User`s Manual - Lincoln Electric

User`s Manual - Lincoln Electric
User's Manual
Spirit II 400
High Current Density Plasma Cutting System
with Manual Gas Console (MGC)
BK718118 Rev F
This information is subject to the controls of the Export Administration Regulations [EAR].
This information shall not be provided to non-U.S. persons or transferred by any means to
any location outside the United States contrary to the requirements of the EAR.
Prologue
Spirit II User’s Manual
Revision History
Rev
ECO#
Author
Date
A
-
CAD
02/04/2013
B
LAD0202
CAD
06/07/2013
C
LAD0217
CAD
08/06/2013
D
LAD0228
CAD
08/28/2013
E
LAD0260
CAD
03/18/2014
F
LAD0264
CAD
03/31/2014
Description of Change
Initial Release
Added 100A/150A silver electrodes, replaced RHF with ISC,
corrected system interconnect diagrams, changed rated inlet
gas pressure to 115 psi, added 100 psi minimum to inlet gas
pressure.
Deionization filter cartridge (500510) replaced sediment filter
(300152). Parts list updated.
Expanded notes on System Interconnection diagrams to
clarify cabling requirements for various configurations.
Corrected contact ratings on page 3-19.
Added pinouts to CII, FII, JII cables in Parts List.
Inductor (707150) replaced by (707155). ISC Console
(300500) replaced by (300505). MGC (300600) replaced by
(300615). Added notes about torch handle vent hole.
Updated Chopper Test Procedure.
Added “BK” prefix to all part numbers. Added PCB Outline
Dwgs and corrected electrode tool in Part List. Corrected
Remote On/Off info in Installation section.
This documentation may not be copied, photocopied, reproduced, translated,
or reduced to any electronic medium or machine-readable format without
explicit written permission from Kaliburn.
FASTON is a trademark of the TE Connectivity Ltd family of companies.
Other logos, products and company names mentioned herein
may be trademarks of their respective owners.
© Copyright 2013-2014 Lincoln Global, Inc.
Kaliburn Inc.
a Lincoln Electric Company
4130 Carolina Commerce Parkway
Ladson, SC 29456 USA
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
ii
Spirit II User’s Manual
Prologue
Table of Contents
Section 1: Safety
General Precautions ......................................................................................... 1-1
Ultraviolet Radiation Protection ......................................................................... 1-1
Noise Protection ................................................................................................ 1-1
Toxic Fume Prevention ..................................................................................... 1-2
Electric Shock Prevention ................................................................................. 1-2
Fire Prevention .................................................................................................. 1-3
Explosion Prevention......................................................................................... 1-3
Health Support Equipment ................................................................................ 1-4
Safety Standards Booklet Index ........................................................................ 1-5
Section 2: Specifications
System Description ........................................................................................... 2-1
System Components ......................................................................................... 2-2
Power Supply Specifications ............................................................................. 2-3
Cooling System Specifications .......................................................................... 2-4
Torch Coolant Specifications............................................................................. 2-5
Manual Gas Console (MGC) Specifications ...................................................... 2-6
Gas Supply Requirements ................................................................................ 2-7
Impulse Start Console (ISC) Specifications....................................................... 2-8
Torch and 2-Gang Manifold Specifications........................................................ 2-9
5-Gang Manifold Specifications ......................................................................... 2-10
Airborne Noise Emissions ................................................................................. 2-11
Section 3: Installation
Initial Inspection ................................................................................................ 3-1
Component Placement ...................................................................................... 3-1
System Interconnection ..................................................................................... 3-2
Power Supply Primary Power Connections ....................................................... 3-5
Power Supply Output Connections ................................................................... 3-7
ISC Control Cable and ISC Ground Connections.............................................. 3-9
Cooling System Connections ............................................................................ 3-9
Torch Leads to Impulse Start Console Connections ......................................... 3-11
Torch Leads to Torch Base Connections .......................................................... 3-13
Torch Gas Connections..................................................................................... 3-14
Gas Supply Connections ................................................................................... 3-17
CAN Communication Connections .................................................................... 3-18
CNC Machine Interface Connections ................................................................ 3-19
Initial Filling of the Cooling System ................................................................... 3-20
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
iii
Prologue
Spirit II User’s Manual
Section 4: Operation
Operating the Manual Gas Console (MGC) ...................................................... 4-1
Setting up to Cut ............................................................................................... 4-2
Setting up to Mark (Overrides Cut) .................................................................... 4-3
Verifying Input Gas Pressures........................................................................... 4-3
Making a Cut or Mark ........................................................................................ 4-4
Piercing Thick Materials .................................................................................... 4-5
Moving Pierces and Edge Starts ....................................................................... 4-5
Cut Quality ........................................................................................................ 4-6
Checking Errors ................................................................................................ 4-7
Checking the Version and Serial Number ......................................................... 4-7
Changing the Language .................................................................................... 4-8
Adjusting the Screen Contrast........................................................................... 4-8
Section 5: Torch Consumables and Cutting Charts
Installing / Removing the Torch Head ............................................................... 5-1
Installing / Replacing Consumables .................................................................. 5-2
Maximizing Consumable Life ............................................................................ 5-3
Inspecting for Damage ...................................................................................... 5-4
Selecting Consumables..................................................................................... 5-5
Cutting Charts ................................................................................................... 5-12
Section 6: Maintenance and Troubleshooting
Routine Maintenance ........................................................................................ 6-1
Replacing the Torch Coolant and Filter ............................................................. 6-4
Microprocessor (DSP) Status Indicators ........................................................... 6-5
Microprocessor (DSP) Sequence of Operation ................................................. 6-5
Error Codes ....................................................................................................... 6-7
General Troubleshooting ................................................................................... 6-9
Chopper Test Procedure ................................................................................... 6-11
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
iv
Spirit II User’s Manual
Prologue
Section 7: Parts List
Power Supply (BK300232 - BK300239) ............................................................ 7-1
Cooling System (BK300275) ............................................................................. 7-4
Manual Gas Console (BK300615) ..................................................................... 7-5
Impulse Start Console (BK300505) ................................................................... 7-7
Torch and Manifold Assemblies ........................................................................ 7-8
Shielded Torch Leads ....................................................................................... 7-9
CAN Communication Cable and Termination Plug ........................................... 7-9
Manifold Control Cables .................................................................................... 7-9
Gas Hose Package with MGC........................................................................... 7-10
Cooling System Control Cable .......................................................................... 7-10
Coolant and Power Leads ................................................................................. 7-11
Work Ground Lead ............................................................................................ 7-11
Oxygen Supply Gas Hose (Optional) ................................................................ 7-12
Nitrogen Supply Gas Hose (Optional) ............................................................... 7-12
Air Supply Gas Hose (Optional) ........................................................................ 7-12
H17 Supply Gas Hose (Optional) ...................................................................... 7-12
"CII" Cable (for Optional External Inova) ........................................................... 7-13
"FII" Cable (for Optional Internal Inova)............................................................. 7-14
"JII" Cable (for Optional Internal Inova) ............................................................. 7-15
PCB Assemblies – Component Reference Locations ....................................... 7-16
Section 8: Internal Inova Console Option
Overview ........................................................................................................... 8-1
Plug Identification .............................................................................................. 8-1
Unique Interconnect Cables .............................................................................. 8-1
Grounding ......................................................................................................... 8-2
Parts List ........................................................................................................... 8-3
Appendix A: Electromagnetic Compatibility (EMC)
Background ....................................................................................................... A-1
Installation and Use ........................................................................................... A-1
Assessment of Area .......................................................................................... A-2
Methods of Reducing Emissions ....................................................................... A-2
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
v
Prologue
Spirit II User’s Manual
Limited Warranty
KALIBURN expressly warrants that this product shall be free from defects in materials
and workmanship, under proper and normal use for the intended function of such
product, for a period of three (3) years for the Spirit II plasma power supply (includes the
cooling system and internally installed Inova option) and one (1) year for all other Spirit
II system component. This warranty does not apply to torch consumable parts.
The warranty period starts three (3) months after the product ships from the factory.
This product is intended for commercial use and is not intended for personal, family, or
household purposes. There are no warranties that extend beyond the express limited
warranty set forth immediately above. All other warranties, whether expressed, implied,
statutory or made herein or in any other communication, including any implied warranty
of merchantability, fitness for any particular purpose or non-infringement, are expressly
excluded.
This warranty will be considered void if the Spirit II system is operated with non-genuine
KALIBURN torch consumables, or if the equipment has been subjected to improper
installation, improper care or abnormal operation.
If this product or any component thereof is determined to be defective in materials or
workmanship, KALIBURN will repair or replace the defective component or product.
The buyer’s remedies are limited to the return of the product for repair or replacement of
any defective product or part at the sole discretion of KALIBURN. No freight charges of
any kind are covered under this warranty. All returned goods shall be at the buyer’s risk
and expense. In no event will KALIBURN be responsible for any special, incidental or
consequential damages or injury to the person or property of anyone by reason of any
defect in any equipment sold hereunder.
Returned Goods Procedure
KALIBURN utilizes a returned goods procedure that must be followed before returning
any items for repair, replacement, or restocking. This means that a returned goods
authorization number must be obtained prior to shipment to KALIBURN. It will be
necessary for the customer to provide a description, along with the part number and
serial number, if applicable, of the item to be returned. In no case will KALIBURN
accept a returned shipment without the proper returned goods authorization number.
For shipments inside the U.S., parts must be returned to KALIBURN within 30 days of
the invoice date to be considered for credit. For shipments outside the U.S., parts must
be returned within 60 days of the invoice date to be considered for credit.
Electromagnetic Compatibility (EMC)
The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit II plasma cutting systems are
manufactured to comply with the European standard EN 60974-10 (Electromagnetic
compatibility (EMC) – Product standard for arc welding equipment). Information about
the EMC standard EN 60974-10 can be found in Appendix A.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
vi
Spirit II User’s Manual
Section 1: Safety
Section 1: Safety
General Precautions
Whereas plasma cutting has been used safely for years, it does require certain
precautions to ensure the safety of the operator and other people around the
equipment. The following safety information must be provided to each person who will
operate, observe, perform maintenance, or work in close proximity to this piece of
equipment.
Installation, operation, and repairs made to the Spirit system should only be performed
by qualified personnel. The system makes use of both A.C. and D.C. circuitry for
operation. Fatal shock hazard does exist. Exercise extreme caution while working
on the system.
Ultraviolet Radiation Protection
Plasma cutting produces ultraviolet radiation similar to a welding arc. This ultraviolet
radiation can cause skin and eye burns. For this reason, it is essential that proper
protection be worn. The eyes are best protected by using safety glasses or a welding
helmet with an AWS No. 12 shade or ISO 4850 No. 13 shade, which provides protection
up to 400 amperes. All exposed skin areas should be covered with flame-retardant
clothing. The cutting area should also be prepared in such a way that ultraviolet light
does not reflect. Walls and other surfaces should be painted with dark colors to reduce
reflected light. Protective screens or curtains should be installed to protect additional
workers in the area from ultraviolet radiation.
Noise Protection
The system generates high noise levels while cutting. Depending on the size of the
cutting area, distance from the cutting torch, and arc current cutting level, acceptable
noise levels may be exceeded. Proper ear protection should be used as defined by
local or national codes. See Section 2 for noise emission levels.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-1
Section 1: Safety
Spirit II User’s Manual
Toxic Fume Prevention
Care should be taken to ensure adequate ventilation in the cutting area. Some
materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the
cutting area. Also, some solvents decompose and form harmful gases when exposed
to ultraviolet radiation. These solvents should be removed from the area prior to cutting.
Galvanized metal can produce harmful gases during the cutting process. Ensure proper
ventilation and use breathing equipment when cutting these materials.
Certain metals coated with or containing lead, cadmium, zinc, beryllium, and mercury
produce harmful toxins. Do not cut these metals unless all people subjected to the
fumes wear proper air breathing equipment.
Electric Shock Prevention
The Spirit system uses high open circuit voltages that can be fatal. Extreme care
should be used when operating or performing maintenance on the system. Only
qualified personnel should service the system. Observe the following guidelines to
protect against electric shock:
•
•
•
•
•
•
•
•
A wall-mounted disconnect switch should be installed and fused according to local
and national electrical codes. The disconnect switch should be located as close as
possible to the power supply so it can be turned off in case of an emergency.
The primary power cord should have a 600 volt minimum rating in order to protect
the operator. In addition, it should be sized according to local and national electrical
codes. Inspect the primary power cord frequently. Never operate the system if the
power cord is damaged in any way.
Make sure the primary power ground wire is connected to the input power ground
stud on the power supply. Make sure the connection is securely tightened.
Make sure the positive output (work ground) of the power supply is connected to a
bare metal area on the cutting table. A driven ground rod should be placed no
further than five feet from this connection. Make sure this ground point on the
cutting table is used as the star ground point for all other ground connections.
Inspect the torch leads frequently. Never use the system if the leads are damaged
in any way.
Do not stand in wet, damp areas when operating or performing maintenance on the
system.
Wear insulated gloves and shoes while operating or performing maintenance on the
system.
Make sure the system is switched off at the wall disconnect before servicing the
power supply or torch.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-2
Spirit II User’s Manual
•
•
•
•
•
•
Section 1: Safety
Never change torch consumable parts unless the system is switched off at the wall
disconnect.
Do not attempt to remove any parts from beneath the torch when cutting.
Remember that the workpiece forms the current path back to the power supply.
Never bypass the safety interlock devices.
Before removing any of the covers, switch the system off at the wall disconnect.
Wait at least five (5) minutes before removing any cover. This will give the
capacitors inside the unit time to discharge. See Section 6 for additional safety
precautions.
Never operate the system without all of the covers in place. See Section 6 for
additional safety precautions.
Preventive maintenance should be performed daily to avoid possible safety hazards.
Fire Prevention
When using the Spirit system, it is necessary to exercise good judgment. While cutting,
the arc produces sparks that could cause a fire if they fall on flammable materials.
Make sure that all flammable materials are a suitable distance away from the cutting
area. All flammable liquids should be at least 40 feet away from the cutting area,
preferably stored in a metal cabinet. Plasma cutting should never be attempted on
containers that contain flammable materials. Make sure that fire extinguishers are
readily accessible in the cutting area.
Make sure that the cutting area is properly ventilated when using oxygen as a cutting
gas.
Explosion Prevention
The Spirit system uses compressed gases. Use proper techniques when handling
compressed gas cylinders and other compressed gas equipment. Observe the
following guidelines to protect against explosion:
•
•
•
•
Never operate the system in the presence of explosive gases or other explosive
materials.
Never cut pressurized cylinders or any closed container.
When using a water table and cutting aluminum under water or with water touching
the underside of the aluminum plate, hydrogen gas is produced. This hydrogen gas
may collect under the plate and explode during the cutting process. Make sure the
water table is properly aerated to help prevent the accumulation of hydrogen gas.
Handle all gas cylinders in accordance with safety standards published by the U.S.
Compressed Gas Association (CGA), American Welding Society (AWS), Canadian
Standards Association (CSA), or other local or national codes.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-3
Section 1: Safety
•
•
•
•
•
•
•
•
•
•
•
•
Spirit II User’s Manual
Compressed gas cylinders should be maintained properly. Never attempt to use a
cylinder that is leaking, cracked, or has other signs of physical damage.
All gas cylinders should be secured to a wall or rack to prevent accidental knock
over.
If a compressed gas cylinder is not being used, replace the protective valve cover.
Never attempt to repair compressed gas cylinders.
Keep compressed gas cylinders away from intense heat, sparks, or flames.
Clear the compressed gas cylinder connection point by opening the valve
momentarily prior to installing a regulator.
Never lubricate compressed gas cylinder valves or pressure regulators with any type
of oil or grease.
Never use a compressed gas cylinder or pressure regulator for any purpose other
than which it is intended.
Never use a pressure regulator for any gas other than which it is intended.
Never use a pressure regulator that is leaking or has other signs of physical
damage.
Never use oxygen hoses and pressure regulators for any gas other than oxygen.
Never use any gas hose that is leaking or has other signs of physical damage.
Health Support Equipment
The Spirit system creates electric and magnetic fields that may interfere with certain
types of health support equipment, such as pacemakers. Any person who uses a
pacemaker or similar item should consult a doctor before operating, observing,
maintaining, or servicing the system. Observe the following guidelines to minimize
exposure to these electric and magnetic fields:
•
•
•
•
Stay as far away from the power supply, torch, torch leads, and impulse start
console as possible.
Route the torch leads as close as possible to the work ground cable.
Never place your body between the torch leads and work ground cable. Keep the
work ground cable and the torch leads on the same side of your body.
Never stand in the center of a coiled up set of torch leads or work ground cable.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-4
Spirit II User’s Manual
Section 1: Safety
Safety Standards Booklet Index
For further information concerning safety practices to be exercised with plasma arc
cutting equipment, please refer to the following publications:
1.
AWS Standard AWN, Arc Welding and Cutting Noise, obtainable from the American
Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
2.
AWS Standard C5.2, Recommended Practices for Plasma Arc Cutting, obtainable
from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
3.
AWS Standard FSW, Fire Safety in Welding and Cutting, obtainable from the
American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
4.
AWS Standard F4.1, Recommended Safe Practices for Preparation for Welding and
Cutting of Containers and Piping, obtainable from the American Welding Society,
550 NW LeJeune Road, Miami, FL 33126.
5.
AWS Standard ULR, Ultraviolet Reflectance of Paint, obtainable from the American
Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
6.
AWS / ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes,
obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL
33126.
7.
ANSI Standard Z41.1, Standard For Men’s Safety-Toe Footwear, obtainable from
the American National Standards Institute, 11 West 42nd Street, New York, NY
10036.
8.
ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding
Processes, obtainable from the American National Standards Institute, 11 West
42nd Street, New York, NY 10036.
9.
ANSI Standard Z87.1, Safe Practices For Occupation and Educational Eye and
Face Protection, obtainable from the American National Standards Institute, 11
West 42nd Street, New York, NY 10036.
10. ANSI Standard Z88.2, Respiratory Protection, obtainable from the American
National Standards Institute, 11 West 42nd Street, New York, NY 10036.
11. OSHA Standard 29CFR 1910.252, Safety and Health Standards, obtainable from
the U.S. Government Printing Office, Washington, D.C. 20402.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-5
Section 1: Safety
Spirit II User’s Manual
12. NFPA Standard 51, Oxygen - Fuel Gas Systems for Welding, Cutting, and Allied
Processes, obtainable from the National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
13. NFPA Standard 51B, Cutting and Welding Processes, obtainable from the National
Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
14. NFPA Standard 70, National Electrical Code, obtainable from the National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
15. CGA booklet P-1, Safe Handling of Compressed Gases in Containers, obtainable
from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202.
16. CGA booklet P-14, Accident Prevention in Oxygen-Rich and Oxygen-Deficient
Atmospheres, obtainable from the Compressed Gas Association, 1725 Jefferson
Davis Highway, Suite 1004, Arlington, VA 22202.
17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the
Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202.
18. CSA Standard W117.2, Safety in Welding, Cutting, and Allied Processes,
obtainable from Canadian Standards Association, 178 Rexdale Boulevard, Toronto,
Ontario M9W lR3, Canada.
19. Canadian Electrical Code Part 1, Safety Standard for Electrical Installations,
obtainable from the Canadian Standards Association, 178 Rexdale Boulevard,
Toronto, Ontario M9W 1R3, Canada.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-6
Spirit II User’s Manual
Section 2: Specifications
Section 2: Specifications
System Description
The Spirit II 400 is a 400 amp microprocessor controlled, 100% duty cycle high current
density plasma cutting and marking system. It utilizes a precision, dual gas torch that is
capable of cutting mild steel up to 3" thick and stainless steel up to 1-1/2” thick.
The system contains a manually controlled gas console, which also provides the
primary interface to the entire Spirit system.
For cutting mild steel, the system uses oxygen for the plasma gas and either oxygen or
air for the shielding gas. When cutting stainless steel or other non-ferrous materials, air
or H17 (17.5% hydrogen, 32.5% argon, 50% nitrogen) is used for the plasma gas and
either air or nitrogen is used for the shielding gas. Oxygen and nitrogen are used for
the preflow and postflow gases.
The torch is water-cooled and consumables are machined to exacting dimensions and
checked with the latest computerized measuring systems. Nine nozzle sizes (30, 50,
70, 100, 150, 200, 260, 275, and 400 amps) are available to produce excellent cut
quality throughout the cutting range.
Each enclosure in the system is rated for IP21S sealing, which is intended for
indoor use only. The system is not suitable for use in rain or snow.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-1
Section 2: Specifications
Spirit II User’s Manual
System Components
The Spirit II 400 System consists of the following components:
Standard Components
• Power Supply
• Cooling System (includes torch coolant)
• Cooling System Control Cable
• Manual Gas Console
• CAN Cable
• CAN Termination Plug
• Impulse Start Console (ISC)
• ISC Control Cable
• ISC Ground Cable
• Torch and Handle Assembly
• Torch Lead Set
• 5-gang Manifold Assembly
• 5-gang Manifold Control Cable
• 2-gang Manifold Assembly
• 2-gang Manifold Control Cable
• 17 Inch Plasma Hose
• Coolant and Power Leads
• Gas Hose Package
• Work Ground Lead
• Spirit II User’s Manual
Optional Components
• Supply Gas Hoses
• Internal Inova Console
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-2
Spirit II User’s Manual
Section 2: Specifications
Power Supply Specifications
Power Supply Description
220 VAC, 3Ø, 60Hz
240 VAC, 3Ø, 60Hz
380 VAC, 3Ø, 50/60Hz
400 VAC, 3Ø, 50/60Hz
415 VAC, 3Ø, 50/60Hz
440 VAC, 3Ø, 50/60Hz
480 VAC, 3Ø, 60Hz
600 VAC, 3Ø, 60Hz
Part Number
BK300232
BK300233
BK300234
BK300235
BK300236
BK300237
BK300238
BK300239
Input Current at
Maximum Output
262 amps
240 amps
152 amps
144 amps
140 amps
131 amps
120 amps
96 amps
Open Circuit Voltage ......................................... 370 VDC
Output Current (drooping characteristic) ........... 10 - 400 amps
Maximum Output Voltage ................................. 200 VDC
Duty Cycle ........................................................ 100% @ 80 kW
Maximum Ambient Temperature ....................... 104° F (40° C)
Weight .................................... .......................... 1922 lb (872 kg)
39.9"
[1013]
34.2" [869]
49.5" [1257]
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-3
Section 2: Specifications
Spirit II User’s Manual
Cooling System Specifications
Part Number ..................................................... BK300275
Discharge pressure .......................................... 150 psi (10.2 bar)
Flow rate .......................................................... 2.1 gal/min (7.9 liters/min)
Coolant fluid ..................................................... Propylene glycol solution
Coolant tank capacity ....................................... 3.2 gal (12 liters)
Weight .............................................................. 141 lb (64 kg) (without coolant)
36.0" [914]

