Automatic Gas Console
HIGH CURRENT DENSITY PLASMA CUTTING SYSTEM
WITH
AUTOMATIC GAS CONSOLE
User’s Manual - Part Number 718085 Rev K
10/15/2012
This information is subject to the controls of the Export Administration
Regulations [EAR]. This information shall not be provided to non-U.S.
persons or transferred by any means to any location outside the United
States contrary to the requirements of the EAR.
REVISION
K
Spirit275a User’s Manual Rev K
REVISION HISTORY
Rev
A
B
C
D
E
F
G
H
I
J
K
ECO#
-
Author
Date
Description of Change
As released
Changed location of coolant level switch
Changed 30A mild steel preflow pressure from 30 to
05/23//07
35 psi
Changed cutting charts to have separate metric and
07/02/07
imperial versions.
Changed 575V control xfmr part number to 706205
Added PAR relay in series with surge injection circuit
10/15/07
to schematic and parts list
Section Updates:
• Contents
• Section 2
10/21/09
• Section 3
• Section 7
• Section 8
Section Updates
• Contents
• Section 3
• Section 4
10/25/10
• Section 5
• Section 6
• Section 7
• Appendix A
• Appendix B - deleted
Section Updates:
• AGC Max Input Pressure change to 145 psi in: 24, 3-1, 3-13, 3-14, 8-8.
05/10/2011
• AGC Fan added to drawings in: 3-1, 3-13.
• Postflow label changed in 8-9.
• Section 1, added pointers to Section 7.
• Section 7, added chopper warning.
08/01/2012
• Section 8, updated drawing of power supply
microprocessor board.
• Added Quick-Disconnect Torch information
10/15/2012
throughout manual.
• Section 7, defective flow switch (25 blinks).
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.
05/08/07
4130 Carolina Commerce Parkway
Ladson, SC 29456 USA
(843) 695-4000 - Phone
(843) 695-4001 - Fax
www.kaliburn.net
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
Spirit275a User’s Manual Rev K
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
equipment, for a period of one (1) year for the Spirit275a torch and leads and three (3)
years for the Spirit275a power supply and automatic gas console. 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 description on the face
hereof. All other warranties, either expressed or implied, including any implied
warranty of merchantability or fitness for any particular purpose, are expressly
excluded.
If this product or any component thereof is determined to be defective in manufacture,
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 nonconforming 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. Beyond this remedy, KALIBURN will not 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.
This warranty will be considered void if torches or
torch consumables manufactured by anyone other
than KALIBURN are incorporated into this product.
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 stock 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 Spirit275a 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.
Spirit275a User’s Manual Rev K
TABLE OF CONTENTS
Section 1 Safety
General Precautions ............................................................................................... 1-1
Ultraviolet Radiation Protection ............................................................................... 1-1
Noise Protection ...................................................................................................... 1-1
Toxic Fume Prevention ........................................................................................... 1-1
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 ................................................................................... 2-2
Automatic Gas Console Specifications ................................................................... 2-4
Remote High Frequency Console Specifications .................................................... 2-5
Torch Specifications ................................................................................................ 2-6
5-Gang Manifold Specifications .............................................................................. 2-7
Airborne Noise Emissions ....................................................................................... 2-8
Section 3 Installation
Initial Inspection ...................................................................................................... 3-1
System Interconnection .......................................................................................... 3-1
Power Supply Installation ........................................................................................ 3-2
Remote High Frequency Installation ....................................................................... 3-2
5-Gang Manifold Installation ................................................................................... 3-2
Torch Installation ..................................................................................................... 3-2
Primary Power Connection ..................................................................................... 3-3
Power Supply Output Connections ......................................................................... 3-5
RHF Console Ground Connection .......................................................................... 3-6
Torch Leads to RHF Console Connections ............................................................ 3-8
Torch Leads to Torch Base Connections................................................................. 3-10
Torch Gas Connections .......................................................................................... 3-11
Torch Head Connection......................................................................................... 3-14
Automatic Gas Console Input Connections ............................................................ 3-15
CNC Machine Interface Connections ...................................................................... 3-16
Torch Coolant Requirements .................................................................................. 3-18
Initial Filling of the Torch Coolant Reservoir............................................................ 3-19
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
Spirit275a User’s Manual Rev K
Section 4 Operation
Power Supply Front Panel Controls ........................................................................ 4-1
Automatic Gas Console Keypad ............................................................................. 4-3
Automatic Gas Console Help Prompt ..................................................................... 4-4
Automatic Gas Console Status Screen ................................................................... 4-5
Setting up a Cut or Mark ......................................................................................... 4-6
Torch Consumable Selection .................................................................................. 4-11
Installing and Removing Torch Consumables........................................................ 4-18
Making a Cut or Mark .............................................................................................. 4-19
Piercing Thick Materials ……………………………………………………………… 4-20
Cut Quality .............................................................................................................. 4-21
Changing Consumable Parts .................................................................................. 4-22
Consumable Life ..................................................................................................... 4-23
Cutting Charts ......................................................................................................... 4-24
Section 5 Automatic Gas Console Advanced Functions
Altering the Current Set Point ................................................................................. 5-1
Setting the Pierce Time ........................................................................................... 5-2
Altering Gas Types ................................................................................................. 5-3
Altering Gas Pressures ........................................................................................... 5-4
Altering Arc Voltage Control and X/Y Machine Parameters .................................... 5-5
Saving a User Created Cutting or Marking Condition ............................................. 5-6
Gas Purge ............................................................................................................... 5-6
Maintenance Screen ............................................................................................... 5-7
Viewing Messages .................................................................................................. 5-8
Viewing Cut Errors .................................................................................................. 5-9
Pressure Diagnostics .............................................................................................. 5-13
Restoring Factory Default Cutting or Marking Conditions....................................... 5-14
Measurement System ............................................................................................. 5-15
Communication Node ............................................................................................. 5-16
Inova Parameter Transmit ...................................................................................... 5-17
Viewing Serial Communication ............................................................................... 5-18
Configuring Hydrogen Cutting ................................................................................. 5-19
Setting an Arc Off Delay ......................................................................................... 5-20
Switching Between Cutting and Marking ................................................................ 5-21
Software Updates ................................................................................................... 5-22
Section 6 Serial Communication
Initializing the Spirit System .................................................................................... 6-1
Transmitting Parameters to the Spirit System ........................................................ 6-1
Communication Error Checking .............................................................................. 6-2
Default Cutting Parameters ..................................................................................... 6-3
Troubleshooting Serial Communication .................................................................. 6-3
RS-422 Serial Commands ...................................................................................... 6-4
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.
Spirit275a User’s Manual Rev K
Section 7 Maintenance and Troubleshooting
Routine Maintenance .............................................................................................. 7-1
Replacing the Torch Coolant .................................................................................. 7-4
Microprocessor Status LED’s .................................................................................. 7-5
Microprocessor Sequence of Operation ................................................................. 7-6
Troubleshooting Using the Control Panel Status LED’s ......................................... 7-7
Troubleshooting Using the Automatic Gas Console Messages Screen ................. 7-8
General Troubleshooting ........................................................................................ 7-9
Chopper Test Procedure ......................................................................................... 7-12
Section 8 Parts List
Power Supply .......................................................................................................... 8-1
Automatic Gas Console .......................................................................................... 8-7
Remote High Frequency Console ........................................................................... 8-10
Torch and Manifold Assemblies .............................................................................. 8-11
Shielded Torch Leads ............................................................................................. 8-12
Gas Hose Package ................................................................................................. 8-13
Coolant and Power Leads ....................................................................................... 8-14
Work Ground Cable ................................................................................................ 8-15
Oxygen Supply Gas Hose (Optional) ...................................................................... 8-15
Nitrogen Supply Gas Hose (Optional) ..................................................................... 8-16
Air Supply Gas Hose (Optional) .............................................................................. 8-16
H17 Supply Gas Hose (Optional) ............................................................................ 8-16
Power Supply Microprocessor P.C. Board .............................................................. 8-17
A.C. Detect P.C. Board ........................................................................................... 8-18
Relay P.C. Board .................................................................................................... 8-19
Power Supply I/O P.C. Board ................................................................................. 8-20
Automatic Gas Console I/O P.C. Board .................................................................. 8-21
Consumable Spare Parts Kit ................................................................................... 8-22
Appendix A Electromagnetic Compatibility (EMC)
Background ............................................................................................................. A-1
Installation and Use ................................................................................................ A-1
Assessment of Area ................................................................................................ A-2
Methods of Reducing Emissions ............................................................................. A-2
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
Safety
Spirit275a User’s Manual Rev K
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 Spirit275a system should
only be performed by qualified personnel. The Spirit 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 Spirit275a 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.
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
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Safety
Spirit275a User’s Manual Rev K
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 Spirit275a 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 Spirit 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 Spirit 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 Spirit power supply. Make sure the
connection is securely tightened.
Make sure the positive output (work ground) of the Spirit 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 Spirit system is switched off at the wall disconnect
before servicing the power supply or torch.
Never change torch consumable parts unless the Spirit system is
switched off at the wall disconnect.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Safety
Spirit275a User’s Manual Rev K
•
•
•
•
•
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 Spirit 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 7 for additional safety precautions.
Never operate the Spirit system without all of the covers in place. See
Section 7 for additional safety precautions.
Preventive maintenance should be performed daily to avoid possible
safety hazards.
Fire Prevention
When using the Spirit275a 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 Spirit275a 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 Spirit system in the presence of explosive gases or
other explosive materials.
Never cut pressurized cylinders or any closed container.
When using a water table and cutting aluminum under water or with
water touching the underside of the aluminum plate, hydrogen gas is
produced. This hydrogen gas may collect under the plate and explode
during the cutting process. Make sure the water table is properly
aerated to help prevent the accumulation of hydrogen gas.
Handle all gas cylinders in accordance with safety standards published
by the U.S. Compressed Gas Association (CGA), American Welding
Society (AWS), Canadian Standards Association (CSA), or other local
or national codes.
Compressed gas cylinders should be maintained properly. Never
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Safety
Spirit275a User’s Manual Rev K
•
•
•
•
•
•
•
•
•
•
•
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 Spirit275a 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
Spirit system. Observe the following guidelines to minimize exposure to
these electric and magnetic fields:
•
•
•
•
Stay as far away from the Spirit power supply, torch, torch leads, and
remote high frequency 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
Safety
Spirit275a User’s Manual Rev K
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.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Safety
Spirit275a User’s Manual Rev K
11. OSHA Standard 29CFR 1910.252, Safety and Health Standards,
obtainable from the U.S. Government Printing Office, Washington,
D.C. 20402.
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 OxygenDeficient 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
Specifications
Spirit275a User’s Manual Rev K
Section 2 Specifications
System Description
The Spirit275a is a 275 amp microprocessor controlled, 100% duty cycle
high current density plasma cutting and marking system. It utilizes a
precision, dual gas torch that is capable of cutting mild steel up to 2" thick
and stainless steel up to 1-1/2” thick. The Spirit275a is equipped with a
computer controlled automatic gas console with VGA display. All cutting
parameters are controlled from the automatic gas console. Setting up a
cut is as simple as entering the material type, material thickness, and
process (cutting or marking). All gas types and pressures are set
automatically and the cutting parameters are transmitted to the Spirit
power supply. Switching to a different screen on the gas console gives
the operator a pictorial view of the torch parts required to make the cut.
Another screen shows the recommended cutting speed and torch height
for making the cut. These parameters can even be transmitted to an x/y
machine controller or an arc voltage control system via RS-422 serial
communication. The RS-422 port also allows for full control of the cutting
parameters from an x/y machine controller. The gas console also tracks
the number of cuts made with a particular set of consumables and keeps a
detailed record of errors that may occur during the cutting sequence. To
aid in troubleshooting, a message screen on the gas console displays all
power supply and gas console sequencing. All gas inlets and outlets are
connected to the rear of the automatic gas console. For cutting mild steel,
the Spirit275a 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 Spirit275a is technologically advanced to produce the highest quality
cuts while maximizing consumable life. The torch is water-cooled and
consumables are machined to exacting dimensions and checked with the
latest computerized measuring systems. Eight nozzle sizes (30, 50, 70,
100, 150, 200, 260 and 275 amps) are available to produce excellent cut
quality throughout the cutting range.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Specifications
Spirit275a User’s Manual Rev K
System Components
The degree of protection provided by the Spirit275a system is IP21S and
as such is intended only for indoor use. It is not suitable for use in rain or
snow.
The Spirit275a system is tested in accordance with CISPR 11, EMC
classification – Group 2 ISM (Class A).
The Spirit275a consists of the following components:
Standard Components
• Power Supply
• Automatic Gas Console
• Remote High Frequency (RHF) Console
• RHF Console Control 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
• Water and Power Leads
• Gas Hose Package
• Work Ground Lead
• System Manual
• Consumable Spare Parts Kit (see Section 8 for details)
Optional Components
• Supply Gas Hoses (see Section 8 for details)
Power Supply Specifications
Stock Number:
208 VAC, 3Ø, 60Hz .......................................................... 280410
230 VAC, 3Ø, 60Hz .......................................................... 280411
380 VAC, 3Ø, 50/60Hz ...................................................... 280414
415 VAC, 3Ø, 50/60Hz ...................................................... 280415
460 VAC, 3Ø, 60Hz .......................................................... 280412
575 VAC, 3Ø, 60Hz .......................................................... 280413
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Specifications
Spirit275a User’s Manual Rev K
Input Current at Maximum Output:
208 VAC, 3Ø, 60Hz .......................................................... 147 amps
230 VAC, 3Ø, 60Hz .......................................................... 133 amps
380 VAC, 3Ø, 50/60Hz ...................................................... 81 amps
415 VAC, 3Ø, 50/60Hz ...................................................... 74 amps
460 VAC, 3Ø, 60Hz .......................................................... 67 amps
575 VAC, 3Ø, 60Hz .......................................................... 53 amps
Open Circuit Voltage ......................................... 325 VDC
Output Current (drooping characteristic)............ 10 - 275 amps
Maximum Output Voltage ................................. 180 VDC
Duty Cycle ......................................................... 100% @ 41.3 kW
Maximum Ambient Temperature ....................... 104° F (40° C)
Dimensions:
Width ............................................................ 32.5 in (826 mm)
Height (including AGC) ................................ 48 in (1219 mm)
Depth ........................................................... 43 in (1092 mm)
Weight (including AGC) .................................... 1315 lb (596 kg)
Torch Cooling System:
Discharge pressure ...................................... 150 psi (10.2 bar)
Flow rate ...................................................... 1 gal/min (3.8 liters/min)
Coolant fluid ................................................. Propylene glycol/deionized water
Coolant tank capacity ................................... 3.2 gal (12 liters)






This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Specifications
Spirit275a User’s Manual Rev K
Automatic Gas Console Specifications
Stock Number ................................................... 280002
Height ................................................................ 9 in (229 mm)
Width ................................................................. 25 in (635 mm)
Depth ................................................................ 23.8 in (605 mm)
Weight ............................................................... 110 lb (50 kg)
Gas Supply Requirements
Plasma gas types:
Mild Steel ............................................... Oxygen or Air
Stainless Steel ....................................... Air or H17
Aluminum ............................................... Air
Shield gas types:
Mild Steel ............................................... Oxygen or Air
Stainless Steel ....................................... Air or Nitrogen
Aluminum ............................................... Air or 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) ................ 79 scfh (2237 liters/hour)
Rated Inlet gas pressure ....................................... 120 psi (8.3 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. Quickconnect 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.
2-4
Specifications
Spirit275a User’s Manual Rev K
Remote High Frequency Console Specifications
Stock Number ................................................... 205500
Height ................................................................ 5.35 in (136 mm)
Width ................................................................. 13.5 in (343 mm)
Depth ................................................................ 10 in (25 mm)
Weight ............................................................... 22 lb (10 kg)
Spark gap distance ........................................... .015 in (.381 mm)













This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Specifications
Spirit275a User’s Manual Rev K
Torch Specifications
Stock Number:
2-Gang Manifold Assembly..................................... 260214
Torch Handle .......................................................... 820134
Torch Base ............................................................. 279050
Torch Head (Copper Electrode).............................. 279150
Torch Head (Silver Electrode) ................................ 279160
Weight:
Manifold/Bracket, Handle, Base and Head ............. 7.3 lbs (3.3 kg)
Manifold
3.38 [86]
Torch Handle
9.20 [234]
1.99
[51]
Torch Base
1.87 [47]
Alignment Indicator
(Slot)
Attachment Ring
Alignment Indicator
(Small 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.
2-6
Specifications
Spirit275a User’s Manual Rev K
5-Gang Manifold Specifications
Stock Number ................................................... 280022
Height ................................................................ 3.035 in (77 mm)
Width ................................................................. 8.35 in (212 mm)
Depth ................................................................ 7 in (178 mm)
Weight ............................................................... 6 lb (2.7 kg)









