RETURN TO MAIN MENU User's Manual Spirit II 275 High Current Density Plasma Cutting System with Automatic Gas Console (AGC) 718115 Rev D This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 08/06/20013 D LAD0228 LAD0223 CAD 08/28/2013 Description of Change Initial Release. Added 100A/150A silver electrodes, replaced RHF with ISC, added argon marking, corrected system interconnect diagrams, changed rated inlet gas pressure to 115 psi, added 100 psi minimum to inlet gas pressure.
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 ...........................................................................
Prologue Spirit II User’s Manual Section 4: Operation Operating the Plasma Console ......................................................................... 4-1 Setting up to Cut or Mark .................................................................................. 4-3 Verifying Important Parameters......................................................................... 4-4 Viewing the Required Torch Parts .....................................................................
Spirit II User’s Manual Prologue Section 7: Parts List Power Supply (300221 - 300229)...................................................................... 7-1 Automatic Gas Console (300400) ..................................................................... 7-5 Plasma Console (300800) ................................................................................. 7-8 Impulse Start Console (300500)........................................................................
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.
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.
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.
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.
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.
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.
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.
Spirit II User’s Manual Section 2: Specifications Section 2: Specifications System Description The Spirit II 275 is a 275 amp microprocessor controlled, 100% duty cycle high current density plasma cutting and marking system. It utilizes a precision, dual gas torch that is capable of cutting mild steel up to 2" thick and stainless steel up to 1-1/2” thick. The system contains a computer controlled automatic gas console with a touch screen interface (plasma console).
Section 2: Specifications Spirit II User’s Manual System Components The Spirit II 275 System consists of the following components: Standard Components • Power Supply • Automatic Gas Console • Plasma Console (Touch Screen) • CAN Cables • 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 Hos
Spirit II User’s Manual Section 2: Specifications Power Supply Specifications Power Supply Description 208 VAC, 3Ø, 60Hz 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 300221 300222 300223 300224 300225 300226 300227 300228 300229 Input Current at Maximum Output 163 amps 153 amps 140 amps 88 amps 84 amps 81 amps 76 amps 70 amps 56 amps Open Circuit Voltage ...........................
Section 2: Specifications Spirit II User’s Manual 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.
Spirit II User’s Manual Section 2: Specifications Automatic Gas Console (AGC) Specifications Part Number ..................................................... 300400 Weight .............................................................. 53 lb (24 kg) 12.4" [315] 13.7" [348] 12.0" [305] (4) Ø .300 [7.6] 10.9" [277] 7.0" [178] This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
Section 2: Specifications Spirit II User’s Manual Gas Supply Requirements Plasma gas types: Mild Steel ..................................................... Oxygen Stainless Steel ............................................ Air or H17 Aluminum .................................................... Air Shield gas types: Mild Steel ..................................................... Oxygen or Air Stainless Steel ............................................. Air or Nitrogen Aluminum ........................
Spirit II User’s Manual Section 2: Specifications Plasma Console Specifications Part Number ..................................................... 300800 Weight .............................................................. 10 lb (4.5 kg) 9.2" [234] 13.4" [340] 3.6" [91] (4) Ø.180 [5] 3.2" [81] 10.1" [257] This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
Section 2: Specifications Spirit II User’s Manual Impulse Start Console (ISC) Specifications Part Number .................................................... 300500 Weight............................................................... 22 lb (10 kg) 8.00" [203] (4) Ø.312 [8] 12.75" [324] 12.00" [305] 13.50" [343] 10.00" [254] 5.
Spirit II User’s Manual Section 2: Specifications Torch and 2-Gang Manifold Specifications Part Number: 2-Gang Manifold Assembly .................................................. 284214 Torch Handle (standard) ...................................................... 278001 Torch Handle (short) ............................................................ 278018 Torch Base........................................................................... 279000 Torch Head (Copper Electrode) .........................
Section 2: Specifications Spirit II User’s Manual 5-Gang Manifold Specifications Part Number .................................................... 300075 Weight .............................................................. 6 lb (2.7 kg) 6.18" [157] 0.327" [8.3] (4) 0.187" [4.8] Mounting Holes 4.20" [107] 0.25" [6.4] 1.18" [30] 3.80" [97] 3.035" [77] 8.
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 275 amps, 145 arc volts.
Section 2: Specifications 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.
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.
Section 3: Installation Spirit II User’s Manual 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.
