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Operation

Spirit200a User’s Manual Rev J

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

4-38

Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

Shield Cap

Nozzle

Electrode

277117

277293

277292

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

277154

277152

277139

279150

Imperial

Material

Thickness

Preflow

Plasma

Shield

Postflow

Arc

Voltage

Travel

Speed

Cutting

Height

Pierce

Height

Pierce

Time

Kerf

Width

(in)

(psi)

(volts)

(ipm)

(in)

(msec)

(in)

1/4

145

150

.160

.250

400

.125

3/8

150

115

.180

.275

500

1/2

155

.210

.300

600

.130

5/8

160

.220

.325

800

3/4

168

.240

.350

1200

.135

Metric

Material

Thickness

Preflow

Plasma

Shield

Postflow

Arc

Voltage

Travel

Speed

Cutting

Height

Pierce

Height

Pierce

Time

Kerf

Width

(mm)

(psi)

(volts)

(mm/m)

(mm)

(msec)

(mm)

144

3910

4.0

6.3

400

3.2

150

2805

4.7

7.0

600

153

2330

5.1

7.4

3.3

160

1510

5.6

8.3

800

170

1030

6.2

9.0

1200

3.4

Marking

Material

Thickness

Preflow

Plasma

Shield

Postflow

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Pierce

Time

(ga) (in) (mm)

(psi)

(volts)

(ipm) (mm/min) (in) (mm) (in) (mm) (msec)

All Thicknesses

N/A

135

250

6350

.100 2.5 .100 2.5

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking

(Revised 12/01/2009)

Summary of Contents for Spirit150a

Page 1: ...er 718086 Rev J 10 15 2012 J REVISION 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 ...

Page 2: ...ction 2 Section 3 Section 7 Section 8 G 10 25 10 Section Updates Contents Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Appendix A Appendix B deleted H 05 10 2011 Section Updates Max Input Pressure changed to 145 psi in 2 4 3 1 3 13 3 14 8 8 AGC fan added to drawings in 3 1 3 13 Postflow label changed in 8 9 I 08 01 2012 Section1 added pointers to Section 7 Section 4 corrected cut ch...

Page 3: ...under this warranty All returned goods shall be at the buyer s risk and expense Beyond this remedy KALIBURN will not be responsible for any special incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any equipment sold hereunder This warranty will be considered void if torches or torch consumables manufactured by anyone other than KALIBURN a...

Page 4: ...mponents 2 2 Power Supply Specifications 2 3 Automatic Gas Console Specifications 2 5 Remote High Frequency Console Specifications 2 6 Torch Specifications 2 7 5 Gang Manifold Specifications 2 8 Airborne Noise Emissions 2 9 Section 3 Installation Initial Inspection 3 1 System Interconnection 3 1 Power Supply Installation 3 2 Remote High Frequency Installation 3 2 5 Gang Manifold Installation 3 2 T...

Page 5: ...tomatic Gas Console Advanced Functions Altering the Current Set Point 5 1 Setting the Pierce Time 5 2 Altering Gas Types 5 3 Altering Gas Pressures 5 4 Altering Arc Voltage Control and X Y Machine Parameters 5 5 Saving a User Created Cutting or Marking Condition 5 6 Gas Purge 5 6 Maintenance Screen 5 7 Viewing Messages 5 8 Viewing Cut Errors 5 9 Pressure Diagnostics 5 12 Restoring Factory Default ...

Page 6: ...een 7 8 General Troubleshooting 7 9 Chopper Test Procedure 7 12 Section 8 Parts List Power Supply 8 1 Automatic Gas Console 8 7 Remote High Frequency Console 8 10 Torch and Manifold Assemblies 8 11 Shielded Torch Leads 8 12 Gas Hose Package 8 13 Coolant and Power Leads 8 14 Work Ground Cable 8 15 Oxygen Supply Gas Hose Optional 8 16 Nitrogen Supply Gas Hose Optional 8 16 Air Supply Gas Hose Option...

Page 7: ...rc This ultraviolet radiation can cause skin and eye burns For this reason it is essential that proper protection be worn The eyes are best protected by using safety glasses or a welding helmet with an AWS No 12 shade or ISO 4850 No 13 shade which provides protection up to 400 amperes All exposed skin areas should be covered with flame retardant clothing The cutting area should also be prepared in...

Page 8: ...rical codes The disconnect switch should be located as close as possible to the power supply so it can be turned off in case of an emergency The primary power cord should have a 600 volt minimum rating in order to protect the operator In addition it should be sized according to local and national electrical codes Inspect the primary power cord frequently Never operate the Spirit system if the powe...