23.0" [584]

15.8" [401]

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-4
Spirit II User’s Manual
Section 2: Specifications
Torch Coolant Specifications
Note: Refer to the supplier’s most current Material Safety Data Sheet for
information regarding safety, handling, and storage of torch coolant.
The Spirit system is shipped without torch coolant in the reservoir. Coolant
must be added before applying power to the system. Only use Kaliburn
approved torch coolant solution for optimal system performance as commercially
available antifreeze contains corrosion inhibitors that will damage the cooling
system. The standard coolant solution consists of 25% industrial grade
propylene glycol and provides freezing protection down to -13º C (9º F). The
standard solution can be ordered in one-gallon containers, PN 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 coolant filter / deionization cartridge should
also be changed at the same time. See Section 6 for details.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-5
Section 2: Specifications
Spirit II User’s Manual
Manual Gas Console (MGC) Specifications
Part Number .................................................... BK300600
Weight .............................................................. 50 lb (23 kg)
12.4" [315]
12.0" [305]
13.7" [348]
(4) Ø .300 [7.6]
10.9" [277]
7.0" [178]
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2-6
Spirit II User’s Manual
Section 2: Specifications
Gas Supply Requirements
Plasma gas types:
Mild Steel ..................................................... Oxygen
Stainless Steel ............................................ Air, Nitrogen, or H17
Aluminum .................................................... Air or Nitrogen
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 ........................................................ 78 scfh (2209 liters/hour)
Air ................................................................ 67 scfh (1897 liters/hour)
H17 or Nitrogen ........................................... 106 scfh (3002 liters/hour)
Shield gas flow rate (maximum):
Oxygen ........................................................ 19 scfh (538 liters/hour)
Air ................................................................ 258 scfh (7306 liters/hour)
Nitrogen ...................................................... 326 scfh (9231 liters/hour)
Preflow gas flow rate (maximum) ...................... 60 scfh (1699 liters/hour)
Marking gas flow rate (maximum) ..................... 89 scfh (2520 liters/hour)
Rated Inlet gas pressure ................................... 115 psi (7.9 bar)
Minimum Inlet gas pressure .............................. 110 psi (7.6 bar)
Maximum Inlet gas pressure ............................. 145 psi (10.0 bar)
Oxygen and nitrogen should be supplied with a purity of at least 99.5%.
H17 should be supplied with a purity of at least 99.995%.
A potential fire hazard exists when cutting with oxygen. KALIBURN recommends
that an exhaust ventilation system be used when cutting with oxygen. Flashback
arrestors must be supplied (unless they are not available for the chosen gases
and pressures) to prevent a possible fire from propagating back to the gas
supplies.
Ensure that oxygen lines remain free from contaminants such as oil and grease. The
mixture of such contaminants with oxygen presents an additional fire hazard.
Compressed air must be clean, dry, and oil-free and may be supplied from compressed
cylinders or from an air compressor. Be aware that shop air systems are prone to oil
and moisture contamination. If shop air is used, it must be cleaned to ISO 8573.1:
Class 1.4.1. Specify dry air when using compressed cylinders. Breathing quality air
contains moisture and must not be used.
3/8” (inside diameter) hoses are required for all inlet gas connections. Mating
connectors are supplied with the unit. Quick-connect fittings must not be used.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-7
Section 2: Specifications
Spirit II User’s Manual
Impulse Start Console (ISC) Specifications
Part Number ..................................................... BK300500
Weight .............................................................. 22 lb (10 kg)

8.00" [203]
(4) Ø.312 [8]


12.00" [305]

12.75" [324]

13.50" [343]
10.00" [254]

5.35" [136]

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-8
Spirit II User’s Manual
Section 2: Specifications
Torch and 2-Gang Manifold Specifications
Part Number:
2-Gang Manifold Assembly .................................................. BK284214
Torch Handle (standard) ...................................................... BK278001
Torch Handle (short) ............................................................ BK278018
Torch Base........................................................................... BK279000
Torch Head (Copper Electrode) ........................................... BK279100
Torch Head (Silver Electrode) .............................................. BK279060
Max Weight:
Manifold/Bracket, Handle (BK278001), Base and Head ...... 8.3 lbs (3.8 kg)

Manifold
3.38" [86]

Torch Handle
BK278001 = 9.46" [240]
BK278018 = 7.06" [179]
1.99"
[51]

Torch Base
1.87" [47]

Alignment Indicator
(Slot)
Attachment Ring
Alignment Indicator
(Circle)

Torch Head
5.08" [129]
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-9
Section 2: Specifications
Spirit II User’s Manual
5-Gang Manifold Specifications
Part Number .................................................... BK280022
Weight .............................................................. 6 lb (2.7 kg)

6.18"
[157]

0.327"
[8.3]
(4) 0.187" [4.8] Mounting Holes

0.25" [6.4]


1.18"
[30]
3.80"
[97]

4.20"

[107]

3.035"
[77]
8.35"
[212]