Spirit II User’s Manual Section 3: Installation Figure 1: Spirit II System with Automatic 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.
Section 3: Installation Spirit II User’s Manual Figure 2: Spirit II System with Automatic 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.
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.
Section 3: Installation Spirit II User’s Manual TB5 L1 (U) L2 (V) L3 (W) Ground Strain Relief L1 L2 L3 Gnd Disconnect Box Connections TB5 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.
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 #1/0AWG power supply electrode lead through the upper strain relief on the rear of the power supply and connect it to the electrode terminal. 2.
Section 3: Installation Spirit II User’s Manual 3 2 Strain Relief 4 1 1 2 3 Strain Relief Figure 4: Power Supply Output 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.
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.
Section 3: Installation Spirit II User’s Manual 6 7 8 5 8 7 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.
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.
Section 3: Installation Spirit II User’s Manual 11 14 12 15 13 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.
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 1. Route the torch leads through the torch handle.
Section 3: Installation Spirit II User’s Manual Torch Gas Connections Perform the following steps to connect the torch gas hoses to the automatic 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.
Spirit II User’s Manual Section 3: Installation Marking Plasma Gas Hose 24 1. Connect one end of the marking plasma gas hose to the marking plasma outlet on the rear of the AGC. 2. Connect the other end of the marking plasma hose to the marking plasma inlet on the 5-gang manifold. Postflow Gas Hose 25 1. Connect one end of the postflow hose to the postflow outlet on the rear of the AGC. Note that the postflow hose fittings have left hand threads. 2.
Section 3: Installation Spirit II User’s Manual Automatic Gas Console 25 28 27 26 BLACK 24 23 RED GREEN 26 30 22 BLACK BLUE GREEN RED 21 REAR PORT 22 20 27 BLUE 23 24 28 29 25 REAR PORT BLACK 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.
Spirit II User’s Manual Section 3: Installation Gas Supply Connections Perform the following steps to connect the gas supply lines to the AGC. 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.
Section 3: Installation Spirit II User’s Manual Plasma Console Connections Perform the following steps to connect the plasma console to the Spirit system. CAN Communications 36 • Insert the male end of the CAN communication cable. See "CAN Communication Connections" for more details. CAN Communications 37 • Insert the female end of the CAN communication cable or the CAN termination plug, depending upon the connection scheme. See "CAN Communication Connections" for more details.
Spirit II User’s Manual Section 3: Installation CAN Communication Connections Choose one of the schemes below to connect the Spirit system for CAN communications. Both schemes require two CAN cables and a CAN termination plug. This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
Section 3: Installation Spirit II User’s Manual 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.
Spirit II User’s Manual Section 3: Installation Filling the Cooling System WARNING: Do not touch the fans inside the power supply. 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.
Section 3: Installation 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.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Section 4: Operation Operating the Plasma Console The Plasma Console is the touch screen interface to the entire Spirit system when the Automatic Gas Console (AGC) is used instead of the Manual Gas Console (MGC). OFF Button Push to disable the Spirit system. Release (turn to the right) to enable the system, which can then be energized using the ON Button.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Important Messages and Icons Messages and icons at the top of the screen provide additional important information.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Setting up to Cut or Mark Press the Material navigation button to setup a cut or mark. Material type, material thickness, and process (cut or mark) are the only parameters that must be selected. All other parameters are adjusted automatically; however, these parameters can be customized. See Customizing Cutting or Marking Settings for more information.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Verifying Important Parameters Prior to making a cut or mark with the system, the torch height control and the X/Y controller must be configured properly. To view the recommended cutting data, press the Parameters navigation button. See RS422 Parameter Control for more information on how to adjust these settings.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Checking System Status To view the system status indicators, press the Status navigation button. Each indicator will be either Green or Red. DC Power Indicator Green when the main contactor has been energized and D.C. current is flowing through the torch. Red when no D.C. current is flowing. ISC Door 3 Phase Power Indicator Green when 3 phase power is satisfactory. Red when there is a problem with main 3 phase power.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Purging Pressure Regulators Press the Purge navigation button to access the screen described below. The background color of the actual pressure reading will change; • Green for pressures at the set point • Yellow for pressures not at the setpoint Press the Adjust button to automatically adjust the gas pressures.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Making a Cut or Mark Once the material type, material thickness, and process have been selected; 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. 1. Release the OFF Button (turn to the right) and then press the ON Button on the Plasma Console. 2.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual 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.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console 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.