Page 9: ... flammable materials are a suitable distance away from the cutting area All flammable liquids should be at least 40 feet away from the cutting area preferably stored in a metal cabinet Plasma cutting should never be attempted on containers that contain flammable materials Make sure that fire extinguishers are readily accessible in the cutting area Make sure that the cutting area is properly ventil...

Page 10: ...or pressure regulator for any purpose other than which it is intended Never use a pressure regulator for any gas other than which it is intended Never use a pressure regulator that is leaking or has other signs of physical damage Never use oxygen hoses and pressure regulators for any gas other than oxygen Never use any gas hose that is leaking or has other signs of physical damage Health Support E...

Page 11: ...ded Safe Practices for Preparation for Welding and Cutting of Containers and Piping obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 5 AWS Standard ULR Ultraviolet Reflectance of Paint obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 6 AWS ANSI Standard Z49 1 Safety in Welding Cutting and Allied Processes obtainable from the American We...

Page 12: ...lectrical Code obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 15 CGA booklet P 1 Safe Handling of Compressed Gases in Containers obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 16 CGA booklet P 14 Accident Prevention in Oxygen Rich and Oxygen Deficient Atmospheres obtainable from the Compressed ...

Page 13: ...d torch height for making the cut These parameters can even be transmitted to an x y machine controller or an arc voltage control system via RS 422 serial communication The RS 422 port also allows for full control of the cutting parameters from an x y machine controller The gas console also tracks the number of cuts made with a particular set of consumables and keeps a detailed record of errors th...

Page 14: ...is not suitable for use in rain or snow The Spirit200a system is tested in accordance with CISPR 11 EMC classification Group 2 ISM Class A The Spirit200a consists of the following components Standard Components Power Supply Automatic Gas Console Remote High Frequency RHF Console RHF Console Control Cable Torch and Handle Assembly Torch Lead Set 5 gang Manifold Assembly 5 gang Manifold Control Cabl...

Page 15: ...0Hz 282411 380 VAC 3Ø 50 60Hz 282413 415 VAC 3Ø 50 60Hz 282414 460 VAC 3Ø 60Hz 282412 575 VAC 3Ø 60Hz 282415 Input Current at Maximum Output 208 VAC 3Ø 60Hz 115 amps 230 VAC 3Ø 60Hz 104 amps 380 VAC 3Ø 50 60Hz 63 amps 415 VAC 3Ø 50 60Hz 58 amps 460 VAC 3Ø 60Hz 52 amps 575 VAC 3Ø 60Hz 42 amps Open Circuit Voltage 300 VDC Output Current drooping characteristic 10 200 amps Maximum Output Voltage 190 ...

Page 16: ...formation shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 4 Torch Cooling System Discharge pressure 150 psi 10 2 bar Flow rate 1 gal min 3 8 liters min Coolant fluid Propylene glycol deionized water Coolant tank capacity 3 2 gal 12 liters ...

Page 17: ...rs hour Rated Inlet gas pressures 120 psi 8 3 bar Maximum Inlet gas pressure 145 psi 10 0 bar Oxygen and nitrogen should be supplied with a purity of at least 99 5 H17 should be supplied with a purity of at least 99 995 A potential fire hazard exists when cutting with oxygen KALIBURN recommends that an exhaust ventilation system be used when cutting with oxygen Flashback arrestors must be supplied...

Page 18: ...nformation shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 6 Remote High Frequency Console Specifications Stock Number 205500 Height 5 35 in 136 mm Width 13 5 in 343 mm Depth 10 in 25 mm Weight 22 lb 10 kg Spark gap distance 015 in 381 mm ...

Page 19: ...United States contrary to the requirements of the EAR 2 7 Torch Specifications Stock Number 2 Gang Manifold Assembly 260214 Torch Handle 820134 Torch Base 279050 Torch Head Copper Electrode 279150 Torch Head Silver Electrode 279160 Weight Manifold Bracket Handle Base and Head 7 3 lbs 3 3 kg Torch Handle 9 20 234 1 99 51 Torch Head 5 08 129 Torch Base 1 87 47 Manifold 3 38 86 Alignment Indicator Sm...

Page 20: ... Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 8 5 Gang Manifold Specifications Stock Number 280022 Height 3 035 in 77 mm Width 8 35 in 212 mm Depth 7 in 178 mm Weight 6 lb 2 7 kg ...

Page 21: ...e 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 Spirit200a when operating at 200 amps 135 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound Pressur...

Page 22: ...tion is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 10 BLANK PAGE ...

Page 23: ...tact KALIBURN so a replacement item can be sent to you Also KALIBURN has taken special care in packaging your Spirit200a system If your system was damaged during shipment you will have to file a claim with the shipping company Next it will be necessary to contact KALIBURN so replacement parts can be ordered If you need additional assistance please contact KALIBURN System Interconnection The Spirit...

