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Spirit II User’s Manual Section 3: Installation
Torch Leads to Impulse Start Console Connections
Perform the following steps to connect the torch leads to the impulse start console.
See Figure 6 on the next page.
Note: When making hose connections, only tighten the brass fittings enough to make water or gas seals. The fittings are subject to damage if over tightened.
Braided Shield 11
1. Remove the threaded ring from the brass shield connector on the end of the braided shield. Route the torch leads through the opening in the impulse start console and push the shield connector through the hole until it is seated against the side of the console.
2. Slide the threaded ring over the torch leads, thread it onto the brass shield connector, and tighten firmly. The shield connector should ground the braided shield to the case of the impulse start console in order to help reduce high frequency noise emission. Using an ohmmeter, measure for zero ohms between the braided shield and the ground stud located on the outside of the impulse start console.
Torch Electrode/Coolant Supply Lead
12
• Connect the torch electrode/coolant supply lead to the brass cathode manifold. Note that the torch electrode/coolant supply lead has right hand threads.
Torch Coolant Return Lead
13
• Connect the torch coolant return lead to the brass cathode manifold. Note that the torch coolant return lead has left hand threads.
Torch Nozzle Lead
14
• Connect the torch nozzle lead to the angled bracket on the red standoff. Note that the torch nozzle lead has right hand threads.
Torch CTP Sensor Lead
15
• Connect the #18AWG torch CTP sensor lead to the red standoff as shown.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
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Section 3: Installation
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13
Spirit II User’s Manual
Figure 6: Torch Leads to Impulse Start Console Connections
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
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Table of contents
- 2 Revision History
- 3 Table of Contents
- 6 Limited Warranty
- 6 Returned Goods Procedure
- 6 Electromagnetic Compatibility (EMC)
- 7 General Precautions
- 11 Safety Standards Booklet Index
- 7 Ultraviolet Radiation Protection
- 7 Noise Protection
- 8 Toxic Fume Prevention
- 8 Electric Shock Prevention
- 9 Fire Prevention
- 9 Explosion Prevention
- 10 Health Support Equipment
- 13 System Description
- 14 System Components
- 15 Power Supply Specifications
- 16 Torch Coolant Specifications
- 17 Manual Gas Console (MGC) Specifications
- 18 Gas Supply Requirements
- 19 Impulse Start Console (ISC) Specifications
- 20 Torch and 2-Gang Manifold Specifications
- 21 5-Gang Manifold Specifications
- 22 Airborne Noise Emissions
- 23 Initial Inspection
- 23 Component Placement
- 24 System Interconnection
- 27 Power Supply Primary Power Connections
- 29 Power Supply Output Connections
- 31 ISC Control Cable and ISC Ground Connections
- 31 Cooling System Connections
- 33 Torch Leads to Impulse Start Console Connections
- 35 Torch Leads to Torch Base Connections
- 36 Torch Gas Connections
- 39 Gas Supply Connections
- 40 CAN Communication Connections
- 41 CNC Machine Interface Connections
- 42 Filling the Cooling System
- 43 Operating the Manual Gas Console (MGC)
- 44 Setting up to Cut
- 45 Setting up to Mark (Overrides Cut)
- 45 Verifying Input Gas Pressures
- 46 Making a Cut or Mark
- 47 Piercing Thick Materials
- 47 Moving Pierces and Edge Starts
- 48 Cut Quality
- 49 Checking Errors
- 49 Checking the Version and Serial Number
- 50 Changing the Language
- 50 Adjusting the Screen Contrast
- 51 Installing / Removing the Torch Head
- 52 Installing / Replacing Consumables
- 53 Maximizing Consumable Life
- 54 Inspecting for Damage
- 55 Selecting Consumables
- 55 Mild Steel Copper Electrode
- 56 Mild Steel Silver Electrode
- 57 Stainless Steel - H17 Plasma Copper Electrode
- 58 Stainless Steel - Air or Nitrogen Plasma Copper Electrode