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Customizing Cutting or Marking Settings Changes to any of these factory default settings will cause the Setup message at the top of the screen to change from Setup: Optimum to Setup: Custom - Not Saved. See the next section to save custom settings. Altering the Current Set Point To alter the current set point from the default setting, press the Current (Amps) button on the Material Screen and choose from the list of available values.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Altering Important Parameters With the RS422 Parameter Control set to Manual, certain values on the Parameters Screen can be changed manually. Press the corresponding data entry button and enter the desired value. Once a value has been changed, press the Manual Transmit button to send the value to the X/Y machine or torch height control.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Restoring or Deleting Customized Settings If a new setup configuration was saved for later use, it can be restored at any time or deleted permanently from the list. Press the Manage Custom Setups button on the Parameters Screen. Press the left (Prev) or right (Next) arrow button to scroll through the list of existing custom setups. The name of the selected setup will appear under Setup Name.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Configuration Tab Press the Config navigation button followed by the Configuration tab to access the screen described below. RS422 Parameter Control Controls how the Spirit communicates with the X/Y controller and height control system. If an Inova arc voltage control system is not being used with the Spirit system, RS422 Parameter Control must be disabled.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Advanced Config Tab Press the Config navigation button followed by the Advanced Config tab to access the screen described below. Set RS422 Node When multiple Spirit systems are being used together on an RS-422 serial communication link, each system must have a unique identification number (node number) to identify itself to the network. To set the communication node number, simply choose from node 1 through 8.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Network Settings Tab Press the Config navigation button followed by the Network Settings tab to access the screen described below. To enable networking, press the red exclamation graphic next to Network Disabled. The graphic will change to a green check mark. Enter the appropriate IP Address, Subnet Mask, and Gateway. If DHCP is necessary, press the red exclamation graphic next to DHCP Disabled.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Software Updates Tab Press the Config navigation button followed by the Software Updates tab to update the Spirit system software. See the next page for details on updating the software. This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Updating the Software 1. Copy the file Installer.exe onto a USB thumbdrive. This file will be emailed or an ftp address will be provided for download. 2. Turn the Plasma Console off. 3. Insert the USB thumbdrive into either port on the back of the Plasma Console. 4. Turn the Plasma Console on. 5. Allow the system to boot to the normal main screen and select “Config” from the Navigation Menu. 6. Select the “Software Updates” tab. 7.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual System Info Tab Press the Config navigation button followed by the System Info tab to access the screen described below. This screen displays the hardware, software and serial number for each of the components in the Spirit system. Tools Tab (Restart Plasma Console) Press the Config navigation button followed by the Tools tab to access the screen described below.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Pressures/Coolant Tab Press the Diagnostics navigation button followed by the Pressures/Coolant tab to access the screen described below. Pressing any of the Output Pressure buttons will cause the corresponding valve to open or close. Note that the preflow valve and the plasma valve cannot be on at the same time. During a cutting or marking sequence, the status of all valves will display N/A.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual RS422 Tab Press the Diagnostics navigation button followed by the RS422 tab to access the screen described below. Note that incoming data is appended to show an “R” before the data and outgoing transmissions are appended to show a “T” before the data. Electrical Tab Press the Diagnostics navigation button followed by the Electrical tab to access the screen described below.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Cut Info Tab Press the Diagnostics navigation button followed by the Cut Info tab to access the screen described below. Press the Save to History button to add the Present Cut Errors to the History list for future reference. This should be done each time consumables are changed. Press any of the History buttons (1 through 5) to display the saved details.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual When any of the following errors occur, measures should be taken to avoid further errors. The following is a description of the errors and possible causes: • Transferred arc not established This error occurs when the arc fails to transfer to the workpiece. It primarily causes nozzle damage and is typically due to a pierce height that is too high.
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Power Supply Tab Press the Diagnostics navigation button followed by the Power Supply tab to access the screen described below. Error Log Tab Press the Diagnostics navigation button followed by the Error Log tab to access the screen described below. Filters along the right side of the screen can be used to limit the data displayed based upon Error #, Date, or Severity. Press the Clear button to remove all filters.
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Messages Tab Press the Diagnostics navigation button followed by the Messages tab to access the screen described below. This screen displays all power supply and gas console messages, sequencing, and errors. The message screen should be the initial starting point when troubleshooting the system. This information is subject to the controls of the Export Administration Regulations [EAR].