Page 24: ...ter than 10º to eliminate the risk of toppling over The power supply must be cleaned as often as necessary to prevent the accumulation of metallic dust inside the unit See Section 2 for power supply dimensions Remote High Frequency Console Installation The remote high frequency RHF console should be mounted in a convenient location that is away from other electronic control devices The high voltag...

Page 25: ... inrush current of the power supply will cause fast acting fuses to blow The disconnect switch should be sized according to local and national codes The rating must meet or exceed the continuous rating of the fuses used See the following chart for recommended fuse sizes 3 Phase Input Voltage VAC Input Current at Maximum Output amps Recommended Time Delay Fuse Size amps 208V 60Hz 115 170 230V 60Hz ...

Page 26: ...on is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 4 TB5 Location ...

Page 27: ... other end of the power supply nozzle Lead through the strain relief on the RHF console and connect it to the pilot terminal on the RHF console printed circuit board Power Supply CTP Sensor Lead 1 Route the end of the 14AWG power supply CTP sensor lead with the ring terminal through the middle strain relief on the rear of the power supply and connect it to the CTP terminal 2 Route the end of the p...

Page 28: ...o the star ground point on the cutting table The star ground point is generally referred to as the common ground point on the cutting table where all subsystems of the machine are grounded This point is then connected to a driven earth ground rod that should be as close as possible to the star ground The ground rod should have no other wires connected to it The ground rod should be at least 3 4 in...

Page 29: ...formation is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 7 ...

Page 30: ...t 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 RHF 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...

Page 31: ...formation is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 9 ...

Page 32: ...fittings are subject to damage if over tightened Also use two wrenches when tightening the torch fittings to avoid damaging the torch Torch Handle Installation 1 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 Connect the torch electrode coolant supply lead to the torch base as shown Torch C...

Page 33: ... torch base being careful not to twist the torch leads and gas hoses when tightening the torch handle 3 Tighten the base to the handle using a pin style adjustable spanner wrench fits 2 diameter with diameter pin 4 Attach the 2 gang manifold assembly to the torch handle The top of the manifold bracket should be flush with the top of the torch handle 5 Mount the torch handle base manifold to the po...

Page 34: ...bly Shield Gas Hose 1 Connect one end of the shield hose to the shield outlet on the rear of the AGC 2 Connect the other end of the shield hose to the shield inlet on the 5 gang torch valve assembly Preflow Gas Hose 1 Connect one end of the preflow hose to the preflow outlet on the rear of the AGC Note that the preflow hose fittings have left hand threads 2 Connect the other end of the preflow hos...

Page 35: ...ormation is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 13 ...

Page 36: ...pply enough upward force to engage the threads while tightening the attachment ring Turn the attachment ring to the LEFT to tighten 4 Keep tightening the attachment ring until it stops As shown below the attachment ring will NOT cover the o ring This is only a visual indicator no seal is created However there should be no gap between the attachment ring and the o ring During the tightening process...

Page 37: ...s Using quick connect fittings to connect and disconnect pressurized hoses may cause damage to the system Note When making hose connections only tighten the brass fittings enough to make gas seals The fittings are subject to damage if over tightened Air Inlet ISO 3821 hose color black Air must be supplied to the unit at all times regardless of the cutting current or material type Oxygen Inlet ISO ...

Page 38: ...re between P8 pins 10 and 11 to inhibit arc starting even though a plasma start signal has been applied to the unit When the contacts are opened the arc is initiated This feature is used to decrease cycle time by allowing pre cut gas and contact sequencing to occur simultaneously with initial torch height positioning The contacts should be rated for 12VDC 10mA Motion Output The Spirit200a provides...

Page 39: ...ommunication Link An RS 422 serial communication link can be connected between the plug on the rear of the automatic gas console and a CNC machine or automatic height control system All process parameters can be controlled via the RS 422 communication link Also cutting or marking information such as initial height cutting or marking height recommended arc voltage and recommended travel speed can b...

Page 40: ...t solution for optimal system performance as commercially available antifreeze contains corrosion inhibitors that will damage the cooling system The standard coolant solution consists of 25 industrial grade propylene glycol and provides freezing protection down to 13º C 9º F The standard solution can be ordered in one gallon containers PN 500695 For operating temperatures below 13º C a 50 solution...

Page 41: ...coolant pump will begin pumping coolant fluid through the system The Coolant Flow LED will remain out until the coolant has filled the entire system and begins flowing back into the tank The coolant pump will turn off if the coolant level drops below the minimum level inside the reservoir If this happens add more coolant solution to the reservoir and return to Step 3 5 When the Coolant Flow LED il...

