptable range. To check the input pressures, follow the steps below.

On the main menu, move the pointer to

Input Gas. Press SELECT.

Verify that all connected gas pressures are at least 120psi. The maximum input gas pressure is 145psi.

Press SELECT to return to the main menu.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

4-3

Section 4: Operation with Manual Gas Console Spirit II User’s Manual

Making a Cut or Mark

Once the process type, gas types and gas pressures have been set in the MGC; the correct torch parts (consumables) installed; and the X/Y controller and torch height control are properly configured; the system is ready to cut or mark.

Release the OFF Button (turn to the right) on the MGC. On the main menu, move the pointer to

On. Press SELECT.

The MGC will purge the gas hoses. The purge icon ( ) is displayed during this process.

Once purging is complete, the ready icon ( ) is displayed. The system is now ready to cut or mark.

When the system receives a start signal from the X/Y controller, the following sequence is initiated:

• Two second gas preflow

• Impulse start 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 deenergized.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

4-4

Spirit II User’s Manual Section 4: Operation with Manual Gas Console

Piercing Thick Materials

Care must be taken when piercing thick materials in order to prevent damage to the shield cap and nozzle. As with all thicknesses, the pierce height must be set high enough so the metal ejected while piercing does not come into contact with the shield cap. Also, some of the material ejected during the pierce may adhere to the top side of the plate and form a ring of solidified material around the pierce point.

Action must be taken so the torch does not move from the pierce height down to the cutting height and come into contact with this solidified metal. The torch should not move from the pierce height down to the cutting height until the X/Y controller has moved the torch away from the pierce point.

One way to accomplish this may be to program the pierce time on the torch height control system to a value that is longer than the X/Y controller motion delay time.

Moving Pierces and Edge Starts

On very thick materials, an edge start or moving pierce may be required to prevent damage to the torch consumables.

With a moving pierce, the X/Y machine should begin moving at approximately 5–10 inches/minute (125–250 mm/min) as soon as the arc transfers to the plate. After the arc completely penetrates the plate, the torch should be positioned at the proper cutting height and the X/Y machine speed should be increased to the correct level.

With an edge start the torch should be positioned at the edge of the material prior to starting the arc.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

4-5

Section 4: Operation with Manual Gas Console Spirit II User’s Manual

Cut Quality

Before the optimum cutting condition can be achieved on a particular material type and thickness, the machine operator must have a thorough understanding of the cutting characteristics of the Spirit system. When the cut quality is not satisfactory, the cutting speed, torch height, or gas pressures may need to be adjusted in small increments until the proper cutting condition is obtained. The following guidelines should be useful in determining which cutting parameter to adjust.

Note: Before making any parameter changes, verify that the torch is square to the workpiece. Also, it is essential to have the correct torch parts in place and to ensure that they are in good condition. Check the electrode for excessive wear and the nozzle and shield cap orifices for 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. A negative cut angle (top dimension of piece larger than the bottom dimension) usually occurs when the torch standoff distance is too low or when the cutting speed is too slow.

3. Top dross usually occurs when the torch standoff distance is too high.

4. Bottom dross usually occurs when the cutting speed is either too slow (slow-speed dross) or too fast (high-speed dross). Low-speed dross is easily removed, while high-speed dross usually requires grinding or chipping off. When using oxygen as the shielding gas, bottom dross can sometimes be removed by increasing the shield gas pressure. However, increasing the shield pressure too much can cause cut face irregularities (see below). Bottom dross also occurs more frequently as the metal heats up. As more pieces are cut out of a particular plate, the more likely they are to form dross.

5. When using oxygen as a shielding gas, cut face irregularities usually indicate that the shield gas pressure is too high or the torch standoff distance is too low.

6. A concave cut face usually indicates that the torch standoff distance is too low or the shield gas 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.

4-6

Spirit II User’s Manual Section 4: Operation with Manual Gas Console

Checking Errors

The last ten (10) system errors are available through the MGC as described below.

On the main menu, move the pointer to Errors.

Press SELECT.

Press SELECT to cycle through the last ten

(10) error codes.

See Section 6 in this manual for details on the error codes.

Simultaneously pressing DOWN and SELECT will erase all ten error codes.

Move the pointer to Return and press

SELECT to return to the main menu.

Checking the Version and Serial Number

The hardware version, software version and serial number for the Power Supply and

Gas Console can be displayed as described below.

On the main menu, move the pointer to

Version. Press SELECT.

Move the pointer to either Power Supply or

Gas Console. Press SELECT.

Review the necessary information.

Press SELECT to return to the previous screen.

Move the pointer to Return and press

SELECT to return to the main menu.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

4-7

Section 4: Operation with Manual Gas Console Spirit II User’s Manual

Changing the Language

The language displayed on the MGC can be changed as described below.

On the main menu, move the pointer to

Configure. Press SELECT.

Press SELECT on Languages.

Adjusting the Screen Contrast

Move the pointer to the desired language and then press SELECT. The display changes immediately to the selected language.

Move the pointer to Return and press SELECT to return to the previous screen. Repeat to return to the main menu.

The contrast of the display on the MGC can be adjusted as described below.

On the main menu, move the pointer to

Configure. Press SELECT.

Move the pointer to

Contrast.

Press SELECT to cycle through the list of contrast settings.

Move the pointer to Return and press SELECT to return to the main menu.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

4-8

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Section 5: Torch Consumables and

Cutting Charts

Installing / Removing the Torch Head

WARNING: Remove primary power from the Spirit system!

1. Each time the torch head is connected to the torch base, use a cotton swab to apply a small amount of o-ring lubricant on each of the seven o-rings on the top of the torch head. Reminder: do not use an excessive amount of o-ring lubricant.

2. Align the indicator on the torch head (circle) with the one on the torch base (slot).

3. Apply enough upward force to engage the threads while tightening the attachment ring. Turn the attachment ring to the RIGHT to tighten.

4. Keep tightening the attachment ring until it stops. There should be no gap between the attachment ring and the o-ring on the torch base.

During this process, a small amount of coolant will collect in the torch head.

It is normal for this coolant to discharge between the o-ring on the torch base and the attachment ring while the system is being pressurized. If coolant continues to discharge after the system is pressurized, turn off the plasma power supply, remove the torch head and inspect the o-rings for damage.

YES NO!

O-ring

O-ring

Torch Base

Torch Head

There is no gap between o-ring and attachment ring

Gap is visible between o-ring and attachment ring

To remove the torch head, turn the attachment ring to the LEFT.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-1

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Installing / Replacing Consumables

WARNING: Remove primary power from the Spirit system!

Note: When installing the consumables, do not use an excessive amount of o-ring lubricant. Also ensure that the lubricant is placed only on the o-rings. Excess lubricant can interfere with gas flow, which can cause starting problems, poor cut quality, and short consumable life.

1. Unthread the torch head from the torch base by turning the attachment ring to the LEFT. Verify the torch base doesn't unthread from the torch handle.

2. Remove the outer retaining cap from the torch head.

3. Remove the inner retaining cap from the torch head.

4. Separate the shield cap from either the inner retaining cap or the outer retaining cap.

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.

YES NO!

PULL

OR

PULL

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:

• All copper electrodes use socket P/N BK277087 & driver P/N BK277086.

• 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.

5-2

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Maximizing Consumable Life

Use the following guidelines to maximize consumable parts life:

1. The Spirit system utilizes the latest advancement in technology for extending the life of the torch consumable parts. To maximize the life of the consumable parts, it is imperative that the shutdown procedure of the arc is carried out properly. The arc

must be extinguished while it is still attached to the workpiece. A popping noise may be heard if the arc extinguishes abnormally. Note that holes are usually programmed without lead-outs to prevent loss of the arc during shutdown. There is a time delay between the reception of a stop signal and when the arc is extinguished. During this time, the gases and cutting current are changed to optimum values for extinguishing the arc. Ideally, the x/y machine controller should provide a plasma stop signal prior to the end of the cut path so the gases and current reach the shut off values at the same time that the part has been completely cut. The shut down times are different for each current and are given below.

Arc Shutdown Times

Current (A) Time (ms)

30

50

70

100

150

490

390

300

300

175

2. Use the recommended pierce height given in the cutting charts. A pierce height that is too low will allow molten metal that is ejected during the piercing process to damage the shield cap and nozzle. A pierce height that is too high will cause the pilot arc time to be excessively long and will cause nozzle damage. See “Piercing

Thick Materials” in Section 4.

3. Never fire the torch in the air. Nozzle damage will occur.

4. Make sure the torch does not touch the plate while cutting. Shield cap and nozzle damage will result.

5. Use a chain cut when possible. Starting and stopping the torch is more detrimental to the consumables than making a continuous cut.

6. Always use error tracking on the plasma console to keep track of cut errors. See

Section 4 for information on error tracking.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-3

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Inspecting for Damage

When the cut quality is not satisfactory, use the following guidelines for determining which consumable parts need to be changed. Inspect all parts for dirt, debris, and excess o-ring lubricant and clean as necessary.

Part Inspect For Corrective Action

Outer Cap

Dents, cracks Replace outer cap

Shield Cap

Retaining Cap

Nozzle

Swirl Ring

Electrode or

Center hole out of round

Dents, Scratches

Dry o-ring

Damaged o-ring

Center hole out of round

Dents, cracks

Dry o-ring

Damage o-ring

Center hole out of round

Erosion or arcing

Dry o-rings

Damaged o-rings

Damage

Clogged holes

Dry o-rings

Damaged o-rings

Pit depth

Erosion or arcing

Dry o-rings

Damaged o-rings

Replace shield cap

Replace shield cap

Apply a thin film of o-ring lubricant

Replace shield cap

Replace retaining cap

Replace retaining cap

Apply a thin film of o-ring lubricant

Replace retaining cap

Replace nozzle

Replace nozzle

Apply a thin film of o-ring lubricant

Replace nozzle

Replace swirl ring

Blow out with compressed air. Replace swirl ring if clogs can’t be removed.

Apply a thin film of o-ring lubricant

Replace swirl ring

Replace electrode if center pit depth is greater than 0.040” (1 mm) for copper electrode or 0.098" (2.5mm) for silver.