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-10
Spirit II User’s Manual
Section 2: Specifications
Airborne Noise Emissions
The system generates high noise levels while cutting. Depending on the size of the
cutting area, distance from the cutting torch, and arc current cutting level, acceptable
noise levels may be exceeded. Proper ear protection should be used as defined by
local or national codes. The following chart gives the noise levels generated by the
system when operating at 400 amps, 205 arc volts. The measurements were made
with a sound level meter.
Distance From Torch
A-Weighted Sound
Pressure Level
C-Weighted Sound
Pressure Level
1 meter horizontal / 1.6
meters above the
workpiece
120 dB
115 dB
The maximum noise level is 131 dB at a distance of 3 inches (76.2 mm) from the torch
while cutting at 400 amps, 205 arc volts.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-11
Section 2: Specifications
Spirit II User’s Manual
BLANK
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2-12
Spirit II User’s Manual
Section 3: Installation
Section 3: Installation
Initial Inspection
All systems undergo full testing before being shipped from Kaliburn. In the unlikely
event that one of the components is defective or missing, please contact Kaliburn so a
replacement item can be sent. Also, Kaliburn has taken special care in packaging the
system. If the system was damaged during shipment, file a claim with the shipping
company, and then contact Kaliburn to order replacement parts.
Component Placement
Plasma Power Supply
The power supply should be lifted by a forklift, pallet jack or crane. In order to prevent
damaging the power supply when lifting with a forklift or pallet jack, the forks should be
of adequate length to protrude on the far side of the power supply. If lifting with a sling
(lifting straps), ensure the following:
• Sling and material handling equipment must comply with local and national laws
and regulations. The personnel involved in the move must be properly trained
and qualified to use such equipment.
• All power supply covers must be securely installed.
• Two slings are required. Each sling should pass through all three (3) structural
members on the bottom of the power supply. See sling access holes below.
• Lift slowly -not more than 8 in. (203 mm) high- to ensure even weight distribution.
• Move slowly to prevent uncontrollable acceleration/deceleration.
WARNING
Falling equipment
can cause injury.
• Lift only with
equipment of
adequate lifting
capacity.
• Be sure power
supply is stable
when lifting.
Sling
Access
Hole
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.
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3-1
Section 3: Installation
Spirit II User’s Manual
The power supply must be cleaned as often as necessary to prevent the accumulation
of metallic dust inside the unit. See Section 2 for unit dimensions.
Manual Gas Console (MGC)
The MGC should be mounted near the CNC controller so that it is easy accessible by
the operator. See Section 2 for mounting dimensions.
Impulse Start Console (ISC)
The ISC should be mounted in a convenient location that is away from other electronic
control devices. The ISC offers significantly reduced emissions compared to traditional
high frequency, however, the high voltage pulse generated inside the unit may interfere
with the operation of sensitive control electronics. The ISC is usually mounted on the
gantry of the cutting machine or on the cutting table. See Section 2 for mounting
dimensions.
5-Gang Manifold
The 5-gang manifold assembly must be mounted within 6 feet (1.8 m) of the torch. See
Section 2 for mounting dimensions.
2-Gang Manifold
The 2-gang manifold assembly must be mounted to the torch.
mounting dimensions.
See Section 2 for
Torch
The torch must be installed on the positioner of an arc voltage control (height control)
capable of maintaining the cutting arc voltage within 1 arc volt. The arc voltage must be
adjustable in 1 arc volt increments. The positioner must be rigid to ensure cut quality
and a torch collision sensor is highly recommended. See Section 2 for mounting
dimensions.
Cooling System
The cooling system must be located within 8 feet (2.4 meters) of the plasma power
supply. The surface on which the cooling system is located should have a grade of no
greater than 10º to eliminate the risk of toppling over. See Section 2 for unit
dimensions.
System Interconnection
The Spirit II system interconnection diagrams on the following pages will assist in the
planning and installation of the system as well as identifying cables and hoses upon
receipt.
The optional Inova torch height control is also shown to assist with its connections,
whether as an external console or internal to the plasma power supply.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-2
Spirit II User’s Manual
Section 3: Installation
Figure 1: Spirit II System with Manual Gas Console and Internal Inova System
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-3
Section 3: Installation
Spirit II User’s Manual
Figure 2: Spirit II System with Manual Gas Console and External Inova System
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-4
Spirit II User’s Manual
Section 3: Installation
Power Supply Primary Power Connections
** Before connecting primary power, check the data plate
on the power supply to verify the voltage required **
A primary disconnect switch, switching all ungrounded supply conductors, should be
provided for each Spirit system. The disconnect switch should be located as close as
possible to the power supply so it can be turned off quickly in case of an emergency.
The disconnect switch should be equipped with time delay fuses only. The
magnetic inrush current of the power supply will cause fast acting fuses to blow. The
disconnect switch should be sized according to local and national codes. The rating
must meet or exceed the continuous rating of the fuses used. See the following chart
for recommended fuse sizes:
3 Phase
Input Voltage (VAC)
220 VAC, 60Hz
240 VAC, 60Hz
380 VAC, 50/60Hz
400 VAC, 50/60Hz
415 VAC, 50/60Hz
440 VAC, 50/60Hz
480 VAC, 60Hz
600 VAC, 60Hz
Input Current
at Maximum
Output (amps)
262
240
152
144
140
131
120
96
Recommended
Time-Delay Fuse
Size (amps)
350
300
200
175
175
175
150
125
Connection to the supply circuit can be by means of flexible supply cables or supply
cables through conduit to a permanent installation. The supply cables should have a
600 volt minimum rating and should be sized according to local and national codes.
Route flexible supply cables through the strain relief on the back of the power supply
and connect to the input terminal block TB5 as shown. For supply cables through
conduit, install the conduit in place of the strain relief and connect the associated supply
cables to the input terminal block TB5. See Figure 3 on the next page.
TB5 is located on the rear of the power supply and is accessible with the right-side
cover removed. Be sure to connect the primary ground cable to the ground stud
on the input terminal block.
Under no circumstances are the supply cables to be routed through the opening in the
power supply cabinet without conduit or an appropriate strain relief as per local and
national codes.
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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.
3-5
Section 3: Installation
Spirit II User’s Manual
TB5
L1 (U)
L2 (V)
L3 (W)
Ground
L1 L2 L3 Gnd
TB5 Connections
Strain Relief
Disconnect Box
Connections
Figure 3: Power Supply Primary Connections
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-6
Spirit II User’s Manual
Section 3: Installation
Power Supply Output Connections
Perform the following steps to connect the output of the power supply to the impulse
start console and the work table. See Figure 4 on the next page.
Power Supply Electrode Lead 1
1. Route one end of the #4/0AWG power supply electrode lead through the upper
strain relief on the rear of the power supply and connect it to the electrode terminal.
2. Route the other end of the power supply electrode lead through the strain relief on
the impulse start console and connect it to the cathode manifold.
Power Supply Nozzle Lead 2
1. Route the larger ring terminal end of the #10AWG power supply nozzle lead through
the bushing on the rear of the power supply and connect it to the nozzle terminal.
2. Route the smaller ring terminal end of the power supply nozzle lead through the
strain relief on the impulse start console and connect it to the pilot terminal on the
printed circuit board.
Power Supply CTP Sensor Lead 3
1. Route the ring terminal end of the #14AWG power supply CTP sensor lead through
the bushing on the rear of the power supply and connect it to the CTP terminal.
2. Route the FASTON end of the power supply CTP sensor lead through the strain
relief on the impulse start console and connect it to the CTP sensor lead with
FASTON connector.
Work Ground Lead 4
1. Route one end of the #4/0AWG work ground lead through the bottom strain relief on
the rear of the power supply and connect it to the work terminal.
2. Connect the other end of the work ground lead to the star ground point on the cutting
table.
The star ground point is generally referred to as the common ground point on the
cutting table where all subsystems of the machine are grounded. This point is then
connected to a driven earth ground rod that should be as close as possible to the
star ground. The ground rod should have no other wires connected to it. The
ground rod should be at least 3/4 inches in diameter and should be driven into the
earth’s permanent moisture layer. The length of the ground rod varies from
installation to 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.
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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.
3-7
Section 3: Installation
Spirit II User’s Manual
3
2
4
1
1
2
3
Strain Relief
Figure 4: Power Supply Output Connections
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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.
3-8
Spirit II User’s Manual
Section 3: Installation
ISC Control Cable and ISC Ground Connections
Perform the following steps to connect the ISC control cable and ISC ground . See
Figure 5 on the next page.
ISC Control Cable 5
1. Connect the ISC control cable plug labeled P16 to the connector labeled P16 on the
rear of the power supply.
2. Connect the ISC control cable plug labeled P1 to the connector labeled P1 on the
impulse start console.
ISC Ground Cable 6
1. Connect one end of the ISC ground cable to the ground stud on the impulse start
console.
2. Connect the other end of the ISC ground cable to the star ground on the cutting
table. Make sure that good metal-to-metal contact is made.
Cooling System Connections
Perform the following steps to connect the cooling system to the power supply and the
impulse start console. See Figure 5 on the next page.
Coolant Supply Hose 7
1. Connect one end of the coolant supply hose to the coolant out fitting on the rear of
the cooling system. Note that the coolant out fitting has right hand threads.
2. Connect the other end of the coolant supply hose to the coolant in fitting on the
impulse start console. Note that the coolant in fitting has right hand threads.
Coolant Return Hose 8
1. Connect one end of the coolant return hose to the coolant in fitting on the rear of the
cooling system. Note that the coolant in fitting has left hand threads.
2. Connect the other end of the coolant return hose to the coolant out fitting on the
impulse start console. Note that the coolant out fitting has left hand threads.
Cooling System Control Cable 9
1. Connect the cooling system control cable plug labeled P14 to the connector labeled
P14 on the rear of the power supply.
2. Connect the cooling system control cable plug labeled P1 to the connector labeled
P1 on the cooling system.
Cooling System Ground Connection 10 (Customer Supplied)
The Cooling System must be connected to protective earth ground in accordance
with national or local codes. The Cooling System receives its power from the
plasma power supply and as such must be connected to the same protective ground
as the plasma power supply.
Use a minimum of 8 AWG (10 mm2) wire connected from the cooling system
grounding stud to the plasma power supply protective earth ground. Note: the
customer must supply grounding wire.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-9
Section 3: Installation
Spirit II User’s Manual
6
7
8
5
9
10
7
8
Figure 5: Cooling System Connections
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-10
Spirit II User’s Manual
Section 3: Installation
Torch Leads to Impulse Start Console Connections
Perform the following steps to connect the torch leads to the impulse start console.
See Figure 6 on the next page.
Note: When making hose connections, only tighten the brass fittings enough to
make water or gas seals. The fittings are subject to damage if over tightened.
Braided Shield 11
1. Remove the threaded ring from the brass shield connector on the end of the braided
shield. Route the torch leads through the opening in the impulse start console and
push the shield connector through the hole until it is seated against the side of the
console.
2. Slide the threaded ring over the torch leads, thread it onto the brass shield
connector, and tighten firmly. The shield connector should ground the braided
shield to the case of the impulse start console in order to help reduce high frequency
noise emission. Using an ohmmeter, measure for zero ohms between the braided
shield and the ground stud located on the outside of the impulse start console.
Torch Electrode/Coolant Supply Lead 12
• Connect the torch electrode/coolant supply lead to the brass cathode manifold. Note
that the torch electrode/coolant supply lead has right hand threads.
Torch Coolant Return Lead 13
• Connect the torch coolant return lead to the brass cathode manifold. Note that the
torch coolant return lead has left hand threads.
Torch Nozzle Lead 14
• Connect the torch nozzle lead to the angled bracket on the red standoff. Note that
the torch nozzle lead has right hand threads.
Torch CTP Sensor Lead 15
• Connect the #18AWG torch CTP sensor lead to the red standoff as shown.
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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.
3-11
Section 3: Installation
Spirit II User’s Manual
11
14
12
15
13
Figure 6: Torch Leads to Impulse Start Console Connections
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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.
3-12
Spirit II User’s Manual
Section 3: Installation
Torch Leads to Torch Base Connections
Perform the following steps to connect the torch leads to the torch base.
Note: When making hose connections, only tighten the brass fittings
enough to make water or gas seals. The fittings are subject to damage if
over tightened. Also, use two wrenches when tightening the torch fittings
to avoid damaging the torch base.
Torch Lead through Torch Handle Installation
• Route the torch leads through the torch handle. Note that the threaded end of
the torch handle mates with the torch base.
Torch Electrode/Coolant Supply Lead 16
• Connect the torch electrode/coolant supply lead to the torch base as shown.
Torch Coolant Return Lead 17
• Connect the torch coolant return lead to the torch base as shown. Note that
the torch coolant return lead fitting has left hand threads.
Torch Nozzle Lead 18
• Connect the torch nozzle lead to the torch base as shown.
Torch CTP Sensor Lead 19
• Connect the torch CTP sensor lead to the torch base as shown.
18
17
19
18
16
17
19
16
Figure 7: Torch Leads to Torch Base Connections
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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.
3-13
Section 3: Installation
Spirit II User’s Manual
Torch Gas Connections
Perform the following steps to connect the torch gas hoses to the manual gas
console, torch base, and manifold assemblies. See figure 8.
Note: When making hose connections, only tighten the brass fittings
enough to make gas seals. The fittings are subject to damage if over
tightened.
7.5 Foot Shield Gas Hose 20
1. Route one end of the 7.5 foot (2.3 m) shield gas hose through the torch
handle and connect to the shield gas fitting on the torch base.
2. Connect the other end of the 7.5 foot (2.3 m) shield gas hose to the shield
gas outlet on the 5-gang manifold.
17 Inch Plasma Gas Hose 21
1. Route one end of the 17 inch (432 mm) plasma gas hose through the torch
handle and connect to the plasma gas fitting on the torch base.
2. Thread the torch handle onto the torch base, being careful not to twist the
torch leads and gas hoses when tightening the torch handle.
3. Tighten the base to the handle using a pin style adjustable spanner wrench
(fits 2" diameter with ¼" diameter pin).
4. Attach the 2-gang manifold assembly to the torch handle. The top of the
manifold bracket should be flush with the top of the torch handle.
5. Connect the other end of the 157 inch (432 mm) plasma gas hose to the
plasma gas outlet on the 2-gang manifold.
6. Mount the torch handle/base/manifold to the positioner. Note the alignment
indicators on the torch base (slot) and torch head (circle). These aid in
aligning the quick-disconnect torch base and head and should be oriented so
they are clearly visible when the operator is changing heads.
6 Foot Preflow/Postflow/Marking Gas Hose 22
1. Connect one end of the 6 foot (1.8 m) preflow/postflow/marking gas hose to
the preflow/postflow/marking outlet on the 5-gang manifold.
2. Connect the other end of the 6 foot (1.8 m) preflow/postflow/marking gas
hose to the preflow/postflow/marking inlet on the 2-gang manifold.
Marking Gas Hose 23
1. Connect one end of the marking shield gas hose to the marking shield outlet
on the rear of the MGC.
2. Connect the other end of the marking shield gas hose to the marking shield
inlet on the 5-gang manifold.
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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.
3-14
Spirit II User’s Manual
Section 3: Installation
Postflow Gas Hose 25
1. Connect one end of the postflow hose to the postflow outlet on the rear of the
MGC. Note that the postflow hose fittings have left hand threads.
2. Connect the other end of the postflow hose to the postflow inlet on the 5-gang
manifold.
Plasma Gas Hose 26
1. Connect on end of the plasma hose to the plasma outlet on the rear of the
MGC.
2. Connect the other end of the plasma hose to the plasma inlet on the 2-gang
manifold.
Shield Gas Hose 27
1. Connect one end of the shield hose to the shield outlet on the rear of the
MGC.
2. Connect the other end of the shield hose to the shield inlet on the 5-gang
manifold.
Preflow Gas Hose 28
1. Connect one end of the preflow hose to the preflow outlet on the rear of the
MGC. Note that the preflow hose fittings have left hand threads.
2. Connect the other end of the preflow hose to the preflow inlet on the 5-gang
manifold.
5-Gang Manifold Control Cable 29
1. Connect the 5-gang manifold control cable plug marked P15 to the 5-gang
manifold as shown.
2. Connect the 5-gang manifold control cable plug labeled P12 to the connector
labeled P12 on the rear of the power supply.
2-Gang Manifold Control Cable 30
1. Connect the 2-gang manifold control cable plug marked P18 to the 2-gang
manifold as shown.
2. Connect the 2-gang manifold control cable plug labeled P13 to the connector
labeled P13 on the rear of the power supply.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-15
Section 3: Installation
Spirit II User’s Manual
Manual Gas
Console
28
27
26
23
25
RED
26
30
GREEN
22
BLUE
21
GREEN RED
REAR
PORT
22
20
27
23
28
29
25
REAR
PORT
BLUE
21
20
Figure 8: Torch Gas Connections
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-16
Spirit II User’s Manual
Section 3: Installation
Gas Supply Connections
Perform the following steps to connect the gas supply lines to the MGC. See Section 2
for gas supply requirements. Mating hose barbs and connectors are supplied with the
system and are sized for 3/8 inch inside diameter hose. Do not change the inlet gas
supply fittings to quick-connect fittings. Using quick-connect fittings to connect
and disconnect pressurized hoses may cause damage to the system.
Note: When making hose connections, only tighten the brass fittings enough to
make gas seals. The fittings are subject to damage if over tightened.
Air Inlet 31 (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 32 (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 33 (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 34 (ISO 3821 hose color - red)
• H17 must be supplied to the unit when stainless steel is being cut with H17 as the
plasma gas. See cutting charts in Section 5 for more information.
32
34
31
33
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-17
Section 3: Installation
Spirit II User’s Manual
CAN Communication Connections
Perform the following steps to connect the plasma power supply to the MGC.
CAN Cable 35
• Connect the male end of the CAN cable to the connector labeled P4 on the rear of
the plasma power supply.
• Connect the female end of the CAN cable to the top connector on the rear of the
MGC.
CAN Termination Plug 36
• If not already installed, connect the CAN termination plug to the bottom connector on
the rear of the MGC.
35
35
36
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
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3-18
Spirit II User’s Manual
Section 3: Installation
CNC Machine Interface Connections
Perform the following steps to properly interface the Spirit system with a CNC cutting
machine. See the system schematic for additional information.
Plasma Start Input
The power supply requires a contact closure between P8 pins 3 and 4 to commence the
cutting or marking sequence. The sequence is terminated when the contacts are
opened. The contacts should be rated for 24VDC - 7.3mA.
Plasma Cut/Mark Input
The power supply requires a contact closure between P8 pins 1 and 2 to put the system
in plasma marking mode. Opening the contacts puts the system in cutting mode. The
operating mode should be selected prior to applying a start signal. The contacts should
be rated for 24VDC - 7.3mA.
Arc Hold Input
The power supply requires a contact closure between P8 pins 10 and 11 to inhibit arc
starting even though a plasma start signal has been applied to the unit. When the
contacts are opened, the arc is initiated. This feature is used to decrease cycle time by
allowing pre-cut gas and contact sequencing to occur simultaneously with initial torch
height positioning. The contacts should be rated for 24VDC - 7.3mA.
Motion Output
The power supply provides a maintained contact closure output between P8 pins 12
and 14 as long as an arc is maintained between the torch and the workpiece. The
motion contacts are rated for 24VDC – 10mA.
Remote On/Off Input
The power supply requires a maintained contact closure between P8 pins 5 and 6 to
energize the system from a remote location, provided that the OFF Button on the
manual gas console is released. The contacts should be rated for 24VAC – 10mA.
Opening the contacts deenergizes the system. If the remote on/off feature is to be
used, remove the jumper between positions 1 and 2 on the J17 connector on the
microprocessor DSP board.
Power Supply Ready Output
The power supply provides a maintained contact closure output between P8 pins 7 and
8 when the system is ready to cut or mark. The contacts are open during gas purge or
when an error occurs. The contacts are rated for 24VDC – 10mA.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-19
Section 3: Installation