Page 42: ...ion is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 20 BLANK PAGE ...

Page 43: ...lluminates to show that the system is energized AC Power Indicator Illuminates when 3 phase power is applied to the Spirit system DC Power Indicator Illuminates when then main contactor has been energized and D C current is flowing through the torch Status Indicators RHF Door Indicator Illuminates when the RHF console door is closed securely Remains extinguished when the RHF console door is open G...

Page 44: ...n the coolant level inside the reservoir is satisfactory Remains extinguished when coolant must be added to the system Coolant Temperature Indicator Illuminates when the torch coolant temperature is satisfactory Remains extinguished when the coolant temperature is too hot If the torch coolant indicator goes out leave the unit energized until it illuminates Automatic Gas Console Display Shows all o...

Page 45: ...nu key is pressed a menu icon will appear in the upper right hand corner of the screen Pressing the Menu key again will clear the icon and return to the previous mode Pressing a split level key while the menu icon is visible will enter the specified mode The following is a list and description of menu key functions Menu Material Enters the material editing mode Menu Current Enters the current edit...

Page 46: ... and down in order to edit or select a particular item Function Keys The Function keys are used for various purposes in the editing and maintenance modes The help prompt instructs the user on the use of the Function keys Numerical Keys The Numerical keys are used for entering and editing parameters Automatic Gas Console Help Prompt Help prompts are displayed on the automatic gas console screen to ...

Page 47: ...reen is displayed as shown The status screen displays all of the primary cutting or marking parameters To edit a parameter on the status screen the arrow keys can be used to scroll through the different parameters or the Menu key can be used as described previously Note that when the Menu key is pressed the Menu icon appears in the upper right hand corner of the screen as shown To return to the st...

Page 48: ...eters that must be set All other parameters are adjusted automatically Perform the following steps to enter the data See Section 5 for advanced functions of the automatic gas console Selecting Material Type From the status mode press the down arrow once to scroll down to substance or press Menu then Material The substance area should be highlighted as shown below and the substance type should be b...

Page 49: ...ide the United States contrary to the requirements of the EAR 4 7 Setting Material Thickness To set the material thickness use the down arrow to scroll down to Thickness The material thickness should be highlighted as shown below and the editing cursor should be blinking Use the numerical keypad to enter the material thickness Use the CLR key to backspace if an error is made Press the enter key wh...

Page 50: ...matic gas console See Section 5 Automatic Gas Console Advanced Functions for instructions on setting up how switching between cutting and marking is performed To set the operating process use the down arrow to scroll down to Process The process area should be highlighted as shown below and the process should be blinking To change the process press F3 as indicated by the help prompt Repeatedly pres...

Page 51: ...y cutting machine must be configured properly To view the recommended cutting data press the Menu key then Voltage The voltage screen will be displayed as shown The x y machine speed should be set to the value shown Also the height control should be set to the proper pierce initial height cutting marking height and arc voltage If a KALIBURN Inova height control is being used simply press the F3 ke...

Page 52: ...location outside the United States contrary to the requirements of the EAR 4 10 Viewing the Torch Parts Required Once the material substance and thickness have been chosen the default cutting parameters are selected and adjusted accordingly To display a pictorial view of the torch parts required to make the cut or mark scroll down to Torch Parts and press enter An example of the torch parts screen...

Page 53: ...EAR 4 11 Torch Consumable Selection Mild Steel Copper Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head 277154 277145 277153 277120 277140 277130 279150 30A 277154 277115 277153 277122 277140 277142 277131 279150 50A 277154 277150 277153 277125 277142 277131 279150 70A 277154 277286 277151 277284 277283 277282 279150 100A 277154 277117 27715...

Page 54: ...shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 12 Mild Steel Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode Torch Head 277154 277274 277266 279489 279443 279440 yellow o ring 279160 200A ...

Page 55: ...ion outside the United States contrary to the requirements of the EAR 4 13 Stainless Steel H17 Plasma Copper Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head 277154 277150 277113 277124 277140 277132 279150 70A 277154 277146 277113 277126 277141 277133 279150 100A 277154 277298 277266 277297 277139 277135 279150 150A 277154 277274 277266 27...

Page 56: ...of the EAR 4 14 Stainless Steel Air or Nitrogen Plasma Copper Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head 277154 277144 277110 277121 277138 277137 279150 30A 277154 277149 277110 277123 277142 277137 279150 50A 277154 277150 277153 277125 277142 277131 279150 70A 277154 277286 277151 277284 277283 277282 279150 100A 277154 277117 2771...