Replace electrode

Apply a thin film of o-ring lubricant

Replace electrode

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-4

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Selecting Consumables

Outer

Retaining Cap

Shield

Cap

Mild Steel

Copper Electrode

Inner

Retaining

Cap

Nozzle

Swirl

Ring

Copper

Electrode

BK284150 BK277145 BK277153 BK277120 BK277140 BK277130

30A

BK284150 BK277115 BK277153 BK277122

BK277140/

BK277142 BK277131

50A

BK284150 BK277150 BK277153 BK277125 BK277142 BK277131

70A

BK284150 BK277286 BK277151 BK277284 BK277283 BK277282

100A

BK284150 BK277117

BK277151/

BK277152 BK277293 BK277139 BK277292

150A

Torch

Head

BK279100

BK279100

BK279100

BK279100

BK279100

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-5

Section 5: Torch Consumables and Cutting Charts

Outer

Retaining Cap

Shield

Cap

Mild Steel

Silver Electrode

Inner

Retaining

Cap

Nozzle

Swirl

Ring

BK284150 BK277286 BK277151 BK279484 BK279483

Silver

Electrode

BK279410

(brown o-ring)

100A

BK284150 BK277117

BK277151/

BK277152 BK279493 BK279439

BK279420

(green o-ring)

150A

Spirit II User’s Manual

Torch

Head

BK279060

BK279060

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-6

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Stainless Steel - H17 Plasma

Copper Electrode

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Nozzle

Swirl

Ring

Copper

Electrode

BK284150 BK277150 BK277113 BK277124 BK277140 BK277132

70A

BK284150 BK277146 BK277113 BK277126 BK277141 BK277133

100A

BK284150 BK277298 BK277266 BK277297 BK277139 BK277135

150A

Torch

Head

BK279100

BK279100

BK279100

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-7

Section 5: Torch Consumables and Cutting Charts

Stainless Steel - Air or Nitrogen Plasma

Copper Electrode

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Nozzle

Swirl

Ring

Copper

Electrode

BK284150 BK277144 BK277110 BK277121 BK277138 BK277137

30A

BK284150 BK277149 BK277110 BK277123 BK277142 BK277137

50A

BK284150 BK277150 BK277153 BK277125 BK277142 BK277131

70A

BK284150 BK277286 BK277151 BK277284 BK277283 BK277282

100A

BK284150 BK277117 BK277152 BK277293 BK277139 BK277292

150A

Spirit II User’s Manual

Torch

Head

BK279100

BK279100

BK279100

BK279100

BK279100

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Outer

Retaining Cap

Stainless Steel - Air or Nitrogen Plasma

Silver Electrode

Shield

Cap

Inner

Retaining Cap

Nozzle

Swirl

Ring

BK284150 BK277286 BK277151 BK279484 BK279483

Silver

Electrode

BK279410

(brown o-ring)

100A

BK284150 BK277117 BK277152 BK279493 BK279439

BK279420

(green o-ring)

150A

Torch

Head

BK279060

BK279060

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Aluminum

Copper Electrode

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Nozzle

Swirl

Ring

Copper

Electrode

BK284150 BK277145 BK277153 BK277120 BK277140 BK277130

30A

BK284150 BK277150 BK277153 BK277122 BK277142 BK277131

50A

BK284150 BK277150 BK277153 BK277125 BK277142 BK277131

70A

BK284150 BK277286 BK277151 BK277284 BK277283 BK277282

100A

BK284150 BK277117 BK277152 BK277293 BK277139 BK277292

150A

Spirit II User’s Manual

Torch

Head

BK279100

BK279100

BK279100

BK279100

BK279100

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Outer

Retaining Cap

Shield

Cap

Aluminum

Silver Electrode

Inner

Retaining Cap

Nozzle

Swirl

Ring

BK284150 BK277286 BK277151 BK279484 BK279483

Silver

Electrode

BK279410

(brown o-ring)

100A

BK284150 BK277117 BK277152 BK279493 BK279439

BK279420

(green o-ring)

150A

Torch

Head

BK279060

BK279060

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-11

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Cutting Charts

The cutting charts shown on the following pages are intended to give the operator the best starting point to use when making a cut on a particular material type and thickness. Small adjustments may have to be made to achieve the best cut. Also, remember that the arc voltage must be increased as the electrode wears in order to maintain the correct cutting height.

Cutting Chart Index

Material

Mild Steel

Mild Steel

Mild Steel

Mild Steel

Mild Steel

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

Aluminum

Aluminum

Aluminum

Aluminum

Aluminum

Current

30 Amps

50 Amps

70 Amps

100 Amps

150 Amps

30 Amps

50 Amps

70 Amps

70 Amps

100 Amps

100 Amps

150 Amps

150 Amps

30 Amps

50 Amps

70 Amps

100 Amps

150 Amps

Plasma Gas

Oxygen

Oxygen

Oxygen

Oxygen

Oxygen

Air

Air

H17

Air

H17

Air

H17

Air

Air

Air

Air

Air

Air

Shield Gas

Oxygen

Oxygen or Air

Air

Air

Air

Air

Nitrogen

Nitrogen

Nitrogen

Nitrogen

Nitrogen

Nitrogen

Nitrogen

Nitrogen

Nitrogen

Nitrogen

Nitrogen

Nitrogen

Copper

Electrode

Page 5-13

Page 5-14

Page 5-15

Page 5-16

Page 5-17

Page 5-18

Page 5-19

Page 5-20

Page 5-21

Page 5-22

Page 5-23

Page 5-24

Page 5-25

Page 5-26

Page 5-27

Page 5-28

Page 5-29

Page 5-30

Silver

Electrode

Page 5-31

Page 5-32

Page 5-33

Page 5-34

Page 5-35

Page 5-36

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-12

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield

Copper Electrode

Shield Cap

BK277145

Nozzle

BK277120

Electrode

BK277130

Outer Cap

BK284150

Imperial*

Material

Thickness

(ga) (in)

20

18

16

14

12

11

10

Metric*

.135

Material

Thickness

(mm)

.036

.048

.060

.075

.105

.120

Retaining Cap

BK277153

Preflow Plasma

(psi)

35

(psi)

77

Preflow Plasma

Shield Postflow

(psi)

6

(psi)

75

Shield Postflow

(psi) (psi) (psi) (psi)

1

1.5

2 35 77 6

2.5

3

Marking* – For All Material Thicknesses

75

Swirl Ring

BK277140

Arc

Voltage

(volts)

120

121

125

126

127

129

131

Travel

Speed

(ipm)

105

97

78

65

55

50

40

Cutting

Height

(in)

.080

.090

.105

.120

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

120

124

126

128

2615

2020

1615

1455

1285

2.0

2.6

2.7

2.9

Pierce

Height

(in)

.110

.125

Pierce

Height

(mm)

2.8

3.1

Torch Head

BK279100

Pierce

Time

(msec)

100

200

300

Pierce

Time

(msec)

100

200

300

Kerf

Width

(in)

.062

.065

.070

Kerf

Width

(mm)

1.6

1.7

1.8

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

145

66

250

100

6350

2540

.177

.100

4.5

2.5

.100 2.5

.100 2.5

0

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 any means to any location outside the United States contrary to the requirements of the EAR.

5-13

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Mild Steel - 50 amps - Oxygen Plasma / Oxygen or Air Shield

Copper Electrode

Shield Cap

BK277115

Nozzle

BK277122

Electrode

BK277131

Outer Cap

BK284150

Imperial*

Material

Thickness

(ga) (in)

Retaining Cap

BK277153

Preflow Plasma

(psi) (psi)

Shield Postflow

(psi) (psi)

Swirl Ring

BK277140/BK277142

Arc

Voltage

(volts)

Travel

Speed

(ipm)

Cutting

Height

(in)

Pierce

Height

(in)

12

11

10

.105

.120

.135

14

12

10

1/4

Metric*

Material

Thickness

.075

.105

.125

.135

3/16

(mm)

25

Cold-Rolled Steel – Oxygen Shield – Swirl Ring BK277140

74 12 72

123

126

128

70

60

50

.120

.125

.135

Hot-Rolled Steel – Air Shield – Swirl Ring BK277142

.135

25 74 19 72

106

110

113

117

200

190

180

170

105

75

.100

.110

.140

.135

.200

.225

Preflow Plasma

(psi) (psi)

Shield Postflow

(psi) (psi)

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

Pierce

Height

(mm)

2.5

3

25

Cold-Rolled Steel – Oxygen Shield – Swirl Ring BK277140

74 12 72

121

125

1895

1555

2.9

3.1

3.4

2.5

3

5

25

Hot-Rolled Steel – Air Shield – Swirl Ring BK277142

74 19

6

Marking* – For All Material Thicknesses

72

106

113

116

4885

4660

2555

2075

2.5

3.6

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

Travel

Speed

3.4

5.1

5.5

Marking

Height

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

(psi)

25

50

(psi)

25

25

(psi)

N/A

N/A

Torch Head

BK279100

Pierce

Time

(msec)

100

200

100

200

300

400

Pierce

Time

(msec)

100

200

100

200

400

Kerf

Width

(in)

.075

.078

.075

.080

.085

.087

Kerf

Width

(mm)

1.9

2.0

1.9

2.0

2.2

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

145 250 6350 .147 3.7 .100 2.5 0

71 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .135” (3.4 mm) for cutting and .100” (2.5 mm) for marking.

** Only available on systems with the Automatic Gas Console.

(Revised 04/26/2013)

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-14

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Mild Steel - 70 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap

BK277150

Nozzle

BK277125

Electrode

BK277131

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

Retaining Cap

BK277153

Preflow Plasma Shield Postflow

1/8

3/16

1/4

3/8

Metric*

Material

Thickness

(mm)

(psi)

25

(psi)

76

Preflow Plasma

(psi)

35

40

(psi)

74

Shield Postflow

(psi) (psi) (psi) (psi)

3 35

5

25 76

40

6

Marking* – For All Material Thicknesses

74

Swirl Ring

BK277142

Arc

Voltage

(volts)

110

113

116

122

Travel

Speed

(ipm)

190

130

120

75

Cutting

Height

(in)

.100

.110

.140

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

109

113

115

4995

3265

3105

2.5

2.7

Pierce

Height

(in)

.150

.200

.225

.250

Pierce

Height

(mm)

3.6

5.1

5.5

Torch Head

BK279100

Pierce

Time

(msec)

100

200

300

400

Pierce

Time

(msec)

100

300

Kerf

Width

(in)

.080

.085

Kerf

Width

(mm)

2.0

2.2

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135 250 6350 .096 2.4 .100 2.5 0

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 Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-15

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Mild Steel - 100 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap

BK277286

Nozzle

BK277284

Electrode

BK277282

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

Retaining Cap

BK277151

Preflow Plasma

(psi) (psi)

Shield Postflow

(psi) (psi)

1/4

3/8

1/2

5/8

3/4

Metric*

Material

Thickness

(mm)

25 83

Preflow Plasma

26 81

Shield Postflow

(psi) (psi) (psi) (psi)

6

10

12

16

25 83 26

20

Marking* – For All Material Thicknesses

81

Swirl Ring

BK277283

Arc

Voltage

(volts)

125

130

143

145

Travel

Speed

(ipm)

150

100

65

47

35

Cutting

Height

(in)

.090

.130

.155

.185

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

124

130

143

145

3950

2405

1850

1180

800

2.1

3.3

3.7

4.7

Pierce

Height

(in)

.200

.250

.300

.325

.350

Pierce

Height

(mm)

4.9

6.5

7.3

8.3

9.0

Type of Gas Preflow Plasma

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Torch Head

BK279100

Pierce

Time

(msec)

300

400

500

800

1000

Pierce

Time

(msec)

300

500

1000

Kerf

Width

(in)

.090

.095

Kerf

Width

(mm)

2.3

2.4

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

130

60

250

100

6350

2540

.100

.100

2.5

2.5

.100 2.5

.100 2.5

0

0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.