Spirit II User’s Manual
Filling the Cooling System
WARNING: Do not touch the fans inside the cooling system.
Important: Never turn on the system when the coolant reservoir is empty.
Important: When handling coolant, wear nitrile gloves and safety glasses.
Important: Only use Kaliburn approved coolant. Commercially available
antifreeze contains corrosion inhibitors that will damage the cooling
system. See Section 2 for more information.
1. Remove primary power from the Spirit system.
2. Ensure the torch base and torch head (with consumables) are properly installed.
3. Ensure the coolant supply (in and out) hoses are properly installed.
4. Remove the coolant reservoir cap/level gauge and then remove the cover from the
cooling system.
5. Ensure the coolant filter housing is tightened securely.
6. Ensure the drain petcock on the bottom of the reservoir is tightened securely.
7. Fill the reservoir with approximately 2 ½ gallons of approved coolant.
8. Apply primary power to the Spirit system and enable it by releasing (turn right) the
OFF Button on the MGC.
9. On the MGC main menu, move the pointer to On. Press SELECT to start the
coolant pump circulating coolant through the system. Note: The coolant pump will
turn off automatically if the coolant level drops below the minimum level inside the
reservoir. If this happens, add more coolant.
10. With the coolant pump running, locate the small red push-button on top of the
coolant filter housing. Press and hold the red button until no air or bubbles are seen
inside the filter housing. Dry any coolant that leaks out.
11. Check for coolant leaks at all hose connections, the impulse start console, and at the
torch.
12. Push the OFF Button on the MGC to stop the coolant pump.
13. Remove primary power from the Spirit system.
14. Fill the reservoir with coolant until the coolant gauge indicates full.
15. Replace the cooling system cover and replace the coolant reservoir cap/level gauge.
16. End of procedure.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-20
Spirit II User’s Manual
Section 4: Operation with Manual Gas Console
Section 4: Operation
Operating the Manual Gas Console (MGC)
The Manual Gas Console (MGC) is the interface to the entire Spirit system when the
MGC is used instead of the Automatic Gas Console (AGC).
OFF Button
Push to disable the Spirit system.
Release (turn to the right) to enable
the system, which can then be
energized by choosing ON and then
SELECT.
Up/Down/Select Buttons
Press the up or down button to move
the pointer ( ) accordingly on the
display. These buttons are
represented as UP and DOWN
throughout this manual.
Press the select button
to access
menu items or settings identified by
the pointer. This button is shown as
SELECT throughout this manual.
Display
The display turns on automatically
when AC power is applied to the
Spirit system. It displays the menu
tree, which is navigated using the
Up/Down/Select buttons and is used
to control the entire Spirit system.
Pressure Regulator Knobs
Turn to the left or right to adjust the
amount of output gas pressure for
PreFlow, PostFlow, Plasma and
Shield gases.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-1
Section 4: Operation with Manual Gas Console
Spirit II User’s Manual
Setting up to Cut
The following procedure uses the information from the cutting charts in Section 5 to
prepare the system to cut. Press the UP or DOWN button on the MGC to move the
pointer through the menu as described below.
Push the OFF Button on the MGC to disable
the system. On the main menu, move the
pointer to Setup. Press SELECT.
Press SELECT to cycle through the list until
Cutting is displayed.
Move the pointer to Current.
Press SELECT to cycle through the list until
the desired amperage is displayed.
Move the pointer to Select Gas.
Press SELECT.
Press SELECT to choose the Plasma gas.
Move the pointer to Shield and press SELECT
to choose the shield gas. Move the pointer to
Return and press SELECT.
Move the pointer to Adjust Gas.
Press SELECT.
Move the pointer to a gas and then press
SELECT to start the flow of that gas. Turn the
corresponding regulator knob on the MGC to
adjust the displayed pressure to match the
value in the cutting chart. Repeat for all other
gases. Move the pointer to Return and press
SELECT. Repeat to return to the main menu.
The system is now setup to cut.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-2
Spirit II User’s Manual
Section 4: Operation with Manual Gas Console
Setting up to Mark (Overrides Cut)
The system will automatically switch between cutting and marking based upon
commands in the part program. However, all cutting commands in the part program can
be overridden with marking commands by simply changing the Process to Marking.
Push the OFF Button on the MGC to disable
the system. On the main menu, move the
pointer to Setup. Press SELECT.
Press SELECT to cycle through the list until
Marking is displayed. Move the pointer to
Return and press SELECT.
The system is now setup to mark instead of
cut.
Verifying Input Gas Pressures
For the system to work properly the input gas pressures must be within an acceptable
range. To check the input pressures, follow the steps below.
On the main menu, move the pointer to
Input Gas. Press SELECT.
Verify that all connected gas pressures are at
least 120psi. The maximum input gas pressure
is 145psi.
Press SELECT to return to the main menu.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-3
Section 4: Operation with Manual Gas Console
Spirit II User’s Manual
Making a Cut or Mark
Once the process type, gas types and gas pressures have been set in the MGC; the
correct torch parts (consumables) installed; and the X/Y controller and torch height
control are properly configured; the system is ready to cut or mark.
Release the OFF Button (turn to the right) on
the MGC. On the main menu, move the
pointer to On. Press SELECT.
The MGC will purge the gas hoses. The purge
icon ( ) is displayed during this process.
Once purging is complete, the ready icon ( )
is displayed. The system is now ready to cut or
mark.
When the system receives a start signal from
the X/Y controller, the following sequence is
initiated:
• Two second gas preflow
• Impulse start circuit energized
• Pilot arc initiation
• Transferred arc (cutting or marking arc)
established
• Motion output relay energized
When the start signal is removed, the arc is
extinguished and the motion output relay is
deenergized.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-4
Spirit II User’s Manual
Section 4: Operation with Manual Gas Console
Piercing Thick Materials
Care must be taken when piercing thick materials in order to prevent damage to the
shield cap and nozzle. As with all thicknesses, the pierce height must be set high
enough so the metal ejected while piercing does not come into contact with the shield
cap. Also, some of the material ejected during the pierce may adhere to the top side of
the plate and form a ring of solidified material around the pierce point.
Action must be taken so the torch does not move from the pierce height down to the
cutting height and come into contact with this solidified metal. The torch should not
move from the pierce height down to the cutting height until the X/Y controller has
moved the torch away from the pierce point.
One way to accomplish this may be to program the pierce time on the torch height
control system to a value that is longer than the X/Y controller motion delay time.
Moving Pierces and Edge Starts
On very thick materials, an edge start or moving pierce may be required to prevent
damage to the torch consumables.
With a moving pierce, the X/Y machine should begin moving at approximately 5–10
inches/minute (125–250 mm/min) as soon as the arc transfers to the plate. After the arc
completely penetrates the plate, the torch should be positioned at the proper cutting
height and the X/Y machine speed should be increased to the correct level.
With an edge start the torch should be positioned at the edge of the material prior to
starting the arc.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-5
Section 4: Operation with Manual Gas Console
Spirit II User’s Manual
Cut Quality
Before the optimum cutting condition can be achieved on a particular material type and
thickness, the machine operator must have a thorough understanding of the cutting
characteristics of the Spirit system. When the cut quality is not satisfactory, the cutting
speed, torch height, or gas pressures may need to be adjusted in small increments until
the proper cutting condition is obtained. The following guidelines should be useful in
determining which cutting parameter to adjust.
Note: Before making any parameter changes, verify that the torch is square to
the workpiece. Also, it is essential to have the correct torch parts in place and to
ensure that they are in good condition. Check the electrode for excessive wear
and the nozzle and shield cap orifices for roundness. Also, check the parts for
any dents or distortions. Irregularities in the torch parts can cause cut quality
problems.
1. A positive cut angle (top dimension of piece smaller than the bottom dimension)
usually occurs when the torch standoff distance is too high, when cutting too fast, or
when excessive power is used to cut a given plate thickness.
2. A negative cut angle (top dimension of piece larger than the bottom dimension)
usually occurs when the torch standoff distance is too low or when the cutting speed
is too slow.
3. Top dross usually occurs when the torch standoff distance is too high.
4. Bottom dross usually occurs when the cutting speed is either too slow (slow-speed
dross) or too fast (high-speed dross). Low-speed dross is easily removed, while
high-speed dross usually requires grinding or chipping off. When using oxygen as
the shielding gas, bottom dross can sometimes be removed by increasing the shield
gas pressure. However, increasing the shield pressure too much can cause cut face
irregularities (see below). Bottom dross also occurs more frequently as the metal
heats up. As more pieces are cut out of a particular plate, the more likely they are to
form dross.
5. When using oxygen as a shielding gas, cut face irregularities usually indicate that
the shield gas pressure is too high or the torch standoff distance is too low.
6. A concave cut face usually indicates that the torch standoff distance is too low or the
shield gas pressure is too high. A convex cut face usually indicates that the torch
standoff distance is too high or the shield gas pressure is too low.
7. Note that different material compositions have an effect on dross formation.
8. If the material is not being completely severed, the likely causes are that the cutting
current is too low, the travel speed is too high, the gas pressures are incorrect, the
incorrect gas types are selected, the incorrect consumables are installed in the
torch, or the consumables are worn.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-6
Spirit II User’s Manual
Section 4: Operation with Manual Gas Console
Checking Errors
The last ten (10) system errors are available through the MGC as described below.
On the main menu, move the pointer to Errors.
Press SELECT.
Press SELECT to cycle through the last ten
(10) error codes.
See Section 6 in this manual for details on the
error codes.
Simultaneously pressing DOWN and SELECT
will erase all ten error codes.
Move the pointer to Return and press
SELECT to return to the main menu.
Checking the Version and Serial Number
The hardware version, software version and serial number for the Power Supply and
Gas Console can be displayed as described below.
On the main menu, move the pointer to
Version. Press SELECT.
Move the pointer to either Power Supply or
Gas Console. Press SELECT.
Review the necessary information.
Press SELECT to return to the previous
screen.
Move the pointer to Return and press
SELECT to return to the main menu.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-7
Section 4: Operation with Manual Gas Console
Spirit II User’s Manual
Changing the Language
The language displayed on the MGC can be changed as described below.
On the main menu, move the pointer to
Configure. Press SELECT.
Press SELECT on Languages.
Move the pointer to the desired language and
then press SELECT. The display changes
immediately to the selected language.
Move the pointer to Return and press SELECT
to return to the previous screen. Repeat to
return to the main menu.
Adjusting the Screen Contrast
The contrast of the display on the MGC can be adjusted as described below.
On the main menu, move the pointer to
Configure. Press SELECT.
Move the pointer to Contrast.
Press SELECT to cycle through the list of
contrast settings.
Move the pointer to Return and press SELECT
to return to the main menu.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-8
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Section 5: Torch Consumables and
Cutting Charts
Installing / Removing the Torch Head
WARNING: Remove primary power from the Spirit system!
1. Each time the torch head is connected to the torch base, use a cotton swab to apply
a small amount of o-ring lubricant on each of the seven o-rings on the top of the
torch head. Reminder: do not use an excessive amount of o-ring lubricant.
2. Align the indicator on the torch head (circle) with the one on the torch base (slot).
3. Apply enough upward force to engage the threads while tightening the attachment
ring. Turn the attachment ring to the RIGHT to tighten.
4. Keep tightening the attachment ring until it stops. There should be no gap between
the attachment ring and the o-ring on the torch base.
During this process, a small amount of coolant will collect in the torch head.
It is normal for this coolant to discharge between the o-ring on the torch base and
the attachment ring while the system is being pressurized. If coolant continues to
discharge after the system is pressurized, turn off the plasma power supply, remove
the torch head and inspect the o-rings for damage.
YES
NO!
O-ring
O-ring
Torch Base
Torch Head
There is no
gap between
o-ring and
attachment
ring
Gap is visible
between
o-ring and
attachment
ring
To remove the torch head, turn the attachment ring to the LEFT.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-1
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Installing / Replacing Consumables
WARNING: Remove primary power from the Spirit system!
Note: When installing the consumables, do not use an excessive amount
of o-ring lubricant. Also ensure that the lubricant is placed only on the
o-rings. Excess lubricant can interfere with gas flow, which can cause
starting problems, poor cut quality, and short consumable life.
1. Unthread the torch head from the torch base by turning the attachment ring to
the LEFT. Verify the torch base doesn't unthread from the torch handle.
2. Remove the outer retaining cap from the torch head.
3. Remove the inner retaining cap from the torch head.
4. Separate the shield cap from either the inner retaining cap or the outer
retaining cap.
5. Use the nozzle removal tool (P/N BK277056) to remove the nozzle from the
torch head. To do this, insert the tool into the groove on the nozzle and hold
the tool/nozzle in the palm of your hand. Pull both hands apart using a linear
motion as shown in the left image below. Do not use a prying or bending
motion as shown in the right image below.
YES
NO!
PULL
OR
PULL
6. Use the swirl ring removal tool (P/N BK260105) to remove the swirl ring from
the nozzle.
7. Remove the electrode from the torch head using the appropriate tool:
• 400A copper electrodes use socket P/N BK284052 & driver P/N BK277086.
• All other copper electrodes use socket P/N BK277087 & driver P/N BK277086.
• All silver electrodes use P/N BK279061.
8. Inspect all consumables and o-rings for damage and excess wear. Replace
with new consumables as necessary.
9. Inspect the cooling tube in the torch head for damage. See Section 6
Maintenance and Troubleshooting if replacement is necessary.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-2
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Maximizing Consumable Life
Use the following guidelines to maximize consumable parts life:
1. The Spirit system utilizes the latest advancement in technology for extending the life
of the torch consumable parts. To maximize the life of the consumable parts, it is
imperative that the shutdown procedure of the arc is carried out properly. The arc
must be extinguished while it is still attached to the workpiece. A popping
noise may be heard if the arc extinguishes abnormally. Note that holes are usually
programmed without lead-outs to prevent loss of the arc during shutdown. There is
a time delay between the reception of a stop signal and when the arc is
extinguished. During this time, the gases and cutting current are changed to
optimum values for extinguishing the arc. Ideally, the x/y machine controller should
provide a plasma stop signal prior to the end of the cut path so the gases and
current reach the shut off values at the same time that the part has been completely
cut. The shut down times are different for each current and are given below.
Arc Shutdown Times
Current (A)
Time (ms)
30
490
50
390
70
300
100
300
150
175
200
195
260
175
275
175
400
375
2. Use the recommended pierce height given in the cutting charts. A pierce height that
is too low will allow molten metal that is ejected during the piercing process to
damage the shield cap and nozzle. A pierce height that is too high will cause the
pilot arc time to be excessively long and will cause nozzle damage. See “Piercing
Thick Materials” in Section 4.
3. Never fire the torch in the air. Nozzle damage will occur.
4. Make sure the torch does not touch the plate while cutting. Shield cap and nozzle
damage will result.
5. Use a chain cut when possible. Starting and stopping the torch is more detrimental
to the consumables than making a continuous cut.
6. Always use error tracking on the plasma console to keep track of cut errors. See
Section 4 for information on error tracking.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-3
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Inspecting for Damage
When the cut quality is not satisfactory, use the following guidelines for
determining which consumable parts need to be changed. Inspect all parts for
dirt, debris, and excess o-ring lubricant and clean as necessary.
Part
Inspect For
Corrective Action
Outer Cap
Shield Cap
Retaining Cap
Nozzle
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 0.040” (1 mm) for copper
electrode or 0.098" (2.5mm) for silver.
Erosion or arcing
Replace electrode
Dry o-rings
Apply a thin film of o-ring lubricant
Damaged o-rings
Replace electrode
Swirl Ring
Electrode
or
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-4
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Selecting Consumables
Mild Steel
Copper Electrode
Outer
Shield
Inner
Swirl
Copper
Nozzle
Retaining Cap
Cap
Retaining Cap
Ring
Electrode
BK284150
BK277145
BK277153
BK277120 BK277140 BK277130
Torch
Head
BK279100
30A
BK284150
BK277115
BK277153
BK277140/
BK277122 BK277142 BK277131
BK279100
BK284150
BK277150
BK277153
BK277125 BK277142 BK277131
BK279100
BK284150
BK277286
BK277151
BK277284 BK277283 BK277282
BK279100
BK284150
BK277117
BK277151/
BK277152
BK277293 BK277139 BK277292
BK279100
BK284150
BK277274
BK277266
BK277289 BK277143 BK277291
BK279100
BK284150
BK277263
BK277266
BK277269 BK277258 BK277270
BK279100
BK284150
BK284123
BK284121
BK284125 BK284122 BK284124
BK279100
50A
70A
100A
150A
200A
275A
400A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-5
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Mild Steel
Silver Electrode
Outer
Retaining Cap
Shield
Cap
Inner
Retaining Cap
BK284150
BK277286
BK277151
BK279484 BK279483
BK284150
BK277117
BK277151/
BK277152
BK279493 BK279439
BK284150
BK277274
BK277266
BK279489 BK279443
BK284150
BK277263
BK277266
BK279469 BK279458
BK284150
BK284123
BK284121
BK284125 BK279422
Nozzle
Swirl
Ring
Silver
Electrode
BK279410
(brown o-ring)
Torch
Head
BK279060
100A
BK279420
(green o-ring)
BK279060
150A
BK279440
(yellow o-ring)
BK279060
200A
BK279450
(red o-ring)
BK279060
275A
BK279460
(black o-ring)
BK279060
400A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-6
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - H17 Plasma
Copper Electrode
Outer
Shield
Inner
Retaining Cap
Cap
Retaining Cap
BK284150
BK277150
BK277113
Swirl
Copper
Ring
Electrode
BK277124 BK277140 BK277132
Torch
Head
BK279100
Nozzle
70A
BK284150
BK277146
BK277113
BK277126 BK277141 BK277133
BK279100
BK284150
BK277298
BK277266
BK277297 BK277139 BK277135
BK279100
BK284150
BK277274
BK277266
BK277287 BK277259 BK277135
BK279100
BK284150
BK277211
BK277280
BK277118 BK277139 BK277135
BK279100
BK284150
BK284155
BK284156
BK284158 BK284122 BK284159
BK279100
100A
150A
200A
260A
400A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-7
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - Air or Nitrogen Plasma
Copper Electrode
Outer
Shield
Inner
Retaining Cap
Cap
Retaining Cap
BK284150
BK277144
BK277110
Swirl
Copper
Ring
Electrode
BK277121 BK277138 BK277137
Torch
Head
BK279100
Nozzle
30A
BK284150
BK277149
BK277110
BK277123 BK277142 BK277137
BK279100
BK284150
BK277150
BK277153
BK277125 BK277142 BK277131
BK279100
BK284150
BK277286
BK277151
BK277284 BK277283 BK277282
BK279100
BK284150
BK277117
BK277152
BK277293 BK277139 BK277292
BK279100
BK284150
BK277274
BK277266
BK277289 BK277143 BK277291
BK279100
BK284150
BK277263
BK277266
BK277276 BK277258 BK277270
BK279100
BK284150
BK284155
BK284156
BK284157 BK284122 BK284159
BK279100
50A
70A
100A
150A
200A
275A
400A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-8
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - Air or Nitrogen Plasma
Silver Electrode
Outer
Retaining Cap
Shield
Cap
Inner
Retaining Cap
BK284150
BK277286
BK277151
BK279484 BK279483
BK284150
BK277117
BK277152
BK279493 BK279439
BK284150
BK277274
BK277266
BK279489 BK279443
Nozzle
Swirl
Ring
Silver
Electrode
BK279410
(brown o-ring)
Torch
Head
BK279060
100A
BK279420
(green o-ring)
BK279060
150A
BK279440
(yellow o-ring)
BK279060
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.
5-9
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Aluminum
Copper Electrode
Outer
Shield
Inner
Retaining Cap
Cap
Retaining Cap
BK284150
BK277145
BK277153
Swirl
Copper
Ring
Electrode
BK277120 BK277140 BK277130
Torch
Head
BK279100
Nozzle
30A
BK284150
BK277150
BK277153
BK277122 BK277142 BK277131
BK279100
BK284150
BK277150
BK277153
BK277125 BK277142 BK277131
BK279100
BK284150
BK277286
BK277151
BK277284 BK277283 BK277282
BK279100
BK284150
BK277117
BK277152
BK277293 BK277139 BK277292
BK279100
BK284150
BK277274
BK277266
BK277289 BK277143 BK277291
BK279100
BK284150
BK277263
BK277266
BK277276 BK277258 BK277270
BK279100
BK284150
BK284155
BK284156
BK284158 BK284122 BK284159
BK279100
50A
70A
100A
150A
200A
275A
400A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-10
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Aluminum
Silver Electrode
Outer
Retaining Cap
Shield
Cap
Inner
Retaining Cap
BK284150
BK277286
BK277151
BK279484 BK279483
BK284150
BK277117
BK277152
BK279493 BK279439
BK284150
BK277274
BK277266
BK279440
BK279489 BK279443 (yellow o-ring)
BK284150
BK277263
BK277266
BK279469 BK279458
Nozzle
Swirl
Ring
Silver
Electrode
BK279410
(brown o-ring)
Torch
Head
BK279060
100A
BK279420
(green o-ring)
BK279060
150A
BK279060
200A
BK279450
(red o-ring)
BK279060
275A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-11
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Cutting Charts
The cutting charts shown on the following pages are intended to give the