Page 57: ...rovided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 15 Stainless Steel Air or Nitrogen Plasma Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode Torch Head 277154 277274 277266 279489 279443 279440 yellow o ring 279160 200A ...

Page 58: ...e requirements of the EAR 4 16 Aluminum Copper Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head 277154 277145 277153 277120 277140 277130 279150 30A 277154 277150 277153 277122 277142 277131 279150 50A 277154 277150 277153 277125 277142 277131 279150 70A 277154 277286 277151 277284 277283 277282 279150 100A 277154 277117 277152 277293 27713...

Page 59: ... shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 17 Aluminum Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode Torch Head 277154 277274 277266 279489 279443 279440 yellow o ring 279160 200A ...

Page 60: ... and short consumable life Note Do not over tighten the consumables Only tighten until the parts are seated properly 1 Unthread the quick disconnect torch head from the torch base by turning the attachment ring to the RIGHT 2 Remove the outer retaining cap from the torch head 3 Remove the inner retaining cap from the torch head 4 Separate the shield cap from either the inner retaining cap or the o...

Page 61: ...en entered the correct torch parts are installed and the x y machine and height control systems have been properly configured perform the following steps to cut or mark with the system 1 Depress and hold the Power On button until the Coolant Flow status LED illuminates If the Coolant Flow led fails to illuminate after 10 seconds see the maintenance section for possible solutions 2 The automatic ga...

Page 62: ... torch does not move from the pierce height down to the cutting height and come into contact with this solidified metal The torch should not move from the pierce height down to the cutting height until the x y machine has moved the torch away from the pierce point One way to accomplish this may be to program the pierce time on the torch height control system to a value that is longer than the x y ...

Page 63: ...plate thickness 2 A negative cut angle top dimension of piece larger than the bottom dimension usually occurs when the torch standoff distance is too low or when the cutting speed is too slow 3 Top dross usually occurs when the torch standoff distance is too high 4 Bottom dross usually occurs when the cutting speed is either too slow slow speed dross or too fast high speed dross Low speed dross is...

Page 64: ...y o ring Damaged o ring Replace shield cap Replace shield cap Apply a thin film of o ring lubricant Replace shield cap Retaining Cap Center hole out of round Dents cracks Dry o ring Damage o ring Replace retaining cap Replace retaining cap Apply a thin film of o ring lubricant Replace retaining cap Nozzle Center hole out of round Erosion or arcing Dry o rings Damaged o rings Replace nozzle Replace...

Page 65: ...ng current are changed to optimum values for extinguishing the arc Ideally the x y machine controller should provide a plasma stop signal prior to the end of the cut path so the gases and current reach the shut off values at the same time that the part has been completely cut The shut down times are different for each current and are given below Arc Shutdown Times Current A Time ms 30 490 50 390 7...

Page 66: ... Gas Shield Gas Copper Electrode Silver Electrode Mild Steel 30 Amps Oxygen Oxygen 4 25 Mild Steel 50 Amps Oxygen Oxygen or Air 4 26 Mild Steel 70 Amps Oxygen Air 4 27 Mild Steel 100 Amps Oxygen Air 4 28 Mild Steel 150 Amps Oxygen Air 4 29 Mild Steel 200 Amps Oxygen Air 4 30 4 47 Stainless Steel 30 Amps Air Air 4 31 Stainless Steel 50 Amps Air Nitrogen 4 32 Stainless Steel 70 Amps H17 Nitrogen 4 3...

Page 67: ...e Height Pierce Time Kerf Width ga in psi psi psi psi volts ipm in in msec in 20 036 35 85 6 84 120 105 080 110 100 062 18 048 121 97 090 16 060 125 78 105 200 065 14 075 126 65 12 105 127 55 070 11 120 129 50 120 125 300 10 135 131 40 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m ...

Page 68: ...23 70 120 135 100 075 11 120 126 60 125 200 078 10 135 128 50 135 Hot Rolled Steel Air Shield Swirl Ring 277142 14 075 25 74 19 73 106 200 100 135 100 075 12 105 190 125 180 200 080 10 135 110 170 110 3 16 113 105 140 200 300 085 1 4 117 75 225 400 087 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi ps...

Page 69: ...age Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 1 8 25 80 35 79 110 190 100 150 100 080 3 16 40 113 130 200 200 1 4 116 120 110 225 300 085 3 8 122 75 140 25 400 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec...

Page 70: ... psi psi psi volts ipm in in msec in 1 4 25 94 26 93 125 150 090 200 300 090 3 8 130 100 130 250 400 1 2 65 155 300 500 5 8 143 47 185 325 800 095 3 4 145 35 350 1000 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 94 26 93 124 3950 2 1 4 9 300 2 3 10 130 2405 3 3 ...