** Only available on systems with the Automatic Gas Console.

(Revised 04/26/2013)

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-16

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Mild Steel - 150 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap

BK277117

Nozzle

BK277293

Electrode

BK277292

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

1/4

3/8

1/2

5/8

3/4

1

1.25 ***

1.50 ***

Metric*

Material

Thickness

(mm)

Retaining Cap

BK277151/BK277152

Preflow Plasma

(psi)

20

20

(psi)

71

71

Preflow Plasma

(psi) (psi)

Swirl Ring

BK277139

Shield Postflow

Arc

Voltage

(volts)

Travel

Speed

(ipm) (psi) (psi)

Retaining Cap BK277151

30 69

118

123

125

Retaining Cap BK277152

165

125

90

45 69

127

130

134

145

155

70

55

40

25

15

Shield Postflow

(psi) (psi)

Cutting

Height

(in)

.105

.135

.140

.140

.150

.200

.225

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

6

10

12

20 71

Retaining Cap BK277151

30 69

117

123

124

4305

3040

2485

16

20

25

32 ***

20 71

Retaining Cap BK277152

45 69

127

130

133

145

154

1760

1340

1040

625

385 38 ***

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

Travel

Speed

2.6

3.4

3.5

3.6

3.7

5.1

5.6

Pierce

Height

(in)

.200

.250

.300

.325

.350

.400

.350

.350

Pierce

Height

(mm)

4.9

6.5

7.3

8.3

9.0

10.1

8.9

8.9

Marking

Height

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

(psi)

25

50

(psi)

25

25

(psi)

N/A

N/A

Torch Head

BK279100

Pierce

Time

(msec)

300

400

500

600

1000

1500

Pierce

Time

(msec)

300

500

1000

1500

Kerf

Width

(in)

.125

.130

.130

.135

.140

Kerf

Width

(mm)

3.2

3.3

3.3

3.4

3.6

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135 250 6350 .100 2.5 .100 2.5 0

61 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.

** Only available on systems with the Automatic Gas Console.

*** Edge start recommended.

(Revised 04/26/2013)

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any 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

Stainless Steel - 30 Amps - Air Plasma / Air Shield

Copper Electrode

Shield Cap

BK277144

Nozzle

BK277121

Electrode

BK277137

Outer Cap

BK284150

Imperial*

Material

Thickness

(ga) (in)

20

18

16

.036

.048

.060

14 .075

Metric*

Material

Thickness

(mm)

Retaining Cap

BK277110

Preflow Plasma

(psi)

35

(psi)

81

Preflow Plasma

Shield Postflow

(psi)

30

(psi)

85

Shield Postflow

(psi) (psi) (psi) (psi)

1

35 81 30

1.5

Marking* – For All Material Thicknesses

85

Swirl Ring

BK277138

Arc

Voltage

(volts)

71

74

75

Travel

Speed

(ipm)

200

165

125

90

Cutting

Height

(in)

.020

.035

.025

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

71

73

4855

3260

0.6

0.9

Pierce

Height

(in)

.050

Pierce

Height

(mm)

1.3

Torch Head

BK279100

Pierce

Time

(msec)

100

200

Pierce

Time

(msec)

100

200

Kerf

Width

(in)

.065

.068

.070

Kerf

Width

(mm)

1.7

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

145 250 6350 .177 4.5 .100 2.5 0

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.

5-18

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap

BK277149

Nozzle

BK277123

Electrode

BK277137

Outer Cap

BK284150

Imperial*

Material

Thickness

(ga) (in)

14

12

11

10

1/4

Metric*

Material

Thickness

(mm)

.075

.105

.120

.135

3/16

Retaining Cap

BK277110

Preflow Plasma

(psi)

25

(psi)

66

Preflow Plasma

Shield Postflow

(psi)

40

(psi)

67

Shield Postflow

(psi) (psi) (psi) (psi)

2

2.5

3

5

25 66 40

6

Marking* – For All Material Thicknesses

67

Swirl Ring

BK277142

Arc

Voltage

(volts)

87

88

89

90

94

100

Travel

Speed

(ipm)

105

75

65

55

50

40

Cutting

Height

(in)

.035

.040

.060

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

87

88

94

98

2565

2080

1685

1235

1075

.9

1.0

1.3

Pierce

Height

(in)

.070

.080

.125

Pierce

Height

(mm)

1.8

2.1

2.9

Torch Head

BK279100

Pierce

Time

(msec)

100

200

300

400

Pierce

Time

(msec)

100

200

400

Kerf

Width

(in)

.105

.110

.115

Kerf

Width

(mm)

2.7

2.8

2.9

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

145 250 6350 .147 3.7 .100 2.5 0

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.

5-19

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)

This gas combination gives the best cut quality and minimum dross levels

Shield Cap

BK277150

Nozzle

BK277124

Electrode

BK277132

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

3/16

Metric*

Material

Thickness

(psi)

35

Retaining Cap

BK277113

Preflow Plasma

(psi)

65

Preflow Plasma

Shield Postflow

(psi)

30

(psi)

60

Shield Postflow

(mm) (psi) (psi) (psi) (psi)

5 35 65 30

Marking* – For All Material Thicknesses

60

Swirl Ring

BK277140

Arc

Voltage

(volts)

135

Travel

Speed

(ipm)

80

Cutting

Height

(in)

.100

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

135 2030 2.5

Type of Gas Preflow Plasma

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Pierce

Height

(in)

.200

Pierce

Height

(mm)

5.1

Torch Head

BK279100

Pierce

Time

(msec)

300

Pierce

Time

(msec)

300

Kerf

Width

(in)

.090

Kerf

Width

(mm)

2.3

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135

80

250

100

6350

2540

.096

.130

2.4

3.3

.100 2.5

.100 2.5

0

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.

5-20

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Stainless Steel - 70 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

Shield Cap

BK277150

Nozzle

BK277125

Electrode

BK277131

Outer Cap

BK284150

Imperial*

Material

Thickness

(ga) (in)

10 .135

3/16

1/4

3/8

Metric*

Material

Thickness

Retaining Cap

BK277153

Preflow Plasma

(psi)

25

(psi)

76

Preflow Plasma

Shield Postflow

(psi)

25

(psi)

76

Shield Postflow

(mm) (psi) (psi) (psi) (psi)

3

5 25 76 25

6

Marking* – For All Material Thicknesses

76

Swirl Ring

BK277142

Arc

Voltage

(volts)

132

134

140

148

Travel

Speed

(ipm)

120

100

75

50

Cutting

Height

(in)

.060

.070

.090

.120

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

131

134

138

3210

2445

2050

1.4

1.8

2.1

Pierce

Height

(in)

.150

.200

.225

.250

Pierce

Height

(mm)

3.3

5.1

5.5

Torch Head

BK279100

Pierce

Time

(msec)

200

300

400

500

Pierce

Time

(msec)

200

400

Kerf

Width

(in)

.085

.090

Kerf

Width

(mm)

2.2

2.3

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135 250 6350 .096 2.4 .100 2.5 0

65 100 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 Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

5-21

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Stainless Steel - 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

BK277146

Nozzle

BK277126

Electrode

BK277133

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

3/16

1/4

3/8

Metric*

Material

Thickness

Retaining Cap

BK277113

Preflow Plasma

(psi)

28

(psi)

72

Preflow Plasma

Shield Postflow

(psi)

40

(psi)

67

Shield Postflow

(mm) (psi) (psi) (psi) (psi)

5

28 72 40

6

Marking* – For All Material Thicknesses

67

Swirl Ring

BK277141

Arc

Voltage

(volts)

138

140

152

Travel

Speed

(ipm)

115

100

65

Cutting

Height

(in)

.105

.125

.180

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

138

139

2865

2625

2.7

3.0

Pierce

Height

(in)

.200

.225

.250

Pierce

Height

(mm)

5.1

5.5

Torch Head

BK279100

Pierce

Time

(msec)

300

400

500

Pierce

Time

(msec)

400

Kerf

Width

(in)

.100

.105

Kerf

Width

(mm)

2.5

2.7

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

130 250 6350 .100 2.5 .100 2.5 0

80 100 2540 .110 2.8 .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.

5-22

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

Shield Cap

BK277286

Nozzle

BK277284

Electrode

BK277282

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

1/4

3/8

1/2

Metric*

Material

Thickness

Retaining Cap

BK277151

Preflow Plasma

(psi)

25

(psi)

80

Preflow Plasma

Shield Postflow

(psi)

35

(psi)

80

Shield Postflow

(mm) (psi) (psi) (psi) (psi)

6

10 25 80 35

12

Marking* – For All Material Thicknesses

80

Swirl Ring

BK277283

Arc

Voltage

(volts)

141

147

154

Travel

Speed

(ipm)

100

80

55

Cutting

Height

(in)

.135

.170

.210

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

140

148

152

2595

1935

1540

3.2

4.4

5.0

Pierce

Height

(in)

.225

.250

.300

Pierce

Height

(mm)

5.6

6.5

7.3

Torch Head

BK279100

Pierce

Time

(msec)

400

500

600

Pierce

Time

(msec)

400

600

Kerf

Width

(in)

.092

.095

Kerf

Width

(mm)

2.3

2.4

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

130

68

250

100

6350

2540

.100

.100

2.5

2.5

.100 2.5

.100 2.5

0

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.