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.
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.
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.
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.
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Selecting Consumables Mild Steel Copper Electrode Outer Retaining Cap 284150 Shield Cap 277145 Inner Retaining Cap 277153 277120 Swirl Ring 277140 Copper Electrode 277130 Torch Head 279100 284150 277115 277153 277122 277140/ 277142 277131 279100 284150 277150 277153 277125 277142 277131 279100 284150 277286 277151 277284 277283 277282 279100 284150 277117 277151/ 277152 277293 277139 277292 279100 2
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode 279410 284150 277286 277151 279484 279483 284150 277117 277151/ 277152 279493 279439 (green o-ring) 284150 277274 277266 279489 279443 (yellow o-ring) 284150 277263 277266 279469 279458 (brown o-ring) Torch Head 279060 100A 279420 279060 150A 279440 279060 200A 279450 (red o-ring) 279060
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - H17 Plasma Copper Electrode Outer Retaining Cap 284150 Shield Cap 277150 Inner Retaining Cap 277113 277124 Swirl Ring 277140 Copper Electrode 277132 Torch Head 279100 284150 277146 277113 277126 277141 277133 279100 284150 277298 277266 277297 277139 277135 279100 284150 277274 277266 277287 277259 277135 279100 284150 277211 277280 277118 277139 277135 279100 Nozzle 70A 100A 15
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - Air or Nitrogen Plasma Copper Electrode Outer Retaining Cap 284150 Shield Cap 277144 Inner Retaining Cap 277110 277121 Swirl Ring 277138 Copper Electrode 277137 Torch Head 279100 284150 277149 277110 277123 277142 277137 279100 284150 277150 277153 277125 277142 277131 279100 284150 277286 277151 277284 277283 277282 279100 284150 277117 277152 277293 277139 277292 279100 284150 2
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 Nozzle Swirl Ring Silver Electrode 279410 284150 277286 277151 279484 279483 284150 277117 277152 279493 279439 (green o-ring) 284150 277274 277266 279489 279443 (yellow o-ring) (brown o-ring) Torch Head 279060 100A 279420 279060 150A 279440 279060 200A This information is subject to the controls
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum Copper Electrode Outer Retaining Cap 284150 Shield Cap 277145 Inner Retaining Cap 277153 277120 Swirl Ring 277140 Copper Electrode 277130 Torch Head 279100 284150 277150 277153 277122 277142 277131 279100 284150 277150 277153 277125 277142 277131 279100 284150 277286 277151 277284 277283 277282 279100 284150 277117 277152 277293 277139 277292 279100 284150 277274 277266 277289 277143 2
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode 279410 284150 277286 277151 279484 279483 284150 277117 277152 279493 279439 (green o-ring) 284150 277274 277266 279489 279443 (yellow o-ring) 284150 277263 277266 279469 279458 (red o-ring) (brown o-ring) Torch Head 279060 100A 279420 279060 150A 279440 279060 200A 279450 279060 275A T
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.
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield Copper Electrode Shield Cap 277145 Outer Cap 284150 Nozzle 277120 Retaining Cap 277153 Swirl Ring 277140 Imperial* Material Thickness Electrode 277130 Torch Head 279100 Preflow Plasma Shield Postflow Arc Voltage Travel Speed (psi) (psi) (psi) (psi) Cutting Height Pierce Height Pierce Time Kerf Width (in) (msec) (in) 100 .
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 277115 Outer Cap 284150 Nozzle 277122 Retaining Cap 277153 Swirl Ring 277140 / 277142 Imperial* Material Thickness (ga) (in) 12 .105 11 .120 10 .135 14 .075 12 .