Page 71: ...00 500 130 Retaining Cap 277152 5 8 20 74 45 67 127 70 140 325 600 130 3 4 130 55 350 1000 135 1 134 40 150 400 1500 140 1 25 145 25 200 350 1 5 155 15 225 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm Retaining Cap 277151 6 20 74 30 67 117 4305 2 6 4 9 300 3 2 10 123...

Page 72: ...00 130 350 600 152 3 4 140 75 150 400 800 153 1 147 50 175 450 1000 155 1 25 155 25 240 500 1500 1 5 165 17 300 350 158 1 75 175 12 350 2 0 185 7 500 500 160 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 82 58 75 124 6100 8 4 9 300 3 8 10 130 3480 2 3 6 5 500 12 ...

Page 73: ...eight Pierce Height Pierce Time Kerf Width ga in psi psi psi psi volts ipm in in msec in 20 036 30 80 30 80 71 200 020 050 100 065 18 048 165 035 16 060 74 125 200 068 14 075 75 90 025 070 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 1 30 80 30 80 71 4855 0 6 1 3 100...

Page 74: ... ga in psi psi psi psi volts ipm in in msec in 14 075 30 70 40 70 87 105 035 070 100 105 12 105 88 75 11 120 89 65 200 10 135 90 55 110 3 16 94 50 040 080 300 1 4 100 40 060 125 400 115 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 2 30 70 40 70 87 2565 9 1 8 100 2 7 ...

Page 75: ...rial Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 3 16 35 60 36 60 135 80 100 200 300 090 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 5 35 60 36 60 13...

Page 76: ...Speed Cutting Height Pierce Height Pierce Time Kerf Width ga in psi psi psi psi volts ipm in in msec in 10 135 25 80 25 79 132 120 060 150 200 085 3 16 134 100 070 200 300 1 4 140 75 090 225 400 090 3 8 148 50 120 250 500 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm ...

Page 77: ...Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 3 16 28 67 46 67 138 115 105 200 300 100 1 4 140 100 125 225 400 105 3 8 152 65 180 250 500 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 5...

Page 78: ...Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 1 4 25 94 35 93 141 100 135 225 400 092 3 8 147 80 170 250 500 095 1 2 154 55 210 300 600 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 94 35 93 14...

Page 79: ...ge Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 1 4 25 81 75 81 165 95 250 250 400 135 3 8 75 150 275 500 1 2 60 165 300 600 140 5 8 50 185 325 800 3 4 40 250 350 1200 145 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m m...

Page 80: ...erce Time Kerf Width in psi psi psi psi volts ipm in in msec in 1 4 25 75 70 67 145 150 160 250 400 125 3 8 150 115 180 275 500 1 2 155 85 210 300 600 130 5 8 160 60 220 325 800 3 4 168 45 240 350 1200 135 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 75 70 67 14...

Page 81: ...Height Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 3 8 37 68 85 68 156 80 195 250 500 150 1 2 148 75 130 300 600 5 8 155 60 190 350 800 155 3 4 160 50 200 400 1200 1 0 170 35 240 450 1500 160 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm ms...

Page 82: ...30 200 070 200 400 150 3 8 133 150 250 500 1 2 140 110 115 300 600 152 5 8 146 75 150 350 800 155 3 4 153 60 190 400 1200 1 0 158 40 210 450 1500 160 1 25 170 20 250 350 165 1 50 180 10 275 350 175 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 82 58 75 129 5220 1...

Page 83: ... Speed Cutting Height Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 040 30 92 20 90 135 150 030 100 100 065 050 120 063 90 150 200 070 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 1 30 92 20 90 135 3885 0 8 2 5 100 1 7 1 5 2520 3 4 2...

Page 84: ...ight Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 050 25 74 19 73 135 180 050 100 100 080 063 138 140 065 150 082 080 143 90 075 150 200 085 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 1 5 25 74 19 73 137 3870 1 5 2 5 150 2 1 2 0 1...

Page 85: ...n msec in 080 25 80 25 79 130 250 050 150 100 080 1 8 135 160 070 175 3 16 145 80 100 200 200 085 1 4 150 50 060 250 300 3 8 155 40 075 275 400 090 1 2 162 30 115 300 500 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 2 25 80 25 79 129 6400 1 2 3 7 100 2 0 3 134 4420 1...

Page 86: ...e Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 1 4 25 94 26 93 158 105 155 250 300 095 3 8 162 90 180 275 400 098 1 2 165 70 195 300 500 100 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 94 26 93 158 2710 3 8 6 3 300 2 4 10 162 2210 4 ...