5-23

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

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

BK277298

Nozzle

BK277297

Electrode

BK277135

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

1/4

3/8

1/2

5/8

Metric*

3/4

Material

Thickness

(mm)

Retaining Cap

BK277266

Preflow Plasma

(psi)

25

(psi)

77

Preflow Plasma

Shield Postflow

(psi)

75

(psi)

81

Shield Postflow

(psi) (psi) (psi) (psi)

10

12

16

25 77 75

20

Marking* – For All Material Thicknesses

81

Swirl Ring

BK277139

Arc

Voltage

(volts)

165

Travel

Speed

(ipm)

95

75

60

50

40

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

155

167

1845

1610

1260

940

3.8

4.1

4.7

6.9

Cutting

Height

(in)

.250

.150

.165

.185

.250

Type of Gas Preflow Plasma

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Pierce

Height

(in)

.250

.275

.300

.325

.350

Pierce

Height

(mm)

7.0

7.4

8.3

9.0

Torch Head

BK279100

Pierce

Time

(msec)

400

500

600

800

1200

Pierce

Time

(msec)

600

800

1200

Kerf

Width

(in)

.135

.140

.145

Kerf

Width

(mm)

3.4

3.6

3.7

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135 250 6350 .100 2.5 .100 2.5 0

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.

5-24

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

Shield Cap

BK277117

Nozzle

BK277293

Electrode

BK277292

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

Retaining Cap

BK277152

Preflow Plasma

(psi) (psi)

Shield Postflow

(psi) (psi)

1/4

3/8

1/2

5/8

3/4

Metric*

Material

Thickness

(mm)

20 71

Preflow Plasma

70 69

Shield Postflow

(psi) (psi) (psi) (psi)

6

10

12

16

20 71 70

20

Marking* – For All Material Thicknesses

69

Swirl Ring

BK277139

Arc

Voltage

(volts)

145

150

155

160

168

Travel

Speed

(ipm)

150

115

85

60

45

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

144

150

153

160

170

3910

2805

2330

1510

1030

4.0

4.7

5.1

5.6

6.2

Cutting

Height

(in)

.160

.180

.210

.220

.240

Pierce

Height

(in)

.250

.275

.300

.325

.350

Pierce

Height

(mm)

6.3

7.0

7.4

8.3

9.0

Type of Gas Preflow Plasma

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Torch Head

BK279100

Pierce

Time

(msec)

400

500

600

800

1200

Pierce

Time

(msec)

400

600

800

1200

Kerf

Width

(in)

.125

.130

.135

Kerf

Width

(mm)

3.2

3.3

3.4

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135 250 6350 .100 2.5 .100 2.5 0

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.

5-25

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Aluminum - 30 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap

BK277145

Nozzle

BK277120

Electrode

BK277130

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

.040

.050

.063

Metric*

Material

Thickness

Retaining Cap

BK277153

Preflow Plasma

(psi)

35

(psi)

81

Preflow Plasma

Shield Postflow

(psi)

20

(psi)

85

Shield Postflow

(mm) (psi) (psi) (psi) (psi)

1

35 81 20

1.5

Marking* – For All Material Thicknesses

85

Swirl Ring

BK277140

Arc

Voltage

(volts)

135

Travel

Speed

(ipm)

150

120

90

Cutting

Height

(in)

.030

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

135

3885

2520

0.8

Pierce

Height

(in)

.100

.150

Pierce

Height

(mm)

2.5

3.4

Torch Head

BK279100

Pierce

Time

(msec)

100

200

Pierce

Time

(msec)

100

200

Kerf

Width

(in)

.065

.070

Kerf

Width

(mm)

1.7

1.8

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

145

75

250

100

6350

2540

.177

.120

4.5

3.0

.100 2.5

.100 2.5

0

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.

5-26

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Aluminum - 50 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap

BK277150

Nozzle

BK277122

Electrode

BK277131

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

.050

.063

.080

Metric*

Material

Thickness

Retaining Cap

BK277153

Preflow Plasma

(psi)

25

(psi)

66

Preflow Plasma

Shield Postflow

(psi)

19

(psi)

67

Shield Postflow

(mm) (psi) (psi) (psi) (psi)

1.5

25 66 19

2.0

Marking* – For All Material Thicknesses

67

Swirl Ring

BK277142

Arc

Voltage

(volts)

135

138

143

Travel

Speed

(ipm)

180

140

90

Cutting

Height

(in)

.050

.065

.075

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

137

142

3870

2360

1.5

1.8

Pierce

Height

(in)

.100

.150

Pierce

Height

(mm)

2.5

3.7

Torch Head

BK279100

Pierce

Time

(msec)

100

150

200

Pierce

Time

(msec)

150

200

Kerf

Width

(in)

.080

.082

.085

Kerf

Width

(mm)

2.1

2.2

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

145

77

250

100

6350

2540

.147

.120

3.7

3.0

.100 2.5

.100 2.5

0

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.

5-27

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Aluminum - 70 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap

BK277150

Nozzle

BK277125

Electrode

BK277131

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

.080

1/8

3/16

1/4

3/8

1/2

Metric*

Material

Thickness

(mm)

Retaining Cap

BK277153

Preflow Plasma

(psi)

25

(psi)

76

Preflow Plasma

Shield Postflow

(psi)

25

(psi)

76

Shield Postflow

(psi) (psi) (psi) (psi)

2

3

5

6

25 76 25

10

12

Marking* – For All Material Thicknesses

76

Swirl Ring

BK277142

Arc

Voltage

(volts)

130

135

145

150

155

162

Travel

Speed

(ipm)

250

160

80

50

40

30

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

129

134

145

148

156

160

6400

4420

1920

1440

975

820

1.2

1.7

2.3

1.7

2.0

2.6

Cutting

Height

(in)

.050

.070

.100

.060

.075

.115

Pierce

Height

(mm)

3.7

4.3

5.2

6.1

7.0

7.4

Pierce

Height

(in)

.150

.175

.200

.250

.275

.300

Torch Head

BK279100

Pierce

Time

(msec)

100

200

300

400

500

Pierce

Time

(msec)

100

300

500

Kerf

Width

(in)

.080

.085

.090

Kerf

Width

(mm)

2.0

2.2

2.3

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135

69

250

100

6350

2540

.096

.120

2.4

3.0

.100 2.5

.100 2.5

0

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.

5-28

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Aluminum - 100 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap

BK277286

Nozzle

BK277284

Electrode

BK277282

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

1/4

3/8

1/2

Metric*

Material

Thickness

Retaining Cap

BK277151

Preflow Plasma

(psi)

25

(psi)

80

Preflow Plasma

Shield Postflow

(psi)

26

(psi)

80

Shield Postflow

(mm) (psi) (psi) (psi) (psi)

6

10 25 80 26

12

Marking* – For All Material Thicknesses

80

Swirl Ring

BK277283

Arc

Voltage

(volts)

158

162

165

Travel

Speed

(ipm)

105

90

70

Cutting

Height

(in)

.155

.180

.195

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

158

162

165

2710

2210

1890

3.8

4.6

4.9

Pierce

Height

(in)

.250

.275

.300

Pierce

Height

(mm)

6.3

7.0

7.4

Torch Head

BK279100

Pierce

Time

(msec)

300

400

500

Pierce

Time

(msec)

300

500

Kerf

Width

(in)

.095

.098

.100

Kerf

Width

(mm)

2.4

2.5

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

130 250 6350 .100 2.5 .100 2.5 0

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.

5-29

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Aluminum - 150 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap

BK277117

Nozzle

BK277293

Electrode

BK277292

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

1/4

3/8

1/2

5/8

3/4

Metric*

Material

Thickness

(mm)

Retaining Cap

BK277152

Preflow Plasma

(psi)

20

(psi)

71

Preflow Plasma

Shield Postflow

(psi)

50

(psi)

69

Shield Postflow

(psi) (psi) (psi) (psi)

6

10

12

16

20 71 50

20

Marking* – For All Material Thicknesses

69

Swirl Ring

BK277139

Arc

Voltage

(volts)

145

155

165

170

Travel

Speed

(ipm)

145

115

90

65

45

Cutting

Height

(in)

.130

.185

.230

.250

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

143

156

162

170

170

3770

2825

2430

1630

990

3.1

4.8

5.5

6.4

Pierce

Height

(in)

.250

.275

.300

.325

.350

Pierce

Height

(mm)

6.3

7.0

7.4

8.3

9.0

Type of Gas Preflow Plasma

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Torch Head

BK279100

Pierce

Time

(msec)

400

500

600

800

1200

Pierce

Time

(msec)

400

600

1200

Kerf

Width

(in)

.125

.130

.135

.140

Kerf

Width

(mm)

3.2

3.3

3.4

3.6

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135 250 6350 .100 2.5 .100 2.5 0

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.

5-30

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Mild Steel - 100 Amps - Oxygen Plasma / Air Shield

Silver Electrode

Shield Cap

BK277286

Nozzle

BK279484

Electrode

BK279410

(brown o-ring)

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

1/4

3/8

1/2

5/8

Metric*

3/4

Material

Thickness

(mm)

Retaining Cap

BK277151

Preflow Plasma

(psi)

25

(psi)

83

Preflow Plasma

Shield Postflow

(psi)

26

(psi)

81

Shield Postflow

(psi) (psi) (psi) (psi)

6

10

12 25 83 26

16

20

Marking* – For All Material Thicknesses

81

Swirl Ring

BK279483

Arc

Voltage

(volts)

125

130

143

145

Travel

Speed

(ipm)

150

100

65

47

35

.185

Cutting

Height

(in)

.090

.130

.155

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

124

130

143

145

3950

2405

1850

1180

800

2.1

3.3

3.7

4.7

Pierce

Height

(mm)

4.9

6.5

7.3

8.3

9.0

Pierce

Height

(in)

.200

.250

.300

.325

.350

Torch Head

BK279060

Pierce

Time

(msec)

300

400

500

800

1000

Pierce

Time

(msec)

300

500

1000

Kerf

Width

(in)

.090

.095

Kerf

Width

(mm)

2.3

2.4

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

130 250 6350 .100 2.5 .100 2.5 0

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.

5-31

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Mild Steel - 150 Amps - Oxygen Plasma / Air Shield

Silver Electrode

Shield Cap

BK277117

Nozzle

BK279493

Electrode

BK279420

(green o-ring)

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

1/4

3/8

1/2

5/8

3/4

1

1.25 ***

1.50 ***

Metric*

Material

Thickness

(mm)

Retaining Cap

BK277151/BK277152

Preflow Plasma

(psi)

20

20

(psi)

71

71

Swirl Ring

BK279439

Shield Postflow

(psi) (psi)

Arc

Voltage

(volts)

Travel

Speed

(ipm)

Retaining Cap BK277151

30 69

118

123

125

165

125

90

Retaining Cap BK277152

45 69

127

130

134

145

155

70

55

40

25

15

Cutting

Height

(in)

.105

.135

.140

.140

.150

.200

.225

Preflow Plasma

(psi) (psi)

Shield Postflow

(psi) (psi)

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

6

10

12

20 71

Retaining Cap BK277151

30 69

117

123

124

4305

3040

2485

16

20

25

32 ***

20 71

Retaining Cap BK277152

127 1760

45 69

130

133

145

154

1340

1040

625

385 38 ***

Marking* – For All Material Thicknesses

2.6

3.4

3.5

3.6

3.7

5.1

5.6

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

Travel

Speed

Pierce

Height

(in)

.200

.250

.300

.325

.350

.400

.350

.350

Pierce

Height

(mm)

4.9

6.5

7.3

8.3

9.0

10.1

8.9

8.9

Marking

Height

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

(psi)

25

50

(psi)

25

25

(psi)

N/A

N/A

Torch Head

BK279060

Pierce

Time

(msec)

300

400

500

600

1000

1500

Pierce

Time

(msec)

300

500

1000

1500

Kerf

Width

(in)

.125

.130

.130

.135

.140

Kerf

Width

(mm)

3.2

3.3

3.3

3.4

3.6

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135 250 6350 .100 2.5 .100 2.5 0

61 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.