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 70 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap 277150 Outer Cap 284150 Nozzle 277125 Electrode 277131 Retaining Cap 277153 Swirl Ring 277142 Imperial* Torch Head 279100 Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width (in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in) 1/8 35 3/16
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 100 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap 277286 Outer Cap 284150 Nozzle 277284 Electrode 277282 Retaining Cap 277151 Swirl Ring 277283 Imperial* Torch Head 279100 Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width (in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in) 1/4 125 3/8
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 150 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap 277117 Outer Cap 284150 Nozzle 277293 Electrode 277292 Retaining Cap 277151 / 277152 Swirl Ring 277139 Imperial* Torch Head 279100 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) Retai
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 200 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap 277274 Outer Cap 284150 Nozzle 277289 Electrode 277291 Retaining Cap 277266 Swirl Ring 277143 Imperial* Torch Head 279100 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
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 275 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap 277263 Outer Cap 284150 Nozzle 277269 Electrode 277270 Retaining Cap 277266 Swirl Ring 277258 Imperial* Torch Head 279100 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
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 30 Amps - Air Plasma / Air Shield Copper Electrode Shield Cap 277144 Outer Cap 284150 Nozzle 277121 Retaining Cap 277110 Swirl Ring 277138 Imperial* Material Thickness (ga) (in) 20 .036 18 .048 16 .060 14 .
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap 277149 Outer Cap 284150 Nozzle 277123 Retaining Cap 277110 Swirl Ring 277142 Imperial* Material Thickness Electrode 277137 Torch Head 279100 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 .
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 70 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap 277150 Outer Cap 284150 Nozzle 277125 Retaining Cap 277153 Swirl Ring 277142 Imperial* Material Thickness (ga) (in) 10 .
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 100 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap 277286 Outer Cap 284150 Nozzle 277284 Electrode 277282 Retaining Cap 277151 Swirl Ring 277283 Imperial* Torch Head 279100 Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed (in) (psi) (psi) (psi) (psi) (volts) (ipm) 141 100 147 80
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 150 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap 277117 Outer Cap 284150 Nozzle 277293 Electrode 277292 Retaining Cap 277152 Swirl Ring 277139 Imperial* Torch Head 279100 Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed (in) (psi) (psi) (psi) (psi) Cutting Height Pierce Height Pie
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 200 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 200 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap 277274 Outer Cap 284150 Nozzle 277289 Electrode 277291 Retaining Cap 277266 Swirl Ring 277143 Imperial* Torch Head 279100 Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height (in) (psi) (psi) (psi) (psi) (in) (volts) (ip
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 260 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 275 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap 277263 Outer Cap 284150 Nozzle 277276 Electrode 277270 Retaining Cap 277266 Swirl Ring 277258 Imperial* Torch Head 279100 Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed (in) (psi) (psi) (psi) (psi) Cutting Height Pierce Height Pie
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 30 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap 277145 Outer Cap 284150 Nozzle 277120 Electrode 277130 Retaining Cap 277153 Swirl Ring 277140 Imperial* Torch Head 279100 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 .
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap 277150 Outer Cap 284150 Nozzle 277122 Electrode 277131 Retaining Cap 277153 Swirl Ring 277142 Imperial* Torch Head 279100 Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed (in) (psi) (psi) (psi) (psi) (volts) 135 .050 25 .063 66 19 67 .
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 70 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap 277150 Outer Cap 284150 Nozzle 277125 Electrode 277131 Retaining Cap 277153 Swirl Ring 277142 Imperial* Torch Head 279100 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) .
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 100 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap 277286 Outer Cap 284150 Nozzle 277284 Electrode 277282 Retaining Cap 277151 Swirl Ring 277283 Imperial* Torch Head 279100 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 25 3/8 80 26 80 1/2 Metric* Cutting Height Pierce Height
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 150 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap 277117 Outer Cap 284150 Nozzle 277293 Electrode 277292 Retaining Cap 277152 Swirl Ring 277139 Imperial* Torch Head 279100 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
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 200 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap 277274 Outer Cap 284150 Nozzle 277289 Electrode 277291 Retaining Cap 277266 Swirl Ring 277143 Imperial* Torch Head 279100 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.