Page 87: ... psi volts ipm in in msec in 1 4 25 75 50 67 145 145 130 250 400 125 3 8 155 115 185 275 500 1 2 165 90 230 300 600 130 5 8 170 65 250 325 800 135 3 4 45 350 1200 140 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 75 50 67 143 3770 3 1 6 3 400 3 2 10 156 2825 4 8 ...

Page 88: ... 1 4 20 82 58 75 150 190 135 250 300 150 3 8 155 145 140 275 400 1 2 110 135 300 500 155 5 8 160 95 350 600 3 4 65 150 400 800 160 1 0 175 35 200 1000 170 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 82 58 75 149 4955 3 3 6 3 300 3 8 10 155 3545 3 5 7 0 500 12 2...

Page 89: ...8 137 100 130 350 600 152 3 4 140 75 150 400 800 153 1 147 50 175 450 1000 155 1 25 155 25 240 500 1500 1 5 165 17 300 350 158 1 75 175 12 350 2 0 185 7 500 500 160 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 82 58 75 124 6100 8 4 9 300 3 8 10 130 3480 2 3 6 5 ...

Page 90: ...3 150 250 500 1 2 140 110 115 300 600 152 5 8 146 75 150 350 800 155 3 4 153 60 190 400 1200 1 0 158 40 210 450 1500 160 1 25 170 20 250 350 165 1 50 180 10 275 350 175 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 82 58 75 129 5220 1 8 4 9 400 3 8 10 134 3655 1 ...

Page 91: ...msec in 1 4 20 82 58 75 150 190 135 250 300 150 3 8 155 145 140 275 400 1 2 110 135 300 500 155 5 8 160 95 350 600 3 4 65 150 400 800 160 1 0 175 35 200 1000 170 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 82 58 75 149 4955 3 3 6 3 300 3 8 10 155 3545 3 5 7 0 5...

Page 92: ...n is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 50 BLANK PAGE ...

Page 93: ...hen non standard cutting or marking conditions are desired Instructions are also given on how to access the various maintenance modes of the system Altering the Current Set Point To alter the current set point from the default setting use the arrow keys to scroll to Current Set Point or press the Menu key then the Current key The current setting should be highlighted as shown and the set point sho...

Page 94: ...emain at the pierce height until the Pierce Time has elapsed at which time the torch should be positioned at the correct cutting or marking height When cutting the Pierce Time should be adjusted so the arc fully penetrates the plate before the torch is moved to the cut height See Piercing Thick Materials in Section 4 When marking the Pierce Time is usually adjusted to zero To alter the Pierce Time...

Page 95: ...ormally be changed the procedure is given here anyway Note that the preflow gas cannot be changed To alter the gas types used for a particular cut use the arrows to scroll to the appropriate gas or press the Menu key then the Plasma Gas or Shielding Gas key The appropriate gas selection should be highlighted as shown and the present gas choice should be blinking Press F3 to scroll through the gas ...

Page 96: ...w gas and plasma gas pressures should not be changed The shield gas can be adjusted in small increments to fine tune a cut To alter the gas pressures use the arrow keys to scroll to the appropriate pressure setting The pressure setting should be highlighted as shown and the editing cursor should be blinking Use the numerical keypad to enter the desired operating pressure Use the CLR key to backspa...

Page 97: ...ransferred by any means to any location outside the United States contrary to the requirements of the EAR 5 5 Altering Arc Voltage Control and X Y Machine Parameters If the pierce initial height cutting marking height arc voltage or x y machine speed must be altered to achieve the desired cut quality switch to the voltage screen use the arrow keys to scroll to the desired parameter and edit the pa...

Page 98: ...roll off all selections on the status screen When none of the parameters are highlighted the Press F3 to Save Settings message will be displayed as shown Pressing F3 will cause the save confirmation window to pop up When this occurs press ENT to save the condition or press CLR to cancel the procedure Pressing ENT will save the settings for the particular material being cut and a User icon will app...

Page 99: ...ny means to any location outside the United States contrary to the requirements of the EAR 5 7 Maintenance Screen To display the maintenance screen press the Menu key then the Maint key The maintenance screen will be displayed as shown From the maintenance screen use the arrow keys to scroll up or down to highlight a selection and press the Ent key to enter the desired maintenance mode The differe...

Page 100: ...de the United States contrary to the requirements of the EAR 5 8 Viewing Messages To view status messages from the Spirit power supply and automatic gas console scroll down to the View Messages selection on the maintenance screen and press ENT The message screen will be displayed as shown The message screen displays all power supply and gas console messages sequencing and errors The message screen...