- 59 Stainless Steel - Air or Nitrogen Plasma Silver Electrode
- 60 Aluminum Copper Electrode
- 61 Aluminum Silver Electrode
- 62 Cutting Charts
- 63 Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield Copper Electrode
- 64 Mild Steel - 50 amps - Oxygen Plasma / Oxygen or Air Shield Copper Electrode
- 65 Mild Steel - 70 Amps - Oxygen Plasma / Air Shield Copper Electrode
- 66 Mild Steel - 100 Amps - Oxygen Plasma / Air Shield Copper Electrode
- 67 Mild Steel - 150 Amps - Oxygen Plasma / Air Shield Copper Electrode
- 68 Stainless Steel - 30 Amps - Air Plasma / Air Shield Copper Electrode
- 69 Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode
- 70 Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield Copper Electrode
- 71 Stainless Steel - 70 Amps - Air Plasma / Nitrogen Shield Copper Electrode
- 72 Stainless Steel - 100 Amps - H17 Plasma / Nitrogen Shield Copper Electrode
- 73 Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield Copper Electrode
- 74 Stainless Steel - 150 Amps - H17 Plasma / Nitrogen Shield Copper Electrode
- 75 Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield Copper Electrode
- 76 Aluminum - 30 Amps - Air Plasma / Nitrogen Shield Copper Electrode
- 77 Aluminum - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode
- 78 Aluminum - 70 Amps - Air Plasma / Nitrogen Shield Copper Electrode
- 79 Aluminum - 100 Amps - Air Plasma / Nitrogen Shield Copper Electrode
- 80 Aluminum - 150 Amps - Air Plasma / Nitrogen Shield Copper Electrode
- 81 Mild Steel - 100 Amps - Oxygen Plasma / Air Shield Silver Electrode
- 82 Mild Steel - 150 Amps - Oxygen Plasma / Air Shield Silver Electrode
- 83 Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield Silver Electrode
- 84 Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield Silver Electrode
- 85 Aluminum - 100 Amps - Air Plasma / Nitrogen Shield Silver Electrode
- 86 Aluminum - 150 Amps - Air Plasma / Nitrogen Shield Silver Electrode
- 87 Routine Maintenance
- 87 Power Supply
- 88 Manual Gas Console (MGC)
- 88 Torch, Torch Leads, and Gas Hoses
- 89 Impulse Start Console (ISC)
- 89 Work Ground
- 90 Replacing the Torch Coolant and Filter
- 91 Microprocessor (DSP) Status Indicators
- 92 Microprocessor (DSP) Sequence of Operation
- 93 Error Codes
- 95 General Troubleshooting
- 97 Chopper Test Procedure
- 101 Power Supply (BK300211 - BK300219)
- 105 Manual Gas Console (BK300600)
- 107 Impulse Start Console (BK300500)
- 108 Torch and Manifold Assemblies
- 109 Shielded Torch Leads
- 109 CAN Communication Cable and Termination Plug
- 109 Manifold Control Cables
- 110 Gas Hose Package with MGC
- 111 Coolant and Power Leads
- 111 Work Ground Lead
- 112 Oxygen Supply Gas Hose (Optional)
- 112 Nitrogen Supply Gas Hose (Optional)
- 112 Air Supply Gas Hose (Optional)
- 112 H17 Supply Gas Hose (Optional)
- 113 “CII” Cable (for Optional External Inova)
- 114 “FII” Cable (for Optional Internal Inova)
- 115 “JII” Cable (for Optional Internal Inova)
- 116 PCB Assemblies – Component Reference Locations
- 116 Power Supply, Microprocessor DSP (BK300101) – Quadrant 1
- 117 Power Supply, Microprocessor DSP (BK300101) – Quadrant 2
- 118 Power Supply, Microprocessor DSP (BK300101) – Quadrant 3
- 119 Power Supply, Microprocessor DSP (BK300101) – Quadrant 4
- 120 Power Supply, Output (BK300108)
- 121 Power Supply, A.C. Detect (BK300112)
- 122 Gas Supply, Microprocessor DSP (BK300301) – Quadrant 1
- 123 Gas Supply, Microprocessor DSP (BK300301) – Quadrant 2
- 124 Gas Supply, Microprocessor DSP (BK300301) – Quadrant 3
- 125 Gas Supply, Microprocessor DSP (BK300301) – Quadrant 4
- 126 Chopper, Gate Driver (BK300106)
- 127 Overview
- 127 Plug Identification
- 127 Unique Interconnect Cables
- 128 Grounding
- 129 Parts List
- 129 Location in Spirit II 150 & 275
- 131 Location in Spirit II 400
- 133 Background
- 133 Installation and Use
- 134 Assessment of Area
- 134 Methods of Reducing Emissions
- 134 Mains Supply
- 134 Maintenance of the Plasma Cutting Equipment
- 134 Plasma Cutting Cables
- 135 Equipotential Bonding
- 135 Earthing of the Workpiece
- 135 Screening and Shielding