** Only available on systems with the Automatic Gas Console.

*** Edge start recommended.

(Revised 04/26/2013)

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any 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 - 100 Amps - Air Plasma / Nitrogen Shield

Silver Electrode

Shield Cap

BK277286

Nozzle

BK279484

Electrode

BK279410

(brown o-ring)

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

Retaining Cap

BK277151

Preflow Plasma

(psi) (psi)

Shield Postflow

(psi) (psi)

1/4

3/8

1/2

Metric*

Material

Thickness

(mm)

25 80

Preflow Plasma

35 80

Shield Postflow

(psi) (psi) (psi) (psi)

6

10 25 80 35

12

Marking* – For All Material Thicknesses

80

Swirl Ring

BK279483

Arc

Voltage

(volts)

141

147

154

Travel

Speed

(ipm)

100

80

55

Cutting

Height

(in)

.135

.170

.210

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

140

148

152

2595

1935

1540

3.2

4.4

5.0

Pierce

Height

(in)

.225

.250

.300

Pierce

Height

(mm)

5.6

6.5

7.3

Torch Head

BK279060

Pierce

Time

(msec)

400

500

600

Pierce

Time

(msec)

400

600

Kerf

Width

(in)

.092

.095

Kerf

Width

(mm)

2.3

2.4

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

130

68

250

100

6350

2540

.100

.100

2.5

2.5

.100 2.5

.100 2.5

0

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.

5-33

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield

Silver Electrode

Shield Cap

BK277117

Nozzle

BK279493

Electrode

BK279420

(green o-ring)

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

Retaining Cap

BK277152

Preflow Plasma

(psi) (psi)

Shield Postflow

(psi) (psi)

1/4

3/8

1/2

5/8

3/4

Metric*

Material

Thickness

(mm)

20 71

Preflow Plasma

70 69

Shield Postflow

(psi) (psi) (psi) (psi)

6

10

12

16

20 71 70

20

Marking* – For All Material Thicknesses

69

Swirl Ring

BK279439

Arc

Voltage

(volts)

145

150

155

160

168

Travel

Speed

(ipm)

150

115

85

60

45

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

144

150

153

160

170

3910

2805

2330

1510

1030

4.0

4.7

5.1

5.6

6.2

Cutting

Height

(in)

.160

.180

.210

.220

.240

Pierce

Height

(in)

.250

.275

.300

.325

.350

Pierce

Height

(mm)

6.3

7.0

7.4

8.3

9.0

Torch Head

BK279060

Pierce

Time

(msec)

400

500

600

800

1200

Pierce

Time

(msec)

400

600

800

1200

Kerf

Width

(in)

.125

.130

.135

Kerf

Width

(mm)

3.2

3.3

3.4

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Nitrogen** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135 250 6350 .100 2.5 .100 2.5 0

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.

5-34

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Aluminum - 100 Amps - Air Plasma / Nitrogen Shield

Silver Electrode

Shield Cap

BK277286

Nozzle

BK279484

Electrode

BK279410

(brown o-ring)

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

Retaining Cap

BK277151

Preflow Plasma

(psi) (psi)

Shield Postflow

(psi) (psi)

1/4

3/8

1/2

Metric*

Material

Thickness

(mm)

25 80

Preflow Plasma

26 80

Shield Postflow

(psi) (psi) (psi) (psi)

6

10 25 80 26

12

Marking* – For All Material Thicknesses

80

Swirl Ring

BK279483

Arc

Voltage

(volts)

158

162

165

Travel

Speed

(ipm)

105

90

70

Cutting

Height

(in)

.155

.180

.195

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

158

162

165

2710

2210

1890

3.8

4.6

4.9

Pierce

Height

(in)

.250

.275

.300

Pierce

Height

(mm)

6.3

7.0

7.4

Torch Head

BK279060

Pierce

Time

(msec)

300

400

500

Pierce

Time

(msec)

300

500

Kerf

Width

(in)

.095

.098

.100

Kerf

Width

(mm)

2.4

2.5

Type of Gas Preflow

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

Plasma

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

130

71

250

100

6350

2540

.100

.120

2.5

3.0

.100 2.5

.100 2.5

0

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.

5-35

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Aluminum - 150 Amps - Air Plasma / Nitrogen Shield

Silver Electrode

Shield Cap

BK277117

Nozzle

BK279493

Electrode

BK279420

(green o-ring)

Outer Cap

BK284150

Imperial*

Material

Thickness

(in)

Retaining Cap

BK277152

Preflow Plasma

(psi) (psi)

Shield Postflow

(psi) (psi)

1/4

3/8

1/2

5/8

3/4

Metric*

Material

Thickness

(mm)

20 71

Preflow Plasma

50 69

Shield Postflow

(psi) (psi) (psi) (psi)

6

10

12

16

20 71 50

20

Marking* – For All Material Thicknesses

69

Swirl Ring

BK279439

Arc

Voltage

(volts)

145

155

165

170

Travel

Speed

(ipm)

145

115

90

65

45

.250

Cutting

Height

(in)

.130

.185

.230

Arc

Voltage

Travel

Speed

Cutting

Height

(volts) (mm/m) (mm)

143

156

162

170

170

3770

2825

2430

1630

990

3.1

4.8

5.5

6.4

Pierce

Height

(in)

.250

.275

.300

.325

.350

Pierce

Height

(mm)

6.3

7.0

7.4

8.3

9.0

Torch Head

BK279060

Pierce

Time

(msec)

400

500

600

800

1200

Pierce

Time

(msec)

400

600

1200

Kerf

Width

(in)

.125

.130

.135

.140

Kerf

Width

(mm)

3.2

3.3

3.4

3.6

Type of Gas Preflow Plasma

(Plasma) (Shield) (psi)

Nitrogen Nitrogen N/A

Argon** Air** N/A

(psi)

25

50

Shield

(psi)

25

25

Postflow

(psi)

N/A

N/A

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

135 250 6350 .100 2.5 .100 2.5 0

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.

5-36

Spirit II User’s Manual Section 6: Maintenance &Troubleshooting

Section 6: Maintenance & Troubleshooting

WARNING: Only qualified maintenance personnel should perform maintenance on the Spirit system.

The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance should be performed with safety in mind.

Use extreme caution when working near the power conversion module (i.e., chopper). The large electrolytic capacitors store large amounts of energy even after power has been removed from the system. Wait at least five minutes after turning off power, and then use a voltmeter to verify that the capacitors are fully discharged before touching the power conversion module.

Capacitor failure can injure and/or cause property damage.

If troubleshooting requires the system to be powered with the enclosure panels removed, remain clear of the capacitors. Failure of a capacitor can result in a sudden release of stored energy causing rupture of the capacitor case.

Routine Maintenance

Note: At minimum, these checks should be performed on a monthly basis. In excessively dirty environments or in heavy usage situations, the checks should be performed more frequently.

Power Supply

1. Remove the left, right, and top covers on the power supply.

2. Using clean, dry, compressed air, blow out all accumulated dust, including dust on

PC boards and fans. Be sure to blow out the fan and heat exchanger at the rear of the unit. In an excessively dirty environment, blow out the unit on a weekly basis.

3. Verify the ground and primary three phase A.C. voltage connections are tight.

4. Verify all PC board connectors are installed securely.

5. Verify all rear cable connectors are installed securely.

6. Verify the electrode lead and work ground lead are secure and free from corrosion.

7. Check the torch coolant filter / deionization cartridge at the rear of the power supply and replace if dirty.

8. 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 &Troubleshooting Spirit II User’s Manual

Manual Gas Console (MGC)

1. Remove the cover of the manual gas console. Using clean, dry, compressed air, blow out all accumulated dust inside the unit. In an excessively dirty environment, blow out the unit on a weekly basis.

2. Verify that all PC board connectors are installed securely.

3. Verify that all gas hose connectors are tight and that there are no leaks. Only

tighten the gas fittings enough to make a gas seal. The fittings are subject to

damage if over tightened.

4. Inspect all gas hoses to ensure no damage exists. Immediately replace any damaged gas hoses.

Torch, Torch Leads, and Gas Hoses

1. Verify that all torch lead and gas hose connections are tight and that there are no gas or water leaks. Only tighten the fittings enough to make a water or gas

seal. The fittings are subject to damage if over tightened.

2. Verify that the braided shield of the torch leads is fastened securely to the brass shield adapter that connects to the impulse start console. Also, make sure the shield adapter is secured tightly to the impulse start console enclosure.

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.

5. Make sure the torch lead insulating sleeves are positioned to properly cover the brass torch fittings at the torch base.

6. Inspect the outer sleeve on the torch base's electrode/coolant supply lead. If nicks, cuts or holes are found, replace the torch base.

7. 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.

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 & 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.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 &Troubleshooting

Impulse Start Console (ISC)

1. Open the cover (door) of the impulse start console and verify that all leads and hoses are tightened securely. Only tighten the fittings enough to make a water

or gas seal. The fittings are subject to damage if over tightened.

Work Ground

1. Verify that the work ground lead is securely fastened to the star ground on the cutting table, and that the connection point is free from corrosion. Use a wire brush to clean the connection point if necessary.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.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 &Troubleshooting Spirit II User’s Manual

Replacing the Torch Coolant and Filter

WARNING: Do not touch the fans inside the power supply.

Important: Never turn on the system when the coolant reservoir is empty.

Important: When handling coolant, wear nitrile gloves and safety glasses.

Important: Only use Kaliburn approved coolant. Commercially available antifreeze contains corrosion inhibitors that will damage the cooling system. See Section 2 for more information.

The torch coolant should be flushed out of the system every six months and replaced with new coolant. Replace the coolant filter / deionization cartridge at the same time.

1. Remove primary power from the Spirit system.

2. Ensure the torch base and torch head (with consumables) are properly installed.

3. Ensure the coolant supply (in and out) hoses are properly installed.

4. Remove the coolant reservoir cap/level gauge.

5. Remove the top, left and right covers from the power supply.

6. 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.