operator the best starting point to use when making a cut on a particular material
type and thickness. Small adjustments may have to be made to achieve the best
cut. 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
Mild Steel
30 Amps
50 Amps
70 Amps
100 Amps
150 Amps
200 Amps
275 Amps
400 Amps
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen or Air
Air
Air
Air
Air
Air
Air
Copper
Electrode
Page 5-13
Page 5-14
Page 5-15
Page 5-16
Page 5-17
Page 5-18
Page 5-19
Page 5-20
Stainless Steel
Stainless Steel
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
400 Amps
400 Amps
Air
Air
H17
Air
H17
Air
H17
Air
H17
Air
H17
Air
H17
Nitrogen
Air
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Air
Page 5-21
Page 5-22
Page 5-23
Page 5-24
Page 5-25
Page 5-26
Page 5-27
Page 5-28
Page 5-29
Page 5-30
Page 5-31
Page 5-32
Page 5-33
Page 5-34
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
30 Amps
50 Amps
70 Amps
100 Amps
150 Amps
200 Amps
275 Amps
400 Amps
Air
Air
Air
Air
Air
Air
Air
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Air
Page 5-35
Page 5-36
Page 5-37
Page 5-38
Page 5-39
Page 5-40
Page 5-41
Page 5-42
Silver
Electrode
Page 5-43
Page 5-44
Page 5-45
Page 5-46
Page 5-47
Page 5-48
Page 5-49
Page 5-50
Page 5-51
Page 5-52
Page 5-53
Page 5-54
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-12
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield
Copper Electrode
Shield Cap
BK277145
Outer Cap
BK284150
Nozzle
BK277120
Electrode
BK277130
Retaining Cap
BK277153
Swirl Ring
BK277140
Torch Head
BK279100
Imperial*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(psi)
(psi)
(psi)
(psi)
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(msec)
(in)
100
.062
(ga)
(in)
(volts)
(ipm)
(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
77
6
75
.110
.105
.065
200
.120
.125
300
.070
Metric*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(mm)
(msec)
(mm)
100
1.6
(volts)
(mm/m)
(mm)
1
120
2615
2.0
1.5
124
2020
2.6
35
2
77
6
75
126
2.5
3
128
1615
2.8
2.7
1455
1285
2.9
3.1
1.7
200
1.8
300
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
145
250
Argon**
N/A
50
25
N/A
66
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.177
4.5
.100
2.5
0
2540
.100
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .100” (2.5 mm) for cutting and marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-13
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Mild Steel - 50 amps - Oxygen Plasma / Oxygen or Air Shield
Copper Electrode
Shield Cap
BK277115
Outer Cap
BK284150
Nozzle
BK277122
Retaining Cap
BK277153
Electrode
BK277131
Swirl Ring
BK277140/BK277142
Torch Head
BK279100
Imperial*
Material
Thickness
(ga)
(in)
12
.105
11
.120
10
.135
14
.075
12
.105
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 BK277140
25
74
12
72
123
70
.120
126
60
.125
128
50
.135
.135
Hot-Rolled Steel – Air Shield – Swirl Ring BK277142
.125
10
.135
200
106
25
74
19
190
.100
.135
180
72
110
170
3/16
113
105
1/4
117
75
.110
.140
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)
100
1.9
200
2.0
100
1.9
200
2.0
400
2.2
Cold-Rolled Steel – Oxygen Shield – Swirl Ring BK277140
2.5
25
3
74
12
72
121
1895
2.9
125
1555
3.1
3.4
Hot-Rolled Steel – Air Shield – Swirl Ring BK277142
2.5
106
3
25
5
74
19
72
6
4885
2.5
4660
113
2555
116
2075
3.4
5.1
3.6
5.5
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
145
250
Argon**
N/A
50
25
N/A
71
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.147
3.7
.100
2.5
0
2540
.100
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .135” (3.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-14
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Mild Steel - 70 Amps - Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
BK277150
Outer Cap
BK284150
Nozzle
BK277125
Electrode
BK277131
Retaining Cap
BK277153
Swirl Ring
BK277142
Torch Head
BK279100
Imperial*
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)
110
190
.150
100
113
130
.200
200
116
120
.110
.225
300
122
75
.140
.250
400
1/8
35
3/16
25
1/4
76
74
40
3/8
.100
.080
.085
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)
109
4995
3.6
100
113
3265
115
3105
3
35
25
5
76
6
74
40
2.5
5.1
2.7
5.5
2.0
300
2.2
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Marking
Height
(in)
(mm)
Initial
Height
Pierce
Time
(in) (mm) (msec)
Nitrogen Nitrogen
N/A
25
25
N/A
135
250
6350
.096
2.4
.100
2.5
0
Argon**
N/A
50
25
N/A
62
100
2540
.100
2.5
.100
2.5
0
Air**
* Use an arc transfer height (ignition height) of .150” (3.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-15
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Mild Steel - 100 Amps - Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
BK277286
Outer Cap
BK284150
Nozzle
BK277284
Electrode
BK277282
Retaining Cap
BK277151
Swirl Ring
BK277283
Torch Head
BK279100
Imperial*
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
150
.090
.200
300
100
.130
.250
400
65
.155
.300
500
1/4
3/8
1/2
25
83
26
130
81
5/8
143
47
3/4
145
35
.185
.090
.325
800
.350
1000
.095
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)
124
3950
2.1
4.9
300
2405
3.3
6.5
1850
3.7
7.3
6
10
25
12
83
26
130
81
16
143
1180
20
145
800
8.3
4.7
9.0
2.3
500
1000
2.4
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
130
250
Argon**
N/A
50
25
N/A
60
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.100
2.5
.100
2.5
0
2540
.100
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-16
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Mild Steel - 150 Amps - Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
BK277117
Outer Cap
BK284150
Nozzle
BK277293
Electrode
BK277292
Retaining Cap
BK277151/BK277152
Swirl Ring
BK277139
Torch Head
BK279100
Imperial*
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 BK277151
1/4
3/8
20
71
30
69
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 BK277152
5/8
127
70
3/4
130
55
134
40
.150
.400
1.25 ***
145
25
.200
.350
1.50 ***
155
15
.225
.350
1
20
71
45
69
.140
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)
300
Retaining Cap BK277151
6
10
20
71
30
69
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 BK277152
16
127
1760
20
130
1340
133
1040
3.7
10.1
32 ***
145
625
5.1
8.9
38 ***
154
385
5.6
8.9
25
20
71
45
69
8.3
3.6
1000
9.0
3.3
3.4
1500
3.6
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Marking
Height
(in)
(mm)
Initial
Height
Pierce
Time
(in) (mm) (msec)
Nitrogen Nitrogen
N/A
25
25
N/A
135
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
61
100
2540
.100
2.5
.100
2.5
0
Air**
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-17
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Mild Steel - 200 Amps - Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
BK277274
Outer Cap
BK284150
Nozzle
BK277289
Electrode
BK277291
Retaining Cap
BK277266
Swirl Ring
BK277143
Torch Head
BK279100
Imperial*
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
1.25
155
25
.240
.500
1.50 ***
165
17
.300
1.75 ***
175
12
.350
2.00 ***
185
7
.500
.500
20
1
74
58
72
.350
.150
1500
.155
158
.160
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)
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
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
20
25
74
58
72
3.8
500
800
1000
3.9
1500
4.0
4.1
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
120
250
Argon**
N/A
50
25
N/A
62
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.100
2.5
.100
2.5
0
2540
.100
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-18
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Mild Steel - 275 Amps - Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
BK277263
Outer Cap
BK284150
Nozzle
BK277269
Electrode
BK277270
Retaining Cap
BK277266
Swirl Ring
BK277258
Torch Head
BK279100
Imperial*
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
1.50 ***
20
81
70
79
.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
.350
1500
.190
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)
139
3290
3.6
7.4
500
2650
3.3
8.3
800
12
16
138
20
25
32
20
38 ***
81
70
79
2190
3.1
9.0
143
1690
4.0
10.1
150
1120
4.4
12.8
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* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
108
250
Argon**
N/A
50
25
N/A
54
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.100
2.5
.100
2.5
0
2540
.120
3.0
.100
2.5
0
* Use an arc transfer height (ignition height) of .300” (7.6 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-19
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Mild Steel - 400 Amps - Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
BK284123
Outer Cap
BK284150
Nozzle
BK284125
Electrode
BK284124
Retaining Cap
BK284121
Swirl Ring
BK284122
Torch Head
BK279100
Imperial*
Material
Thickness
(in)
1/2
5/8
3/4
1
1.25
1.5
1.75
2.00
2.25 ***
2.50 ***
2.75 ***
3.00 ***
Preflow
Plasma
Shield
Postflow
(psi)
(psi)
(psi)
(psi)
Arc
Voltage
(volts)
Travel
Speed
(ipm)
Cutting
Height
(in)
Pierce
Height
(in)
Pierce
Time
(msec)
Kerf
Width
(in)
140
.140
150
155
160
162
165
170
182
185
195
160
135
110
85
60
50
40
33
20
15
12
8
.160
.175
.225
.260
.270
.280
.300
.325
.350
.300
.350
.400
.500
.600
.700
.800
1.00
.350
.350
.350
.350
500
600
800
1000
1500
2000
3000
4500
1000
1300
1500
2000
.150
.155
.160
.180
Arc
Voltage
(volts)
Travel
Speed
(mm/m)
Cutting
Height
(mm)
Pierce
Height
(mm)
Pierce
Time
(msec)
Kerf
Width
(mm)
138
4205
3405
2700
2200
1500
1275
995
860
620
450
365
300
220
3.6
3.3
3.4
4.0
4.4
5.6
6.6
6.8
6.9
7.2
7.7
8.3
8.7
7.3
8.9
10.5
12.5
15.3
17.7
20.5
25.4
11.9
500
800
3.8
3.9
4.1
4.6
145
30
79
70
76
Preflow
Plasma
Shield
Postflow
(psi)
(psi)
(psi)
(psi)
.130
.190
.200
.210
.235
.245
.245
.250
Metric*
Material
Thickness
(mm)
12
16
20
25
32
38
45
50
55 ***
60 ***
65 ***
70 ***
75 ***
145
30
79
70
149
155
159
162
164
168
175
182
185
193
76
8.9
1000
1500
2000
3000
4500
1000
1300
1500
2000
4.8
5.1
5.3
6.0
6.2
6.4
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
112
250
Argon**
N/A
50
25
N/A
53
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.100
2.5
.100
2.5
0
2540
.120
3.0
.100
2.5
0
* Use an arc transfer height (ignition height) of .300” (7.6 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-20
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - 30 Amps - Air Plasma / Air Shield
Copper Electrode
Shield Cap
BK277144
Outer Cap
BK284150
Nozzle
BK277121
Electrode
BK277137
Retaining Cap
BK277110
Swirl Ring
BK277138
Torch Head
BK279100
Imperial*
Material
Thickness
(ga)
(in)
20
.036
18
.048
16
.060
14
.075
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(psi)
(psi)
(psi)
(psi)
(volts)
71
35
81
30
85
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(ipm)
(in)
(in)
(msec)
(in)
200
.020
100
.065
165
.035
74
125
75
90
.025
.050
.068
200
.070
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)
35
81
30
85
71
4855
0.6
73
3260
0.9
1
1.5
1.3
100
1.7
200
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
145
250
6350
.177
4.5
.100
2.5
0
N/A
50
25
N/A
55
100
2540
.140
3.6
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .050” (1.3 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-21
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
BK277149
Outer Cap
BK284150
Nozzle
BK277123
Electrode
BK277137
Retaining Cap
BK277110
Swirl Ring
BK277142
Torch Head
BK279100
Imperial*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(in)
(in)
(msec)
(in)
.035
.070
(ga)
(in)
(volts)
(ipm)
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
25
66
40
67
100
.105
200
.110
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)
.9
1.8
2
87
2.5
25
3
66
40
67
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* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(ipm) (mm/min)
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
145
250
N/A
50
25
N/A
65
100
Argon** Nitrogen**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.147
3.7
.100
2.5
0
2540
.100
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .070” (1.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-22
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)
This gas combination gives the best cut quality and minimum dross levels
Shield Cap
BK277150
Outer Cap
BK284150
Nozzle
BK277124
Electrode
BK277132
Retaining Cap
BK277113
Swirl Ring
BK277140
Torch Head
BK279100
Imperial*
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)
3/16
35
65
30
60
135
80
.100
.200
300
.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)
5
35
65
30
60
135
2030
2.5
5.1
300
2.3
Metric*
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
135
250
6350
.096
2.4
.100
2.5
0
N/A
50
25
N/A
80
100
2540
.130
3.3
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .150” (3.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-23
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - 70 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
BK277150
Outer Cap
BK284150
Nozzle
BK277125
Electrode
BK277131
Retaining Cap
BK277153
Swirl Ring
BK277142
Torch Head
BK279100
Imperial*
Material
Thickness
(ga)
(in)
10
.135
3/16
1/4
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
132
120
134
100
140
148
25
76
25
76
3/8
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.060
.150
200
.070
.200
300
75
.090
.225
400
50
.120
.250
500
.085
.090
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)
131
3210
1.4
3.3
200
25
76
25
76
134
2445
1.8
5.1
138
2050
2.1
5.5
3
5
6
2.2
400
2.3
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
(in)
(mm)
Nitrogen
Nitrogen
N/A
25
25
N/A
135
250
6350
.096
2.4
.100
2.5
0
N/A
50
25
N/A
65
100
2540
.100
2.5
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .150” (3.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-24
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - 100 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)
This gas combination gives the best cut quality and minimum dross levels
Shield Cap
BK277146
Outer Cap
BK284150
Nozzle
BK277126
Electrode
BK277133
Retaining Cap
BK277113
Swirl Ring
BK277141
Torch Head
BK279100
Imperial*
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
72
40
67
140
100
.125
.225
400
152
65
.180
.250
500
3/16
1/4
3/8
.105
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)
138
2865
2.7
5.1
139
2625
3.0
5.5
5
28
6
72
40
67
2.5
400
2.7
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
(in)
(mm)
Nitrogen
Nitrogen
N/A
25
25
N/A
130
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
80
100
2540
.110
2.8
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-25
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
BK277286
Outer Cap
BK284150
Nozzle
BK277284
Electrode
BK277282
Retaining Cap
BK277151
Swirl Ring
BK277283
Torch Head
BK279100
Imperial*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
141
100
147
80
154
55
1/4
25
3/8
80
35
80
1/2
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.135
.225
400
.092
.170
.250
500
.210
.300
600
.095
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)
140
2595
3.2
5.6
400
2.3
25
80
35
80
148
1935
4.4
6.5
152
1540
5.0
7.3
600
2.4
6
10
12
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
130
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
68
100
2540
.100
2.5
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-26
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - 150 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)
This gas combination gives the best cut quality and minimum dross levels
Shield Cap
BK277298
Outer Cap
BK284150
Nozzle
BK277297
Electrode
BK277135
Retaining Cap
BK277266
Swirl Ring
BK277139
Torch Head
BK279100
Imperial*
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
1/2
25
77
75
81
165
.135
60
.165
.300
600
5/8
50
.185
.325
800
3/4
40
.250
.350
1200
.145
.140
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)
1845
3.8
7.0
1610
4.1
7.4
1260
4.7
8.3
800
940
6.9
9.0
1200
10
12
25
16
77
75
155
81
20
167
3.4
600
3.6
3.7
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
135
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
81
100
2540
.140
3.6
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-27
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
BK277117
Outer Cap
BK284150
Nozzle
BK277293
Electrode
BK277292
Retaining Cap
BK277152
Swirl Ring
BK277139
Torch Head
BK279100
Imperial*
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
145
150
.160
.250
400
3/8
150
115
.180
.275
500
20
1/2
71
70
69
.125
155
85
.210
.300
600
5/8
160
60
.220
.325
800
3/4
168
45
.240
.350
1200
.135
.130
Metric*
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
20
12
71
70
69
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
3.4
Initial
Height
Pierce
Time
3.3
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(in) (mm) (msec)
Nitrogen
Nitrogen
N/A
25
25
N/A
135
250
6350
.100
2.5
.100
2.5
0
Argon**
Nitrogen**
N/A
50
25
N/A
65
100
2540
.100
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-28
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - 200 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)
This gas combination gives the good cut quality and minimum dross levels
Shield Cap
BK277274
Outer Cap
BK284150
Nozzle
BK277287
Electrode
BK277135
Retaining Cap
BK277266
Swirl Ring
BK277259
Torch Head
BK279100
Imperial*
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
5/8
37
72
79
68
.150
155
60
.190
.350
800
3/4
160
50
.200
.400
1200
1.0
170
35
.240
.450
1500
.160
.155
Metric*
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
16
155
1515
4.8
8.9
20
37
72
79
68
161
1215
5.2
10.3
25
169
915
6.0
11.3
800
3.9
1500
4.1
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
120
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
72
100
2540
.120
3.0
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-29
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - 200 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
BK277274
Outer Cap
BK284150
Nozzle
BK277289
Electrode
BK277291
Retaining Cap
BK277266
Swirl Ring
BK277143
Torch Head
BK279100
Imperial*
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
20
3/4
74
58
72
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
.200
400
.250
500
.115
.300
600
.150
.350
800
60
.190
.400
1200
.070
1.0
158
40
.210
.450
1.25 ***
170
20
.250
.350
1.50 ***
180
10
.275
.350
.150
.152
.155
.160
1500
.165
.175
Metric*
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
74
58
72
25
157
1050
5.2
11.3
32 ***
170
495
6.4
8.9
38 ***
179
260
6.9
8.9
3.8
600
3.9
800
1500
4.1
4.2
4.4
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(ipm) (mm/min)
Marking
Height
(mm)
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
120
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
70
100
2540
.100
2.5
.100
2.5
0
Argon** Nitrogen**
(in)
Initial
Height
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-30
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - 260 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)
This gas combination gives the best cut quality and minimum dross levels
Shield Cap
BK277211
Outer Cap
BK284150
Nozzle
BK277118
Electrode
BK277135
Retaining Cap
BK277280
Swirl Ring
BK277139
Torch Head
BK279100
Imperial*
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
1.0
160
33
.250
.450
1.25 ***
170
26
.280
.350
5/8
40
3/4
63
64
63
.190
1500
.195
.200
.205
Metric*
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
4.8
(volts)
(mm/m)
(mm)
(mm)
10
144
2140
4.0
6.5
12
142
2060
3.7
7.3
145
1640
4.7
8.9
151
1315
5.8
10.3
25
159
875
6.3
11.3
32 ***
170
650
7.1
8.7
16
40
20
63
64
63
800
5.0
1500
5.1
5.2
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
(in)
(mm)
Nitrogen
Nitrogen
N/A
25
25
N/A
108
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
75
100
2540
.160
4.1
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-31
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - 275 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
BK277263
Outer Cap
BK284150
Nozzle
BK277276
Electrode
BK277270
Retaining Cap
BK277266
Swirl Ring
BK277258
Torch Head
BK279100
Imperial*
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)
1/2
143
120
.125
.300
600
5/8
148
90
.140
.350
800
152
80
.180
.400
1200
165
55
.210
.450
3/4
20
1.0
73
70
75
1.25 ***
175
35
.250
.350
1.50 ***
185
25
.300
.350
.165
1500
.170
.180
Metric*
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)
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
73
70
75
4.2
4.3
1500
4.6
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
108
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
55
100
2540
.130
3.3
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-32
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - 400 Amps - H17 Plasma / Nitrogen Shield
Copper Electrode
(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)
This gas combination gives the best cut quality and minimum dross levels
Shield Cap
BK284155
Outer Cap
BK284150
Nozzle
BK284158
Electrode
BK284159
Retaining Cap
BK284156
Swirl Ring
BK284122
Torch Head
BK279100
Imperial*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
105
90
1/2
5/8
165
3/4
1
30
1.25
80
82
96
Cutting
Height
Pierce
Height
Pierce
Time
(in)
(in)
(msec)
(in)
.190
.300
600
.165
.180
.350
800
.175
75
.170
.400
1200
170
50
.185
.500
1500
175
40
.210
.700
2000
.800
2500
1.5
185
30
.270
1.75 ***
193
23
.300
2.00 ***
200
18
.350
.350
1500
Kerf
Width
.200
.225
.235
.250
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)
2750
4.8
7.3
600
4.2
165
2270
4.5
8.9
800
4.4
1810
4.3
10.5
169
1310
4.6
12.5
175
1005
5.3
18.0
2000
2500
12
16
20
25
30
32
80
82
96
38
184
765
6.8
20.2
45 ***
193
570
7.6
7.8
50 ***
199
470
8.7
8.9
1500
1500
5.1
5.7
6.0
6.4
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
100
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
68
100
2540
.160
4.1
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .300” (7.6 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-33
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - 400 Amps - Nitrogen Plasma / Air Shield
Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
Shield Cap
BK284155
Outer Cap
BK284150
Nozzle
BK284157
Electrode
BK284159
Retaining Cap
BK284156
Swirl Ring
BK284122
Torch Head
BK279100
Imperial*
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)
1/2
175
130
.210
.300
600
5/8
170
110
.170
.350
800
3/4
165
90
.150
.400
1200
1
170
65
.150
.500
1500
175
45
.160
.700
2000
2500
30
1.25
85
63
96
1.5
180
35
.170
.800
1.75 ***
190
25
.190
.350
2.00 ***
205
15
.210
.350
.165
1500
.200
.205
Metric*
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)
12
176
3415
5.5
7.3
600
16
169
2775
4.2
8.9
800
20
165
2190
25
169
1690
175
1120
4.1
18.0
2000
2500
30
32
85
63
96
10.5
3.8
12.5
38
179
895
4.2
20.2
45 ***
190
610
4.8
7.8
50 ***
203
410
5.2
8.9
4.2
1500
1500
5.1
5.2
Marking* – For All Material Thicknesses
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
(in)
(mm)
Nitrogen
Nitrogen
N/A
25
25
N/A
107
250
6350
.100
2.5
.100
2.5
0
Argon**
Nitrogen**
N/A
50
25
N/A
71
100
2540
.160
4.1
.100
2.5
0
Type of Gas
(Plasma)
Marking
Height
Initial
Height
Pierce
Time
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .300” (7.6 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-34
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Aluminum - 30 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
BK277145
Outer Cap
BK284150
Nozzle
BK277120
Electrode
BK277130
Retaining Cap
BK277153
Swirl Ring
BK277140
Torch Head
BK279100
Imperial*
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)
.100
100
.065
.150
200
.070
.040
150
.050
35
81
20
85
135
.063
120
.030
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
35
1.5
81
20
85
135
3885
0.8
2520
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
145
250
Argon**
N/A
50
25
N/A
75
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.177
4.5
.100
2.5
0
2540
.120
3.0
.100
2.5
0
* Use an arc transfer height (ignition height) of .100” (2.5 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-35
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Aluminum - 50 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