This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Specifications
Spirit275a User’s Manual Rev K
Airborne Noise Emissions
The Spirit275a 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
Spirit275a when operating at 275 amps, 145 arc volts.
The
measurements were made with a sound level meter.
Distance From Torch
1 meter horizontal / 1.6
meters above the
workpiece
A-Weighted Sound
Pressure Level
C-Weighted Sound
Pressure Level
110 dB
107 dB
The maximum noise level is 127 dB at a distance of 3 inches (76.2 mm)
from the torch while cutting at 275 amps, 145 arc volts.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Installation
Spirit275a User’s Manual Rev K
Section 3 Installation
Initial Inspection
All systems undergo full testing before being shipped from KALIBURN. In
the unlikely event that one of your components is defective or missing,
please contact KALIBURN so a replacement item can be sent to you.
Also, KALIBURN has taken special care in packaging your Spirit275a
system. If your system was damaged during shipment, you will have to
file a claim with the shipping company. Next, it will be necessary to
contact KALIBURN so replacement parts can be ordered. If you need
additional assistance, please contact KALIBURN.
System Interconnection
The Spirit275a system interconnection diagram shown below will assist
you in identifying cables and hoses upon receipt of your system. Electrical
cables are marked with the appropriate plug number or letter and can be
identified on the diagram. The Inova arc voltage control is also shown to
assist in its hookup.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Installation
Spirit275a User’s Manual Rev K
Power Supply Installation
The Spirit 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 power
supply dimensions.
Remote High Frequency Console Installation
The remote high frequency (RHF) console should be mounted in a
convenient location that is away from other electronic control devices.
The high voltage, high frequency signal generated inside the unit can
interfere with the operation of certain control systems. The RHF console
is usually mounted on the gantry of the cutting machine or on the cutting
table. See Section 2 for RHF console mounting dimensions.
5-Gang Manifold Installation
The 5-gang manifold assembly must be mounted within 6 feet (1.8 m) of
the torch. See Section 2 for 5-gang manifold mounting dimensions.
Torch Installation
The Spirit275a torch must be installed on the positioner of an arc voltage
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 torch 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.
3-2
Installation
Spirit275a User’s Manual Rev K
Primary Power Connection
** Before connecting primary power, check the data plate to verify
the voltage required by the Spirit power supply **
A primary disconnect switch, switching all ungrounded supply conductors,
should be provided for each Spirit power supply. 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)
208V 60Hz
230V 60Hz
380V 50/60Hz
415V 50/60Hz
460V 60Hz
575V 60Hz
147
133
81
74
67
53
Recommended
Time-Delay Fuse
Size
(amps)
200
190
125
100
95
75
Use a Type SO power cable to connect the primary power to the Spirit
power supply. The power cable should have a 600 volt minimum rating
and should be sized according to local and national codes. Route the
power cable through the lower strain relief on the rear of the power supply
and connect it to the input terminal block TB5 as shown. TB5 is located
on the base of the power supply behind the left side cover. Be sure to
connect the primary ground cable to the ground stud on the input
terminal block.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-3
Installation
Spirit275a User’s Manual Rev K



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
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
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

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 


 
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
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
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
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

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
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





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
 

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
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
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












































This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Installation
Spirit275a User’s Manual Rev K
Power Supply Output Connections
Perform the following steps to connect the output of the power supply to
the RHF console and the work table. See figure below.
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 RHF console and connect it to the cathode manifold.
Power Supply Nozzle Lead 2
1. Route one end of the #10AWG power supply nozzle lead through the
upper strain relief on the rear of the power supply and connect it to the
nozzle terminal.
2. Route the other end of the power supply nozzle Lead through the
strain relief on the RHF console and connect it to the pilot terminal on
the RHF console printed circuit board.
Power Supply CTP Sensor Lead 3
1. Route the end of the #14AWG power supply CTP sensor lead with the
ring terminal through the middle strain relief on the rear of the power
supply and connect it to the CTP terminal.
2. Route the end of the power supply CTP sensor lead with the fast-on
terminal through the strain relief on the RHF console and connect it to
the CTP sensor lead filter assembly.
RHF Console Control Cable 4
1. Connect the RHF console control cable plug labeled P16 to the
connector labeled P16 on the rear of the power supply.
2. Connect the RHF console control cable plug labeled P1 to the
connector labeled P1 on the RHF console.
Power Supply Coolant Supply Hose 5
1. Connect one end of the power supply coolant supply hose to the
coolant supply fitting on the rear of the power supply. Note that the
coolant supply fitting has right hand threads.
2. Connect the other end of the power supply coolant supply hose to the
coolant in fitting on the RHF console. Note that the coolant in fitting
has right 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.
3-5
Installation
Spirit275a User’s Manual Rev K
Power Supply Coolant Return Hose 6
1. Connect one end of the power supply coolant return hose to the
coolant return fitting on the rear of the power supply. Note that the
coolant return fitting has left hand threads.
2. Connect the other end of the power supply coolant return hose to the
coolant out fitting on the RHF console. Note that the coolant out fitting
has left hand threads.
Work Ground Lead 7
1. Route one end of the #1/0AWG work ground lead through the middle
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.
RHF Console Ground Connection
8
Perform the following steps to connect the chassis of the RHF console to
the cutting table. See figure below.
1. Connect one end of the RHF console ground lead to the ground stud
on the RHF console.
2. Connect the other end of the RHF console ground lead to chassis
ground on the cutting table. Make sure that good metal-to-metal
contact is made.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Installation
Spirit275a User’s Manual Rev K
 