7. Remove the coolant supply hose (coolant out) from the rear of the power supply.

Note that the coolant supply hose has right hand threads. Be prepared for some coolant to escape from the fitting on the power supply and from the supply hose.

8. 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.

9. Tighten the drain petcock and remove the hose and bucket.

10. Protect the area beneath the coolant filter housing as coolant will leak during this step. Unscrew the coolant filter housing and remove it from the power supply. Use caution as the housing will be full of coolant. Install a new coolant filter / deionization cartridge and replace the coolant filter housing. Remove the protective material and dry any leaked coolant.

11. Reconnect the coolant supply hose on the rear of the power supply.

12. Follow all of the steps in "Filling the Cooling System" in Section 3 of this manual to complete this procedure.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

6-4

Spirit II User’s Manual Section 6: Maintenance &Troubleshooting

Microprocessor (DSP) Status Indicators

The microprocessor DSP board controls all of the functions of the Spirit power supply. It contains diagnostic LEDs and OPTO LEDs which aid in troubleshooting the system. These indicators illuminate when a particular event occurs. Illuminated LEDs indicate the following:

Indication LED

D7 – RS232 OUT Isolated

D10 – RS232 T1 OUT

Serial transmission

Serial transmission

D11 – CAN RXD

D12 – CAN TXD

D24 – PWM

D37 – ARC HOLD

D33 – COOLANT LEVEL

D36 – PLASMA START

D38 – MARKING

D39 – CORNER

CAN transmission

CAN transmission

Chopper(s) energized

Coolant reservoir level is sufficient

Plasma start signal applied to Spirit

Arc hold input enabled

Marking input enabled

Corner current input enabled

Off button disengaged

Motion output signal activated

D40 – EOFF

D41 – MOTION

D42 – PLASMA READY

D43 – PAT

D48 – RMT ON/OFF

D50 – ISC DOOR

D77 – 3.3V uP PWR

D78 – 1.8V uP PWR

Power supply ready output signal activated

Pilot arc transistor energized

Remote On/Off input enabled

ISC door is closed

3.3V Microprocessor power

1.8V Microprocessor power

OPTO U21 – MTR/SOL

OPTO U22 – PAR

OPTO U23 – CON

OPTO U24 – SURGE

OPTO U26 – FAN

OPTO U27 – PREFLOW

OPTO U28 – PLASMA

OPTO U29 – SHIELD

OPTO U30 – VENT

Coolant pump relay CR5 energized (Pump On)

Pilot arc relay energized

DC power output (main contactor energized)

CR3 and K1 (I/O PCB) relays energized

Fans energized

Preflow gas valve 1 energized

Plasma gas valve 2 energized

Shield gas valve 3 energized

Vent gas valve 4 energized

OPTO U31 – POSTFLOW

OPTO U32 – MARKING

Postflow gas valve 5 energized

Marking gas valves 6 and 7 energized

OPTO U34 – IMPULSE START Impulse start 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 &Troubleshooting Spirit II User’s Manual

Microprocessor (DSP) Sequence of Operation

The following DSP Indicators should illuminate after primary power is applied:

 D77

 D78

3.3V Supply

1.8V Supply

 D50

 D33

ISC (Door)

Coolant Level

 D37

 D10

 D11

 D12

Arc Hold (if INOVA is being used)

RS232 T1 Out (Blinking)

CAN RXD (Dim Flashing)

CAN TXD (Dim Flashing)

The following DSP Indicators should illuminate when the OFF Button is released:

 D40

OFF Button

The following DSP Indicators should illuminate when the ON Button is activated:

 U21 Opto

Motor / Solenoid

 U19 Opto

Solenoid (not used)

 U26 Opto

Fan

 D42

Plasma Ready

The following DSP Indicators should illuminate when a START signal is applied (begin cut cycle):

 D36

Start

 U27 Opto

Preflow

 U29 Opto

Shield

 U24 Opto

Surge (only over 100 amps)

 U23 Opto

Contactor

 D24

PWM (Chopper ON)

 U22 Opto

Pilot Arc Relay ON

 D43

PAT ON (Blinks during a START)

 U34 Opto

ISC (Blinks during a START)

The following DSP Indicators should illuminate with an arc transfer:

 U31 Opto

Postflow

 U28 Opto

Plasma

 D41

Motion

The following LEDs should turn OFF after the Motion Indicator turns ON:

 U34 Opto

ISC

 U27 Opto

Preflow

 D43

PAT

When the START signal is removed, OPTO U30 (Vent) will illuminate. It will then go out with the rest of the cut cycle indicators.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

6-6

Spirit II User’s Manual Section 6: Maintenance &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

10121 ISC Door ISC Door is open

Long Description

10138 Stop Pressed (Off Button) OFF Button on Plasma Console or Manual Gas

Console is pressed.

10140 Phase R

10150 Phase Y

10160 Phase B

10161 CON1

10170 Coolant Level

10180 Coolant Flow Low

10190 Coolant Flow High

Transformer Secondary phase voltage is low

Transformer Secondary phase voltage is low

Transformer Secondary phase voltage is low

Main Contactor failed to open

Coolant Level is low

Coolant flow is low

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

10320 FCC Invalid

Lost CAN communication with Plasma Console

Final Cut Current invalid

10330 PAC Invalid

10340 AH IHS Timeout

10350 PAT Not Established

10360 TAC Not Established

10370 Current Unbalanced

Pilot Arc Current invalid

Arc Hold for Initial Height Sense has timed out

Pilot Arc Current not established within 2 seconds

Transferred Arc Current not established within 2 seconds

Current is not balanced between chopper assemblies (275A and 400A systems)

Transferred Arc lost during TAC hold time 10380 TAC Lost 1

10390 TAC Lost 2

10400 TAC Lost 3

Transferred Arc lost during Upslope

Transferred Arc lost during Cutting

Transferred Arc lost during Downslope

Did not achieve final cut current

10410 TAC Lost 4

10420 FCC Unreached

10430 Output Over Current

10432 Output Over Current TZ

10440 Output Over Voltage

10450 Start Premature Removal

10461 Chopper1 Temp

10462

10463

Chopper2 Temp

Chopper3 Temp

Chopper has exceeded its maximum rated current

Instantaneous Over Current detected

Maximum Cutting Voltage has been exceeded.

Start Signal removed prior to completion of upslope

Chopper 1 maximum operating temperature exceeded

Chopper 2 maximum operating temperature exceeded

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 &Troubleshooting Spirit II User’s Manual

Code Short Description

20100 Plasma Adjust

20110 Shield Adjust

20120 Preflow Adjust

20130 Postflow Adjust

20140 Marking Adjust

20160 N2 Mix Adjust

20170 O2 Mix Adjust

20200 O2 Low

20210 N2 Low

20220 Argon Low

20230 O2N2 Low

20240 H17 Low

20250 O2 High

20260 N2 High

20270 Argon High

20280 O2N2 High

20290 H17 High

20300 PS Quiet

20310 PC Quiet

Gas Console

Long Description

Could not adjust Plasma Gas

Could not adjust Shield Gas

Could not adjust Preflow Gas

Could not adjust Postflow Gas

Could not adjust Marking Gas (Automatic Gas Console)

Could not adjust N2 Mix Gas

Could not adjust O2 Mix Gas

O2 Input Pressure is low

N2 Input Pressure is low

Argon Input Pressure is low

Air Input Pressure is low

H17 Input Pressure is low

O2 Input Pressure is high

N2 Input Pressure is high

Argon Input Pressure is high

Air Input Pressure is high

H17 Input Pressure is high

Lost CAN communication with Power Supply

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 &Troubleshooting

General Troubleshooting

The following contains general troubleshooting guidelines for the Spirit system. Please contact KALIBURN technical support for any issues not covered in this section. Before any tests are performed, make sure that all system fuses are good; remove top cover of power supply to check these fuses.

Problem

Power supply indicator

(white light) will not illuminate

Power Supply will not energize after choosing ON and then SELECT on the

MGC.

Power supply will not stay on after choosing ON and then

SELECT on the MGC.

Possible Cause

1. Primary disconnect fuse blown.

2. Internal power supply fuse is blown (F1A, F1B).

3. Power supply indicator light is burned out or the associated wiring is bad.

4. Control Transformer or associated wiring bad.

1. ISC door open.

2. Low coolant level.

3. Fuse is blown (F1-F6).

4. Faulty OFF Button or associated wiring.

5. Off Relay faulty.

1. Faulty DSP board.

2. Off Relay faulty.

No arc at the torch

The arc will not transfer to the workpiece

1. Incorrect torch consumables installed.

2. Incorrect gas pressure settings.

3. Pilot arc transistor (PAT) is not operating properly.

Check the PAT LED (D43) on the DSP microprocessor board.

4. Damaged or loose torch lead connections.

5. Shorted torch or torch leads. Check the continuity between the Electrode lead and the Nozzle lead to make sure they are not shorted.

6. Open torch or torch leads. Check the continuity from the Electrode lead to the torch electrode and the Nozzle lead to the large brass body of the torch.

1. Loose work ground connection.

2. Pierce height too high.

3. Incorrect, damaged, or worn consumables.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

6-9

Section 6: Maintenance &Troubleshooting Spirit II User’s Manual

Problem

Primary power has been applied to the system, but the manual gas console screen is blank

The manual gas console screen is on, but the screen doesn't work

Gas pressures will not adjust properly

Low pressure error

Pressure error during cut

Liquid or torch coolant leaking from drain hole in torch handle.

Possible Cause

1. Check power/communications CAN cable connection on back of manual gas console.

2. Check for blown DIN rail fuse.

3. Check for 120v on pins of power/communications

CAN cable at back of the manual gas console.

1. Cycle primary power to the Spirit system.

2. Check the connection of the ribbon cable that connects the keypad to the DSP PCB in the manual gas console.

1. Wrong consumables installed in torch.

2. Loose pressure transducer cable on PC board in the MGC.

3. Check connectors on the MGC valve associated with the malfunction.

1. Supply gas pressure(s) less than 120 psi.

1. Supply gas pressure(s) fluctuating during cut.

Infrequent dripping from the drain hole may be condensation; no action is required.

Noticeable flow from the drain hole indicates a problem with the torch leads and/or connections.

1. Check for damaged or loose torch lead connections within the torch handle.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 &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 rupture of the capacitor case.

IMPORTANT: Depending upon the system, there are one, two or three chopper assemblies in the power supply. The following steps must be performed on each chopper with the other chopper(s) disabled. To disable a chopper, remove the plug from J1 on the chopper PCB (see drawing on next page).