BK277150
Outer Cap
BK284150
Nozzle
BK277122
Electrode
BK277131
Retaining Cap
BK277153
Swirl Ring
BK277142
Torch Head
BK279100
Imperial*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
135
.050
.063
25
66
19
67
.080
Cutting
Height
Pierce
Height
Pierce
Time
(ipm)
(in)
(in)
(msec)
(in)
180
.050
100
.080
138
140
.065
150
.082
143
90
.075
.150
200
.085
.100
Kerf
Width
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)
137
3870
1.5
2.5
150
2.1
142
2360
1.8
3.7
200
2.2
1.5
25
2.0
66
19
67
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
145
250
Argon**
N/A
50
25
N/A
77
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.147
3.7
.100
2.5
0
2540
.120
3.0
.100
2.5
0
* Use an arc transfer height (ignition height) of .100” (2.5 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-36
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Aluminum - 70 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
BK277150
Outer Cap
BK284150
Nozzle
BK277125
Electrode
BK277131
Retaining Cap
BK277153
Swirl Ring
BK277142
Torch Head
BK279100
Imperial*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(msec)
(in)
100
.080
(volts)
(ipm)
(in)
(in)
.080
130
250
.050
.150
1/8
135
160
.070
.175
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
76
25
76
.085
.090
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)
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
5
25
6
76
25
76
10
156
975
2.0
7.0
12
160
820
2.6
7.4
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
135
250
Argon**
N/A
50
25
N/A
69
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.096
2.4
.100
2.5
0
2540
.120
3.0
.100
2.5
0
* Use an arc transfer height (ignition height) of .150” (3.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-37
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Aluminum - 100 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
BK277286
Outer Cap
BK284150
Nozzle
BK277284
Electrode
BK277282
Retaining Cap
BK277151
Swirl Ring
BK277283
Torch Head
BK279100
Imperial*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
158
105
162
90
165
70
1/4
3/8
25
80
26
80
1/2
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.155
.250
300
.095
.180
.275
400
.098
.195
.300
500
.100
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
10
25
80
26
80
12
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
130
250
Argon**
N/A
50
25
N/A
71
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.100
2.5
.100
2.5
0
2540
.120
3.0
.100
2.5
0
* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-38
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Aluminum - 150 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
BK277117
Outer Cap
BK284150
Nozzle
BK277293
Electrode
BK277292
Retaining Cap
BK277152
Swirl Ring
BK277139
Torch Head
BK279100
Imperial*
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
145
145
.130
.250
400
3/8
155
115
.185
.275
500
165
90
.230
.300
600
.130
.325
800
.135
.350
1200
.140
1/2
20
71
50
69
5/8
170
3/4
65
.250
45
.125
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)
6
143
3770
3.1
6.3
400
10
156
2825
4.8
7.0
5.5
7.4
12
162
2430
16
20
71
50
69
170
1630
20
170
990
8.3
6.4
9.0
3.2
600
3.3
1200
3.4
3.6
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Marking
Height
(in)
(mm)
Initial
Height
Pierce
Time
(in) (mm) (msec)
Nitrogen Nitrogen
N/A
25
25
N/A
135
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
69
100
2540
.100
2.5
.100
2.5
0
Air**
* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-39
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Aluminum - 200 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
BK277274
Outer Cap
BK284150
Nozzle
BK277289
Electrode
BK277291
Retaining Cap
BK277266
Swirl Ring
BK277143
Torch Head
BK279100
Imperial*
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
74
58
72
160
3/4
1.0 ***
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
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)
149
4955
3.3
6.3
300
3545
3.5
7.0
6
10
155
12
20
16
74
58
72
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* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
120
250
Argon**
N/A
50
25
N/A
71
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.100
2.5
.100
2.5
0
2540
.100
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-40
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Aluminum - 275 Amps - Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
BK277263
Outer Cap
BK284150
Nozzle
BK277276
Electrode
BK277270
Retaining Cap
BK277266
Swirl Ring
BK277258
Torch Head
BK279100
Imperial*
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
73
65
75
.160
.165
800
.400
1000
.170
.180
Metric*
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
16
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
20
20
73
65
75
10.2
1000
4.3
4.6
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
108
250
Argon**
N/A
50
25
N/A
56
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.100
2.5
.100
2.5
0
2540
.120
3.0
.100
2.5
0
* Use an arc transfer height (ignition height) of .275” (7.0 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-41
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Aluminum - 400 Amps - Nitrogen Plasma / Air Shield
Copper Electrode
Shield Cap
BK284155
Outer Cap
BK284150
Nozzle
BK284157
Electrode
BK284159
Retaining Cap
BK284156
Swirl Ring
BK284122
Torch Head
BK279100
Imperial*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/2
175
150
.170
.300
600
.200
5/8
180
125
.190
.400
700
.205
3/4
185
100
.205
.500
800
190
75
.215
.600
1200
1.25
200
55
.220
.700
1500
.225
1.5
205
35
.225
.800
2000
.240
30
1
85
63
96
.210
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)
12
173
3950
4.1
7.0
600
5.1
16
180
3150
4.8
10.3
800
5.2
20
185
2445
5.2
13.0
189
1945
5.4
15.0
1200
5.3
32
200
1375
5.6
17.9
1500
5.7
38
204
895
5.6
20.2
2000
6.1
30
25
85
63
96
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
106
250
Argon**
N/A
50
25
N/A
75
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.100
2.5
.100
2.5
0
2540
.140
3.6
.100
2.5
0
* Use an arc transfer height (ignition height) of .300” (7.6 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-42
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Mild Steel - 100 Amps - Oxygen Plasma / Air Shield
Silver Electrode
Shield Cap
BK277286
Nozzle
BK279484
Electrode
BK279410
(brown o-ring)
Outer Cap
BK284150
Retaining Cap
BK277151
Swirl Ring
BK279483
Torch Head
BK279060
Imperial*
Material
Thickness
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
125
150
100
65
1/4
3/8
1/2
25
83
26
130
81
5/8
143
47
3/4
145
35
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.090
.200
300
.130
.250
400
.155
.300
500
.185
.090
.325
800
.350
1000
.095
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)
124
3950
2.1
4.9
300
2405
3.3
6.5
1850
3.7
7.3
6
10
12
25
83
26
130
81
16
143
1180
20
145
800
8.3
4.7
9.0
2.3
500
1000
2.4
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Marking
Height
(in)
(mm)
Initial
Height
Pierce
Time
(in) (mm) (msec)
Nitrogen Nitrogen
N/A
25
25
N/A
130
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
60
100
2540
.100
2.5
.100
2.5
0
Air**
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-43
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Mild Steel - 150 Amps - Oxygen Plasma / Air Shield
Silver Electrode
Shield Cap
BK277117
Nozzle
BK279493
Electrode
BK279420
(green o-ring)
Outer Cap
BK284150
Retaining Cap
BK277151/BK 277152
Swirl Ring
BK279439
Torch Head
BK279060
Imperial*
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 BK277151
1/4
3/8
20
71
30
69
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 BK277152
5/8
127
70
3/4
130
55
134
40
1
20
71
45
69
.140
.150
.400
1.25 ***
145
25
.200
.350
1.50 ***
155
15
.225
.350
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)
300
Retaining Cap BK277151
6
10
20
71
30
69
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 BK277152
16
127
1760
20
130
1340
20
25
71
45
69
8.3
3.6
1000
9.0
133
1040
3.7
10.1
32 ***
145
625
5.1
8.9
38 ***
154
385
5.6
8.9
3.3
3.4
1500
3.6
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
(in)
(mm)
Nitrogen Nitrogen
N/A
25
25
N/A
135
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
61
100
2540
.100
2.5
.100
2.5
0
Air**
Marking
Height
Initial
Height
Pierce
Time
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-44
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Mild Steel - 200 Amps - Oxygen Plasma / Air Shield
Silver Electrode
Shield Cap
BK277274
Nozzle
BK279489
Electrode
BK279440
(yellow o-ring)
Outer Cap
BK284150
Retaining Cap
BK277266
Swirl Ring
BK279443
Torch Head
BK279060
Imperial*
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
1.25
155
25
.240
.500
1.50 ***
165
17
.300
1.75 ***
175
12
.350
2.00 ***
185
7
.500
.500
20
1
74
58
72
.350
.150
1500
.155
158
.160
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)
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
12.7
20
25
74
58
72
32
155
610
6.1
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* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
(in)
(mm)
Nitrogen Nitrogen
N/A
25
25
N/A
120
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
62
100
2540
.100
2.5
.100
2.5
0
Air**
Marking
Height
Initial
Height
Pierce
Time
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-45
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Mild Steel - 275 Amps - Oxygen Plasma / Air Shield
Silver Electrode
Shield Cap
BK277263
Nozzle
BK279469
Electrode
BK279450
(red o-ring)
Outer Cap
BK284150
Retaining Cap
BK277266
Swirl Ring
BK279458
Torch Head
BK279060
Imperial*
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
1.50 ***
20
81
70
79
.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
.350
1500
.190
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)
139
3290
3.6
7.4
500
2650
3.3
8.3
800
12
16
138
20
25
32
20
38 ***
81
70
79
2190
3.1
9.0
143
1690
4.0
10.1
150
1120
4.4
12.8
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* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
(in)
(mm)
Nitrogen Nitrogen
N/A
25
25
N/A
108
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
54
100
2540
.120
3.0
.100
2.5
0
Air**
Marking
Height
Initial
Height
Pierce
Time
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .300” (7.6 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-46
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Mild Steel - 400 Amps - Oxygen Plasma / Air Shield
Silver Electrode
Shield Cap
BK284123
Nozzle
BK284125
Electrode
BK279460
(black o-ring)
Outer Cap
BK284150
Retaining Cap
BK284121
Swirl Ring
BK279422
Torch Head
BK279060
Imperial*
Material
Thickness
(in)
1/2
5/8
3/4
1
1.25
1.5
1.75
2.00
2.25 ***
2.50 ***
2.75 ***
3.00 ***
Preflow
Plasma
Shield
Postflow
(psi)
(psi)
(psi)
(psi)
Arc
Voltage
(volts)
Travel
Speed
(ipm)
Cutting
Height
(in)
Pierce
Height
(in)
Pierce
Time
(msec)
Kerf
Width
(in)
140
.140
150
155
160
162
165
170
182
185
195
160
135
110
85
60
50
40
33
20
15
12
8
.160
.175
.225
.260
.270
.280
.300
.325
.350
.300
.350
.400
.500
.600
.700
.800
1.00
.350
.350
.350
.350
500
600
800
1000
1500
2000
3000
4500
1000
1300
1500
2000
.150
.155
.160
.180
Arc
Voltage
(volts)
Travel
Speed
(mm/m)
Cutting
Height
(mm)
Pierce
Height
(mm)
Pierce
Time
(msec)
Kerf
Width
(mm)
138
4205
3405
2700
2200
1500
1275
995
860
620
450
365
300
220
3.6
3.3
3.4
4.0
4.4
5.6
6.6
6.8
6.9
7.2
7.7
8.3
8.7
7.3
8.9
10.5
12.5
15.3
17.7
20.5
25.4
11.9
500
800
3.8
3.9
4.1
4.6
145
30
79
70
76
Preflow
Plasma
Shield
Postflow
(psi)
(psi)
(psi)
(psi)
.130
.190
.200
.210
.235
.245
.245
.250
Metric*
Material
Thickness
(mm)
12
16
20
25
32
38
45
50
55 ***
60 ***
65 ***
70 ***
75 ***
145
30
79
70
149
155
159
162
164
168
175
182
185
193
76
8.9
1000
1500
2000
3000
4500
1000
1300
1500
2000
4.8
5.1
5.3
6.0
6.2
6.4
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
(in)
(mm)
Nitrogen Nitrogen
N/A
25
25
N/A
112
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
53
100
2540
.120
3.0
.100
2.5
0
Air**
Marking
Height
Initial
Height
Pierce
Time
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .300” (7.6 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-47
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
BK277286
Nozzle
BK279484
Electrode
BK279410
(brown o-ring)
Outer Cap
BK284150
Retaining Cap
BK277151
Swirl Ring
BK279483
Torch Head
BK279060
Imperial*
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
80
35
80
147
80
.170
.250
500
154
55
.210
.300
600
1/4
3/8
1/2
.095
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)
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
10
25
80
35
80
12
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(ipm) (mm/min)
Marking
Height
(mm)
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
130
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
68
100
2540
.100
2.5
.100
2.5
0
Argon** Nitrogen**
(in)
Initial
Height
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-48
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
BK277117
Nozzle
BK279493
Electrode
BK279420
(green o-ring)
Outer Cap
BK284150
Retaining Cap
BK277152
Swirl Ring
BK279439
Torch Head
BK279060
Imperial*
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
1/2
20
71
70
69
.125
155
85
.210
.300
600
5/8
160
60
.220
.325
800
3/4
168
45
.240
.350
1200
.135
.130
Metric*
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
20
12
71
70
69
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
3.4
Initial
Height
Pierce
Time
3.3
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
135
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
65
100
2540
.100
2.5
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-49
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Stainless Steel - 200 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
BK277274
Nozzle
BK279489
Electrode
BK279440
(yellow o-ring)
Outer Cap
BK284150
Retaining Cap
BK277266
Swirl Ring
BK279443
Torch Head
BK279060
Imperial*
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
.200
400
3/8
133
150
.250
500
1/2
140
110
.115
.300
600
5/8
146
75
.150
.350
800
153
60
.190
.400
1200
20
3/4
74
58
72
.070
1.0
158
40
.210
.450
1.25 ***
170
20
.250
.350
1.50 ***
180
10
.275
.350
.150
.152
.155
.160
1500
.165
.175
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)
400
6
129
5220
1.8
4.9
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
74
58
72
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
3.9
1500
4.1
4.2
4.4
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
Marking
Height
(ipm) (mm/min)
(in)
(mm)
Initial
Height
Pierce
Time
(Plasma)
(Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
Nitrogen
Nitrogen
N/A
25
25
N/A
120
250
6350
.100
2.5
.100
2.5
0
N/A
50
25
N/A
70
100
2540
.100
2.5
.100
2.5
0
Argon** Nitrogen**
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-50
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Aluminum - 100 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
BK277286
Nozzle
BK279484
Electrode
BK279410
(brown o-ring)
Outer Cap
BK284150
Retaining Cap
BK277151
Swirl Ring
BK279483
Torch Head
BK279060
Imperial*
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
80
26
80
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
10
25
80
26
80
12
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Marking
Height
(in)
(mm)
Initial
Height
Pierce
Time
(in) (mm) (msec)
Nitrogen Nitrogen
N/A
25
25
N/A
130
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
71
100
2540
.120
3.0
.100
2.5
0
Air**
* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-51
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Aluminum - 150 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
BK277117
Nozzle
BK279493
Electrode
BK279420
(green o-ring)
Outer Cap
BK284150
Retaining Cap
BK277152
Swirl Ring
BK279439
Torch Head
BK279060
Imperial*
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
1/2
20
71
50
69
5/8
170
3/4
65
.250
45
.125
Metric*
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
143
3770
3.1
6.3
400
10
156
2825
4.8
7.0
5.5
7.4
20
12
71
50
69
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* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Nitrogen Nitrogen
N/A
25
25
N/A
135
250
Argon**
N/A
50
25
N/A
69
100
Air**
Marking
Height
Initial
Height
Pierce
Time
(in)
(mm)
(in) (mm) (msec)
6350
.100
2.5
.100
2.5
0
2540
.100
2.5
.100
2.5
0
* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-52
Spirit II User’s Manual
Section 5: Torch Consumables and Cutting Charts
Aluminum - 200 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
BK277274
Nozzle
BK279489
Electrode
BK279440
(yellow o-ring)
Outer Cap
BK284150
Retaining Cap
BK277266
Swirl Ring
BK279443
Torch Head
BK279060
Imperial*
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)
150
190
.135
.250
300
145
.140
.275
400
.300
500
.350
600
1/4
3/8
155
1/2
20
5/8
74
58
72
160
3/4
1.0 ***
110
.135
95
65
.150
175
35
.200
.400
.150
.155
800
.160
1000
.170
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)
149
4955
3.3
6.3
300
3545
3.5
7.0
6
10
155
12
20
16
74
58
72
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* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
(in)
(mm)
Nitrogen Nitrogen
N/A
25
25
N/A
120
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
71
100
2540
.100
2.5
.100
2.5
0
Air**
Marking
Height
Initial
Height
Pierce
Time
(in) (mm) (msec)
* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-53
Section 5: Torch Consumables and Cutting Charts
Spirit II User’s Manual
Aluminum - 275 Amps - Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
BK277263
Nozzle
BK279469
Electrode
BK279450
(red o-ring)
Outer Cap
BK284150
Retaining Cap
BK277266
Swirl Ring
BK279458
Torch Head
BK279060
Imperial*
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
3/4
20
73
65
75
.160
.165
800
.400
1000
.170
.180
Metric*
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
73
65
75
10.2
1000
4.3
4.6
Marking* – For All Material Thicknesses
Type of Gas
Preflow
Plasma
Shield
Postflow
Arc
Voltage
Travel
Speed
(Plasma) (Shield)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm) (mm/min)
Marking
Height
(in)
(mm)
Initial
Height
Pierce
Time
(in) (mm) (msec)
Nitrogen Nitrogen
N/A
25
25
N/A
108
250
6350
.100
2.5
.100
2.5
0
Argon**
N/A
50
25
N/A
56
100
2540
.120
3.0
.100
2.5
0
Air**
* Use an arc transfer height (ignition height) of .275” (7.0 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-54
Spirit II User’s Manual
Section 6: Maintenance &Troubleshooting
Section 6: Maintenance & Troubleshooting
WARNING: Only qualified maintenance personnel should perform
maintenance on the Spirit system.
The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance
should be performed with safety in mind.
Use extreme caution when working near the power conversion module (i.e.,
chopper). The large electrolytic capacitors store large amounts of energy
even after power has been removed from the system. Wait at least five
minutes after turning off power, and then use a voltmeter to verify that the
capacitors are fully discharged before touching the power conversion module.
Capacitor failure can injure and/or cause property damage.
If troubleshooting requires the system to be powered with the enclosure
panels removed, remain clear of the capacitors. Failure of a capacitor can
result in a sudden release of stored energy causing rupture of the capacitor
case.
Routine Maintenance
Note: At minimum, these checks should be performed on a monthly basis. In
excessively dirty environments or in heavy usage situations, the checks
should be performed more frequently.
Power Supply
1. Remove the left, right, and top covers on the power supply.
2. Using clean, dry, compressed air, blow out all accumulated dust, including dust on
PC boards and fans. In an excessively dirty environment, blow out the unit on a
weekly basis.
3. Verify the ground and primary three phase A.C. voltage connections are tight.
4. Verify all PC board connectors are installed securely.
5. Verify all rear cable connectors are installed securely.
6. Verify the electrode lead and work ground lead are secure and free from corrosion.
Cooling System
1. Remove the cover on the cooling system.
deionization cartridge and replace if dirty.
Check the torch coolant filter /
2. Flush the cooling system every six months and replace the coolant and coolant filter
/ deionization cartridge.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-1
Section 6: Maintenance &Troubleshooting
Spirit II User’s Manual
Manual Gas Console (MGC)
1. Remove the cover of the manual gas console. Using clean, dry, compressed air,
blow out all accumulated dust inside the unit. In an excessively dirty environment,
blow out the unit on a weekly basis.
2. Verify that all PC board connectors are installed securely.
3. Verify that all gas hose connectors are tight and that there are no leaks. Only
tighten the gas fittings enough to make a gas seal. The fittings are subject to
damage if over tightened.
4. Inspect all gas hoses to ensure no damage exists.
damaged gas hoses.
Immediately replace any
Torch, Torch Leads, and Gas Hoses
1. Verify that all torch lead and gas hose connections are tight and that there are no
gas or water leaks. Only tighten the fittings enough to make a water or gas
seal. The fittings are subject to damage if over tightened.
2. Verify that the braided shield of the torch leads is fastened securely to the brass
shield adapter that connects to the impulse start console. Also, make sure the
shield adapter is secured tightly to the impulse start console enclosure.
3. Inspect the braided shield for nicks or cuts and replace if necessary.
4. Remove the torch handle and verify that the connections at the torch base are
tightened securely. Only tighten the fittings enough to make a water or gas
seal. The fittings are subject to damage if over tightened. Coolant leaking from
the drain hole in the torch handle indicates damaged or loose torch leads.
5. Make sure the torch lead insulating sleeves are positioned to properly cover the
brass torch fittings at the torch base.
6. Inspect the outer sleeve on the torch base's electrode/coolant supply lead. If
nicks, cuts or holes are found, replace the torch base.
7. Remove the torch consumables from the torch head and inspect all o-rings.
Replace any o-rings with cuts, nicks, abrasions, or any other signs of wear.
Faulty o-rings may cause gas or water leaks, which will affect cut quality.
8. With the electrode removed, inspect the cooling tube in the torch head for
damage.
If using the copper electrode, the torch head uses cooling tube P/N BK277007. If
replacement is required, use tool P/N BK200109.
If using the silver electrode, the torch head uses cooling tube holder assembly
P/N BK279216. Remove this using the tool (socket P/N BK277087 & driver P/N
BK277086) and inspect the o-rings for damage. Apply a small amount of o-ring
lubricant before re-installing in the torch head.
9. Wipe any excess o-ring lubricant off of the torch base and head.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-2
Spirit II User’s Manual
Section 6: Maintenance &Troubleshooting
Impulse Start Console (ISC)
1. Open the cover (door) of the impulse start console and verify that all leads and
hoses are tightened securely. Only tighten the fittings enough to make a water
or gas seal. The fittings are subject to damage if over tightened.
Work Ground
1. Verify that the work ground lead is securely fastened to the star ground on the
cutting table, and that the connection point is free from corrosion. Use a wire brush
to clean the connection point if necessary.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-3
Section 6: Maintenance &Troubleshooting
Spirit II User’s Manual
Replacing the Torch Coolant and Filter
WARNING: Do not touch the fans inside the cooling system.
Important: Never turn on the system when the coolant reservoir is empty.