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 275 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap 277263 Outer Cap 284150 Nozzle 277276 Electrode 277270 Retaining Cap 277266 Swirl Ring 277258 Imperial* Torch Head 279100 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
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 100 Amps - Oxygen Plasma / Air Shield Silver Electrode Shield Cap 277286 Outer Cap 284150 Nozzle 279484 Electrode 279410 (brown o-ring) Retaining Cap 277151 Swirl Ring 279483 Imperial* Torch Head 279060 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 25 1/2 83 26 130 81 5/8 143 47 3/4 145 35 M
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 150 Amps - Oxygen Plasma / Air Shield Silver Electrode Shield Cap 277117 Outer Cap 284150 Nozzle 279493 Electrode 279420 (green o-ring) Retaining Cap 277151 / 277152 Swirl Ring 279439 Imperial* Torch Head 279060 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) (ms
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 200 Amps - Oxygen Plasma / Air Shield Silver Electrode Shield Cap 277274 Outer Cap 284150 Nozzle 279489 Electrode 279440 (yellow o-ring) Retaining Cap 277266 Swirl Ring 279443 Imperial* Torch Head 279060 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
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 275 Amps - Oxygen Plasma / Air Shield Silver Electrode Shield Cap 277263 Outer Cap 284150 Nozzle 279469 Electrode 279450 (red o-ring) Retaining Cap 277266 Swirl Ring 279458 Imperial* Torch Head 279060 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
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap 277286 Outer Cap 284150 Nozzle 279484 Electrode 279410 (brown o-ring) Retaining Cap 277151 Swirl Ring 279483 Imperial* Torch Head 279060 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
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap 277117 Outer Cap 284150 Nozzle 279493 Electrode 279420 (green o-ring) Retaining Cap 277152 Swirl Ring 279439 Imperial* Torch Head 279060 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
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 200 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap 277274 Outer Cap 284150 Nozzle 279489 Electrode 279440 (yellow o-ring) Retaining Cap 277266 Swirl Ring 279443 Imperial* Torch Head 279060 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) (mse
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 100 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap 277286 Outer Cap 284150 Nozzle 279484 Electrode 279410 (brown o-ring) Retaining Cap 277151 Swirl Ring 279483 Imperial* Torch Head 279060 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)
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 150 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap 277117 Outer Cap 284150 Nozzle 279493 Electrode 279420 (green o-ring) Retaining Cap 277152 Swirl Ring 279439 Imperial* Torch Head 279060 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)
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 200 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap 277274 Outer Cap 284150 Nozzle 279489 Electrode 279440 (yellow o-ring) Retaining Cap 277266 Swirl Ring 279443 Imperial* Torch Head 279060 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
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 275 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap 277263 Outer Cap 284150 Nozzle 279469 Electrode 279450 (red o-ring) Retaining Cap 277266 Swirl Ring 279458 Imperial* Torch Head 279060 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
Section 5: Torch Consumables and Cutting Charts 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.
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).
Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Automatic Gas Console (AGC) 1. Remove the cover of the automatic 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.
Spirit II User’s Manual Section 6: Maintenance &Troubleshooting 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 277007. If replacement is required, use tool P/N 200109. If using the silver electrode, the torch head uses cooling tube holder assembly P/N 279216. Remove this using the tool (socket P/N 277087 & driver P/N 277086) and inspect the o-rings for damage.
Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Replacing the Torch Coolant and Filter WARNING: Do not touch the fans inside the power supply. 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.
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.
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.
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.
Section 6: Maintenance &Troubleshooting 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 Spirit II User’s Manual Gas Console Long Description Could not adjust Plasma Gas Could not adjust Shield Gas Could not adju
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.
Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Problem Primary power has been applied to the system, but the plasma console screen is blank Possible Cause 1. Check power/communications CAN cable connection on back of plasma console. 2. Check for blown DIN rail fuse. 3. Check for 120v on pins of power/communications CAN cable at back of plasma console. The plasma console screen is on, but the touch screen doesn't work 1. Cycle primary power to the Spirit system.
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.
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.
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.
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.
Spirit II User’s Manual Section 7: Parts List Section 7: Parts List Power Supply (300221 - 300229) Right Side View Item 4 5 6 15 30 31 35 38 44 Part Number 707150 706409 706410 706405 706502 709105 708121 702076 709167 300250 200204 Quantity 2 1 1 1 1 1 1 2 2 Description L1/L2 inductor T2 Control Transformer, 200-480 V / 60 Hz T2 Control Transformer, 600 V / 60 Hz T1 Main Transformer, 200-480 V / 60 Hz / 3Ø T1 Main Transformer, 600 V / 60 Hz / 3Ø Strain Relief CON 1 Main Contactor EMI Filter, 380/415
Section 7: Parts List Spirit II User’s Manual Power Supply (300221 - 300229) Left Side View Item 12 16 32 33 34 36 37 39 40 43 44 46 47 50 51 52 53 54 58 59 60 Part Number 300101 300112 708118 705011 702075 300108 301200 709117 280003 708105 200204 709252 709227 284029 300130 300129 300153 300156 701165 701141 701083 Quantity 1 1 2 1 2 1 1 1 2 2 1 1 2 2 2 2 1 1 2 1 3 53 54 43 Description Printed Circuit Board (PCB), Microprocessor (DSP) Printed Circuit Board (PCB), A.C.