1. Remove primary power from the Spirit system.

2. Open the impulse start console door and disconnect the Green P1 Plug from the impulse start PCB. Close the impulse start console door to activate the door interlock switch.

3. Remove the top, left, right and front covers from the power supply to expose the

DSP PCB, input and output terminal blocks and chopper(s).

4. Remove the Electrode, Work and Nozzle leads from the output terminal block, which is located on the left side of the unit.

5. Ensure the torch head (with a full set of consumables) is properly installed onto the torch base.

6. Apply primary power to the Spirit system.

7. Release the OFF Button on the Plasma Controller or Manual Gas Console to enable the system. Press or SELECT the ON Button to energize the system. After the gases set, prepare to apply a start signal to the unit.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

6-11

Section 6: Maintenance &Troubleshooting Spirit II User’s Manual

8. With a start signal applied, check the three phase voltage input to each chopper at the diode bridge terminals (three screws on the left side of each chopper). Refer to

TABLE 1 for the proper three phase AC voltage.

Note that the system will only energize for approximately two seconds each time a start signal is applied.

If the voltage is not present, check for primary voltage on the main contactor

(CON 1) and on the primary side of the power transformer.

Diode Bridge Terminals

Chopper PCB

J1 Plug

D2 (Green LED) is under J1 Plug

Top View of Chopper

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.

Spirit II

400 Amp

Spirit II

275 Amp

Spirit II

150 Amp

Chopper 1

3 Phase OCV

AC (DC)

255 370

225

208

325

300

TABLE 1

Chopper 2

3 Phase

AC

OCV

(DC)

255 370

225 325

N/A N/A

Chopper 3

3 Phase OCV

AC (DC)

255 370

N/A N/A

N/A N/A

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

6-12

Spirit II User’s Manual Section 6: Maintenance &Troubleshooting

10. If the proper DC voltage is not present at the output terminal block, check the 200 amp fuse F9 (chopper 1), fuse F10 (chopper 2) or fuse F11 (chopper 3) located on the bottom right of the output bus bars.

If the fuse is open, replace chopper and fuse.

11. If the fuse(s) is good, check if the chopper PWM LED illuminates when a start signal is applied: a) check D24 on the DSP PCB – If D24 doesn’t illuminate, replace DSP PCB. b) check D2 on the chopper PCB – If D2 doesn’t illuminate green, go to step 12.

12. Check PCB power to the chopper from the DSP: a) Push the OFF Button. b) Disconnect the J1 plug from the 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

J1-5 (ground) to J1-2

J1-5 (ground) to J1-3

+15vdc Supply

+5vdc Supply

+5vdc (PWM Signal)

If ALL of the voltages are present, replace chopper. If any of the voltages are not present, go to step 13:

13. Remove primary power from the Spirit system. Check cable continuity between the chopper PCB and DSP PCB. Use a digital voltmeter set up to read resistance

(ohms) and make the following measurements:

Chopper (1) J1-1 to DSP J7-1

Chopper (1) J1-2 to DSP J7-2

Chopper (1) J1-3 to DSP J7-3

Chopper (1) J1-5 to DSP J7-4

Chopper (2) J1-1 to DSP J8-1

Chopper (2) J1-2 to DSP J8-2

Chopper (2) J1-3 to DSP J8-3

Chopper (2) J1-5 to DSP J8-4

Chopper (3) J1-1 to DSP J9-1

Chopper (3) J1-2 to DSP J9-2

Chopper (3) J1-3 to DSP J9-3

Chopper (3) J1-5 to DSP J9-4

If ALL of the continuity readings are good, replace DSP PCB.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

6-13

Section 6: Maintenance &Troubleshooting

BLANK

Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 (BK300211 - BK300219)

Right Side View

Item

4

5

6

15

30

31

35

38

44

Part Number Quantity

BK707155

BK706409

BK706410

1

1

1 BK706405

BK706501

BK709105

BK708121

BK702076

BK709167

BK300250

BK200204

1

1

1

1

1

1

Description

L1 Inductor

T2 Control Transformer, 200-480 V / 60 Hz

T2 Control Transformer, 600 V / 60 Hz

T1 Main Transformer, 200-480 V / 60 Hz / 3Ø

T1 Main Transformer, 600 V / 60 Hz / 3Ø

Strain Relief

CON 1 Contactor

EMI Filter, 380/415 V units only

TB5 3 Phase Input Power Terminal Block

Chopper Assembly

Fan (4.7")

5

38

44

35

15

4 31 6 30

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Power Supply (BK300211 - BK300219)

Left Side View

46

47

50

51

39

40

43

44

Item

12

16

32

33

34

36

37

52

53

54

58

59

60

BK300108

BK301200

BK709117

BK280003

BK708105

BK200204

BK709252

BK709227

BK284029

BK300130

BK300129

BK300153

BK300156

BK701165

BK701141

BK701083

Part Number Quantity

BK300101

BK300112

BK708118

BK705011

BK702075

1

1

1

1

2

2

2

1

2

1

1

1

1

1

1

1

2

2

2

1

3

Description

Printed Circuit Board (PCB), Microprocessor (DSP)

Printed Circuit Board (PCB), A.C. Detect

CR3/PAR Relay

PAT IGBT

PAT IGBT Filter Capacitor

Printed Circuit Board (PCB), Power Supply Output (I/O)

(Optional) Printed Circuit Board (PCB), Voltage Divider

I/O Terminal Block (small)

Power Supply, 24VDC

Relay Hold Down Clip

Fan (4.7")

I/O Terminal Block (large)

Strain Relief

Current Sensor

F9 Fuse, 200A

F9 Fuse Holder

Off Relay

Off Relay Socket

R1/R2 Resistor, 300W, 3 Ohm

R3 Resistor, 300W, 2 Ohm

Resistor Mounting Hardware

53 54 43 12 16 40 40

37

BEHIND

PANEL

60 58

60 58

60

59

PAR

32

44

CR3

33 34

32

36

51 52

50

47

47

39 46 50

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Power Supply (BK300211 - BK300219)

Top View

Item

1

2

3

5

13

14

18

38

7

8

9

10

41

42

43

Part Number Quantity

BK501163

BK501164

BK501162

BK706409

BK706410

BK709359

BK709358

BK709358

BK709360

BK709061

BK709128

BK500518

BK300250

BK708103

BK708104

BK708105

1

1

2

1

1

2

2

4

1

1

1

2

1

1

1

Description

Light Housing

Bulb

White Lens

T2 Control Transformer, 200-480 V / 60 Hz

T2 Control Transformer, 600 V / 60 Hz

F3 Fuse, 5A, Slow Blow

F4 Fuse, 5A, Medium Blow

F5 Fuse, 5A, Medium Blow

F6 Fuse, 6.3A

F1A/F1B Fuse Holder

F1A/F1B Fuse, FNM 6.25A

Coolant Reservoir Cap/Level Gauge

Chopper Assembly

Fan/CR5 Relay

Relay Socket

Relay Hold Down Clip

1 2 3

Section 7: Parts List

38

5

18

14 13

F1A

FANS

F1B

CR5

43 42 41 7 8 9 10

F3 F4 F5 F6

(pos 1) (pos 4) (pos 12) (pos 17)

41 42 43

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 II User’s Manual

Power Supply (BK300211 - BK300219)

Cooling Section View

27

28

29

45

23

24

25

26

49

61

Item

15

17

18

19

20

21

22

Part Number Quantity

BK709105

BK200092

BK500518

BK300135

BK505024

BK500052

BK500513

BK500511

BK708061

BK715118

BK300134

BK260250

BK500509

BK500510

BK500526

BK500525

BK284031

1

1

3

2

1

1

1

1

1

1

1

1

1

1

1

1

1

Description

Strain Relief

Coolant Reservoir, without Fittings or Cap

Coolant Reservoir Cap/Level Gauge

Coolant Level Switch

Coolant Temperature Switch

Coolant Pump Motor, 1/3hp-230V-50/60 Hz

V-Band Clamp

Coolant Pump, 70 gph

Solenoid Valve, 220/240VAC

Check Valve, Coolant Return

Coolant Flow Sensor

Heat Exchanger

Coolant Filter Housing

Coolant Filter / Deionization Cartridge

Fan Guard (Mounted Outside)

Fan (6")

Fan (10")

18 17

19

20

49 45

27

49 45

26

29 28

61 45

24

25

15

21

23 22

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

7-4

Spirit II User’s Manual Section 7: Parts List

Manual Gas Console (BK300600)

Right Side View

Item

1

2

3

4

5

6

8

9

10

Part Number Quantity

BK300412

BK300301

BK280030

BK300602

BK300603

BK708111

BK280032

BK500570

BK300605

1

1

1

1

1

1

1

2

1

Description

Power Supply, 24VDC, 8.3A

Printed Circuit Board (PCB), Gas Console DSP

Fan, 24VDC

Keypad

LCD Display

Switch, Pushbutton (OFF Button)

Marking Regulator, 0-60 PSI, 145 PSI Max Input

Plasma/Shield Regulator, 0-125 PSI

Manifold Block, Gas Outputs

3 1

6

5

4

2

9

8

10

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.

7-5

Section 7: Parts List Spirit II User’s Manual

Manual Gas Console (BK300600)

Left Side View

Item

1

2

3

6

7

8

9

11

Part Number Quantity

BK300412

BK300301

BK280030

BK708111

BK500562

BK280032

BK500570

BK300414

1

1

1

1

1

1

1

1

Description

Power Supply, 24VDC, 8.3A

Printed Circuit Board (PCB), Gas Console DSP

Fan, 24VDC

Switch, Pushbutton (OFF Button)

Preflow Regulator, 0-60 PSI

Marking Regulator, 0-60 PSI, 145 PSI Max Input

Postflow Regulator, 0-125 PSI

Manifold Block, Gas Inputs

1 3

6

2

7

11

8

9

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

7-6

Spirit II User’s Manual

Impulse Start Console (BK300500)

Item

1

2

3

4

5

6

7

8

9

Part Number Quantity

BK715051

BK715050

BK715021

BK709001

BK708057

2

1

BK500503

BK980200

BK980201

BK707300

1

1

1

1

1

1

1

Description

Coolant Return Fitting (left hand)

Coolant Supply Fitting (right hand)

Coolant Supply Fitting (right hand)

4 Pin Receptacle

Door Interlock Switch

Cathode Manifold

Printed Circuit Board (PCB), Impulse Start

Impulse Start Manifold

Inductor

Section 7: Parts List

1

3

6

7

8

5

2 9 1 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.