Important: When handling coolant, wear nitrile gloves and safety glasses.
Important: Only use Kaliburn approved coolant. Commercially available
antifreeze contains corrosion inhibitors that will damage the cooling
system. See Section 2 for more information.
The torch coolant should be flushed out of the system every six months and replaced
with new coolant. Replace the coolant filter / deionization cartridge at the same time.
1. Remove primary power from the Spirit system.
2. Ensure the torch base and torch head (with consumables) are properly installed.
3. Ensure the coolant supply (in and out) hoses are properly installed.
4. Remove the coolant reservoir cap/level gauge.
5. Remove the cover from the cooling system.
6. Connect a 3/8" ID hose and bucket to the drain petcock on the bottom of the
reservoir. Unscrew the petcock to drain the reservoir. Leave the hose and bucket in
place after the coolant drains out.
7. Remove the coolant supply hose (coolant out) from the rear of the cooling system.
Note that the coolant supply hose has right hand threads. Be prepared for some
coolant to escape from the fitting on the cooling system and from the supply hose.
8. Blow compressed air (100 psi maximum) into the coolant supply hose. This will force
the remaining coolant from the torch, torch leads, and supply hose into the reservoir
and out of the drain petcock. Continue until coolant stops flowing into the bucket.
9. Tighten the drain petcock and remove the hose and bucket.
10. Unscrew the coolant filter housing and remove the coolant filter / deionization
cartridge. Install a new coolant filter / deionization cartridge and replace the coolant
filter housing. Dry any leaked coolant.
11. Reconnect the coolant supply hose on the rear of the cooling system.
12. Follow all of the steps in "Filling the Cooling System" in Section 3 of this manual to
complete this procedure.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-4
Spirit II User’s Manual
Section 6: Maintenance &Troubleshooting
Microprocessor (DSP) Status Indicators
The microprocessor DSP board controls all of the functions of the Spirit power
supply. It contains diagnostic LEDs and OPTO LEDs which aid in
troubleshooting the system. These indicators illuminate when a particular event
occurs. Illuminated LEDs indicate the following:
LED
Indication
D7 – RS232 OUT Isolated
D10 – RS232 T1 OUT
D11 – CAN RXD
D12 – CAN TXD
D24 – PWM
D33 – COOLANT LEVEL
D36 – PLASMA START
D37 – ARC HOLD
D38 – MARKING
D39 – CORNER
D40 – EOFF
D41 – MOTION
D42 – PLASMA READY
D43 – PAT
D48 – RMT ON/OFF
D50 – ISC DOOR
D77 – 3.3V uP PWR
D78 – 1.8V uP PWR
Serial transmission
Serial transmission
CAN transmission
CAN transmission
Chopper(s) energized
Coolant reservoir level is sufficient
Plasma start signal applied to Spirit
Arc hold input enabled
Marking input enabled
Corner current input enabled
Off button disengaged
Motion output signal activated
Power supply ready output signal activated
Pilot arc transistor energized
Remote On/Off input enabled
ISC door is closed
3.3V Microprocessor power
1.8V Microprocessor power
OPTO U21 – MTR/SOL
OPTO U22 – PAR
OPTO U23 – CON
OPTO U24 – SURGE
OPTO U26 – FAN
OPTO U27 – PREFLOW
OPTO U28 – PLASMA
OPTO U29 – SHIELD
OPTO U30 – VENT
OPTO U31 – POSTFLOW
OPTO U32 – MARKING
OPTO U34 – IMPULSE START
OPTO U37 – RHF
Coolant pump relay CR5 energized (Pump On)
Pilot arc relay energized
DC power output (main contactor energized)
CR3 and K1 (I/O PCB) relays energized
Fans energized
Preflow gas valve 1 energized
Plasma gas valve 2 energized
Shield gas valve 3 energized
Vent gas valve 4 energized
Postflow gas valve 5 energized
Marking gas valves 6 and 7 energized
Impulse start circuit energized
HF transformer energized
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-5
Section 6: Maintenance &Troubleshooting
Spirit II User’s Manual
Microprocessor (DSP) Sequence of Operation
The following DSP Indicators should illuminate after primary power is applied:
 D77
3.3V Supply
 D78
1.8V Supply
 D50
ISC (Door)
 D33
Coolant Level
 D37
Arc Hold (if INOVA is being used)
 D10
RS232 T1 Out (Blinking)
 D11
CAN RXD (Dim Flashing)
 D12
CAN TXD (Dim Flashing)
The following DSP Indicators should illuminate when the OFF Button is released:
 D40
OFF Button
The following DSP Indicators should illuminate when the ON Button is activated:
 U21 Opto
Motor / Solenoid
 U19 Opto
Solenoid (not used)
 U26 Opto
Fan
 D42
Plasma Ready
The following DSP Indicators should illuminate when a START signal is applied (begin
cut cycle):
 D36
Start
 U27 Opto
Preflow
 U29 Opto
Shield
 U24 Opto
Surge (only over 100 amps)
 U23 Opto
Contactor
 D24
PWM (Chopper ON)
 U22 Opto
Pilot Arc Relay ON
 D43
PAT ON (Blinks during a START)
 U34 Opto
ISC (Blinks during a START)
The following DSP Indicators should illuminate with an arc transfer:
 U31 Opto
Postflow
 U28 Opto
Plasma
 D41
Motion
The following LEDs should turn OFF after the Motion Indicator turns ON:
 U34 Opto
ISC
 U27 Opto
Preflow
 D43
PAT
When the START signal is removed, OPTO U30 (Vent) will illuminate. It will then go out
with the rest of the cut cycle indicators.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-6
Spirit II User’s Manual
Section 6: Maintenance &Troubleshooting
Error Codes
The following is a comprehensive list of error codes for the Spirit system. When the system
uses a Manual Gas Console, only the numeric error code is displayed. When an Automatic
Gas Console is used, the text description is also displayed.
Power Supply
Code
10121
10138
Short Description
ISC Door
Stop Pressed (Off Button)
10140
10150
10160
10161
10170
10180
10190
10220
10290
10300
10320
10330
10340
10350
10360
Phase R
Phase Y
Phase B
CON1
Coolant Level
Coolant Flow Low
Coolant Flow High
Coolant Temperature High
GC Quiet
PC Quiet
FCC Invalid
PAC Invalid
AH IHS Timeout
PAT Not Established
TAC Not Established
10370
Current Unbalanced
10380
10390
10400
10410
10420
10430
10432
10440
10450
10461
TAC Lost 1
TAC Lost 2
TAC Lost 3
TAC Lost 4
FCC Unreached
Output Over Current
Output Over Current TZ
Output Over Voltage
Start Premature Removal
Chopper1 Temp
10462
Chopper2 Temp
10463
Chopper3 Temp
Long Description
ISC Door is open
OFF Button on Plasma Console or Manual Gas
Console is pressed.
Transformer Secondary phase voltage is low
Transformer Secondary phase voltage is low
Transformer Secondary phase voltage is low
Main Contactor failed to open
Coolant Level is low
Coolant flow is low
Coolant flow is high
The coolant temperature is high
Lost CAN communication with Gas Console
Lost CAN communication with Plasma Console
Final Cut Current invalid
Pilot Arc Current invalid
Arc Hold for Initial Height Sense has timed out
Pilot Arc Current not established within 2 seconds
Transferred Arc Current not established within 2
seconds
Current is not balanced between chopper
assemblies (275A and 400A systems)
Transferred Arc lost during TAC hold time
Transferred Arc lost during Upslope
Transferred Arc lost during Cutting
Transferred Arc lost during Downslope
Did not achieve final cut current
Chopper has exceeded its maximum rated current
Instantaneous Over Current detected
Maximum Cutting Voltage has been exceeded.
Start Signal removed prior to completion of upslope
Chopper 1 maximum operating temperature
exceeded
Chopper 2 maximum operating temperature
exceeded
Chopper 3 maximum operating temperature
exceeded
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-7
Section 6: Maintenance &Troubleshooting
Spirit II User’s Manual
Gas Console
Code
20100
20110
20120
20130
20140
20160
20170
20200
20210
20220
20230
20240
20250
20260
20270
20280
20290
20300
20310
Short Description
Plasma Adjust
Shield Adjust
Preflow Adjust
Postflow Adjust
Marking Adjust
N2 Mix Adjust
O2 Mix Adjust
O2 Low
N2 Low
Argon Low
O2N2 Low
H17 Low
O2 High
N2 High
Argon High
O2N2 High
H17 High
PS Quiet
PC Quiet
Long Description
Could not adjust Plasma Gas
Could not adjust Shield Gas
Could not adjust Preflow Gas
Could not adjust Postflow Gas
Could not adjust Marking Gas (Automatic Gas Console)
Could not adjust N2 Mix Gas
Could not adjust O2 Mix Gas
O2 Input Pressure is low
N2 Input Pressure is low
Argon Input Pressure is low
Air Input Pressure is low
H17 Input Pressure is low
O2 Input Pressure is high
N2 Input Pressure is high
Argon Input Pressure is high
Air Input Pressure is high
H17 Input Pressure is high
Lost CAN communication with Power Supply
Lost CAN communication with Plasma Controller
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-8
Spirit II User’s Manual
Section 6: Maintenance &Troubleshooting
General Troubleshooting
The following contains general troubleshooting guidelines for the Spirit system. Please
contact KALIBURN technical support for any issues not covered in this section. Before
any tests are performed, make sure that all system fuses are good; remove top cover of
power supply to check these fuses.
Problem
Possible Cause
Power supply indicator
(white light) will not
illuminate
1. Primary disconnect fuse blown.
2. Internal power supply fuse is blown (F1A, F1B).
3. Power supply indicator light is burned out or the
associated wiring is bad.
4. Control Transformer or associated wiring bad.
Power Supply will not
energize after choosing ON
and then SELECT on the
MGC.
1.
2.
3.
4.
5.
Power supply will not stay on
after choosing ON and then
SELECT on the MGC.
1. Faulty DSP board.
2. Off Relay faulty.
No arc at the torch
1. Incorrect torch consumables installed.
2. Incorrect gas pressure settings.
3. Pilot arc transistor (PAT) is not operating properly.
Check the PAT LED (D43) on the DSP
microprocessor board.
4. Damaged or loose torch lead connections.
5. Shorted torch or torch leads. Check the continuity
between the Electrode lead and the Nozzle lead to
make sure they are not shorted.
6. Open torch or torch leads. Check the continuity
from the Electrode lead to the torch electrode and
the Nozzle lead to the large brass body of the
torch.
The arc will not transfer to
the workpiece
1. Loose work ground connection.
2. Pierce height too high.
3. Incorrect, damaged, or worn consumables.
ISC door open.
Low coolant level.
Fuse is blown (F1-F6).
Faulty Off Button or associated wiring.
Off Relay faulty.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-9
Section 6: Maintenance &Troubleshooting
Spirit II User’s Manual
Problem
Primary power has been
applied to the system, but
the manual gas console
screen is blank
Possible Cause
1. Check power/communications CAN cable
connection on back of manual gas console.
2. Check for blown DIN rail fuse.
3. Check for 120v on pins of power/communications
CAN cable at back of the manual gas console.
The manual gas console
screen is on, but the screen
doesn't work
1. Cycle primary power to the Spirit system.
2. Check the connection of the ribbon cable that
connects the keypad to the DSP PCB in the
manual gas console.
Gas pressures will not adjust
properly
1. Wrong consumables installed in torch.
2. Loose pressure transducer cable on PC board in
the MGC.
3. Check connectors on the MGC valve associated
with the malfunction.
Low pressure error
1. Supply gas pressure(s) less than 120 psi.
Pressure error during cut
1. Supply gas pressure(s) fluctuating during cut.
Liquid or torch coolant
leaking from drain hole in
torch handle.
Infrequent dripping from the drain hole may be
condensation; no action is required.
Noticeable flow from the drain hole indicates a
problem with the torch leads and/or connections.
1. Check for damaged or loose torch lead
connections within the torch handle.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-10
Spirit II User’s Manual
Section 6: Maintenance &Troubleshooting
Chopper Test Procedure
WARNING: Only qualified maintenance personnel should perform the chopper
test procedure. The system utilizes potentially fatal A.C. and D.C. voltages. All
maintenance should be performed with safety in mind.
Use extreme caution when working near the power conversion module (i.e.,
chopper). The large electrolytic capacitors store large amounts of energy even
after power has been removed from the system. Wait at least five minutes after
turning off power, and then use a voltmeter to verify that the capacitors are fully
discharged before touching the power conversion module.
Capacitor failure can injure and/or cause property damage. If troubleshooting
requires the system to be powered with the enclosure panels removed, remain
clear of the capacitors. Failure of a capacitor can result in a sudden release of
stored energy causing rupture of the capacitor case.
IMPORTANT: Depending upon the system, there are one, two or three chopper
assemblies in the power supply. The following steps must be performed on each
chopper with the other chopper(s) disabled. To disable a chopper, remove the
plug from J1 on the chopper PCB (see drawing on next page).
1. Remove primary power from the Spirit system.
2. Open the impulse start console door and disconnect the Green P1 Plug from the
impulse start PCB. Close the impulse start console door to activate the door
interlock switch.
3. Remove the top, left, right and front covers from the power supply to expose the
DSP PCB, input and output terminal blocks and chopper(s).
4. Remove the Electrode, Work and Nozzle leads from the output terminal block, which
is located on the left side of the unit.
5. Ensure the torch head (with a full set of consumables) is properly installed onto the
torch base.
6. Apply primary power to the Spirit system.
7. Release the OFF Button on the Plasma Controller or Manual Gas Console to enable
the system. Press or SELECT the ON Button to energize the system. After the
gases set, prepare to apply a start signal to the unit.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-11
Section 6: Maintenance &Troubleshooting
Spirit II User’s Manual
8. With a start signal applied, check the three phase voltage input to each chopper at
the diode bridge terminals (three screws on the left side of each chopper). Refer to
TABLE 1 for the proper three phase AC voltage.
Note that the system will only energize for approximately two seconds each
time a start signal is applied.
If the voltage is not present, check for primary voltage on the main contactor
(CON 1) and on the primary side of the power transformer.
Diode Bridge Terminals
Chopper PCB
J1 Plug
D2 (Green LED) is
under J1 Plug
Top View of Chopper
9. With a start signal applied, check for the proper DC voltage (refer to TABLE 1) at the
output terminal block between Electrode and Work, which is located on the left side
of the unit.
If the proper DC voltage is present, the chopper is working properly.
Chopper 1
3 Phase
OCV
AC
(DC)
Spirit II
400 Amp
Spirit II
275 Amp
Spirit II
150 Amp
TABLE 1
Chopper 2
3 Phase
OCV
AC
(DC)
Chopper 3
3 Phase
OCV
AC
(DC)
255
370
255
370
255
370
225
325
225
325
N/A
N/A
208
300
N/A
N/A
N/A
N/A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-12
Spirit II User’s Manual
Section 6: Maintenance &Troubleshooting
10. If the proper DC voltage is not present at the output terminal block, check the 200
amp fuse F9 (chopper 1), fuse F10 (chopper 2) or fuse F11 (chopper 3) located on
the bottom right of the output bus bars.
If the fuse is open, replace chopper and fuse.
11. If the fuse(s) is good, check if the chopper PWM LED illuminates when a start signal
is applied:
a) check D24 on the DSP PCB – If D24 doesn’t illuminate, replace DSP PCB.
b) check D2 on the chopper PCB – If D2 doesn’t illuminate green, go to step 12.
12. Check PCB power to the chopper from the DSP:
a) Push the OFF Button.
b) Disconnect the J1 plug from the chopper PCB.
c) Leave the OFF Button pushed in.
d) With a digital voltmeter, measure the following voltages on the J1 plug:
J1-5 (ground) to J1-1
+15vdc Supply
J1-5 (ground) to J1-2
+5vdc Supply
J1-5 (ground) to J1-3
+5vdc (PWM Signal)
If ALL of the voltages are present, replace chopper. If any of the voltages are not
present, go to step 13:
13. Remove primary power from the Spirit system. Check cable continuity between the
chopper PCB and DSP PCB. Use a digital voltmeter set up to read resistance
(ohms) and make the following measurements:
Chopper (1) J1-1 to DSP J7-1
Chopper (1) J1-2 to DSP J7-2
Chopper (1) J1-3 to DSP J7-3
Chopper (1) J1-5 to DSP J7-4
Chopper (2) J1-1 to DSP J8-1
Chopper (2) J1-2 to DSP J8-2
Chopper (2) J1-3 to DSP J8-3
Chopper (2) J1-5 to DSP J8-4
Chopper (3) J1-1 to DSP J9-1
Chopper (3) J1-2 to DSP J9-2
Chopper (3) J1-3 to DSP J9-3
Chopper (3) J1-5 to DSP J9-4
If ALL of the continuity readings are good, replace DSP PCB.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-13
Section 6: Maintenance &Troubleshooting
Spirit II User’s Manual
BLANK
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-14
Spirit II User’s Manual
Section 7: Parts List
Section 7: Parts List
Power Supply (BK300232 - BK300239)
Right Side View
Item
4
5
6
15
30
31
35
38
44
59
60
Part Number
BK707155
BK500557
BK706410
BK706406
BK706503
BK709296
BK708120
BK702076
BK709251
BK300250
BK200204
BK284031
BK500526
Quantity
3
2
1
1
1
1
2
3
3
2
2
Description
L1/L2/L3 Inductor
T2/T3 Control Transformer, 208/220/240/460 V / 60 Hz
T2/T3 Control Transformer, 600 V / 60 Hz
T1 Main Transformer, 208/220/240/460 V / 60 Hz / 3Ø
T1 Main Transformer, 600 V / 60 Hz / 3Ø
Strain Relief
CON 1 Main Contactor
EMI Filter, 380/415 V units only
TB5 3 Phase Input Power Terminal Block
Chopper Assembly
Fan (4.7")
Fan (10")
Fan guard (Mounted Outside)
5
5
38
59 60
44
35
59 60
15
4
31
6
30
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-1
Section 7: Parts List
Spirit II User’s Manual
Power Supply (BK300232 - BK300239)
Left Side View
Item
4
12
16
32
33
34
36
37
39
40
43
44
46
47
50
51
52
53
54
55
56
57
Part Number
BK707150
BK300101
BK300112
BK708118
BK705011
BK702075
BK300108
BK301200
BK709117
BK280003
BK708105
BK200204
BK709252
BK709253
BK284029
BK300130
BK300129
BK300153
BK300156
BK701165
BK701141
BK701083
Quantity
3
1
1
2
1
2
1
1
1
2
2
1
1
2
4
3
3
1
1
2
1
3
53 54 43
Description
L1/L2/L3 Inductor
Printed Circuit Board (PCB), Microprocessor (DSP)
Printed Circuit Board (PCB), A.C. Detect
CR3/PAR Relay
PAT IGBT
PAT IGBT Filter Capacitor
Printed Circuit Board (PCB), I/O
(Optional) Printed Circuit Board (PCB), Voltage Divider
I/O Terminal Block (small)
Power Supply, 24VDC
Relay Hold Down Clip
Fan (4.7")
I/O Terminal Block (large)
Strain Relief
Current Sensor
F9/F10/F11 Fuse, 200A
F9/F10/F11 Fuse Holder
Off Relay
Off Relay Socket
R1/R2 Resistor, 300W, 3 Ohm
R3 Resistor, 300W, 2 Ohm
Resistor Mounting Hardware
12
BEHIND PANEL
16
50
33 34
57 55
57 56
PAR
40
44
57 55
37
40
CR3
32
CS3
32
47
36
52
51
CS2
CS1
F11
F10
F9
CS4
47
39 46
50
4
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-2
Spirit II User’s Manual
Section 7: Parts List
Power Supply (BK300232 - BK300239)
Top View
Item
1
2
3
5
7
8
9
10
11
13
14
38
41
42
43
1
2
Part Number
BK501163
BK501164
BK501162
BK500557
BK706410
BK709359
BK709358
BK709358
BK709360
BK709360
BK709061
BK709128
BK300250
BK708103
BK708104
BK708105
Quantity
1
1
1
2
1
1
1
1
1
4
4
3
1
1
2
Description
Light Housing
Bulb
White Lens
T2/T3 Control Transformer, 208/220/240/460 V / 60 Hz
T2/T3 Control Transformer, 600 V / 60 Hz
F3 Fuse, 5A, Slow Blow
F4 Fuse, 5A, Medium Blow
F5 Fuse, 5A, Medium Blow
F6 Fuse, 6.3A
F7 Fuse, 6.3A
F1A/F1B and F2A/F2B Fuse Holder
F1A/F1B and F2A/F2B Fuse, FNM 6.25A
CA1/CA2/CA3 Chopper Assembly
Fan Relay
Relay Socket
Relay Hold Down Clip
3
38
CA1
38
5
5
T2
T3
CA2
F1A
38
F1B
F2A
F2B
13 14
CA3
43 42 41
7
8
9 10 11
F3
F4
F5
F6
F7
(pos 1) (pos 4) (pos 12) (pos 17) (pos 19)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-3
Section 7: Parts List
Spirit II User’s Manual
Cooling System (BK300275)
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Part Number
BK200092
BK500518
BK300135
BK505024
BK284033
BK500513
BK284032
BK708061
BK715118
BK708068
BK300134
BK284031
BK500514
BK500509
BK500510
BK715052
BK709086
BK709007
BK709262
BK500526
Quantity
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
2
Description
Coolant Reservoir, without Fittings or Cap
Coolant Reservoir Cap/Level Gauge
Coolant Level Switch
Coolant Temperature Switch
Pump Motor, 1/2hp-230V-50/60 Hz
V-Band Clamp
Coolant Pump, 125 gph
Solenoid Valve, 220/240VAC
Check Valve, Coolant Return
CR5 Relay
Coolant Flow Sensor
Fan (10"), Aluminum
Heat Exchanger
Coolant Filter Housing
Coolant Filter / Deionization Cartridge
Drain Petcock
TB3, Terminal Block Marker, 14 Position
TB3, Terminal Block, 14 Position
P1, 16 Pin Receptacle
Fan Guard (10")
19
2
1
3
12
20
13
4
17 18
10
16
12
20
11
14 15
13
9
8
7
6
5
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-4
Spirit II User’s Manual
Section 7: Parts List
Manual Gas Console (BK300615)
Right Side View
Item
1
2
3
4
5
6
8
9
10
Part Number
BK300412
BK300301
BK280030
BK300602
BK300603
BK708111
BK280032
BK500570
BK300605
Quantity
1
1
1
1
1
1
1
2
1
Description
Power Supply, 24VDC, 8.3A
Printed Circuit Board (PCB), Gas Console DSP
Fan, 24VDC
Keypad
LCD Display
Switch, Pushbutton (OFF Button)
Marking Regulator, 0-60 PSI, 145 PSI Max Input
Plasma/Shield Regulator, 0-125 PSI
Manifold Block, Gas Outputs
3
1
6
5
2
4
9
8
10
9
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-5
Section 7: Parts List
Spirit II User’s Manual
Manual Gas Console (BK300615)
Left Side View
Item
1
2
3
6
7
8
9
11
Part Number
BK300412
BK300301
BK280030
BK708111
BK500562
BK280032
BK500570
BK300414
1
Quantity
1
1
1
1
1
1
1
1
Description
Power Supply, 24VDC, 8.3A
Printed Circuit Board (PCB), Gas Console DSP
Fan, 24VDC
Switch, Pushbutton (OFF Button)
Preflow Regulator, 0-60 PSI
Marking Regulator, 0-60 PSI, 145 PSI Max Input
Postflow Regulator, 0-125 PSI
Manifold Block, Gas Inputs
3
6
2
7
8
11
9
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-6
Spirit II User’s Manual
Section 7: Parts List
Impulse Start Console (BK300505)
Item
1
2
3
4
5
6
7
8
9
Part Number
BK715051
BK715050
BK715021
BK709001
BK708057
BK500503
BK980200
BK980201
BK707300
Quantity
2
1
1
1
1
1
1
1
1
Description
Coolant Return Fitting (left hand)
Coolant Supply Fitting (right hand)
Coolant Supply Fitting (right hand)
4 Pin Receptacle
Door Interlock Switch
Cathode Manifold
Printed Circuit Board (PCB), Impulse Start
Impulse Start Manifold
Inductor
1
3
7
6
8
5
2
9
1
4
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-7
Section 7: Parts List
Spirit II User’s Manual
Torch and Manifold Assemblies
Item
1
2
3
Part Number
BK284214
BK277195
BK278001
BK278018
BK279000
BK279100
BK279060
BK820209
BK500024
BK500018
BK279013
BK279112
BK279113
BK284039
BK280022
BK716012
BK277056
BK277086
BK284052
BK277087
BK279061
4
5
6
7
8
9
10
11
12
13
Not shown
Not shown
Not shown
Not shown
Not shown
Quantity
1
1
1
1
1
1
1
1
1
1
6
1
1
1
1
1
1
1
Description
2-Gang Manifold (includes Bracket)
2-Gang Manifold Bracket
Torch Handle – Standard
Torch Handle – Short
Torch Base
Torch Head (Copper Electrode)
Torch Head (Silver Electrode)
O-ring (red)
O-ring (blue)
O-ring (red)
O-ring (red) - indicator only, not a seal
O-ring (red)
O-ring (red)
(17") Torch Solenoid Plasma Hose
5-Gang Manifold for Manual Gas Console
O-ring Lubricant
Nozzle Removal Tool
Electrode Removal Tool Driver
Copper Electrode Removal Tool (400 Amp)
Copper Electrode Removal Tool (All others)
Silver Electrode Removal Tool
12
1
13
2
3
10
4
5
11
9
11
11
6
8
7
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-8
Spirit II User’s Manual
Section 7: Parts List
Shielded Torch Leads
Part Number
BK284304-XX
Length
Where -XX is the length in feet. Available
in 5 foot increments up to 40 feet.
CAN Communication Cable and Termination Plug
Item
CAN Termination Plug
CAN Cable
Part Number
BK300408
BK300177-XX
Length
N/A
Where -XX is the length in feet.
Available in 5 foot increments.
Manifold Control Cables
Item
2-Gang Manifold
5-Gang Manifold
Part Number
BK280312-XX
BK280321-XX
Length
Where -XX is the length in feet.
Available in 5 foot increments.






