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Spirit II User’s Manual Section 3: Installation
Torch Leads to Torch Base Connections
Perform the following steps to connect the torch leads to the torch base.
Note: When making hose connections, only tighten the brass fittings enough to make water or gas seals. The fittings are subject to damage if over tightened. Also, use two wrenches when tightening the torch fittings to avoid damaging the torch base.
Torch Lead through Torch Handle Installation
• Route the torch leads through the torch handle. Note that the threaded end of the torch handle mates with the torch base.
Torch Electrode/Coolant Supply Lead
16
• Connect the torch electrode/coolant supply lead to the torch base as shown.
Torch Coolant Return Lead
17
• Connect the torch coolant return lead to the torch base as shown. Note that the torch coolant return lead fitting has left hand threads.
Torch Nozzle Lead
18
• Connect the torch nozzle lead to the torch base as shown.
Torch CTP Sensor Lead
19
• Connect the torch CTP sensor lead to the torch base as shown.
18 19
18
19
17 16 17 16
Figure 7: Torch Leads to Torch Base Connections
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
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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