This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Installation
Spirit275a User’s Manual Rev K
Torch Leads to RHF Console Connections
Perform the following steps to connect the torch leads to the RHF console.
See figure below.
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 9
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
RHF 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 RHF 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 RHF console.
Torch Electrode/Coolant Supply Lead 10
• 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 11
• 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 12
• 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 13
• 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.
3-8
Installation
Spirit275a User’s Manual Rev K
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Installation
Spirit275a User’s Manual Rev K
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
Torch Handle Installation
1. 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 10
• Connect the torch electrode/coolant supply lead to the torch base as
shown.
Torch Coolant Return Lead 11
• 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 12
• Connect the torch nozzle lead to the torch base as shown.
Torch CTP Sensor Lead 13
• Connect the torch CTP sensor lead to the torch base as shown.
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3-10
Installation
Spirit275a User’s Manual Rev K
Torch Gas Connections
Perform the following steps to connect the torch gas hoses to the
automatic gas console, torch base, and torch valve assemblies. See
figure below.
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 14
1. Route one end of the 7.5foot (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.
15 Inch Plasma Gas Hose 15
1. Route one end of the 15 inch (380 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. Mount the torch handle/base/manifold to the positioner. Note the
alignment indicators on the torch base (slot) and torch head (small
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. Connect the other end of the 15 inch (380 mm) plasma gas hose to the
plasma gas outlet on the 2-gang manifold.
6 Foot Preflow/Postflow/Marking Gas Hose 16
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 17
1. Connect one end of the marking gas hose to the marking outlet on the
rear of the AGC.
2. Connect the other end of the marking hose to the marking inlet on the
5-gang torch valve assembly.
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3-11
Installation
Spirit275a User’s Manual Rev K
Postflow Gas Hose 18
1. Connect one end of the postflow hose to the postflow outlet on the rear
of the AGC. Note that the postflow hose fittings have left hand
threads.
2. Connect the other end of the postflow hose to the postflow inlet on the
5-gang torch valve assembly.
Plasma Gas Hose 19
1. Connect on end of the plasma hose to the plasma outlet on the rear of
the AGC.
2. Connect the other end of the plasma hose to the plasma inlet on the 2gang torch valve assembly.
Shield Gas Hose 20
1. Connect one end of the shield hose to the shield outlet on the rear of
the AGC.
2. Connect the other end of the shield hose to the shield inlet on the 5gang torch valve assembly.
Preflow Gas Hose 21
1. Connect one end of the preflow hose to the preflow outlet on the rear
of the AGC. Note that the preflow hose fittings have left hand threads.
2. Connect the other end of the preflow hose to the preflow inlet on the 5gang torch valve assembly.
5-Gang Manifold Control Cable 22
1. Connect the 5-gang manifold control cable plug marked P15 to the 5gang 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 23
1. Connect the 2-gang manifold control cable plug marked P18 to the 2gang 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.
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3-12
Installation
Spirit275a User’s Manual Rev K
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Installation
Spirit275a User’s Manual Rev K
Torch Head Connection
Perform the following steps to connect the torch head to the torch base.
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 oring lubricant.
2. Align the indicator on the torch head (small 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 LEFT to tighten.
4. Keep tightening the attachment ring until it stops. As shown below, the
attachment ring will NOT cover the o-ring. This is only a visual indicator; no
seal is created. However, there should be no gap between the attachment
ring and the o-ring.
During the tightening process (after the initial install) 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.
CORRECT
INCORRECT!
O-ring
Correct
There is no
gap between
o-ring and
attachment
ring
O-ring
Incorrect!
Gap is visible
between
o-ring and
attachment
ring
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3-14
Installation
Spirit275a User’s Manual Rev K
Automatic Gas Console Input Connections
Perform the following steps to connect the gas supply lines to the
automatic gas console. 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 24 (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 25 (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 26 (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 27 (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 4 for more
information.
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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
Installation
Spirit275a User’s Manual Rev K
CNC Machine Interface Connections
Perform the following steps to properly interface the Spirit275a system
with a CNC cutting machine. See the system schematic for additional
information.
Plasma Start Input
• The Spirit275a 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 12VDC - 10mA.
Plasma Cut/Mark Input
• The Spirit275a 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
12VDC - 10mA.
Arc Hold Input
• The Spirit275a 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 12VDC - 10mA.
Motion Output
• The Spirit275a 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 .6A - 125VAC /
.6A - 110VDC / 2A - 30VDC.
Remote On/Off Input
• The Spirit275a requires a maintained contact closure between P8 pins
5 and 6 to energize the system from a remote location, provided that
the emergency stop button on the front panel is not activated. Opening
the contacts deenergizes the system. If the remote on/off feature is
not used, install a jumper between terminal block TB1 positions 7 and
8. The contacts should be rated for 24VAC – 115mA.
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3-16
Installation
Spirit275a User’s Manual Rev K
Power Supply Ready Output
• The Spirit275a 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 .6A - 125VAC / .6A - 110VDC / 2A - 30VDC.
RS-422 Serial Communication Link
• An RS-422 serial communication link can be connected between the
plug on the rear of the automatic gas console and a CNC machine or
automatic height control system. All process parameters can be
controlled via the RS-422 communication link. Also, cutting or marking
information such as initial height, cutting or marking height,
recommended arc voltage, and recommended travel speed can be
transmitted from the automatic gas console to the CNC machine or
height control. See Section 6 for additional information.
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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
Installation
Spirit275a User’s Manual Rev K
Torch Coolant Requirements
Note: Refer to the supplier’s most current Material Safety Data Sheet
for information regarding safety, handling, and storage of
torch coolant.
The Spirit275a 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 500695. For operating temperatures
below -13º C, a 50% solution of industrial grade propylene glycol can be
ordered in one-gallon containers, PN 500895, 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 water filter/deionization
cartridge should also be changed at the same time. See Section 7 for
details.
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3-18
Installation
Spirit275a User’s Manual Rev K
Initial Filling of the Torch Coolant Reservoir
Note: Never turn on the power supply before filling the torch
coolant reservoir with the proper coolant solution.
When handling coolant, it is recommended that you wear
nitrile gloves and safety glasses.
1. Remove the coolant reservoir cap and fill the reservoir with 2 gallons of
coolant solution.
2. Apply main power to the Spirit unit.
3. Depress and hold the green ON button on the Spirit control panel.
4. The coolant pump will begin pumping coolant fluid through the system.
The Coolant Flow LED will remain out until the coolant has filled the
entire system and begins flowing back into the tank. The coolant pump
will turn off if the coolant level drops below the minimum level inside
the reservoir. If this happens, add more coolant solution to the
reservoir and return to Step 3.
5. When the Coolant Flow LED illuminates, release the green ON switch.
The Spirit system should remain energized and continue pumping
coolant through the system.
6. Locate the small red push-button on top of the coolant
filter/deionization cartridge. Depress and hold the button until no air is
seen inside the clear filter housing.
7. Fill the reservoir with coolant solution until the coolant gauge indicates
full. Coolant should be added to the system any time the level drops
below half full.
8. Check for coolant leaks at all hose connections inside the power
supply, RHF console, and at the torch.
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3-19
Installation
Spirit275a User’s Manual Rev K
BLANK PAGE
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3-20
Operation
Spirit275a User’s Manual Rev K
Section 4 Operation
Power Supply Front Panel Controls
All of the Spirit controls and status indicator lights are located on the front
panel of the system as shown below. This section describes the function
of each control and indicator.
Power Off Button 1
Deenergizes the Spirit system and turns off the cooling fans and coolant
pump.
Power On Button/Indicator 2
Energizes the Spirit system and turns on the cooling fans and coolant
pump. Also illuminates to show that the system is energized.
AC Power Indicator 3
Illuminates when 3 phase power is applied to the Spirit system.
DC Power Indicator 4
Illuminates when the main contactor has been energized and D.C. current
is flowing through the torch.
Status Indicators 5
•
RHF Door Indicator
Illuminates when the RHF console door is closed securely. Remains
extinguished when the RHF console door is open.
•
Gas Console Indicator
Illuminates when the automatic gas console is operational. Remains
extinguished when there is a problem with the gas system. Check the
message screen on the automatic gas console for errors.
•
3 Phase Power Indicator
Illuminates when 3 phase power is satisfactory. Remains extinguished
when there is a problem with main 3 phase power to the system.
•
Coolant Flow Indicator
Illuminates when the coolant flow through the system is satisfactory.
Remains extinguished when the coolant flow through the system is
restricted.
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4-1
Operation
Spirit275a User’s Manual Rev K
•
Coolant Level Indicator
Illuminates when the coolant level inside the reservoir is satisfactory.
Remains extinguished when coolant must be added to the system.
•
Coolant Temperature Indicator
Illuminates when the torch coolant temperature is satisfactory.
Remains extinguished when the coolant temperature is too hot. If the
torch coolant indicator goes out, leave the unit energized until it
illuminates.
Automatic Gas Console Display 6
Shows all of the power supply and gas console settings, errors, and
sequencing.
Automatic Gas Console Keypad 7
Operator interface to automatic gas console.
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4-2
Operation
Spirit275a User’s Manual Rev K
Automatic Gas Console Keypad
All cutting information is entered on the keypad of the automatic gas
console as shown below. This section provides a description of each key
and its function.
Menu Key
The Menu key is used to select the bottom portion of a split-level key.
When the Menu key is pressed, a menu icon will appear in the upper right
hand corner of the screen. Pressing the Menu key again will clear the
icon and return to the previous mode. Pressing a split-level key while the
menu icon is visible will enter the specified mode. The following is a list
and description of menu key functions:
Menu + Material:
Menu + Current:
Menu + Voltage:
Menu + Preflow Gas:
Menu + Plasma Gas:
Menu + Shield Gas:
Menu + Pierce Delay:
Menu + Maint:
Menu + Gas Purge:
Menu + Status:
Enters the material editing mode
Enters the current editing mode
Displays the voltage screen
Enters the preflow gas editing mode
Enters the plasma gas editing mode
Enters the shield gas editing mode
Enters the pierce time editing mode
Enters the maintenance mode
Purges the cutting gases
Displays the main status screen
Arrow Keys
The Arrow keys are used to scroll up and down in order to edit or select a
particular item.
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4-3
Operation
Spirit275a User’s Manual Rev K
Function Keys
The Function keys are used for various purposes in the editing and
maintenance modes. The help prompt instructs the user on the use of the
Function keys.
Numerical Keys
The Numerical keys are used for entering and editing parameters.
Automatic Gas Console Help Prompt
Help prompts are displayed on the automatic gas console screen to assist
the user. Different screens may have more than one help prompt, but the
help prompts will always appear near the bottom of the screen.
Help Prompt
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4-4
Operation
Spirit275a User’s Manual Rev K
Automatic Gas Console Status Screen
When the automatic gas console is in the status mode, the status screen
is displayed as shown. The status screen displays all of the primary
cutting or marking parameters. To edit a parameter on the status screen,
the arrow keys can be used to scroll through the different parameters or
the Menu key can be used as described previously. Note that when the
Menu key is pressed, the Menu icon appears in the upper right hand
corner of the screen as shown. To return to the status mode from another
mode, press the Menu key then the Status key. The status screen also
displays the Please Wait icon while the gas pressures are being adjusted
or when an error occurs with the gas system.
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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
Operation
Spirit275a User’s Manual Rev K
Setting up a Cut or Mark
The automatic gas console makes it very simple to set up the machine.
Material type, material thickness, and process (cutting or marking) are the
only parameters that must be set. All other parameters are adjusted
automatically. Perform the following steps to enter the data. See Section
5 for advanced functions of the automatic gas console.
Selecting Material Type
From the status mode, press the down arrow once to scroll down to
substance, or press Menu, then Material. The substance area should be
highlighted as shown below and the substance type should be blinking.
To change the substance type, press F3 as indicated by the help prompt.
Pressing F3 repeatedly will scroll through the list of possible substance
choices. The available substance types are as follows:
•
•
•
•
•
Mild Steel - Cold Rolled
Mild Steel - Hot Rolled
Stainless Steel
Aluminum
Other
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4-6
Operation
Spirit275a User’s Manual Rev K
Setting Material Thickness
To set the material thickness, use the down arrow to scroll down to
Thickness. The material thickness should be highlighted as shown below
and the editing cursor should be blinking. Use the numerical keypad to
enter the material thickness. Use the CLR key to backspace if an error is
made. Press the enter key when the correct value has been entered.
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4-7
Operation
Spirit275a User’s Manual Rev K
Selecting Process
The Spirit system has the capability of plasma cutting and plasma marking
with the same set of consumables. The process (cutting or marking) can
be set by the RS-422 serial interface, by a hard signal on the CNC
interface plug, or locally at the automatic gas console. See Section 5,
Automatic Gas Console Advanced Functions, for instructions on setting up
how switching between cutting and marking is performed. To set the
operating process, use the down arrow to scroll down to Process. The
process area should be highlighted as shown below and the process
should be blinking. To change the process, press F3 as indicated by the
help prompt. Repeatedly pressing F3 will alternate between cutting and
marking. Press the enter key when the desired process has been
selected. At this point, the default parameters are selected and adjusted
automatically for the material type, material thickness, and process
selected. Note that the CNC machine can override the selected process
unless the cut/mark/cut configuration is set to Local.
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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
Operation
Spirit275a User’s Manual Rev K
Viewing Recommended Height Control and X/Y Machine Settings
Prior to making a cut or mark with the system, the torch height control and
the x/y cutting machine must be configured properly. To view the
recommended cutting data, press the Menu key, then Voltage. The
voltage screen will be displayed as shown. The x/y machine speed should
be set to the value shown. Also, the height control should be set to the
proper pierce (initial) height, cutting (marking) height and arc voltage. If a
KALIBURN Inova height control is being used, simply press the F3 key to
automatically transmit the parameters to the Inova. Optionally, the Spirit
system can be set to automatically send the cutting/marking parameters.
See Section 5 for information on configuring the Inova height control
parameter transmit feature.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-9
Operation
Spirit275a User’s Manual Rev K
Viewing the Torch Parts Required
Once the material substance and thickness have been chosen, the default
cutting parameters are selected and adjusted accordingly. To display a
pictorial view of the torch parts required to make the cut or mark, scroll
down to Torch Parts and press enter. An example of the torch parts
screen is displayed below.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-10
Operation
Spirit275a User’s Manual Rev K
Torch Consumable Selection
Mild Steel
Copper Electrode
Outer
Retaining Cap
277154
Shield
Cap
277145
Inner
Retaining Cap
277153
277120
Swirl
Ring
277140
Copper
Electrode
277130
Torch
Head
279150
277154
277115
277153
277122
277140/
277142
277131
279150
277154
277150
277153
277125
277142
277131
279150
277154
277286
277151
277284
277283
277282
279150
277154
277117
277151/
277152
277293
277139
277292
279150
277154
277274
277266
277289
277143
277291
279150
277154
277263
277266
277269
277258
277270
279150
Nozzle
30A
50A
70A
100A
150A
200A
275A
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-11
Operation
Spirit275a User’s Manual Rev K
Mild Steel
Silver Electrode
Outer
Retaining Cap
Shield
Cap
Inner
Retaining Cap
Nozzle
Swirl
Ring
277154
277274
277266
279489
279443
277154
277263
277266
279469
279458
Silver
Electrode
279440
(yellow o-ring)
Torch
Head
279160
200A
279450
(red o-ring)
279160
275A
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-12
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - H17 Plasma
Copper Electrode
Outer
Retaining Cap
277154
Shield
Cap
277150
Inner
Retaining Cap
277113
277124
Swirl
Ring
277140
Copper
Electrode
277132
Torch
Head
279150
277154
277146
277113
277126
277141
277133
279150
277154
277298
277266
277297
277139
277135
279150
277154
277274
277266
277287
277259
277135
279150
277154
277211
277280
277118
277139
277135
279150
Nozzle
70A
100A
150A
200A
260A
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-13
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - Air or Nitrogen Plasma
Copper Electrode
Outer
Retaining Cap
277154
Shield
Cap
277144
Inner
Retaining Cap
277110
277121
Swirl
Ring
277138
Copper
Electrode
277137
Torch
Head
279150
277154
277149
277110
277123
277142
277137
279150
277154
277150
277153
277125
277142
277131
279150
277154
277286
277151
277284
277283
277282
279150
277154
277117
277152
277293
277139
277292
279150
277154
277274
277266
277289
277143
277291
279150
277154
277263
277266
277276
277258
277270
279150
Nozzle
30A
50A
70A
100A
150A
200A
275A
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-14
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - Air or Nitrogen Plasma
Silver Electrode
Outer
Retaining Cap
Shield
Cap
Inner
Retaining Cap
Nozzle
Swirl
Ring
277154
277274
277266
279489
279443
Silver
Electrode
279440
(yellow o-ring)
Torch
Head
279160
200A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-15
Operation
Spirit275a User’s Manual Rev K
Aluminum
Copper Electrode
Outer
Retaining Cap
277154
Shield
Cap
277145
Inner
Retaining Cap
277153
277120
Swirl
Ring
277140
Copper
Electrode
277130
Torch
Head
279150
277154
277150
277153
277122
277142
277131
279150
277154
277150
277153
277125
277142
277131
279150
277154
277286
277151
277284
277283
277282
279150
277154
277117
277152
277293
277139
277292
279150
277154
277274
277266
277289
277143
277291
279150
277154
277263
277266
277276
277258
277270
279150
Nozzle
30A
50A
70A
100A
150A
200A
275A
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-16
Operation
Spirit275a User’s Manual Rev K
Aluminum
Silver Electrode
Outer
Retaining Cap
Shield
Cap
Inner
Retaining Cap
Nozzle
Swirl
Ring
Silver
Electrode
279440
277154
277274
277266
279489
279443
(yellow o-ring)
277154
277263
277266
279469
279458
(red o-ring)
Torch
Head
279160
200A
279450
279160
275A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-17
Operation
Spirit275a User’s Manual Rev K
Installing and Removing Torch Consumables
Turn off the plasma power supply before continuing with this procedure.
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.
Note: Do not over tighten the consumables! Only tighten until the
parts are seated properly.
1. Unthread the quick-disconnect torch head from the torch base by