7-7

Section 7: Parts List Spirit II User’s Manual

Torch and Manifold Assemblies

Item

1

2

3

4

5

10

11

12

13

6

7

8

9

Not shown

Not shown

Not shown

Not shown

Not shown

Part Number

BK284214

BK277195

BK278001

BK278018

BK279000

BK279100

BK279060

BK820209

BK500024

BK500018

BK279013

BK279112

BK279113

BK284039

BK280022

BK716012

BK277056

BK277086

BK277087

BK279061

Quantity

1

1

1

1

1

1

1

6

1

1

1

1

1

1

1

1

1

1

Description

2-Gang Manifold (includes Bracket)

2-Gang Manifold Bracket

Torch Handle – Standard

Torch Handle – Short

Torch Base

Torch Head (Copper Electrode)

Torch Head (Silver Electrode)

O-ring (red)

O-ring (blue)

O-ring (red)

O-ring (red) - indicator only, not a seal

O-ring (red)

O-ring (red)

(17") Torch Solenoid Plasma Hose

5-Gang Manifold for Manual Gas Console

O-ring Lubricant

Nozzle Removal Tool

Electrode Removal Tool Driver

Copper Electrode Removal Tool

Silver Electrode Removal Tool

12

1

13

2

3

4

5

6

9

10

11

11

11

8

7

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

7-8

Spirit II User’s Manual

Shielded Torch Leads

Part Number Length

BK284304-XX Where -XX is the length in feet. Available in 5 foot increments up to 40 feet.

Section 7: Parts List

CAN Communication Cable and Termination Plug

Item

CAN Termination Plug

CAN Cable

Part Number

BK300408

BK300177-XX

Length

N/A

Where -XX is the length in feet.

Available in 5 foot increments.

Manifold Control Cables

Item

2-Gang Manifold

5-Gang Manifold

Part Number

BK280312-XX

BK280321-XX

Length

Where -XX is the length in feet.

Available in 5 foot increments.



 



 

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Gas Hose Package with MGC

Part Number

BK300085-20

BK300085-30

BK300085-40

BK300085-50

BK300085-60

Length*

20 ft. (6.1m)

30 ft. (9.1m)

40 ft. (12.2m)

50 ft. (15.2m)

60 ft. (18.3m)

*Custom lengths are available. Contact factory.























 









Spirit II User’s Manual















This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

7-10

Spirit II User’s Manual Section 7: Parts List

Coolant and Power Leads

Part Number

(Non-CSA Systems)

BK280306-XX

Part Number

(CSA Systems)

BK288306-XX

Length

Where -XX is the length in feet.

Available in 5 foot increments.



 



 



 



 



 





Work Ground Lead

Part Number

(Non-CSA Systems)

BK280318-XX

Part Number

(CSA Systems)

BK288318-XX

Length

Where -XX is the length in feet.

Available in 5 foot increments.



 

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

7-11

Section 7: Parts List Spirit II User’s Manual

Oxygen Supply Gas Hose (Optional)

Part Number

BK200362-25

BK200362-50

Length

25 ft. (7.6 m)

50 ft. (15.2 m)

BLUE

Nitrogen Supply Gas Hose (Optional)

Part Number

BK200365-25

BK200365-50

Length

25 ft. (7.6 m)

50 ft. (15.2 m)

BLACK BLACK

Air Supply Gas Hose (Optional)

Part Number

BK200364-25

BK200364-50

BLACK

Length

25 ft. (7.6 m)

50 ft. (15.2 m)

BLACK

H17 Supply Gas Hose (Optional)

Part Number

BK200363-25

BK200363-50

Length

25 ft. (7.6 m)

50 ft. (15.2 m)

RED

BLUE

RED

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

“CII” Cable (for Optional External Inova)

Part Number

BK300902-XX

Length

Where -XX is the length in feet.

Available in 10 foot increments.

STRAIN RELIEF BK709015

CABLE BK711001

PLUG BK709016

BK709018 SOCKET

STRAIN RELIEF BK709025

PLUG BK709364

BK709365 PIN

Section 7: Parts List

BK709365 PIN

BK709018 SOCKET

BK709019 KEY

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

7-13

Section 7: Parts List

“FII” Cable (for Optional Internal Inova)

Part Number

BK300903-XX

Length

Where -XX is the length in feet.

Available in 10 foot increments.

Spirit II User’s Manual

PLUG BK709364

BK709365 PINS

CABLE BK711002

STRAIN RELIEF BK709025

STRAIN RELIEF BK709021

PLUG BK709095

BK709018 SOCKET

BK709018 SOCKET

BK709365 PINS

BK709018 SOCKET

BK709018 SOCKET

BK711005

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

“JII” Cable (for Optional Internal Inova)

Part Number

BK300904-XX

Length

Where -XX is the length in feet.

Available in 10 foot increments.

STRAIN RELIEF BK709025

PLUG BK709020

STRAIN RELIEF BK709021

CABLE BK711049

PLUG BK709364

Section 7: Parts List

BK709018 SOCKET

BK709365 PIN

BK709018 SOCKET

BK709019 KEY

BK709365 PIN

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 II User’s Manual

PCB Assemblies – Component Reference Locations

Power Supply, Microprocessor DSP (BK300101) – Quadrant 1

1

2

3

4

PCB Quadrant Map

J17

U37 - RHF

J13

U36

U35

U34 – Impulse Start

U32 - Marking

U31 – Postflow

U30 - Vent

U29 - Shield

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Power Supply, Microprocessor DSP (BK300101) – Quadrant 2

1 3

2

4

PCB Quadrant Map

U28 - Plasma

Section 7: Parts List

U27 - Preflow

U19 – Solenoid

(not used)

U21 – Mtr / Sol

U22 - PAR

U24 - Surge

U26 - Fan

U23 - Con

J15

J14

J1

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Power Supply, Microprocessor DSP (BK300101) – Quadrant 3

1 3

2

4

PCB Quadrant Map

J18 J11

Spirit II User’s Manual

J3

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Power Supply, Microprocessor DSP (BK300101) – Quadrant 4

1 3

2

4

PCB Quadrant Map

Section 7: Parts List

J21

J3

J4-1

J4-2

J10

J7

J8

J9

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

7-19

Section 7: Parts List

Power Supply, Output (BK300108)

Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Power Supply, A.C. Detect (BK300112)

Section 7: Parts List

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

7-21

Section 7: Parts List

Gas Supply, Microprocessor DSP (BK300301) – Quadrant 1

1 3

Spirit II User’s Manual

2 4

PCB Quadrant Map

J25 J19

J4

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Gas Supply, Microprocessor DSP (BK300301) – Quadrant 2

1 3

J6

2

4

PCB Quadrant Map

Section 7: Parts List

J5

J31

J28

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Gas Supply, Microprocessor DSP (BK300301) – Quadrant 3

1 3

Spirit II User’s Manual

J19

2

4

PCB Quadrant Map

J20 J21

J17

J13

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Gas Supply, Microprocessor DSP (BK300301) – Quadrant 4

1 3

2

4

PCB Quadrant Map

Section 7: Parts List

J13

J9

J18

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Chopper, Gate Driver (BK300106)

Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

7-26

Spirit II User’s Manual Section 8: Internal Inova Console Option

Section 8: Internal Inova Console Option

Overview

This optional Inova system is designed to provide arc voltage control to any plasma cutting system, however, combining it with the Spirit II 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).

POSITIONER

CONSOLE #2

REMOTE

POSITIONER

CONSOLE #2

REMOTE

X/Y MACHINE

RS-422 IN

RS-422

OUT

RS-422

IN

X/Y

MACHINE

RS-422 OUT

Spirit II 150/275 Spirit II 400

Unique Interconnect Cables

Two unique interconnect cables are required for this option with the Spirit II system.

The FII cable is used to connect the Spirit II internal Inova console (IP4) to the X/Y

Machine (CNC controller). The JII cable is used to connect multiple Spirit II internal

Inova consoles (IP8). See the parts list in Section 7 for more details on these cables.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

8-1

Section 8: Internal Inova Console Option Spirit II User’s Manual

Grounding

The internal Inova console must be connected to the same protective earth ground as the plasma power supply and in accordance with national or local codes. The figures below describe two methods. Use a minimum of #8AWG (10 mm

2

) wire.

Note: the customer must supply the ground cable.

Direct to star ground:

Ground

Point

Ground

Point

Spirit II 150/275

Jumper to the work ground lead:

Ground

Point

Spirit II 400

Ground

Point

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

Location in Spirit II 150 & 275

Item

1

2

3

4

5

6

7

8

Part Number Quantity

BK110200 1

BK110705

BK110900

1

1

BK706003

BK709360

BK709370

BK301200

BK709276

1

1

1

1

1

4

Description

Printed Circuit Board (PCB), Microprocessor

Printed Circuit Board (PCB), Power Distribution

Printed Circuit Board (PCB), H-Bridge

Transformer

F7 Fuse, 6.3A

F8 Fuse, 3A

Printed Circuit Board (PCB), Voltage Divider

Power Distribution Block,1 Pole

3 2

1

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

Location in Spirit II 150 & 275 - Continued

7

8

Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

Location in Spirit II 400

Section 8: Internal Inova Console Option

4 3 2

1

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.

8-5

Section 8: Internal Inova Console Option

Location in Spirit II 400 - Continued

7

8

Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

8-6

Spirit II User’s Manual Appendix A: Electromagnetic Compatibility (EMC)

Appendix A:

Electromagnetic Compatibility (EMC)

Background

The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit plasma cutting systems are manufactured to comply with the European standard EN 60974-10 (Electromagnetic compatibility (EMC) – Product standard for arc welding equipment). The system has been tested in accordance with CISPR 11, EMC classification – Group 2 ISM (Class A).

The limits used in this standard are based on practical experience. However, the ability of plasma cutting equipment to work in a compatible manner with other radio and electronic systems is greatly influenced by the manner in which it is installed and used.

For this reason, it is important that the plasma cutting equipment be installed and used in accordance with the information below if electromagnetic compatibility is to be achieved.

Plasma cutting equipment is primarily intended for use in an industrial environment.

There may be potential difficulties in ensuring electromagnetic compatibility in other environments.

Installation and Use

The user is responsible for installing and using the plasma cutting equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the plasma cutting equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the plasma cutting circuit, see Note. In other cases it could involve constructing an electromagnetic screen enclosing the plasma power source and the work, complete with associated input filters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer troublesome.

Note: The plasma cutting circuit may or may not be earthed for safety reasons.

Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel plasma cutting current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC 974-13 Arc welding

equipment – Installation and use.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any 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 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 of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Plasma Cutting Cables

The plasma cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

A-2

Spirit II User’s Manual Appendix A: Electromagnetic Compatibility (EMC)

Equipotential Bonding

Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered. However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances.

Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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)

BLANK

Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals

Download PDF

advertisement

Table of contents