Spirit II User’s Manual Section 7: Parts List Power Supply (300221 - 300229) Top View Item 1 2 3 5 Part Number 501163 501164 501162 706409 706410 709359 709358 709358 709360 709061 709128 500518 300250 708103 708104 708105 7 8 9 10 13 14 18 38 41 42 43 1 2 Quantity 1 1 1 1 1 1 1 1 2 2 1 2 2 2 4 Description Light Housing Bulb White Lens T2 Control Transformer, 200-480 V / 60 Hz T2 Control Transformer, 600 V / 60 Hz F3 Fuse, 5A, Slow Blow F4 Fuse, 5A, Medium Blow F5 Fuse, 5A, Medium Blow F6 Fuse, 6.
Section 7: Parts List Spirit II User’s Manual Power Supply (300221 - 300229) Cooling Section View Item 15 17 18 19 20 21 22 23 24 25 26 27 28 29 45 49 61 Part Number 709105 200092 500518 300135 505024 500052 500513 500511 708061 715118 300134 260250 500509 500510 500526 500525 500516 Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 2 1 Description Strain relief Coolant reservoir, without fittings or cap Coolant Reservoir Cap/Level Gauge Coolant Level Switch Coolant Temperature Switch Coolant Pump Motor, 1/3hp-23
Spirit II User’s Manual Section 7: Parts List Automatic Gas Console (300400) Front View Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part Number 300412 300301 280030 260109 260111 260109 260111 260109 260111 260109 260111 260109 260111 260109 260111 260109 260111 Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Power Supply, 24VDC, 8.
Section 7: Parts List Spirit II User’s Manual Automatic Gas Console (300400) Right Side View Item 1 2 3 10 11 12 13 14 15 16 17 19 Part Number 300412 300301 280030 260109 260111 260109 260111 260109 260111 260109 260111 300303 Quantity 1 1 1 1 1 1 1 1 1 1 1 1 Description Power Supply, 24VDC, 8.
Spirit II User’s Manual Section 7: Parts List Automatic Gas Console (300400) Left Side View Item 1 2 3 4 5 6 7 8 9 10 11 18 Part Number 300412 300301 280030 260109 260111 260109 260111 260109 260111 260109 260111 300414 1 Quantity 1 1 1 1 1 1 1 1 1 1 1 1 Description Power Supply, 24VDC, 8.
Section 7: Parts List Spirit II User’s Manual Plasma Console (300800) Item 1 2 3 4 5 Part Number 300712 300701 300706 300707 708111 Quantity 1 1 1 1 1 Description Power Supply, 12VDC Printed Circuit Board (PCB), RS422 Isolation Printed Circuit Board (PCB), Computer 10.4" LCD Touchscreen Switch, Pushbutton (OFF Button) 5 4 3 2 1 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
Spirit II User’s Manual Section 7: Parts List Impulse Start Console (300500) Item 1 2 3 4 5 6 7 8 9 Part Number 715051 715050 715021 709001 708057 500503 980200 980201 707300 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 subjec
Section 7: Parts List Spirit II User’s Manual Torch and Manifold Assemblies Item 1 2 3 Part Number 284214 277195 278001 278018 279000 279100 279060 820209 500024 500018 279013 279112 279113 284039 300075 716012 277056 277086 284052 279061 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 El
Spirit II User’s Manual Section 7: Parts List Shielded Torch Leads Part Number 284304-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 300408 300177-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 280312-XX 280321-XX Length Where -XX is the length in feet.
Section 7: Parts List Spirit II User’s Manual Gas Hose Package with AGC Part Number Length* 300080-20 20 ft. (6m) 300080-30 30 ft. (9m) 300080-40 40 ft. (12m) 300080-50 50 ft. (15m) 300080-60 60 ft. (18m) *Custom lengths are available. Contact factory.
Spirit II User’s Manual Section 7: Parts List Coolant and Power Leads Part Number Part Number (Non-CSA Systems) (CSA Systems) 280306-XX 288306-XX Length Where -XX is the length in feet. Available in 5 foot increments.