turning the attachment ring to the RIGHT.
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 277056) 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 in the left image below. Do not use a
prying or bending motion as in the right image below.
CORRECT
INCORRECT!
PULL
OR
PULL
6. Use the swirl ring removal tool (P/N 260105) to remove the swirl ring
from the nozzle.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-18
Operation
Spirit275a User’s Manual Rev K
7. If using a copper electrode, use the tool (P/N 277087) to remove the
electrode from the torch head. If using a silver electrode, use the tool
(P/N 279061) to remove the silver electrode from the torch head.
8. Inspect all consumables and o-rings for damage and excess wear.
Exchange for new consumables as necessary.
9. Inspect the cooling tube in the torch head for damage. See Section 7
Maintenance and Troubleshooting if replacement is necessary.
Making a Cut or Mark
Once the material type, thickness, and process have been entered, the
correct torch parts are installed, and the x/y machine and height control
systems have been properly configured, perform the following steps to cut
or mark with the system:
1. Depress and hold the Power On button until the Coolant Flow status
LED illuminates. If the Coolant Flow led fails to illuminate after 10
seconds, see the maintenance section for possible solutions.
2. The automatic gas console will purge the gas hoses and set the
correct gas pressures automatically. After the pressures have been
set correctly, the Gas Console status LED will illuminate.
3. Once the Gas Console LED illuminates, the unit is ready for cutting or
marking. Upon the reception of a cycle start signal, the following
sequence will take place:
• Two second gas preflow
• High frequency starting circuit energized
• Pilot arc initiation
• Transferred arc (cutting or marking arc) established
• Motion output relay energized
4. Upon removal of the cycle start signal, the arc will be extinguished and
the motion output relay will be 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.
4-19
Operation
Spirit275a User’s Manual Rev K
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
machine 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 machine motion delay
time. 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.
4-20
Operation
Spirit275a User’s Manual Rev K
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 (slowspeed 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.
4-21
Operation
Spirit275a User’s Manual Rev K
Changing Consumable Parts
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
Outer Cap
Shield Cap
Retaining Cap
Nozzle
Swirl Ring
Electrode
Inspect For
Corrective Action
Dents, cracks
Replace outer cap
Center hole out of round
Replace shield cap
Dents, Scratches
Replace shield cap
Dry o-ring
Apply a thin film of o-ring lubricant
Damaged o-ring
Replace shield cap
Center hole out of round
Replace retaining cap
Dents, cracks
Replace retaining cap
Dry o-ring
Apply a thin film of o-ring lubricant
Damage o-ring
Replace retaining cap
Center hole out of round
Replace nozzle
Erosion or arcing
Replace nozzle
Dry o-rings
Apply a thin film of o-ring lubricant
Damaged o-rings
Replace nozzle
Damage
Replace swirl ring
Clogged holes
Blow out with compressed air. Replace
swirl ring if clogs can’t be removed.
Dry o-rings
Apply a thin film of o-ring lubricant
Damaged o-rings
Replace swirl ring
Pit depth
Replace electrode if center pit depth is
greater than .040” (1 mm)
Erosion or arcing
Replace electrode
Dry o-rings
Apply a thin film of o-ring lubricant
Damaged o-rings
Replace electrode
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-22
Operation
Spirit275a User’s Manual Rev K
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
490
50
390
70
300
100
300
150
175
200
195
260
175
275
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.
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 the error tracking feature on the automatic gas console to
keep track of cut errors. See Section 5 for information on the error
tracking feature.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-23
Operation
Spirit275a User’s Manual Rev K
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
Current
Plasma Gas
Shield Gas
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Mild Steel
30 Amps
50 Amps
70 Amps
100 Amps
150 Amps
200 Amps
275 Amps
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen or Air
Air
Air
Air
Air
Air
Copper
Electrode
Page 4-25
Page 4-26
Page 4-27
Page 4-28
Page 4-29
Page 4-30
Page 4-31
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
30 Amps
50 Amps
70 Amps
70 Amps
100 Amps
100 Amps
150 Amps
150 Amps
200 Amps
200 Amps
260 Amps
275 Amps
Air
Air
H17
Air
H17
Air
H17
Air
H17
Air
H17
Air
Air
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Page 4-32
Page 4-33
Page 4-34
Page 4-35
Page 4-36
Page 4-37
Page 4-38
Page 4-39
Page 4-40
Page 4-41
Page 4-42
Page 4-43
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
30 Amps
50 Amps
70 Amps
100 Amps
150 Amps
200 Amps
275 Amps
Air
Air
Air
Air
Air
Air
Air
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Page 4-44
Page 4-45
Page 4-46
Page 4-47
Page 4-48
Page 4-49
Page 4-50
Silver
Electrode
Page 4-51
Page 4-52
Page 4-53
Page 4-54
Page 4-55
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-24
Operation
Spirit275a User’s Manual Rev K
Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield
Copper Electrode
Shield Cap
277145
Outer Cap
277154
Nozzle
277120
Retaining Cap
277153
Swirl Ring
277140
Imperial
Material
Thickness
Electrode
277130
Torch Head
279150
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
100
.062
(ga)
(in)
20
.036
120
105
.080
18
.048
121
97
.090
16
.060
125
78
14
.075
126
65
12
.105
127
55
11
.120
129
50
10
.135
131
40
35
85
6
84
Metric
.110
.105
.065
200
.120
.125
300
.070
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
1
120
2615
2.0
100
1.6
1.5
124
2020
2.6
35
2
85
6
84
126
2.5
3
128
1615
2.8
1455
1285
2.9
1.7
200
2.7
3.1
1.8
300
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
145
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.177
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
4.5
.100
2.5
0
1. Revised on 10/21/2009
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-25
Operation
Spirit275a User’s Manual Rev K
Mild Steel - 50 Amps - Oxygen Plasma / Oxygen or Air Shield
Copper Electrode
Shield Cap
277115
Outer Cap
277154
Nozzle
277122
Retaining Cap
277153
Swirl Ring
277140 / 277142
Imperial
Material
Thickness
(ga)
(in)
12
.105
11
.120
10
.135
14
.075
12
.105
Electrode
277131
Torch Head
279150
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
100
.075
200
.078
100
.075
200
.080
.200
300
.085
.225
400
.087
Cold-Rolled Steel – Oxygen Shield – Swirl Ring 277140
25
74
12
73
123
70
.120
126
60
.125
128
50
.135
.135
Hot-Rolled Steel – Air Shield – Swirl Ring 277142
190
110
170
3/16
113
105
1/4
117
75
.125
10
200
106
.135
25
74
19
.100
.135
180
73
Metric
.110
.140
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
Cold-Rolled Steel – Oxygen Shield – Swirl Ring 277140
2.5
25
3
74
12
73
121
1895
2.9
125
1555
3.1
3.4
100
1.9
200
2.0
Hot-Rolled Steel – Air Shield – Swirl Ring 277142
2.5
106
3
25
5
74
19
73
6
4885
2.5
4660
113
2555
116
2075
3.4
5.1
3.6
5.5
100
1.9
200
2.0
400
2.2
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
145
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.147
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
3.7
.100
2.5
0
1. Revised 10/21/2009
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-26
Operation
Spirit275a User’s Manual Rev K
Mild Steel - 70 Amps - Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
277150
Outer Cap
277154
Nozzle
277125
Electrode
277131
Retaining Cap
277153
Swirl Ring
277142
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/8
35
3/16
25
1/4
80
40
79
3/8
Metric
110
190
113
130
116
120
122
75
.150
100
.200
200
.110
.225
300
.140
.250
400
.100
.080
.085
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
109
4995
3.6
100
113
3265
115
3105
3
35
25
5
80
6
40
79
2.5
5.1
2.7
2.0
300
5.5
2.2
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
135
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.096
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
2.4
.100
2.5
0
1. Revised on 12/01/2009
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-27
Operation
Spirit275a User’s Manual Rev K
Mild Steel - 100 Amps - Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
277286
Outer Cap
277154
Nozzle
277284
Electrode
277282
Retaining Cap
277151
Swirl Ring
277283
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/4
125
3/8
25
1/2
94
26
130
93
150
.090
.200
300
100
.130
.250
400
65
.155
.300
500
5/8
143
47
3/4
145
35
Metric
.185
.090
.325
800
.350
1000
.095
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
124
3950
2.1
4.9
300
2405
3.3
6.5
1850
3.7
7.3
6
10
25
12
94
26
130
93
16
143
1180
20
145
800
8.3
4.7
9.0
2.3
500
1000
2.4
Initial
Height
Pierce
Time
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
130
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
(mm)
(in)
(mm)
(msec)
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
1. Revised on 10/21/2009
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-28
Operation
Spirit275a User’s Manual Rev K
Mild Steel - 150 Amps – Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
277117
Outer Cap
277154
Nozzle
277293
Electrode
277292
Retaining Cap
277151 / 277152
Swirl Ring
277139
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
Retaining Cap 277151
1/4
20
3/8
74
30
67
1/2
118
165
.105
.200
300
123
125
.135
.250
400
125
90
.140
.300
500
.130
.325
600
.130
.350
1000
.135
1500
.140
.125
Retaining Cap 277152
5/8
127
70
3/4
130
55
134
40
.150
1.25 **
145
25
.200
1.5 **
155
15
.225
20
1
74
45
67
Metric
.140
.400
.350
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
300
Retaining Cap 277151
6
20
10
74
30
67
12
117
4305
2.6
4.9
123
3040
3.4
6.5
124
2485
3.5
7.3
3.2
500
3.3
Retaining Cap 277152
16
127
1760
130
1340
133
1040
3.7
10.1
32 **
145
625
5.1
8.9
38 **
154
385
5.6
8.9
20
20
25
74
45
67
8.3
3.6
1000
9.0
3.3
3.4
1500
3.6
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
135
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
** Edge start recommended
1. Revised on 12/01/09
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-29
Operation
Spirit275a User’s Manual Rev K
Mild Steel - 200 Amps – Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
277274
Outer Cap
277154
Nozzle
277289
Electrode
277291
Retaining Cap
277266
Swirl Ring
277143
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/4
125
230
.040
.200
300
3/8
130
140
.090
.250
400
1/2
133
120
.115
.300
500
5/8
137
100
.130
.350
600
.152
3/4
140
75
.150
.400
800
.153
147
50
.175
.450
1000
155
25
.240
.500
20
1
82
58
75
1.25
1.5 **
165
17
.300
1.75 **
175
12
.350
2.0 **
185
7
.500
.500
Metric
.350
.150
1500
.155
158
.160
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
300
6
124
6100
.8
4.9
10
130
3480
2.3
6.5
12
132
3160
2.7
7.3
16
137
2515
3.3
8.9
20
141
1810
3.8
10.3
146
1310
4.3
11.3
20
25
82
58
75
32
155
610
6.1
12.7
38 **
164
435
7.5
8.9
45 **
175
295
9.2
9.2
50 **
183
195
12.2
12.2
3.8
500
800
1000
3.9
1500
4.0
4.1
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
120
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
** Edge start recommended
(Revised 12/01/09
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-30
Operation
Spirit275a User’s Manual Rev K
Mild Steel - 275 Amps - Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
277263
Outer Cap
277154
Nozzle
277269
Electrode
277270
Retaining Cap
277266
Swirl Ring
277258
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
125
.140
.300
500
105
.135
.325
600
1/2
139
5/8
.165
3/4
138
90
.120
.350
800
1
144
65
.160
.400
1000
150
45
.175
.500
1.25
20
1.50 **
93
70
83
.170
.185
163
25
.235
1.75 **
170
20
.290
2.00 **
180
15
.350
2.25 **
185
13
.375
.375
.260
2.50 **
190
9
.385
.385
.275
Metric
.350
1500
.190
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
139
3290
3.6
7.4
500
2650
3.3
8.3
800
12
16
138
20
2190
3.1
9.0
25
143
1690
4.0
10.1
32
150
1120
4.4
12.8
20
38 **
93
70
83
4.2
1000
4.3
4.7
162
645
5.9
45 **
170
495
7.5
50 **
178
395
8.7
55 **
183
345
9.2
9.2
6.6
60 **
187
285
9.6
9.6
6.9
8.9
1500
4.8
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
108
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .300” (7.6 mm) for cutting and .100” (2.5 mm) for marking
** Edge start recommended.
(Revised 10/22/09)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-31
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 30 Amps - Air Plasma / Air Shield
Copper Electrode
Shield Cap
277144
Outer Cap
277154
Nozzle
277121
Retaining Cap
277110
Swirl Ring
277138
Imperial
Material
Thickness
(ga)
(in)
20
.036
18
.048
16
.060
14
.075
Electrode
277137
Torch Head
279150
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
200
.020
100
.065
71
30
80
30
80
Metric
165
.050
.035
74
125
75
90
.025
.068
200
.070
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
71
4855
0.6
73
3260
0.9
1
1.5
30
80
30
80
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
145
100
1.3
1.7
200
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.177
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
4.5
.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
(Revised 12/1/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-32
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 50 Amps – Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277149
Outer Cap
277154
Nozzle
277123
Retaining Cap
277110
Swirl Ring
277142
Imperial
Material
Thickness
Electrode
277137
Torch Head
279150
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
(ga)
(in)
14
.075
87
105
12
.105
88
75
11
.120
89
65
10
.135
90
55
3/16
94
50
.040
.080
300
1/4
100
40
.060
.125
400
.115
30
70
40
70
Metric
100
.035
.105
.070
200
.110
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
.9
1.8
2
87
2.5
30
3
70
40
70
2565
2080
88
1685
5
94
1235
1.0
2.1
6
98
1075
1.3
2.9
100
2.7
200
2.8
400
2.9
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
145
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.147
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
3.7
.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
(Revised 10/21/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-33
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives the best cut quality and minimum dross levels
Shield Cap
277150
Outer Cap
277154
Nozzle
277124
Electrode
277132
Retaining Cap
277113
Swirl Ring
277140
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
3/16
35
60
36
60
135
80
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
5
35
60
36
60
135
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
135
Metric
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.100
.200
300
.090
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm/m)
(mm)
(mm)
(msec)
(mm)
2030
2.5
5.1
300
2.3
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.096
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
2.4
.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
(Revised 12/1/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-34
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 70 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
277150
Outer Cap
277154
Nozzle
277125
Retaining Cap
277153
Swirl Ring
277142
Imperial
Material
Thickness
(ga)
(in)
10
Electrode
277131
Torch Head
279150
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
.135
132
120
.060
.150
200
3/16
134
100
.070
.200
300
140
75
.090
.225
400
148
50
.120
.250
500
1/4
25
80
25
79
3/8
Metric
.085
.090
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
131
3210
1.4
3.3
200
134
2445
1.8
5.1
138
2050
2.1
5.5
3
25
5
80
25
79
6
2.2
400
2.3
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
135
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.096
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
2.4
.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
(Revised 10/22/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-35
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 100 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives the best cut quality and minimum dross levels
Shield Cap
277146
Outer Cap
277154
Nozzle
277126
Electrode
277133
Retaining Cap
277113
Swirl Ring
277141
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
138
115
.105
.200
300
.100
28
67
46
67
140
100
.125
.225
400
152
65
.180
.250
500
3/16
1/4
3/8
Metric
.105
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
138
2865
2.7
5.1
139
2625
3.0
5.5
5
6
28
67
46
67
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
130
2.5
400
2.7
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
(Revised 12/1/09)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-36
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
277286
Outer Cap
277154
Nozzle
277284
Electrode
277282
Retaining Cap
277151
Swirl Ring
277283
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
141
100
.135
.225
400
.092
25
94
35
93
147
80
.170
.250
500
154
55
.210
.300
600
1/4
3/8
1/2
Metric
.095
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
140
2595
3.2
5.6
400
2.3
148
1935
4.4
6.5
152
1540
5.0
7.3
600
2.4
6
25
10
94
35
93
12
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
130
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
(Revised 10/21/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-37
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 150 Amps – H17 Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives the best cut quality and minimum dross levels
Shield Cap
277298
Outer Cap
277154
Nozzle
277297
Electrode
277135
Retaining Cap
277266
Swirl Ring
277139
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/4
95
.250
.250
400
3/8
75
.150
.275
500
25
1/2
81
75
81
165
.135
60
.165
.300
600
5/8
50
.185
.325
800
3/4
40
.250
.350
1200
.145
Metric
.140
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
1845
3.8
7.0
1610
4.1
7.4
1260
4.7
8.3
800
940
6.9
9.0
1200
3.7
Initial
Height
Pierce
Time
10
12
25
16
81
75
155
81
20
167
3.4
600
3.6
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
135
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
(mm)
(in)
(mm)
(msec)
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
(Revised 12/01/09)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-38
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
277117
Outer Cap
277154
Nozzle
277293
Electrode
277292
Retaining Cap
277152
Swirl Ring
277139
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/4
145
150
.160
.250
400
3/8
150
115
.180
.275
500
25
1/2
75
70
67
.125
155
85
.210
.300
600
5/8
160
60
.220
.325
800
3/4
168
45
.240
.350
1200
.135
Metric
.130
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(mm)
(volts)
(mm/m)
(mm)
(mm)
(msec)
6
144
3910
4.0
6.3
400
10
150
2805
4.7
7.0
25
12
75
70
67
3.2
600
153
2330
5.1
7.4
16
160
1510
5.6
8.3
800
20
170
1030
6.2
9.0
1200
3.3
3.4
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
135
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
(Revised 12/01/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-39
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 200 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives the good cut quality and minimum dross levels
Shield Cap
277274
Outer Cap
277154
Nozzle
277287
Electrode
277135
Retaining Cap
277266
Swirl Ring
277259
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
3/8
156
80
.195
.250
500
1/2
148
75
.130
.300
600
37
5/8
68
85
68
.150
155
60
.190
.350
800
3/4
160
50
.200
.400
1200
1.0
170
35
.240
.450
1500
.160
Metric
.155
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(msec)
(mm)
600
3.8
(volts)
(mm/m)
(mm)
(mm)
10
154
2010
4.7
6.5
12
149
1935
3.6
7.3
37
16
68
85
68
155
1515
4.8
8.9
20
161
1215
5.2
10.3
25
169
915
6.0
11.3
800
3.9
1500
4.1
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
120
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
(Revised 12/01/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-40
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 200 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
277274
Outer Cap
277154
Nozzle
277289
Electrode
277291
Retaining Cap
277266
Swirl Ring
277143
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/4
130
200
3/8
133
150
.200
400
.250
500
1/2
140
110
5/8
146
75
.115
.300
600
.150
.350
800
153
60
.190
.400
1200
1.0
158
40
.210
.450
1.25 **
170
20
.250
.350
1.50 **
180
10
.275
.350
20
3/4
82
58
75
Metric
.070
.150
.152
.155
.160
1500
.165
.175
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
400
6
129
5220
1.8
4.9
10
134
3655
1.9
6.5
12
138
3020
2.6
7.3
146
1890
3.8
8.9
16
20
20
82
58
75
153
1450
4.8
10.3
25
157
1050
5.2
11.3
32 **
170
495
6.4
8.9
38 **
179
260
6.9
8.9
3.8
600
800
1500
3.9
4.1
4.2
4.4
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
25
25
N/A
120
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
** Edge start recommended
(Revised 12/01/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-41
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 260 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives the best cut quality and minimum dross levels
Shield Cap
277211
Outer Cap
277154
Nozzle
277118
Electrode
277135
Retaining Cap
277280
Swirl Ring
277139
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
3/8
145
85
.160
.250
500
1/2
142
80
.140
.300
600
145
65
.185
.350
800
150
55
.225
.400
1200
5/8
40
3/4
63
70
63
1.0
160
33
.250
.450
1.25 **
170
26
.280
.350
Metric
.190
1500
.195
.200
.205
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
10
144
2140
4.0
6.5
12
142
2060
3.7
7.3
600
4.8
145
1640
4.7
8.9
151
1315
5.8
10.3
16
40
20
63
70
63
25
159
875
6.3
11.3
32 **
170
650
7.1
8.7
800
5.0
1500
5.1
5.2
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
108
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
** Edge start recommended
(Revised 12/01 /2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-42
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 275 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
277263
Outer Cap
277154
Nozzle
277276
Electrode
277270
Retaining Cap
277266
Swirl Ring
277258
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/2
143
120
.125
.300
600
5/8
148
90
.140
.350
800
152
80
.180
.400
1200
165
55
.210
.450
1.25 **
175
35
.250
.350
1.50 **
185
25
.300
.350
3/4
20
1.0
93
70
83
Metric
.165
1500
.170
.180
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
12
141
3220
3.1