This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-9
Section 7: Parts List
Spirit II User’s Manual
Gas Hose Package with MGC
Part Number
Length*
BK300085-20
20 ft. (6.1m)
BK300085-30
30 ft. (9.1m)
BK300085-40
40 ft. (12.2m)
BK300085-50
50 ft. (15.2m)
BK300085-60
60 ft. (18.3m)
*Custom lengths are available. Contact factory.
























Cooling System Control Cable
Part Number
BK300276-10
Length
10 ft. (3.0 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.
7-10
Spirit II User’s Manual
Section 7: Parts List
Coolant and Power Leads
Part Number
Part Number
(Non-CSA Systems) (CSA Systems)
BK284306-XX
BK288406-XX
Length
Where -XX is the length in feet.
Available in 5 foot increments.


















Work Ground Lead
Part Number
Part Number
(Non-CSA Systems) (CSA Systems)
BK284318-XX
BK288418-XX

Length
Where -XX is the length in feet.
Available in 5 foot increments.

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-11
Section 7: Parts List
Spirit II User’s Manual
Oxygen Supply Gas Hose (Optional)
Part Number
BK200362-25
BK200362-50
Length
25 ft. (7.6 m)
50 ft. (15.2 m)
BLUE
BLUE
Nitrogen Supply Gas Hose (Optional)
Part Number
BK200365-25
BK200365-50
Length
25 ft. (7.6 m)
50 ft. (15.2 m)
BLACK
BLACK
Air Supply Gas Hose (Optional)
Part Number
BK200364-25
BK200364-50
Length
25 ft. (7.6 m)
50 ft. (15.2 m)
BLACK
BLACK
H17 Supply Gas Hose (Optional)
Part Number
BK200363-25
BK200363-50
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.
7-12
Spirit II User’s Manual
Section 7: Parts List
“CII” Cable (for Optional External Inova)
Part Number
BK300902-XX
Length
Where -XX is the length in feet.
Available in 10 foot increments.
STRAIN RELIEF BK709015
CABLE BK711001
PLUG BK709016
STRAIN RELIEF BK709025
PLUG BK709364
BK709365 PIN
BK709018 SOCKET
BK709365 PIN
BK709018 SOCKET
BK709019 KEY
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-13
Section 7: Parts List
Spirit II User’s Manual
“FII” Cable (for Optional Internal Inova)
Part Number
BK300903-XX
Length
Where -XX is the length in feet.
Available in 10 foot increments.
CABLE BK711002
PLUG BK709364
STRAIN RELIEF BK709025
PLUG BK709095
STRAIN RELIEF BK709021
BK709018 SOCKET
BK709365 PINS
BK709018 SOCKET
BK709365 PINS
BK711005
BK709018 SOCKET
BK709018 SOCKET
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-14
Spirit II User’s Manual
Section 7: Parts List
“JII” Cable (for Optional Internal Inova)
Part Number
BK300904-XX
Length
Where -XX is the length in feet.
Available in 10 foot increments.
STRAIN RELIEF BK709025
STRAIN RELIEF BK709021
PLUG BK709020
CABLE BK711049
PLUG BK709364
BK709365 PIN
BK709018 SOCKET
BK709365 PIN
BK709018 SOCKET
BK709019 KEY
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-15
Section 7: Parts List
Spirit II User’s Manual
PCB Assemblies – Component Reference Locations
Power Supply, Microprocessor DSP (BK300101) – Quadrant 1
1
3
2
4
PCB Quadrant Map
J17
J13
U37 - RHF
J20
U36
U35
J22
U34 – Impulse Start
U32 - Marking
U31 – Postflow
J19
U30 - Vent
U29 - Shield
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-16
Spirit II User’s Manual
Section 7: Parts List
Power Supply, Microprocessor DSP (BK300101) – Quadrant 2
1
3
2
4
PCB Quadrant Map
U28 - Plasma
U27 - Preflow
J12
U19 – Solenoid (not used)
U21 – Mtr / Sol
U22 - PAR
J16
U24 - Surge
U26 - Fan
J15
J14
J1
U23 - Con
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-17
Section 7: Parts List
Spirit II User’s Manual
Power Supply, Microprocessor DSP (BK300101) – Quadrant 3
1
3
2
4
PCB Quadrant Map
J18
J11
J3
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-18
Spirit II User’s Manual
Section 7: Parts List
Power Supply, Microprocessor DSP (BK300101) – Quadrant 4
1
3
2
4
PCB Quadrant Map
J21
J7
J4-1
J3
J4-2
J8
J10
J9
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-19
Section 7: Parts List
Spirit II User’s Manual
Power Supply, Output (BK300108)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-20
Spirit II User’s Manual
Section 7: Parts List
Power Supply, A.C. Detect (BK300112)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-21
Section 7: Parts List
Spirit II User’s Manual
Gas Supply, Microprocessor DSP (BK300301) – Quadrant 1
1
3
2
4
PCB Quadrant Map
J25
J19
J4
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-22
Spirit II User’s Manual
Section 7: Parts List
Gas Supply, Microprocessor DSP (BK300301) – Quadrant 2
1
3
2
4
PCB Quadrant Map
J6
J5
J31
J28
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-23
Section 7: Parts List
Spirit II User’s Manual
Gas Supply, Microprocessor DSP (BK300301) – Quadrant 3
1
3
2
4
PCB Quadrant Map
J19
J20
J21
J17
J13
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-24
Spirit II User’s Manual
Section 7: Parts List
Gas Supply, Microprocessor DSP (BK300301) – Quadrant 4
1
3
2
4
PCB Quadrant Map
J13
J9
J18
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-25
Section 7: Parts List
Spirit II User’s Manual
Chopper, Gate Driver (BK300106)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
7-26
Spirit II User’s Manual
Section 8: Internal Inova Console Option
Section 8: Internal Inova Console Option
Overview
This optional Inova system is designed to provide arc voltage control to any plasma
cutting system, however, combining it with the Spirit II provides the added convenience
of having Inova console built directly into the plasma power supply.
This section only covers topics unique to the Spirit II system with the internally installed
Inova console. See the standard Inova manual for all other Inova information.
Plug Identification
Connections for the internal Inova console option are distinguished from other
connections on the back of the power supply by the addition of the letter "I" before the
plug number. The function of each plug (e.g., IP1) is the same as the corresponding
plug found on the external Inova console (e.g., P1).
POSITIONER
POSITIONER
CONSOLE #2
CONSOLE #2
REMOTE
REMOTE
X/Y MACHINE
RS-422
OUT
RS-422 IN
RS-422
IN
X/Y
MACHINE
RS-422 OUT
Spirit II 150/275
Spirit II 400
Unique Interconnect Cables
Two unique interconnect cables are required for this option with the Spirit II system.
The FII cable is used to connect the Spirit II internal Inova console (IP4) to the X/Y
Machine (CNC controller). The JII cable is used to connect multiple Spirit II internal
Inova consoles (IP8). See the parts list in Section 7 for more details on these cables.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-1
Section 8: Internal Inova Console Option
Spirit II User’s Manual
Grounding
The internal Inova console must be connected to the same protective earth ground as
the plasma power supply and in accordance with national or local codes. The figures
below describe two methods. Use a minimum of #8AWG (10 mm2) wire.
Note: the customer must supply the ground cable.
Direct to star ground:
Ground
Point
Ground
Point
Spirit II 150/275
Spirit II 400
Jumper to the work ground lead:
Ground
Point
Ground
Point
Spirit II 150/275
Spirit II 400
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-2
Spirit II User’s Manual
Section 8: Internal Inova Console Option
Parts List
Item
1
2
3
4
5
6
7
8
Part Number
BK110200
BK110705
BK110900
BK706003
BK709360
BK709370
BK301200
BK709276
Quantity
1
1
1
1
1
1
1
1
Description
Printed Circuit Board (PCB), Microprocessor
Printed Circuit Board (PCB), Power Distribution
Printed Circuit Board (PCB), H-Bridge
Transformer
F7 Fuse, 6.3A
F8 Fuse, 3A
Printed Circuit Board (PCB), Voltage Divider
Power Distribution Block,1 Pole
Location in Spirit II 150 & 275
4
3
2
1
5
6
F7
F8
(pos A) (pos B)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-3
Section 8: Internal Inova Console Option
Spirit II User’s Manual
Location in Spirit II 150 & 275 - Continued
7
8
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-4
Spirit II User’s Manual
Section 8: Internal Inova Console Option
Location in Spirit II 400
4
3
2
1
5
6
F7
F8
(pos A) (pos B)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-5
Section 8: Internal Inova Console Option
Spirit II User’s Manual
Location in Spirit II 400 - Continued
7
8
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
8-6
Spirit II User’s Manual
Appendix A: Electromagnetic Compatibility (EMC)
Appendix A:
Electromagnetic Compatibility (EMC)
Background
The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit plasma cutting systems are
manufactured to comply with the European standard EN 60974-10 (Electromagnetic
compatibility (EMC) – Product standard for arc welding equipment). The system has
been tested in accordance with CISPR 11, EMC classification – Group 2 ISM (Class A).
The limits used in this standard are based on practical experience. However, the ability
of plasma cutting equipment to work in a compatible manner with other radio and
electronic systems is greatly influenced by the manner in which it is installed and used.
For this reason, it is important that the plasma cutting equipment be installed and used
in accordance with the information below if electromagnetic compatibility is to be
achieved.
Plasma cutting equipment is primarily intended for use in an industrial environment.
There may be potential difficulties in ensuring electromagnetic compatibility in other
environments.
Installation and Use
The user is responsible for installing and using the plasma cutting equipment according
to the manufacturer’s instructions. If electromagnetic disturbances are detected then it
shall be the responsibility of the user of the plasma cutting equipment to resolve the
situation with the technical assistance of the manufacturer. In some cases this remedial
action may be as simple as earthing the plasma cutting circuit, see Note. In other cases
it could involve constructing an electromagnetic screen enclosing the plasma power
source and the work, complete with associated input filters.
In all cases,
electromagnetic disturbances shall be reduced to the point where they are no longer
troublesome.
Note: The plasma cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a person who is
competent to assess whether the changes will increase the risk of injury, e.g. by
allowing parallel plasma cutting current return paths which may damage the earth
circuits of other equipment. Further guidance is given in IEC 974-13 Arc welding
equipment – Installation and use.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
A-1
Appendix A: Electromagnetic Compatibility (EMC)
Spirit II User’s Manual
Assessment of Area
Before installing plasma cutting equipment, the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The following shall be
taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below
and adjacent to the plasma cutting equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g. guarding of industrial equipment;
e) the health of the people around, e.g. the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment; the user shall ensure that other
equipment being used in the environment is compatible; this may require additional
protection measures;
h) the time of day that plasma cutting or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the
building and other activities that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Plasma cutting equipment should be connected to the mains supply according to the
manufacturer’s recommendations. If interference occurs, it may be necessary to take
additional precautions such as filtering of the mains supply. Consideration should be
given to shielding the supply cable of permanently installed plasma cutting equipment in
metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the plasma power source so that good
electrical contact is maintained between the conduit and the plasma power source
enclosure.
Maintenance of the Plasma Cutting Equipment
The plasma cutting equipment should be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and covers should be
closed and properly fastened when the plasma cutting equipment is in operation. The
plasma cutting equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturer’s instructions. In particular, the spark
gaps of arc striking and stabilizing devices should be adjusted and maintained
according to the manufacturer’s recommendations.
Plasma Cutting Cables
The plasma cutting cables should be kept as short as possible and should be positioned
close together, running at or close to the floor level.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
A-2
Spirit II User’s Manual
Appendix A: Electromagnetic Compatibility (EMC)
Equipotential Bonding
Bonding of all metallic components in the plasma cutting installation and adjacent to it
should be considered. However, metallic components bonded to the workpiece will
increase the risk that the operator could receive a shock by touching these metallic
components and the electrode at the same time. The operator should be insulated from
all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth
because of its size and position, e.g. ship’s hull or building steelwork, a connection
bonding the workpiece to earth may reduce emissions in some, but not all instances.
Care should be taken to prevent the earthing of the workpiece increasing the risk of
injury to users, or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct connection to the
workpiece, but in some countries where direct connection is not permitted, the bonding
should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding
area may alleviate problems of interference. Screening of the entire welding installation
may be considered for special applications.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
A-3
Appendix A: Electromagnetic Compatibility (EMC)
Spirit II User’s Manual
BLANK
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
A-4
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