Section 7: Parts List Spirit II User’s Manual Oxygen Supply Gas Hose (Optional) Part Number 200362-25 200362-50 Length 25 ft. (7.6 m) 50 ft. (15.2 m) BLUE BLUE Nitrogen Supply Gas Hose (Optional) Part Number 200365-25 200365-50 Length 25 ft. (7.6 m) 50 ft. (15.2 m) BLACK BLACK Air Supply Gas Hose (Optional) Part Number 200364-25 200364-50 Length 25 ft. (7.6 m) 50 ft. (15.2 m) BLACK BLACK H17 Supply Gas Hose (Optional) Part Number 200363-25 200363-50 Length 25 ft. (7.6 m) 50 ft. (15.
Spirit II User’s Manual Section 7: Parts List “CII” Cable (for Optional External Inova) Part Number 300902-XX Length Where -XX is the length in feet. Available in 10 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.
Section 7: Parts List Spirit II User’s Manual “FII” Cable (for Optional Internal Inova) Part Number 300903-XX Length Where -XX is the length in feet. Available in 10 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.
Spirit II User’s Manual Section 7: Parts List “JII” Cable (for Optional Internal Inova) Part Number 300904-XX Length Where -XX is the length in feet. Available in 10 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.
Section 7: Parts List 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.
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.
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.
Spirit II User’s Manual Section 8: Internal Inova Console Option Parts List Item 1 2 3 4 5 6 7 8 Part Number 110200 110705 110900 706003 709360 709370 301200 709276 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.
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.
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.
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.
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).
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.
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.
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.
Spirit II User’s Manual Appendix B: Serial Communication Appendix B: Serial Communication Initializing the Spirit System The Spirit system uses an RS-422 serial communication port located on the rear of the plasma console to receive and respond to commands that are transmitted from an x/y controller. The communications ground is isolated to prevent ground loops. System initialization is simple.
Appendix B: Serial Communication Spirit II User’s Manual look up the Set Cutting Pierce Time command in the command table. You will see the following table entry: Command Set Pierce Time # Hex String 4 AA nn FA 04 -- -- 0D Additional Information Time in mS (seconds / 1000) Valid range: 0 to 5000 Once again, AA hex signifies the start of the command, “nn” is the net node of the power supply, and FA hex is the Spirit identifier.
Spirit II User’s Manual Appendix B: Serial Communication Default Cutting Parameters In order to initialize parameters on a Spirit system an external device must communicate, in sequence, the material type, material thickness, process (cutting or marking) and the cutting current. Once the Spirit system receives the cutting current, all other parameters will be set to their default values.
Appendix B: Serial Communication Spirit II User’s Manual RS-422 Serial Commands Note: In the following commands, “nn” represents the net node of the power supply that is to receive the command. To send a global command to all power supplies in a network configuration, “nn” should be set to C8 hex (200 decimal). The “-- --” in the hex string is the MSB followed by the LSB of a type int. The integer is the value found in the additional information column.
Spirit II User’s Manual Command Appendix B: Serial Communication # Hex String Additional Information Torch Body Part Number (msw) 16 AA nn FA 10 -- -- 0D If requested in command #30, the system will transmit the most significant word of the torch body part number. Torch Body Part Number (lsw) 17 AA nn FA 11 -- -- 0D If requested in command #30, the system will transmit the least significant word of the torch body part number.
Appendix B: Serial Communication Command # Spirit II User’s Manual Hex String Additional Information Torch Outer Cap Part Number (lsw) 29 AA nn FA 1D -- -- 0D If requested in command #30, the system will transmit the least significant word of the outer cap part number.
Spirit II User’s Manual Command Appendix B: Serial Communication # Hex String Additional Information Cutting Chart Version 34 AA nn FA 22 00 -- 0D If requested in command #30, the system will transmit the cutting chart version x 10. Number of Pierces 35 AA nn FA 23 00 -- 0D Number of Pierce Errors 36 AA nn FA 24 00 -- 0D If requested in command #30, the system will transmit the number of pierces.
Appendix B: Serial Communication Command # Spirit II User’s Manual Hex String Additional Information Restore Factory Condition 47 AA nn FA 2F 00 01 0D Restores the factory cutting condition for the present material type and thickness. Cutting Condition Type 48 AA nn FA 30 00 -- 0D If requested in command #30, the system will transmit whether the present cutting condition is a factory default setting or a custom user setting.