7.3
600
16
148
2275
3.6
8.9
800
153
1940
4.7
10.3
164
1435
5.2
11.3
32 **
175
880
6.4
8.9
38 **
184
640
7.5
8.9
20
20
25
93
70
83
4.2
4.3
1500
4.6
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
108
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
** Edge start recommended
(Revised 10/22/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-43
Operation
Spirit275a User’s Manual Rev K
Aluminum - 30 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277145
Outer Cap
277154
Nozzle
277120
Electrode
277130
Retaining Cap
277153
Swirl Ring
277140
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
30
92
20
90
135
.100
100
.065
.150
200
.070
.040
150
.050
.063
.030
120
90
Metric
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
2.5
100
1.7
3.4
200
1.8
1
1.5
30
92
20
90
135
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
145
3885
0.8
2520
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.177
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
4.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .100” (2.5 mm) for cutting and .100” (2.5 mm) for marking
(Revised 12/01/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-44
Operation
Spirit275a User’s Manual Rev K
Aluminum - 50 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277150
Outer Cap
277154
Nozzle
277122
Electrode
277131
Retaining Cap
277153
Swirl Ring
277142
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
135
180
.050
100
.080
25
74
19
73
138
140
.065
150
.082
143
90
.075
.150
200
.085
.050
.063
.080
Metric
.100
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
137
3870
1.5
2.5
150
2.1
142
2360
1.8
3.7
200
2.2
1.5
2.0
25
74
19
73
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
145
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.147
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
3.7
.100
2.5
0
* Use an arc transfer height (ignition height) of .100” (2.5 mm) for cutting and .100” (2.5 mm) for marking
(Revised 10/21/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-45
Operation
Spirit275a User’s Manual Rev K
Aluminum - 70 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277150
Outer Cap
277154
Nozzle
277125
Electrode
277131
Retaining Cap
277153
Swirl Ring
277142
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
.080
130
250
.050
.150
1/8
135
160
.070
.175
100
.080
145
80
.100
.200
200
150
50
.060
.250
300
3/8
155
40
.075
.275
400
1/2
162
30
.115
.300
500
3/16
25
1/4
80
25
79
Metric
.085
.090
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
100
2.0
300
2.2
500
2.3
2
129
6400
1.2
3.7
3
134
4420
1.7
4.3
145
1920
2.3
5.2
148
1440
1.7
6.1
10
156
975
2.0
7.0
12
160
820
2.6
7.4
5
25
6
80
25
79
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
135
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.096
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
2.4
.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
(Revised 10/22/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-46
Operation
Spirit275a User’s Manual Rev K
Aluminum - 100 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277286
Outer Cap
277154
Nozzle
277284
Electrode
277282
Retaining Cap
277151
Swirl Ring
277283
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
158
105
.155
.250
300
.095
25
94
26
93
162
90
.180
.275
400
.098
165
70
.195
.300
500
.100
1/4
3/8
1/2
Metric
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
158
2710
3.8
6.3
300
2.4
162
2210
4.6
7.0
165
1890
4.9
7.4
500
2.5
6
25
10
94
26
93
12
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
130
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
(Revised 02/23/2010)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-47
Operation
Spirit275a User’s Manual Rev K
Aluminum - 150 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277117
Outer Cap
277154
Nozzle
277293
Electrode
277292
Retaining Cap
277152
Swirl Ring
277139
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/4
145
145
.130
.250
400
3/8
155
115
.185
.275
500
165
90
.230
.300
600
.130
.325
800
.135
.350
1200
.140
25
1/2
75
50
67
5/8
170
3/4
Metric
65
.250
45
.125
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
6
143
3770
3.1
6.3
400
10
156
2825
4.8
7.0
5.5
7.4
25
12
75
50
67
162
2430
16
170
1630
20
170
990
8.3
6.4
9.0
3.2
600
3.3
1200
3.4
3.6
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
135
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
(Revised 12/01/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-48
Operation
Spirit275a User’s Manual Rev K
Aluminum - 200 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277274
Outer Cap
277154
Nozzle
277289
Electrode
277291
Retaining Cap
277266
Swirl Ring
277143
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/4
150
3/8
155
1/2
20
5/8
82
58
75
160
3/4
1.0 **
Metric
190
.135
.250
300
145
.140
.275
400
.300
500
.350
600
110
.135
95
65
.150
175
35
.200
.400
.150
.155
800
.160
1000
.170
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
149
4955
3.3
6.3
300
3545
3.5
7.0
6
10
155
12
20
16
82
58
75
2995
7.4
3.4
160
2380
20
162
1575
3.9
25 **
174
940
5.0
3.8
500
3.9
8.9
800
10.2
1000
4.1
4.3
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
120
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
** Edge start recommended
(Revised 10/21/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-49
Operation
Spirit275a User’s Manual Rev K
Aluminum - 275 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277263
Outer Cap
277154
Nozzle
277276
Electrode
277270
Retaining Cap
277266
Swirl Ring
277258
Imperial
Torch Head
279150
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
3/8
160
160
.160
.275
400
1/2
165
125
.180
.300
500
168
105
.190
.350
600
172
85
.200
1.00 **
180
60
.240
1.25 **
185
45
.260
1.50 **
190
25
.270
5/8
20
3/4
93
65
83
Metric
.160
.165
800
.400
1000
.170
.180
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
10
160
3930
4.1
7.1
12
163
3375
4.4
7.4
500
4.1
168
2645
4.8
8.9
173
2055
5.3
800
4.2
25 **
179
1565
6.0
32 **
185
1120
6.6
38 **
189
645
6.8
16
20
20
93
65
83
10.2
1000
4.3
4.6
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
108
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .275” (7.0 mm) for cutting and .100” (2.5 mm) for marking
** Edge start recommended
(Revised10/22/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-50
Operation
Spirit275a User’s Manual Rev K
Mild Steel - 200 Amps – Oxygen Plasma / Air Shield
Silver Electrode
Shield Cap
277273
Outer Cap
277154
Nozzle
279489
Electrode
279440
(yellow o-ring)
Retaining Cap
277266
Swirl Ring
279443
Imperial
Torch Head
279160
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(volts)
(ipm)
(in)
(in)
(msec)
1/4
125
230
.040
.200
300
3/8
130
140
.090
.250
400
1/2
133
120
.115
.300
500
5/8
137
100
.130
.350
600
.152
3/4
140
75
.150
.400
800
.153
147
50
.175
.450
1000
155
25
.240
.500
20
1
82
58
75
1.25
1.5 **
165
17
.300
1.75 **
175
12
.350
2.0 **
185
7
.500
.500
Metric
.350
.150
1500
.155
158
.160
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
300
6
124
6100
.8
4.9
10
130
3480
2.3
6.5
12
132
3160
2.7
7.3
16
137
2515
3.3
8.9
20
141
1810
3.8
10.3
146
1310
4.3
11.3
20
25
82
58
75
32
155
610
6.1
12.7
38 **
164
435
7.5
8.9
45 **
175
295
9.2
9.2
50 **
183
195
12.2
12.2
3.8
500
800
1000
3.9
1500
4.0
4.1
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
120
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
** Edge start recommended
(Revised 12/01/09
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-51
Operation
Spirit275a User’s Manual Rev K
Mild Steel - 275 Amps - Oxygen Plasma / Air Shield
Silver Electrode
Shield Cap
277263
Outer Cap
277154
Nozzle
279469
Electrode
279450
(red o-ring)
Retaining Cap
277266
Swirl Ring
279458
Imperial
Torch Head
279160
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
125
105
1/2
139
5/8
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.140
.300
500
.135
.325
600
.165
3/4
138
90
.120
.350
800
1
144
65
.160
.400
1000
1.25
150
45
.175
.500
20
1.50 **
93
70
83
.170
.185
163
25
.235
1.75 **
170
20
.290
2.00 **
180
15
.350
2.25 **
185
13
.375
.375
.260
2.50 **
190
9
.385
.385
.275
Metric
.350
1500
.190
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
139
3290
3.6
7.4
500
2650
3.3
8.3
800
12
16
138
20
4.2
2190
3.1
9.0
143
1690
4.0
10.1
150
1120
4.4
12.8
162
645
5.9
45 **
170
495
7.5
50 **
178
395
8.7
55 **
183
345
9.2
9.2
6.6
60 **
187
285
9.6
9.6
6.9
25
32
20
38 **
93
70
83
8.9
1000
4.3
4.7
1500
4.8
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
28
N/A
108
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .300” (7.6 mm) for cutting and .100” (2.5 mm) for marking
** Edge start recommended.
(Revised 10/22/09)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-52
Operation
Spirit275a User’s Manual Rev K
Stainless Steel - 200 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
277274
Outer Cap
277154
Nozzle
279489
Electrode
279440
(yellow o-ring)
Retaining Cap
277266
Swirl Ring
279443
Imperial
Torch Head
279160
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
(in)
(psi)
(psi)
(psi)
(psi)
(in)
(volts)
(ipm)
1/4
130
200
3/8
133
150
1/2
140
110
5/8
146
75
153
60
20
3/4
82
58
75
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
.200
400
.250
500
.115
.300
600
.150
.350
800
.190
.400
1200
.070
1.0
158
40
.210
.450
1.25 **
170
20
.250
.350
1.50 **
180
10
.275
.350
Metric
.150
.152
.155
.160
1500
.165
.175
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(mm)
(volts)
(mm/m)
(mm)
(mm)
(msec)
6
129
5220
1.8
4.9
400
10
134
3655
1.9
6.5
12
138
3020
2.6
7.3
16
146
1890
3.8
8.9
153
1450
4.8
10.3
20
20
82
58
75
25
157
1050
5.2
11.3
32 **
170
495
6.4
8.9
38 **
179
260
6.9
8.9
3.8
600
800
1500
3.9
4.1
4.2
4.4
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
25
25
N/A
120
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
** Edge start recommended
(Revised 12/01/2009)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-53
Operation
Spirit275a User’s Manual Rev K
Aluminum - 200 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
277274
Outer Cap
277154
Nozzle
279489
Electrode
279440
(yellow o-ring)
Retaining Cap
277266
Swirl Ring
279443
Imperial
Torch Head
279160
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
150
190
145
.140
1/4
3/8
155
1/2
20
5/8
82
58
75
160
3/4
1.0 **
Metric
Cutting
Height
110
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.135
.250
300
.275
400
.300
500
.350
600
.135
95
65
.150
175
35
.200
.400
.150
.155
800
.160
1000
.170
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
149
4955
3.3
6.3
300
3545
3.5
7.0
6
10
155
12
20
16
82
58
75
2995
7.4
3.4
160
2380
20
162
1575
3.9
25 **
174
940
5.0
3.8
500
3.9
8.9
800
10.2
1000
4.1
4.3
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
120
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
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
** Edge start recommended
(Revised 10/21/2009)
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4-54
Operation
Spirit275a User’s Manual Rev K
Aluminum - 275 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
277263
Outer Cap
277154
Nozzle
279469
Electrode
279450
(red o-ring)
Retaining Cap
277266
Swirl Ring
279458
Imperial
Torch Head
279160
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(volts)
(ipm)
(in)
(in)
(msec)
3/8
160
160
.160
.275
400
1/2
165
125
.180
.300
500
5/8
168
105
.190
.350
600
172
85
.200
1.00 **
180
60
.240
1.25 **
185
45
.260
1.50 **
190
25
.270
3/4
20
93
65
83
Metric
.160
.165
800
.400
1000
.170
.180
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(msec)
(mm)
500
4.1
800
4.2
(volts)
(mm/m)
(mm)
(mm)
10
160
3930
4.1
7.1
12
163
3375
4.4
7.4
168
2645
4.8
8.9
173
2055
5.3
25 **
179
1565
6.0
32 **
185
1120
6.6
38 **
189
645
6.8
16
20
20
93
65
83
10.2
1000
4.3
4.6
Marking
Material
Thickness
(ga)
(in)
(mm)
All Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
(psi)
(psi)
(psi)
(psi)
(volts)
N/A
28
25
N/A
108
Travel
Speed
Marking
Height
(ipm) (mm/min) (in)
250
6350
.100
Initial
Height
Pierce
Time
(mm)
(in)
(mm)
(msec)
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .275” (7.0 mm) for cutting and .100” (2.5 mm) for marking
** Edge start recommended
(Revised10/22/2009)
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4-55
Operation
Spirit275a User’s Manual Rev K
BLANK PAGE
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4-56
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Section 5 Automatic Gas Console
Advanced Functions
This section describes how to operate the Spirit system when nonstandard cutting or marking conditions are desired. Instructions are also
given on how to access the various maintenance modes of the system.
Altering the Current Set Point
To alter the current set point from the default setting, use the arrow keys
to scroll to Current Set Point, or press the Menu key then the Current key.
The current setting should be highlighted as shown and the set point
should be blinking. Press F3 to scroll through the available current
choices. The current can only be set to values of 30, 50, 70, 100, 150,
200, 260, or 275 amps when cutting. When marking, the current cannot
be changed. Once the desired value is blinking, press ENT.
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5-1
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Setting the Pierce Time
After the Spirit cutting or marking arc transfers to the workpiece, a motion
signal (ok to move signal) is sent to the x/y controller or torch height
control. When the motion signal is issued, the x/y controller or torch
height control should position the torch to the correct pierce height. The
torch should remain at the pierce height until the Pierce Time has elapsed,
at which time the torch should be positioned at the correct cutting or
marking height. When cutting, the Pierce Time should be adjusted so the
arc fully penetrates the plate before the torch is moved to the cut height.
See “Piercing Thick Materials” in Section 4. When marking, the Pierce
Time is usually adjusted to zero. To alter the Pierce Time, use the arrow
keys to scroll to Cutting Pierce Time or Marking Pierce Time. The pierce
time should be highlighted as shown and the editing cursor should be
blinking. Use the numerical keypad to enter the desired Pierce Time.
Note that the units are in milliseconds (1000 milliseconds = 1 second).
Use the CLR key to backspace if an error is made. When the correct
value has been entered, press ENT. Note that the maximum allowable
Pierce Time is 5000 milliseconds (5 seconds).
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5-2
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Altering Gas Types
Although the gas types should not normally be changed, the procedure is
given here anyway. Note that the preflow gas cannot be changed. To
alter the gas types used for a particular cut, use the arrows to scroll to the
appropriate gas or press the Menu key then the Plasma Gas or Shielding
Gas key. The appropriate gas selection should be highlighted as shown
and the present gas choice should be blinking. Press F3 to scroll through
the gas choices. When the desired gas type is blinking, press ENT to
accept the gas type. The plasma gas can be changed to air, oxygen, or
H17 and the shield gas can be changed to air, oxygen, or nitrogen.
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5-3
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Altering Gas Pressures
Normally, the preflow gas and plasma gas pressures should not be
changed. The shield gas can be adjusted in small increments to fine-tune
a cut. To alter the gas pressures, use the arrow keys to scroll to the
appropriate pressure setting. The pressure setting should be highlighted
as shown and the editing cursor should be blinking. Use the numerical
keypad to enter the desired operating pressure. Use the CLR key to
backspace if an error is made. Press ENT when the correct value has
been entered. Note that all of the gases have minimum and maximum
limits and cannot be programmed beyond these limits.
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5-4
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Altering Arc Voltage Control and X/Y Machine
Parameters
If the pierce (initial) height, cutting (marking) height, arc voltage, or x/y
machine speed must be altered to achieve the desired cut quality, switch
to the voltage screen, use the arrow keys to scroll to the desired
parameter, and edit the parameter using the keypad.
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5-5
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Saving a User Created Cutting or Marking Condition
If one of the default cutting or marking parameters must be altered to
achieve the desired quality, the new condition can be saved for later use.
To save a user created cutting or marking condition, use the arrow keys to
scroll off all selections on the status screen. When none of the
parameters are highlighted the “Press F3 to Save Settings” message will
be displayed as shown. Pressing F3 will cause the save confirmation
window to pop up. When this occurs, press ENT to save the condition or
press CLR to cancel the procedure. Pressing ENT will save the settings
for the particular material being cut and a User icon will appear in the
upper right hand corner of the screen. The User icon indicates that the
parameters for the particular material being cut are not factory defaults but
are user created. The factory default condition can be restored as
described later in this section.
Gas Purge
The gas lines can be purged at any time by pressing the Menu key then
the Gas Purge key. The gas pressures are also readjusted at this time.
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5-6
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Maintenance Screen
To display the maintenance screen, press the Menu key then the Maint
key. The maintenance screen will be displayed as shown. From the
maintenance screen, use the arrow keys to scroll up or down to highlight a
selection and press the Ent key to enter the desired maintenance mode.
The different maintenance modes are described below.
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5-7
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Viewing Messages
To view status messages from the Spirit power supply and automatic gas
console, scroll down to the View Messages selection on the maintenance
screen and press ENT. The message screen will be displayed as shown.
The message screen displays all power supply and gas console
messages, sequencing, and errors. The message screen should be the
initial starting point when troubleshooting the system.
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5-8
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Viewing Cut Errors
The Spirit has an error tracking system that keeps a record of certain
faults that occur during operation. These faults affect the consumable
parts life and measures should be taken to prevent them from occurring.
To view the cut errors, scroll down to the View Cut Errors selection on the
maintenance screen and press ENT. The cut errors screen will be
displayed as shown. The error tracking system keeps a record of the total
number of pierces, the number of errors, and the error percentage. Any
time the consumables are changed, the pierce counter should be reset to
zero by pressing CLR. When this occurs, the data from the present count
will move into the first previous errors position. The data that was in the
first previous errors position will move to the second previous errors
position, and so on.
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5-9
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Selecting an Error Set to View
When the cut errors screen is being displayed, press F3 to view the actual
cut errors. When F3 is pressed the error selection screen is displayed as
shown. Use the arrow keys to scroll to the error set that is to be viewed
and press ENT.
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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
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Viewing Actual Errors
Once the error set is selected and the ENT key is pressed on the error
selection screen, the actual cut errors will be displayed as shown.
When any of the errors listed on the actual cut errors screen occur,
measures should be taken to avoid further errors. The following is a
description of the errors and possible causes:
• Transferred arc not established - This error occurs when the arc fails
to transfer to the workpiece. It primarily causes nozzle damage and is
typically due to a pierce height that is too high.
• Transferred arc lost before upslope - This error occurs when the arc
transfers to the workpiece but is lost immediately. It primarily causes
nozzle damage and is typically due to a pierce height that is too high.
• Transferred arc lost during upslope - This error occurs when the arc
transfers to the workpiece but is lost before steady state operation. It
primarily causes electrode damage and is typically due to a pierce time
that is too long or when cutting a given thickness with excessive
current.
• Transferred arc lost during cut - This error occurs when the arc is
lost during steady state operation. It substantially shortens the
electrode life and is typically due to a torch standoff distance that is too
high or a travel speed that is to slow.
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5-11
Automatic Gas Console Advanced Functions
•
Spirit275a User’s Manual Rev K
Transferred arc lost during downslope - This error occurs when the
arc is lost after a stop signal is received but before the current
downslope completes. It substantially shortens the electrode life and is
typically due to an incorrect lead-out or when cutting a given material
thickness with excessive current. When cutting small pieces that tend
to drop into the table after being cut, there should be a very short lead
out or none at all. On thicker materials, the arc is sometimes lost when
crossing the kerf during the lead out. It is critical that the lead-outs
be fine tuned so the arc is not lost before downslope is complete.
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5-12
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Pressure Diagnostics
To enter the pressure diagnostics mode, scroll down to the Pressure
Diagnostics selection on the maintenance screen and press ENT. The
pressure diagnostics screen will be displayed as shown. Pressing the
Preflow Gas, Plasma Gas, and Shielding Gas buttons will toggle the
