User`s Manual

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

General Troubleshooting

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

Problem

Power supply indicator

(white light) will not illuminate

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

MGC.

Power supply will not stay on after choosing ON and then

SELECT on the MGC.

Possible Cause

1. Primary disconnect fuse blown.

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

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

4. Control Transformer or associated wiring bad.

1. ISC door open.

2. Low coolant level.

3. Fuse is blown (F1-F6).

4. Faulty OFF Button or associated wiring.

5. Off Relay faulty.

1. Faulty DSP board.

2. Off Relay faulty.

No arc at the torch

The arc will not transfer to the workpiece

1. Incorrect torch consumables installed.

2. Incorrect gas pressure settings.

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

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

4. Damaged or loose torch lead connections.

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

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

1. Loose work ground connection.

2. Pierce height too high.

3. Incorrect, damaged, or worn consumables.

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

6-9

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

Problem

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

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

Gas pressures will not adjust properly

Low pressure error

Pressure error during cut

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

Possible Cause

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

2. Check for blown DIN rail fuse.

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

CAN cable at back of the manual gas console.

1. Cycle primary power to the Spirit system.

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

1. Wrong consumables installed in torch.

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

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

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

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

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

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

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

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

6-10