corresponding valves between the off and on states. Note that the preflow
valve and the plasma valve cannot be on at the same time. During a
cutting or marking sequence, the status of all valves will display N/A.
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5-13
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Restoring Factory Default Cutting or Marking
Conditions
To restore a factory default cutting or marking condition, scroll down to the
Restore Factory Defaults selection on the maintenance screen and press
ENT. The restore screen will be displayed as shown. Note that the
present material type and thickness selected on the status screen will be
automatically displayed on the restore screen. Press ENT to restore the
factory default setting for the material type and thickness displayed. To
change the material type, press the F3 key. To edit the material
thickness, use the arrow keys to scroll to Thickness and use the numerical
keypad to enter the thickness. To restore the factory default cutting and
marking conditions for all user saved files, press 1, then 2, then 3 as
shown on the screen below. To restore corrupted cutting or marking
conditions, press 7, then 8, then 9 as shown on the screen below.
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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
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Measurement System
The Spirit system will operate using Imperial units or Metric units. To
change the units of operation, scroll down to the Measurement System
selection on the maintenance screen and press ENT. The measurement
system screen will be displayed as shown. Press F3 to toggle the
measurement system between Imperial and Metric. When the desired
selection is highlighted, press ENT.
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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
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Communication Node
When multiple Spirit systems are being used together on an RS-422 serial
communication link, each system must have a unique identification
number (node number) to identify itself to the network. To set the
communication node number for the Spirit system, scroll down to the Set
Communication Node selection on the maintenance screen and press
ENT. The communication node selection screen will be displayed as
shown. Press F3 to scroll through the available node numbers. When
using an Inova torch height control system with the Spirit, the
communication node feature must be disabled.
To disable the
communication node, press F3 until “disabled” is displayed in the node
number selection box. When the desired selection is highlighted, press
ENT.
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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
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Inova Parameter Transmit
If an Inova arc voltage control system is not being used with the Spirit
system, the Inova Parameter Transmit feature must be disabled. With the
Inova Parameter Transmit feature set to automatic, the Inova is
automatically updated with the correct arc voltage, pierce (initial) height,
and cutting (marking) height any time a new condition is loaded, the
process (cutting or marking) is changed, or when the arc voltage, pierce
(initial) height, or cutting (marking) height is changed on the Voltage
screen. With the Inova Parameter Transmit feature set to manual,
pressing F3 while the voltage screen is being displayed will automatically
transmit the pierce (initial) height, cutting (marking) height, and arc voltage
set points to the Inova. To view the status of the Inova Parameter
Transmit setting, scroll down to the Inova Parameter Transmit selection on
the maintenance screen and press ENT. The Inova parameter transmit
screen will be displayed as shown. Pressing F3 will toggle the Inova
Parameter Transmit setting between automatic, manual, and disabled.
When the desired selection is highlighted, press ENT.
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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
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Viewing Serial Communications
To view the serial communication between the Spirit and an external
device, scroll down to the View Serial Communication selection on the
Maintenance screen and press enter. The Serial Communication screen
will be displayed as shown. All incoming and outgoing data is displayed in
decimal (base 10) format. Note that incoming data is appended to show
an “R” before the data and outgoing transmissions are appended to show
a “T” before the data. Pressing F3 will toggle the display on and off and
pressing CLR will clear the screen.
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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
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Configuring Hydrogen Cutting
When hydrogen cutting is enabled, the H17 hydrogen mixture will
automatically be selected as the plasma gas for certain material types and
thicknesses. To prevent the use of H17, hydrogen cutting must be
disabled. To disable hydrogen cutting, scroll down to the Configure
Hydrogen Cutting selection on the Maintenance Screen and press enter.
The Configure Hydrogen Cutting screen will be displayed as shown.
Pressing F3 will toggle the hydrogen cutting setting between enabled and
disabled. When the desired selection is highlighted, press ENT.
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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
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Setting an Arc Off Delay
In some instances, such as when cutting thicker stainless steel materials,
it may be desirable to delay the extinction of the cutting arc after a stop
signal is received. To program an arc off delay, scroll down to the Set Arc
Off Delay selection on the Maintenance Screen and press enter. The Set
Arc Off Delay screen will be displayed as shown. Use the keypad to enter
the desired delay time in milliseconds. The delay can be set from 0 to
2000 mS.
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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
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Switching Between Cutting and Marking
The Spirit system has the capability of plasma cutting and plasma marking
with the same set of consumables. The process (cutting or marking) can
be set by the RS-422 serial interface, by a hard signal on the CNC
interface plug, or locally at the automatic gas console. To control how
switching between processes is performed, scroll down to the
Cut/Mark/Cut selection on the Maintenance Screen and press enter. The
Cut/Mark/Cut Configuration screen will be displayed as shown. Pressing
F3 will toggle the cut/mark/cut configuration between hard signal, RS-422,
and local. When the desired selection is highlighted, press ENT.
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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
Automatic Gas Console Advanced Functions
Spirit275a User’s Manual Rev K
Software Updates
The Automatic Gas Console has a floppy disk drive that is used to update
the software as new revisions are released. To access the floppy disk
drive, remove the floppy disk drive cover on the rear panel of the console.
The software update may either be installed on one floppy disk or two
floppy disks. Follow the instructions below for the appropriate update.
One-Disk Update
1. Remove primary power from the Spirit system.
2. Insert the floppy disk containing the software update into the floppy
disk drive.
3. Apply primary power to the system and wait until the “AGC Updated
Successfully” message appears.
4. Remove the floppy disk from the floppy disk drive.
5. Remove primary power from the system.
6. Reinstall the floppy disk drive cover.
7. Apply primary power to the system.
Two-Disk Update
1. Remove primary power from the Spirit system
2. Insert the first floppy disk containing the software update into the floppy
disk drive.
3. Apply primary power to the system and wait until the “AGC Updated
Successfully” message appears.
4. Remove the floppy disk from the floppy disk drive.
5. Remove primary power from the system, wait five seconds, then
reapply primary power to the system.
6. Wait for the “Please Insert Update Disk 2” message to appear.
7. Install the second floppy disk containing the software update into the
floppy disk drive.
8. Press any key on the keypad.
9. Wait for the “AGC Updated Successfully” message to appear.
10. Leave the second update disk in the floppy disk drive, remove primary
power from the system, wait five seconds, then reapply primary power.
11. Wait for the “AGC Updated Successfully” message to appear.
12. Remove the floppy disk from the floppy disk drive.
13. Remove primary power from the system.
14. Reinstall the floppy disk drive cover.
15. Apply primary power to the system.
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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
Serial Communication
Spirit275a User’s Manual Rev K
Section 6 Serial Communication
Initializing the Spirit System
The Spirit system uses an RS-422 serial communication port located on the rear
of the automatic gas console to receive and respond to commands that are
transmitted from an x/y controller. The communications ground is isolated to
prevent ground loops. System initialization is simple. Apply power, wait until the
automatic gas console (AGC) has finished booting, then transmit the desired
material type, material thickness, and optionally the process (cutting or marking)
and the system will be ready for operation. All other parameters will be set to
their default values and may be changed at any time.
Transmitting Parameters to the Spirit System
To transmit parameters to the Spirit, convert the following hex strings to 8 bit
binary arrays (AA = 10101010) and transmit them using a 9600 baud RS-422
serial communication port. The port settings should have a start bit, one stop bit,
and no parity. A table can be found in this section that lists the RS-422
commands and their descriptions. This table contains the necessary hex strings
for sending different commands and parameters to the system. For example, to
switch the material type from mild steel to stainless steel, look up the command
for setting material type in the table. You will see the following table entry:
Command
Set Material Type
# Hex String
1
AA nn FA 01 00 -- 0D
Additional Information
00 = Mild Steel – Hot Rolled
01 = Stainless Steel
02 = Aluminum
03 = Other
04 = Mild Steel – Cold Rolled
Note that spaces in the command string are shown for clarity only and should not
be sent as part of the command. A command string always begins with the value
AA hex. The “nn” is the net node (communication node) of the Spirit system that
is to receive the command. The net node value of a system is set via the Set
Communication Node selection on the maintenance screen. See Section 5 for
detailed information on setting the net node. The value FA hex is the Spirit
identifier. The value 01 hex is the value that signifies the Set Material Type
command. The value 0D hex is the end of command character. In the above
example, the following hex string would need to be transmitted to switch the
material type to stainless steel for a Spirit system on node 1:
AA 01 FA 01 00 01 0D
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6-1
Serial Communication
Spirit275a User’s Manual Rev K
To send a parameter, the parameter value needs to be sent as part of the
command. For example, to send a desired cutting pierce time of 1000
milliseconds to the system, look up the Set Cutting Pierce Time command in the
command table. You will see the following table entry:
Command
Set Pierce Time
# Hex String
4
AA nn FA 04 -- -- 0D
Additional Information
Time in mS (seconds / 1000)
Valid range: 0 to 5000
Once again, AA hex signifies the start of the command, “nn” is the net node of
the power supply, and FA hex is the Spirit identifier. The value 04 hex signifies
the Set Cutting Pierce Time command, and 0D hex signifies the end of the
command. The “-- --” in the hex string is the MSB followed by the LSB of a type
int. The integer is the value used in the additional information column. Thus, the
“-- --” is sometimes referred to as the additional information value. In the
example, we wanted to transmit a Cutting Pierce Time of 1000 mS (1 second).
This value in hexadecimal would be 03E8 (msb=03, lsb=E8). In this example,
the following string would be transmitted in order to set the cutting pierce time to
1000mS for a power supply on net node 1:
AA 01 FA 04 03 E8 0D
For multiple power supply installations, commands can be sent to all power
supplies at the same time. This is referred to as a global command. To send a
global command, set the net node value to C8 hex (200 decimal). In the
example above, the following string would be transmitted to set the Cutting
Pierce Time to 1000mS for all power supplies connected on the network:
AA C8 FA 04 03 E8 0D
Communication Error Checking
With a single torch system, all commands and parameters transmitted to the
Spirit will be back transmitted in exactly the same form for error checking. With a
multiple torch system, only the system with node focus will back transmit the
commands. The purpose of the node focus command (#254) is to allow one
Spirit system to use the transmission lines at a time. If no node focus is set on
initialization, the first system to receive a command will receive node focus
automatically. Commands may be transmitted to systems without node focus,
but there will be no back transmission from those systems. Also, all parameters
can be read at any time by transmitting a Send Parameter command (#30) to the
Spirit, followed by the appropriate parameter to be read.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-2
Serial Communication
Spirit275a User’s Manual Rev K
Default Cutting Parameters
In order to initialize parameters on a spirit system an external device must
communicate, in sequence, the material type, material thickness, process
(cutting or marking) and the cutting current. Once the Spirit system receives the
cutting current, all other parameters will be set to their default values. Whenever
the material type, material thickness, process or cutting current is changed, new
default values will be retrieved for all other parameters. If a change is desired,
cutting current must be sent last for the update to occur. To use non-standard
parameter, first set the material type, material thickness, process and cutting
current (in sequence), and then set the remaining parameter (i.e. pierce time) to
the desired values.
Troubleshooting Serial Communication
When troubleshooting serial communication with the Spirit system, switch to the
View Serial Communication Screen to view incoming and outgoing data. See
Section 5 for information on the Serial Communication Screen.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Serial Communication
Spirit275a User’s Manual Rev K
RS-422 Serial Commands
Note: In the following commands, “nn” represents the net node of the power
supply that is to receive the command. To send a global command to all power
supplies in a network configuration, “nn” should be set to C8 hex (200 decimal).
The “-- --” in the hex string is the MSB followed by the LSB of a type int. The
integer is the value found in the additional information column.
Command
#
Hex String
Additional Information
Set Thickness
2
AA nn FA 02 -- -- 0D
Thickness in mils (inches x 1000)
Valid Range: 0 to 2000
Set Operating
Current
3
AA nn FA 03 00 -- 0D
01 = 30A
02 = 50A
03 = 70A
04 = 100A
05 = 150A
06 = 200A
0A = 260A
0B = 275A
0C = 400A
Set Cutting Pierce
Time
4
AA nn FA 04 -- -- 0D
Cutting pierce time in ms
Valid Range: 0 to 9999
Set Preflow
Pressure
6
AA nn FA 06 -- -- 0D
Preflow psi x 10
Valid Range: 0 to 1200
Set Plasma Gas
Type
7
AA nn FA 07 00 -- 0D
00 = Oxygen
02 = Air
04 = H17
Set Plasma
Pressure
8
AA nn FA 08 -- -- 0D
Plasma psi x 10
Valid Range: 0 to 1200
Set Shield Gas Type
9
AA nn FA 09 00 -- 0D
00 = Oxygen
01 = Nitrogen
02 = Air
Set Shield Pressure
10
AA nn FA 0A -- -- 0D
Shield psi x 10
Valid Range: 0 to 1200
Cutting Travel
Speed
15
AA nn FA 0F -- -- 0D
If requested in command #30, the AGC
will transmit the cutting travel speed in
inches per minute. Range: 0 to 999
Set Material Type
1
AA nn FA 01 00 -- 0D
00 = Mild Steel – Hot Rolled
01 = Stainless Steel
02 = Aluminum
03 = Other
04 = Mild Steel – Cold Rolled
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Serial Communication
Command
Spirit275a User’s Manual Rev K
#
Hex String
Additional Information
Torch Body Part
Number (msw)
16
AA nn FA 10 -- -- 0D
If requested in command #30, the AGC
will transmit the most significant word of
the torch body part number.
Torch Body Part
Number (lsw)
17
AA nn FA 11 -- -- 0D
If requested in command #30, the AGC
will transmit the least significant word of
the torch body part number.
Torch Electrode Part
Number (msw)
18
AA nn FA 12 -- -- 0D
If requested in command #30, the AGC
will transmit the most significant word of
the electrode part number.
Torch Electrode Part
Number (lsw)
19
AA nn FA 13 -- -- 0D
If requested in command #30, the AGC
will transmit the least significant word of
the electrode part number.
Torch Swirl Ring
Part Number (msw)
20
AA nn FA 14 -- -- 0D
If requested in command #30, the AGC
will transmit the most significant word of
the swirl ring part number.
Torch Swirl Ring
Part Number (lsw)
21
AA nn FA 15 -- -- 0D
If requested in command #30, the AGC
will transmit the least significant word of
the swirl ring part number.
Torch Nozzle Part
Number (msw)
22
AA nn FA 16 -- -- 0D
If requested in command #30, the AGC
will transmit the most significant word of
the nozzle part number.
Torch Nozzle Part
Number (lsw)
23
AA nn FA 17 -- -- 0D
If requested in command #30, the AGC
will transmit the least significant word of
the nozzle part number.
Torch Retaining Cap
Part Number (msw)
24
AA nn FA 18 -- -- 0D
If requested in command #30, the AGC
will transmit the most significant word of
the retaining cap part number.
Torch Retaining Cap
Part Number (lsw)
25
AA nn FA 19 -- -- 0D
If requested in command #30, the AGC
will transmit the least significant word of
the retaining cap part number.
Torch Shield Cap
Part Number (msw)
26
AA nn FA 1A -- -- 0D
If requested in command #30, the AGC
will transmit the most significant word of
the shield cap part number.
Torch Shield Cap
Part Number (lsw)
27
AA nn FA 1B -- -- 0D
If requested in command #30, the AGC
will transmit the least significant word of
the shield cap part number.
Torch Outer Cap
Part Number (msw)
28
AA nn FA 1C -- -- 0D
If requested in command #30, the AGC
will transmit the most significant word of
the outer cap part number.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-5
Serial Communication
Command
Spirit275a User’s Manual Rev K
#
Hex String
Additional Information
Torch Outer Cap
Part Number (lsw)
29
AA nn FA 1D -- -- 0D
If requested in command #30, the AGC
will transmit the least significant word of
the outer cap part number.
Send Parameter
30
AA nn FA 1E -- -- 0D
01 = Send material type
02 = Send material thickness
03 = Send current set point
04 = Send cutting pierce time
05 = Send preflow gas type
06 = Send preflow pressure
07 = Send plasma gas type
08 = Send plasma gas pressure
09 = Send shield gas type
10 = Send shield gas pressure
15 = Send cutting travel speed
16 = Send torch body part number msw
17 = Send torch body part number lsw
18 = Send electrode part number msw
19 = Send electrode part number lsw
20 = Send swirl ring part number msw
21 = Send swirl ring part number lsw
22 = Send nozzle part number msw
23 = Send nozzle part number lsw
24 = Send retaining cap part number msw
25 = Send retaining cap part number lsw
26 = Send shield cap part number msw
27 = Send shield cap part number lsw
28 = Send outer cap part number msw
29 = Send outer cap part number lsw
32 = Send process select
33 = Send software version
34 = Send cutting chart version
35 = Send number of pierces
36 = Send number of pierce errors
42 = Send cutting arc voltage
43 = Send cutting height
44 = Send cutting pierce height
48 = Send cutting condition type
51 = Send arc off delay time
52 = Send machine type
53 = Send marking arc voltage
54 = Send marking height
55 = Send marking start height
56 = Send marking travel speed
57 = Send marking pierce time
59 = Send cut/mark/cut configuration
Set Process
32
AA nn FA 20 00 -- 0D
00 = Cutting
01 = Marking
Software Version
33
AA nn FA 21 00 -- 0D
If requested in command #30, the AGC
will transmit the software version x 10.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-6
Serial Communication
Command
Spirit275a User’s Manual Rev K
#
Hex String
Additional Information
Cutting Chart
Version
34
AA nn FA 22 00 -- 0D
If requested in command #30, the AGC
will transmit the cutting chart version x 10.
Number of Pierces
35
AA nn FA 23 00 -- 0D
Number of Pierce
Errors
36
AA nn FA 24 00 -- 0D
If requested in command #30, the AGC
will transmit the number of pierces.
Range: 0 to 9999
If requested in command #30, the AGC
will transmit the number of pierce errors.
Range: 0 to 9999
Reset Pierce
Counter
37
AA nn FA 25 00 01 0D
Resets number of pierces and errors to 0
Power On
38
AA nn FA 26 00 01 0D
Energizes power supply, torch coolant
pump and cooling fans. If torch coolant
flow switch not satisfied within 8 seconds,
unit will power down.
Power Off
39
AA nn FA 27 00 01 0D
Request System
Status
40
AA nn FA 28 00 01 0D
Purge Gases
41
AA nn FA 29 00 01 0D
Deenergizes power supply, torch coolant
pump and cooling fans
System status can only be requested after
a Power On command (#38) is
transmitted. The status is returned in the
following form: (All bits: 0=fault; 1=ok)
LSB Bit 0 = RHF Door
LSB Bit 1 = AC Power
LSB Bit 2 = Coolant Flow
LSB Bit 3 = Coolant Level
LSB Bit 4 = Coolant Temp
LSB Bit 5 = AGC status
LSB Bit 6 = Inlet Gas Pressures
LSB Bit 7 = Not used
MSB Bit 0 = Not used
MSB Bit 1 = Hydrogen Cutting Enabled
Purges gas lines
Set Cutting Arc
Voltage
42
AA nn FA 2A -- -- 0D
Sets cutting arc voltage in Volts x 100
Valid Range: 5000 to 20000
Set Cutting Height
43
AA nn FA 2B -- -- 0D
Sets cutting height in mils (inches / 1000)
Valid Range: 0 to 999
Set Cutting Pierce
Height
44
AA nn FA 2C -- -- 0D
Sets cutting pierce height in mils (inches /
1000)
Valid Range: 0 to 999
Set Cutting Travel
Speed
45
AA nn FA 2D -- -- 0D
Sets cutting travel speed (inches / min)
displayed on the voltage screen
Valid Range: 0 to 999
Save as User File
46
AA nn FA 2E 00 01 0D
Saves the present cutting conditions as a
user file.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Serial Communication
Command
Spirit275a User’s Manual Rev K
#
Hex String
Additional Information
Restore Factory
Condition
47
AA nn FA 2F 00 01 0D
Restores the factory cutting condition for
the present material type and thickness.
Cutting Condition
Type
48
AA nn FA 30 00 -- 0D
If requested in command #30, the AGC
will transmit whether the present cutting
condition is a factory default setting or a
custom user setting. Note: This is only
valid when initially loading material type,
thickness, and process.
0 = factory / 1 = custom
Configure H17
Cutting
49
AA nn FA 31 00 -- 0D
0 = Disable H17 cutting
1 = Enable H17 cutting
Reload Cutting
Condition
50
AA nn FA 32 00 01 0D
Reloads the cutting conditions for the
present material type and thickness
Set Arc Off Delay
Time
51
AA nn FA 33 -- -- 0D
Sets the delay time in mS between the
reception of a stop signal and the
extinction of the arc.
Valid Range: 0 to 2000 mS
Machine Type
52
AA nn FA 34 -- -- 0D
If requested in command #30, the AGC
will transmit the machine type.
153 = Spirit150a
203 = Spirit200a
273 = Spirit275a
403 = Spirit400a
Set Marking Arc
Voltage
53
AA nn FA 35 -- -- 0D
Sets marking arc voltage in Volts x 100
Valid Range: 5000 to 20000
Set Marking Height
54
AA nn FA 36 -- -- 0D
Sets marking height in mils (inches /
1000)
Valid Range: 0 to 999
Set Marking Start
Height
55
AA nn FA 37 -- -- 0D
Sets marking start height in mils (inches /
1000)
Valid Range: 0 to 999
Set Marking Travel
Speed
56
AA nn FA 38 -- -- 0D
Sets marking travel speed (inches / min)
Valid Range: 0 to 999
Set Marking Pierce
Time
57
AA nn FA 39 -- -- 0D
Sets marking pierce time in ms
Valid Range: 0 to 9999
Configure
Cut/Mark/Cut
59
AA nn FA 3B 00 -- 0D
0 = Local at power supply
1 = Hard signal via interface plug
2 = RS-422
Node Focus
254 AA C8 FA FE 00 nn 0D
Sends a global command to all systems
and sets the node focus to system nn
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-8
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
Section 7 Maintenance and
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, front, and rear panels of the power supply.
2. Using clean, dry, compressed air, blow out all accumulated dust inside
the power supply, including dust on p.c. 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 that all torch lead and work ground connections are secure and
free from corrosion.
4. Verify that the primary three phase A.C. voltage connections are tight
5. Verify that all p.c. board connectors are installed securely.
6. Verify that the rear panel cable connectors are installed securely.
7. Verify that the automatic gas console connector is installed securely to
the plug on the bottom of the gas console.
8. Check the torch coolant filter/deionization cartridge at the rear of the
power supply and replace if dirty.
9. 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.
7-1
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
Automatic Gas Console
1. Remove the cover of the automatic gas console.
2. 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.
3. Verify that all p.c. board connectors are installed securely.
4. 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.
5. 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 remote high frequency console.
Also, make sure the shield adapter is secured tightly to the high frequency
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.
5. Make sure the torch lead insulating sleeves are positioned to properly
cover the brass torch fittings at the rear of 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 orings. 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 a copper electrode, the torch head uses cooling tube
P/N 277007. If replacement is required, use tool P/N 200109.
If using a silver electrode, the torch head uses cooling tube P/N 279117
and cooling tube holder P/N 279116. Remove the cooling tube holder
using tool P/N 277087 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.
7-2
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
Remote High Frequency Console
1. Open the cover of the RHF console and verify that all leads and hoses
are tightened securely. Only tighten the fittings enough to make a
water or gas seal. The fittings are subject to damage if over
tightened.
2. Check the spark gap electrodes for signs of wear. Replace electrodes
that have rounded faces. Use a clean feeler gauge and set the spark
gap to .015” (.38 mm).
Work Ground
1. Verify that the work ground lead is securely fastened to the star ground
on the cutting table, and that the connection point is free from
corrosion. Use a wire brush to clean the connection point if necessary.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-3
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
Replacing the Torch Coolant
The torch coolant should be flushed out of the system every six months
and replaced with new coolant. The following procedure should be used
to prevent damage to the cooling system.
Note:
When handling coolant, it is recommended that you wear
nitrile gloves and safety glasses.
1. Remove primary power to the system.
2. Remove the rear cover of the power supply to expose the cooling
system.
3. Remove the coolant reservoir cap/level gauge.
4. Make sure that consumables are properly installed in the torch head
and that the torch head is installed on the torch base.
5. Using a funnel to collect the coolant, unscrew the drain petcock on
the bottom of the coolant reservoir. Leave the funnel in place after
the coolant drains out of the reservoir.
6. Remove the torch coolant supply hose from the rear of the power
supply. Note that the coolant supply hose has right hand threads.
7. Blow compressed air (100 psi maximum) into the coolant supply
hose. This will clear the coolant out of the torch, torch leads, and
heat exchanger. Note that the coolant will be forced into the reservoir
and will drain out of the drain petcock.
8. Unscrew the lower portion of the coolant filter housing and remove
the coolant filter/deionization cartridge. Replace with a new filter.
9. Reconnect the coolant supply hose.
10. Refer to Section 3 for the remaining steps required for Filling the
Torch Coolant Reservoir. Only use Kaliburn approved torch
coolant solution.
Commercially available antifreeze contains
corrosion inhibitors that will damage the cooling system. See Section
3 for more information on Torch Coolant Requirements.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
Microprocessor Status LED’s
The microprocessor p.c. board controls all of the functions of the Spirit
system. It has diagnostic LED’s which aid in troubleshooting the system.
The LED’s illuminate when a particular event occurs. Illuminated LED’s
indicate the following:
Indication
LED
OPTO 1 LED – PAR
OPTO 2 LED – CON
OPTO 3 LED - SURGE
OPTO 4 LED - LATCH
OPTO 5 LED - PUMP
OPTO 6 LED - 3 PHASE
OPTO 8 LED – Aux 2
OPTO 9 LED - HIGH FREQ
OPTO 10 LED - PREFLOW
OPTO 11 LED - PLASMA
OPTO 12 LED - SHIELD
OPTO 13 LED - GSV4
OPTO 14 LED – GSV5
OPTO 15 LED – MARKING
LED 8 - START
LED 9 - CHOPPER
LED 10 - PAT
LED 11 - TAC
LED 12 - MOTION
LED 13 - HOLD IN
LED 14 - HOLD OUT
LED 15 - MAN CONSOLE
LED 16 - 5V uP PWR
LED 17 - 12V uP PWR
LED 18 - ILK PWR
LED 19 - ANALOG PWR
LED 20 - GAS PWR
LED 21 - OVER CURRENT
LED 22 - ERROR
LED 28 - COMM PWR
LED 29 –15V
LED 30 - XMIT
LED 31 - RECV
Pilot Arc Relay Energized
Main contactor CON1 energized
CR3 and K1 relays energized
Latch relay energized
Coolant pump relay CR5 energized
Three phase power satisfactory
Power Supplied to ACG
High frequency transformer TR5
energized
Preflow gas valve 1 energized
Plasma gas valve 2 energized
Shield gas valve 3 energized
Vent gas valve 4 energized
Postflow gas valve 5 energized
Marking gas valves 6 and 7 energized
Plasma start signal applied to Spirit
Chopper energized
Pilot arc transistor energized
Transferred arc established from torch
to workpiece
Motion relay energized
Arc hold input enabled
Power supply ready relay energized
Not used
5V microprocessor power supply
satisfactory
12V microprocessor power supply
satisfactory
12V interlock power supply satisfactory
15V analog power satisfactory
24V gas solenoid power satisfactory
Over current / power down to reset
Blinks on and off to display error codes
5V communication power supply
satisfactory
-15V analog power satisfactory
Indicates serial transmission to AGC
Indicates serial transmission from AGC
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
Microprocessor Sequence of Operation
The following LED’s should illuminate after primary power is applied:
• OPTO 8 LED - Aux 2
• LED 16 - 5V uP PWR
• LED 17 - 12V uP PWR
• LED 18 - ILK PWR
• LED 19 - ANALOG PWR
• LED 20 - GAS PWR
• LED 28 - COMM PWR
• LED 29 - 15V
The following LED’s should illuminate when the ON button is
depressed:
• OPTO 6 LED - 3 PHASE
• OPTO 5 LED - PUMP
• OPTO 4 LED - LATCH
The following LED’s should illuminate in sequence after a start
signal is received in the cutting mode:
• LED 8 - START
• OPTO 10 LED - PREFLOW
• OPTO 12 LED - SHIELD
• OPTO 3 LED - SURGE (OPTIONAL)
• OPTO 2 LED – CON
• OPTO 1 LED - PAR
• LED 10 - PAT
• LED 9 - CHOPPER
• OPTO 9 LED - HIGH FREQ
• LED 11 - TAC
• OPTO 11 LED - PLASMA
• OPTO 14 LED - GSV5
• LED 12 - MOTION
After a transferred cutting arc is established, the following LED’s will
go out:
• OPTO 9 LED - HIGH FREQ
• OPTO 10 LED - PREFLOW
• LED 10 - PAT
When the start signal is removed, OPTO 11 LED - PLASMA will
extinguish and OPTO 13 LED - GSV4 will illuminate and then go out
with the rest of the cut cycle LED’s.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-6
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
Troubleshooting Using the Control Panel Status LED’s
If the Spirit system develops a problem, first check the control panel status
LED’s. If one or more of the LED’s does not illuminate after the ON button
is depressed, use the status LED’s to pinpoint the problem.
•
•
•
•
•
•
RHF Door LED - Extinguishes when the RHF door switch opens.
Check the RHF door, switch, and associated wiring.
Gas Console LED - Extinguishes when there is a problem with the
gas console or when the unit is adjusting gas pressures. Switch to the
messages screen on the gas console to pinpoint the problem.
3 Phase Power LED - Extinguishes when there is a problem with the
three phase power being supplied to the chopper assembly. Verify
that the primary wall disconnect fuses are good and check the main
transformer, main contactor and A.C. Detect p.c. board for proper
operation. Also, this LED should turn on immediately when the green
“ON” button is pressed. If not, check P28-3 to P28-4 for 10 VDC first.
This should drop to 0 VDC when the ON button is pushed. If not, then
check CR1 and associated wiring.
Coolant Flow LED - Extinguishes when there is a problem with the
torch coolant system. Check the coolant pump fuse F2 and verify that
230VAC is present between TB3-13 and TB3-14. Also check for clogs
in the coolant leads and coolant filter/deionization cartridge.
Coolant Level LED - Extinguishes when the coolant level in the tank
has dropped below the required minimum level. Add more coolant to
clear the error.
Coolant Temperature LED - Extinguishes when the coolant
temperature has risen above the maximum operating temperature.
Ensure that the heat exchanger fan is running and that the heat
exchanger is free from dust. Blow out the heat exchanger and fan with
clean, dry, oil-free compressed air. Leave the unit running until the
LED illuminates.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
Troubleshooting Using the Automatic Gas Console
Messages Screen
If all of the status LED’s are illuminated but the Spirit system still has a
problem, switch to the messages screen on the automatic gas console
(see Section 5 for specific instructions on switching to the messages
mode). The gas console may display information that is useful in
pinpointing the problem. While the automatic gas console is displaying an
error message, the power supply microprocessor displays an error code
by blinking LED22 on and off to indicate that an error has occurred. The
number of blinks can be counted to determine which error has occurred.
The following chart lists the errors and the corresponding number of
blinks.
LED22 Number of
Blinks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Error
No transferred arc (TAC) established
TAC lost before current slope up
TAC lost during current slope up
TAC lost while cutting
TAC lost during current slope down
Start signal applied prematurely
Start signal removed prematurely
Output voltage below 60V
Output voltage above 210V
Invalid current set point
Current feedback circuit open
TAC not established within 2 seconds
Arc hold timed out
Pilot arc not established
Low current during cut
TAC sensed when start signal applied
Faulty AC phase
Low torch coolant flow
Gas console error
RHF door switch open
Low torch coolant level
High torch coolant temperature
Main contactor shorted
AGC Fan not operational
Defective Flow Switch
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
General Troubleshooting
The following chart lists general troubleshooting guidelines for the Spirit
system when the status LED’s or the automatic gas console messages
screen do not give any insight to the particular problem being
experienced. 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. The primary system fuse F1 is located on
the rear panel of the unit. All of the control fuses are located behind the
front panel of the unit beside the microprocessor p.c. board. The
automatic gas console fuse is located behind the right side panel of the
system. Also check all of the voltage LED’s on the system p.c. boards
before performing any tests.
Problem
Front panel white A.C. power light
will not illuminate
Possible Cause
1.
2.
3.
4.
Primary disconnect fuse blown.
Fuse F1A, F1B, or F4 blown.
White light or associated wiring bad.
Transformer TR2 or associated wiring bad.
Unit will not energize when the ON
button is pressed
1.
2.
3.
4.
Power supply will not stay on when
the front panel ON button is
pressed and released
1. Check the control panel status LED’s and
troubleshoot accordingly.
2. Check the gas console messages screen
and troubleshoot accordingly.
3. Faulty latch relay on relay p.c. board.
4. Faulty relay p.c. board.
5. Faulty microprocessor p.c. board.
6. Relay CR1 defective.
No arc at the torch
1. Incorrect torch consumables installed.
2. Incorrect gas pressure settings.
3. Check the control panel status LED’s and
troubleshoot accordingly.
4. Check the spark gap assembly inside the
RHF console for proper arcing after a start
signal is applied. Open the RHF door and
pull up on the door interlock switch plunger
to defeat the interlock. If there is no spark,
skip to the next test.
RHF door open.
Low coolant level.
Fuse F4 blown.
Faulty ON switch or associated wiring.
The ON switch is normally open.
5. Faulty OFF switch or associated wiring.
The OFF switch is normally closed.
6. Relay CR1 coil open.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Maintenance and Troubleshooting
Problem
Spirit275a User’s Manual Rev K
Possible Cause
5. Check the automatic gas console
messages screen and troubleshoot
accordingly. If the “output voltage low”
error is present, perform the chopper test
in this section.
6. Pilot arc transistor PAT is not operating
properly. Check the PAT LED’s on the
microprocessor p.c. board and PAT drive
p.c. board.
7. Damaged or loose torch lead connections.
8. Shorted torch or torch leads. Check the
continuity between the Electrode lead and
the Nozzle lead to make sure they are not
shorted.
9. 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.
No spark between the spark gap
electrodes
1. Improper spark gap. Set gap to .015”
(.381 mm).
Clean
2. Worn spark gap electrodes.
electrodes with 600 grit sandpaper and
regap. Replace electrodes that have a
rounded face.
3. Bad high frequency transformer TR5.
Check for signs of arcing.
4. Check for 120VAC on the input side of
filter FL1 inside the RHF console after a
start signal has been given. If 120V is not
present, check associated wiring back to
the power supply.
The arc will not transfer to the
workpiece
1. Loose work ground connection.
2. Pierce height too high.
3. Incorrect, damaged, or worn consumables.
The gas console screen is blank
1. Blown gas console fuse F10.
2. Loose cables inside the gas console.
Remove and reinstall all plugs on the
interface p.c. board, computer, video
board, and display.
3. Bad power supply inside gas console.
Check for all voltage LED’s on the
interface board and computer.
4. Loose plug P17 on the bottom of the gas
console. Remove and reinstall the plug.
No response from the gas console
keypad
1. Loose keypad cable inside the gas
console. Remove and reinstall the keypad
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.
7-10
Maintenance and Troubleshooting
Problem
Gas pressures will not adjust
properly
Spirit275a User’s Manual Rev K
Possible Cause
1. Wrong consumables installed in torch.
2. Loose
pressure
transducer
cable.
Remove and reinstall P8 and P9 on the
gas console I/O p.c. board.
3. Loose motorized regulator plugs. Remove
and reinstall the motor plugs and P4-P7 on
the gas console I/O p.c. board.
4. Pressure regulator orifice clogged with dirt
or debris. Turn off primary power and turn
motorized regulator screw all the way in by
hand.
5. Binding regulator. Turn off primary power
and turn all motorized regulators to their
mid positions by hand.
6. Loose shield valve plug. Remove and
reinstall P3 on the gas console I/O p.c.
board.
Low pressure error
1. Supply gas pressure(s) less than 120 psi.
2. Faulty pressure switch or associated wiring
inside gas console.
Pressure error during cut
1. Supply gas pressure(s) fluctuating during
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.
7-11
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
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.
Note: A chopper troubleshooting flow chart can be found at the end
of this section.
1. Turn off all power to the Spirit power supply.
2. Open the RHF console door and disconnect the black primary wires
of the high frequency transformer from the 120 VAC line filter. Close
the RHF console door to activate the door interlock switch.
3. Remove the front and left side panels from the power supply to
expose the output terminal block and the microprocessor p.c. board.
4. Remove the Electrode and Nozzle leads from the bottom
connections of the output terminal block (#59 & #79, page 8-5).
5. Apply three phase power to the unit and check the primary power on
the input terminal block TB5.
6. Depress the ON button to energize the Spirit system, and then apply
a start signal to the unit. Note that the unit will only energize for
approximately two seconds each time a start signal is applied.
When making the following readings, be sure the red DC Power
light is illuminated on the front control panel of the unit. After
applying the start signal, check the three phase voltage input to the
chopper at the diode bridge terminals (three right side screws on the
chopper assembly) for 225 VAC. If the voltage is not present, check
for primary voltage on the main contactor CON and on the primary
side of the power transformer.
7. With a start signal applied, check for 325 VDC at the Spirit output
terminal block between Electrode and Work. If 325 VDC is present,
the chopper is working properly.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Maintenance and Troubleshooting
Spirit275a User’s Manual Rev K
8. If 325 VDC is not present at the output terminal block, install a jumper
wire between P28-7 & P28-8 (ILK1). With a start signal applied,
check for 325 VDC at the Spirit output terminal block between
Electrode and Work. If 325 VDC is present, the chopper is working
properly.
Check the I/O PCB (HV- Output) and its wiring to the
Microprocessor PCB.
9. If 325 VDC is not present at the output terminal block, leave the
jumper wire installed between P28-7 & P28-8 (ILK1). Check the
chopper status LED’s when a start signal is applied:
a) LED’s 4 & 5 off - go to step 10.
b) LED’s 4 & 5 on, LED 6 off - go to step 11.
c) LED’s 4 & 5 on, LED 6 on, LED 7 off - go to step 12.
d) Only LED 4 or LED 5 on (not both) - replace chopper.
e) All LED’s on – replace chopper.
10. Check the 120 VAC supply to the chopper between P1-1 and P1-3 on
the chopper p.c. board. If 120 V is present, replace the chopper. If
120 V is not present, check fuse F3 and associated wiring.
11. Apply a start signal to the power supply and check the DC voltage
between P2-4 (ground) and P2-5 (signal) on the chopper p.c. board.
This voltage should change from approximately 15.5 VDC to less
than 1 VDC after the main contactor of the power supply is energized.
If 15.5 VDC is not present, replace the chopper. If no voltage change
occurs, check for approximately 15.5 VDC between P26-1 (ground)
and P26-2 (signal) on the microprocessor p.c. board. If 15.5 VDC is
not present, check continuity between P26 on the microprocessor p.c.
board and P2 on the chopper p.c. board. If 15.5 VDC is present at
the microprocessor p.c. board, replace the microprocessor.
12. Turn off primary power to the power supply. Disconnect P2 from
the chopper p.c. board and P26 from the microprocessor p.c. board.
Check continuity between P26-8 and P2-1 and between P26-7 and
P2-2. Also check that these wires are not shorted to each other. If
the cable is OK, connect P26 to the microprocessor p.c. board, but
leave P2 disconnected from the chopper. With power applied, give
the power supply a start signal and check for approximately 10 VDC
between P26-7 (ground) and P26-8 (signal) when the main contactor
is energized. If 10 VDC is not present, replace the microprocessor
p.c. board. If 10 VDC is present, turn all power off, reconnect P2 to
the chopper p.c. board, and repeat the test for 10 VDC between P2-2
(ground) and P2-1 (signal). If 10 VDC is present and LED 7 is not
illuminated, replace the chopper.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-13
Maintenance and Troubleshooting


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Spirit275a User’s Manual Rev K
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
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

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
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




















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

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This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Parts List
Spirit275a User’s Manual Rev K
Section 8 Parts List
Power Supply
Note: See Figures Below
Item Number Part Number Quantity
1
2
3
4
5
6
7
8
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Not shown
32
33
34
35
708088
708111
708090
708089
501163
501164
501162
501161
707260
500557
706205
500559
706264
706263
706262
706261
706260
706265
709086
709007
709058
709012
709011
709059
709076
709033
280275
709002
709001
709124
709061
709128
709060
500810
200092
200292
500518
708062
505024
500052
1
1
1
1
2
2
1
1
1
1
1
4
4
10
1
2
1
4
1
1
3
1
1
2
2
1
1
1
1
1
1
1
1
Description
Off switch, red
Off actuator, red
On switch, green
On actuator, green / illuminated
Light housing
Bulb
White lens
Red lens
L1 inductor
TR2 control transformer, 208/230/460 V / 60 Hz
TR2 control transformer, 575 V / 60 Hz
TR2 control transformer, 380/415 V / 50/60 Hz
TR1 main transformer, 208 V / 60 Hz / 3Ø
TR1 main transformer, 230 V / 60 Hz / 3Ø
TR1 main transformer, 380 V / 50/60 Hz / 3Ø
TR1 main transformer, 415 V / 50/60 Hz / 3Ø
TR1 main transformer, 460 V / 60 Hz / 3Ø
TR1 main transformer, 575 V / 60 Hz / 3Ø
TB1 – TB4 terminal block marker, 14 position
TB1 – TB4 terminal block, 14 position
F2-F11 fuse holder
F10 fuse, AGC 3A fuse
F3/F4 fuse, AGC 5A
F8 fuse, AGC 2A
F6/F7/F9/F11 fuse, AGC 1/2A
F5 fuse, AGC 1A
Microprocessor p.c. board assembly
P8/P12/P13, 14 socket receptacle
P7, 4 pin receptacle
P16, 9 socket receptacle
F1A/F1B fuse holder
F1A/F1B fuse, FNM 6.25A
Strain relief
A.C. detect p.c. board assembly
Coolant reservoir, without fittings or cap
Coolant reservoir assembly, with fittings and cap
Coolant reservoir cap/level gauge
LS1 coolant level switch
TS1 Coolant temperature switch
Pump motor, 1/3hp-230V-50/60 Hz
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Parts List
Item Number
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
62
63
64
65
66
67
68
69
72
73
74
75
76
77
78
79
80
81
82
83
Spirit275a User’s Manual Rev K
Part Number Quantity
Description
500513
1
V-band clamp
500511
1
Coolant pump, 70 gph
708061
1
Solenoid valve, 220/240VAC
715084
1
Check valve, coolant return
708068
2
CR2/CR5 relay
708059
1
FS1 coolant flow switch
500516
1
Fan, front panel
260250
1
Heat exchanger
260012
1
Shunt
500509
1
Coolant filter housing
500510
1
Coolant filter/deionization cartridge
708117
1
CON main contactor
500348
1
Relay p.c. board assembly
702076
1
EMI filter, 380/415 V units only
708118
2
CR3/PAR relay
701165
2
R7/R8, 3 ohm pilot arc resistor
500536
1
PAT IGBT drive p.c. board assembly
705011
1
PAT IGBT
709167
1
TB5 3Ø power terminal block
702075
2
PAT IGBT filter capacitor
277452
1
I/O p.c. board assembly
Contact factory
1
Height control voltage divider p.c. board assembly
280130
1
Chopper assembly
709117
1
I/O terminal block (small)
706036
1
TR8 transformer, 241-4-36
706041
2
TR4/TR7 transformer, 241-3-12
706042
1
TR5 transformer, 241-4-12
706043
1
TR3 transformer, 241-6-12
280003
1
Power supply, 24VDC
708103
1
CR1 relay
708104
1
CR1 relay socket
708105
1
CR1 hold-down clip
709190
1
TB6 terminal block marker, 4 position
709191
1
TB6 terminal block, 4 position
740106
1
Bulb, power on switch
704050
6
LED/lens, green
200204
1
Fan, 120V
715052
1
Drain petcock
500526
2
Fan guard (large) – outside
500574
2
Fan guard (small) - inside
709228
1
I/O terminal block (large)
709227
2
Strain relief
709231
1
F2 fuse, MDL 5A
500525
701141
4
1
Fan, heat exchanger / front panel
R9, 2 ohm pilot arc resistor
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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
Parts List
Spirit275a User’s Manual Rev K
Power Supply – 1 of 4
Front panel fans not shown (item numbers 42 and 82)
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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
Parts List
Spirit275a User’s Manual Rev K
Power Supply – 2 of 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.
8-4
Parts List
Spirit275a User’s Manual Rev K
Power Supply – 3 of 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.
8-5
Parts List
Spirit275a User’s Manual Rev K
Power Supply – 4 of 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.
8-6
Parts List
Spirit275a User’s Manual Rev K
Automatic Gas Console
(Assembly 280002)
Note: See Figures Below
Item Number Part Number Quantity
Description
1
280005
1
AGC decal / membrane switch
2
501146
1
AGC aluminum display panel
3
500860
1
AGC display window
4
710199
4
Aluminum standoff
5
500861
1
AGC EL display
6
706044
1
Transformer, 241-7-16
9
709003
2
Receptacle, 9 position
10
700404
1
Filter bracket
11
702037
5
Filter
12
709179
1
Terminal block, 10 position
13
709192
1
Terminal block marker, 10 position
14
505039
1
Floppy disk drive
15
500021
1
Floppy disk drive cover
Not shown
505047
1
Floppy disk drive cable
16
501145
9
Manifold
17
708097
4
Pressure switch, 80-200 psi
18
715097
6
Transducer isolator
19
260217
5
Solenoid valve
20
500867
3
Motorized regulator assembly
22
500868
1
Motorized regulator assembly, oxygen
23
709007
1
Terminal block, 14 position
24
709009
1
Terminal block marker, 14 position
25
200082
1
Solenoid valve assembly, 3 gang
26
500907
1
Solenoid valve bracket
27
200083
1
Solenoid valve assembly, 4 gang
28
501170
1
Power supply
29
505041
1
Video card (upper p.c. board)
30
280049
1
CPU (middle p.c. board)
31
200288
1
I/O p.c. board assembly (lower p.c. board)
Not shown
280286
1
Video card / CPU / I/O p.c. board assembly
33
280001
1
Regulator
34
708078
6
Transducer, 0-150 psi
35
280007
1
Pressure gauge, 0-60 psi
36
260111
1
Proportional valve amplifier
37
260109
1
Proportional valve
38
260104
1
Power supply
39
280030
1
Fan
40
280031
1
Fan Guard
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-7
Parts List
Spirit275a User’s Manual Rev K
Automatic Gas Console – 1 of 2
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-8
Parts List
Spirit275a User’s Manual Rev K
Automatic Gas Console – 2 of 2
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-9
Parts List
Spirit275a User’s Manual Rev K
Remote High Frequency Console
(Assembly 205500)
Item Number Part Number Quantity
Description
1
715051
2
Coolant return fitting (left hand)
2
715050
1
Coolant supply fitting (right hand)
3
709227
1
Strain relief
5
709001
1
4 pin receptacle
6
707001
1
Line filter
7
706109
1
Transformer – 5000V, 20 mA
8
702069
1
Capacitor – 15 kV
9
708057
1
Door interlock switch
10
500014
1
Spark gap assembly
11
740039
3
Spark gap electrode
12
505043
1
High frequency inductor
13
740072
1
Standoff
14
800041
1
Busbar
15
500505
1
RHF console p.c. board assembly
16
715021
1
Coolant supply fitting (right hand)
17
500503
1
Cathode manifold
18
205010
1
CTP sensor lead filter assembly
19
200287
1
Transformer insulating plate
22
500098
1
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.
8-10
Parts List
Spirit275a User’s Manual Rev K
Torch and Manifold Assemblies
Item Number Part Number Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
Not shown
Not shown
Not shown
Not shown
Not shown
260214
277195
820134
279050
279150
279160
820209
500024
500018
280022
500740
279013
279113
279112
716012
277056
277086
277087
279061
1
1
1
1
1
1
1
1
1
1
1
6
1
1
1
1
1
1
Description
2-gang manifold assembly (includes bracket)
2-gang manifold bracket
Torch handle
Torch Base
Torch Head (Copper Electrode)
Torch Head (Silver Electrode)
O-ring (red)
O-ring (blue)
O-ring (red)
5-gang manifold assembly
Torch solenoid plasma hose
O-ring (red) - indicator only, not a seal
O-ring (red)
O-ring (red)
O-ring lubricant
Nozzle removal tool
Electrode removal tool driver
Copper Electrode removal tool
Silver Electrode removal tool
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-11
Parts List
Spirit275a User’s Manual Rev K
Shielded Torch Leads
Part Number
280304-10
280304-15
280304-20
280304-25
280304-30
280304-35
280304-40
280304-45
280304-50
Length
10 ft. (3.0 m)
15 ft. (4.6 m)
20 ft. (6.1 m)
25 ft. (7.6 m)
30 ft. (9.1 m)
35 ft. (10.7 m)
40 ft. (12.2 m)
45 ft. (13.7 m)
50 ft. (15.2 m)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-12
Parts List
Spirit275a User’s Manual Rev K
Gas Hose Package
Part Number
280317-20
280317-25
280317-30
280317-35
280317-40
280317-45
280317-50
280317-55
280317-60
280317-65
280317-70
280317-75
280317-80
280317-85
280317-90
280317-95
280317-100
Length
20 ft. (6.1 m)
25 ft. (7.6 m)
30 ft. (9.1 m)
35 ft. (10.7 m)
40 ft. (12.2 m)
45 ft. (13.7 m)
50 ft. (15.2 m)
55 ft. (16.8 m)
60 ft. (18.3 m)
65 ft. (19.8 m)
70 ft. (21.3 m)
75 ft. (22.9 m)
80 ft. (24.4 m)
85 ft. (25.9 m)
90 ft. (27.4 m)
95 ft. (29.0 m)
100 ft. (30.5 m)



























This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-13
Parts List
Spirit275a User’s Manual Rev K
Coolant and Power Leads
Part Number
(Non-CSA Systems)
280306-5
280306-10
280306-15
280306-20
280306-25
280306-30
280306-35
280306-40
280306-45
280306-50
280306-55
280306-60
280306-65
280306-70
280306-75
280306-80
280306-85
280306-90
280306-95
280306-100
Part Number
(CSA Systems)
288306-5
288306-10
288306-15
288306-20
288306-25
288306-30
288306-35
288306-40
288806-45
288306-50
288306-55
288306-60
288306-65
288306-70
288306-75
288306-80
288306-85
288306-90
288306-95
288306-100
Length
5 ft. (1.5 m)
10 ft. (3.0 m)
15 ft. (4.6 m)
20 ft. (6.1 m)
25 ft. (7.6 m)
30 ft. (9.1 m)
35 ft. (10.7 m)
40 ft. (12.2 m)
45 ft. (13.7 m)
50 ft. (15.2 m)
55 ft. (16.8 m)
60 ft. (18.3 m)
65 ft. (19.8 m)
70 ft. (21.3 m)
75 ft. (22.9 m)
80 ft. (24.4 m)
85 ft. (25.9 m)
90 ft. (27.4 m)
95 ft. (29.0 m)
100 ft. (30.5 m)


















This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-14
Parts List
Spirit275a User’s Manual Rev K
Work Ground Cable
Part Number
(Non-CSA Systems)
280318-10
280318-15
280318-20
280318-25
280318-30
280318-35
280318-40
280318-45
280318-50
280318-55
280318-60
280318-65
280318-70
280318-75
280318-80
280318-85
280318-90
280318-95
280318-100
Part Number
(CSA Systems)
288318-10
288318-15
288318-20
288318-25
288318-30
288318-35
288318-40
288318-45
288318-50
288318-55
288318-60
288318-65
288318-70
288318-75
288318-80
288318-85
288318-90
288318-95
288318-100

Length
10 ft. (3.0 m)
15 ft. (4.6 m)
20 ft. (6.1 m)
25 ft. (7.6 m)
30 ft. (9.1 m)
35 ft. (10.7 m)
40 ft. (12.2 m)
45 ft. (13.7 m)
50 ft. (15.2 m)
55 ft. (16.8 m)
60 ft. (18.3 m)
65 ft. (19.8 m)
70 ft. (21.3 m)
75 ft. (22.9 m)
80 ft. (24.4 m)
85 ft. (25.9 m)
90 ft. (27.4 m)
95 ft. (29.0 m)
100 ft. (30.5 m)

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-15
Parts List
Spirit275a User’s Manual Rev K
Oxygen Supply Gas Hose (Optional)
Part Number
200362-25
200362-50
Length
25 ft. (7.6 m)
50 ft. (15.2 m)
BLUE
BLUE
Nitrogen Supply Gas Hose (Optional)
Part Number
200365-25
200365-50
Length
25 ft. (7.6 m)
50 ft. (15.2 m)
BLACK
BLACK
Air Supply Gas Hose (Optional)
Part Number
200364-25
200364-50
Length
25 ft. (7.6 m)
50 ft. (15.2 m)
BLACK
BLACK
H17 Supply Gas Hose (Optional)
Part Number
200363-25
200363-50
Length
25 ft. (7.6 m)
50 ft. (15.2 m)
RED
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.
8-16
Parts List
Spirit275a User’s Manual Rev K
Power Supply Microprocessor P.C. Board
(Assembly 280275)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-17
Parts List
Spirit275a User’s Manual Rev K
A.C. Detect P.C. Board
(Assembly 500810)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-18
Parts List
Spirit275a User’s Manual Rev K
Relay P.C. Board
(Assembly 500348)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-19
Parts List
Spirit275a User’s Manual Rev K
Power Supply I/O P.C. Board
(Assembly 277452)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-20
Parts List
Spirit275a User’s Manual Rev K
Automatic Gas Console I/O P.C. Board
(Assembly 200288)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-21
Parts List
Spirit275a User’s Manual Rev K
Consumable Spare Parts Kit
(Part Number 280267)
Part Number
277130
277137
277131
277132
277282
277133
277292
277291
277135
277270
277120
277121
277122
277123
277125
277124
277284
277126
277293
277289
Quantity
Description
3
Electrode
30A Mild Steel - 30A Aluminum
2
Electrode
30/50A Stainless (Air)
6
Electrode
50/70A Mild Steel - 70A Stainless (Air) - 50/70A Aluminum
2
Electrode
70A Stainless (H17)
3
Electrode
100A Mild Steel - 100A Stainless (Air) - 100A Aluminum
2
Electrode
100A Stainless (H17)
3
Electrode
150A Mild Steel – 150A Stainless (Air) – 150A Aluminum
3
Electrode
200A Mild Steel - 200A Stainless (Air) - 200A Aluminum
2
Electrode
150/200/260A Stainless (H17)
3
Electrode
275A Mild Steel – 275A Stainless (Air) – 275A Aluminum
5
Nozzle
30A Mild Steel - 30A Aluminum
3
Nozzle
30A Stainless (Air)
5
Nozzle
50A Mild Steel - 50A Aluminum
3
Nozzle
50A Stainless (Air)
5
Nozzle
70A Mild Steel - 70A Stainless (Air) - 70A Aluminum
3
Nozzle
70A Stainless (H17)
5
Nozzle
100A Mild Steel – 100A Stainless (Air) - 100A Aluminum
3
Nozzle
100A Stainless (H17)
5
Nozzle
150A Mild Steel – 150A Stainless (Air) – 150A Aluminum
5
Nozzle
200A Mild Steel – 200A Stainless (Air) - 200A Aluminum
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-22
Parts List
Part Number
277287
277118
277269
277276
277145
277144
277149
277115
277150
277286
277146
277117
277298
277274
277211
277263
277138
277140
277142
277283
277141
Spirit275a User’s Manual Rev K
Quantity
Description
3
Nozzle
200A Stainless (H17)
3
Nozzle
260A Stainless (H17)
5
Nozzle
275A Mild Steel
3
Nozzle
275A Stainless (Air) – 275A Aluminum
3
Shield Cap
30A Mild Steel - 30A Aluminum
3
Shield Cap
30A Stainless (Air)
3
Shield Cap
50A Stainless (Air)
3
Shield Cap
50A Mild Steel
3
Shield Cap
70A Mild Steel - 70A Stainless - 50/70A Aluminum
3
Shield Cap
100A Mild Steel - 100A Stainless (Air) - 100A Aluminum
3
Shield Cap
100A Stainless (H17)
3
Shield Cap
150A Mild Steel – 150A Stainless (Air) – 150A Aluminum
3
Shield Cap
150A Stainless (H17)
3
Shield Cap
200A Mild Steel - 200A Stainless – 200A Aluminum
3
Shield Cap
260A Stainless (H17)
3
Shield Cap
275A Mild Steel – 275A Stainless (Air) – 275A Aluminum
1
Swirl Ring
30A Stainless (Air)
1
Swirl Ring
30/50A Mild Steel - 70A Stainless (H17) - 30A Aluminum
1
Swirl Ring
50/70A Mild Steel - 50/70A Stainless (Air) - 50/70A Aluminum
1
Swirl Ring
100A Mild Steel – 100A Stainless (Air) – 100A Aluminum
1
Swirl Ring
100A Stainless (H17)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-23
Parts List
Part Number
277139
277143
277259
277258
277110
277153
277151
277152
277113
277266
277280
716012
500024
500018
820209
277056
277086
277087
260105
277154
Spirit275a User’s Manual Rev K
Quantity
Description
1
Swirl Ring
150A Mild Steel – 150A Stainless – 150A Aluminum
260A Stainless (H17)
1
Swirl Ring
200A Mild Steel – 200A Stainless (Air) - 200A Aluminum
1
Swirl Ring
200A Stainless (H17)
1
Swirl Ring
275A Mild Steel – 275A Stainless (Air) – 275A Aluminum
1
Inner Retaining Cap
30/50A Stainless (Air)
1
Inner Retaining Cap
30/50/70A Mild Steel - 70A Stainless (Air)
30/50/70A Aluminum
1
Inner Retaining Cap
100A Mild Steel - 100A Stainless (Air) - 100A Aluminum
150A Mild Steel – 1/2” and below
1
Inner Retaining Cap
150A Mild Steel – 5/8” and above – 150A Stainless (Air)
150A Aluminum
1
Inner Retaining Cap
70/100A Stainless (H17)
1
Inner Retaining Cap
150A Stainless (H17)
200/275A Mild Steel – 200A Stainless – 200/275A Aluminum
275A Stainless (Air)
1
Inner Retaining Cap
260A Stainless (H17)
1
O-ring Lubricant
2
Torch O-ring – blue, lower
2
Torch O-ring – red, middle
2
Torch O-ring –black/red, upper
1
Nozzle Removal Tool
1
Electrode Removal Tool Driver
1
Electrode Removal Tool Socket
1
Swirl Ring Removal Tool
1
Outer Retaining Cap
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-24
Electromagnetic Compatibility (EMC)
Spirit275a User’s Manual Rev K
Appendix A Electromagnetic
Compatibility (EMC)
Background
The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit275a 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.
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Electromagnetic Compatibility (EMC)
Spirit275a User’s Manual Rev K
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.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
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Electromagnetic Compatibility (EMC)
Spirit275a User’s Manual Rev K
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.
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
Electromagnetic Compatibility (EMC)
Spirit275a User’s Manual Rev K
BLANK PAGE
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
A-4
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