Page 101: ...fect the consumable parts life and measures should be taken to prevent them from occurring To view the cut errors scroll down to the View Cut Errors selection on the maintenance screen and press ENT The cut errors screen will be displayed as shown The error tracking system keeps a record of the total number of pierces the number of errors and the error percentage Any time the consumables are chang...

Page 102: ...d to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 10 Selecting an Error Set to View When the cut errors screen is being displayed press F3 to view the actual cut errors When F3 is pressed the error selection screen is displayed as shown Use the arrow keys to scroll to the error set that is to be viewed and press ENT...

Page 103: ...ished 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 Transferred arc lost before upslope This error occurs when the arc transfers to the workpiece but is lost immediately It primarily causes nozzle damage and is typically due to a pierce height that is too high Transferred arc lost during ...

Page 104: ...ror occurs when the arc is lost after a stop signal is received but before the current downslope completes It substantially shortens the electrode life and is typically due to an incorrect lead out or when cutting a given material thickness with excessive current When cutting small pieces that tend to drop into the table after being cut there should be a very short lead out or none at all On thick...

Page 105: ...nts of the EAR 5 13 Pressure Diagnostics To enter the pressure diagnostics mode scroll down to the Pressure Diagnostics selection on the maintenance screen and press ENT The pressure diagnostics screen will be displayed as shown Pressing the Preflow Gas Plasma Gas and Shielding Gas buttons will toggle the corresponding valves between the off and on states Note that the preflow valve and the plasma...

Page 106: ...ntenance screen and press ENT The restore screen will be displayed as shown Note that the present material type and thickness selected on the status screen will be automatically displayed on the restore screen Press ENT to restore the factory default setting for the material type and thickness displayed To change the material type press the F3 key To edit the material thickness use the arrow keys ...

Page 107: ...ion outside the United States contrary to the requirements of the EAR 5 15 Measurement System The Spirit system will operate using Imperial units or Metric units To change the units of operation scroll down to the Measurement System selection on the maintenance screen and press ENT The measurement system screen will be displayed as shown Press F3 to toggle the measurement system between Imperial a...

Page 108: ...ink each system must have a unique identification number node number to identify itself to the network To set the communication node number for the Spirit system scroll down to the Set Communication Node selection on the maintenance screen and press ENT The communication node selection screen will be displayed as shown Press F3 to scroll through the available node numbers When using an Inova torch...

Page 109: ...ce initial height and cutting marking height any time a new condition is loaded the process cutting or marking is changed or when the arc voltage pierce initial height or cutting marking height is changed on the Voltage screen With the Inova Parameter Transmit feature set to manual pressing F3 while the voltage screen is being displayed will automatically transmit the pierce initial height cutting...

Page 110: ... Serial Communications To view the serial communication between the Spirit and an external device scroll down to the View Serial Communication selection on the Maintenance screen and press enter The Serial Communication screen will be displayed as shown All incoming and outgoing data is displayed in decimal base 10 format Note that incoming data is appended to show an R before the data and outgoin...

Page 111: ...drogen Cutting When hydrogen cutting is enabled the H17 hydrogen mixture will automatically be selected as the plasma gas for certain material types and thicknesses To prevent the use of H17 hydrogen cutting must be disabled To disable hydrogen cutting scroll down to the Configure Hydrogen Cutting selection on the Maintenance Screen and press enter The Configure Hydrogen Cutting screen will be dis...

Page 112: ... the requirements of the EAR 5 20 Setting an Arc Off Delay In some instances such as when cutting thicker stainless steel materials it may be desirable to delay the extinction of the cutting arc after a stop signal is received To program an arc off delay scroll down to the Set Arc Off Delay selection on the Maintenance Screen and press enter The Set Arc Off Delay screen will be displayed as shown ...

Page 113: ...as the capability of plasma cutting and plasma marking with the same set of consumables The process cutting or marking can be set by the RS 422 serial interface by a hard signal on the CNC interface plug or locally at the automatic gas console To control how switching between processes is performed scroll down to the Cut Mark Cut selection on the Maintenance Screen and press enter The Cut Mark Cut...

Page 114: ...e floppy disk from the floppy disk drive 5 Remove primary power from the system 6 Reinstall the floppy disk drive cover 7 Apply primary power to the system Two Disk Update 1 Remove primary power from the Spirit system 2 Insert the first floppy disk containing the software update into the floppy disk drive 3 Apply primary power to the system and wait until the AGC Updated Successfully message appea...

Page 115: ... port The port settings should have a start bit one stop bit and no parity A table can be found in this section that lists the RS 422 commands and their descriptions This table contains the necessary hex strings for sending different commands and parameters to the system For example to switch the material type from mild steel to stainless steel look up the command for setting material type in the ...

Page 116: ...ce time of 1000 mS 1 second This value in hexadecimal would be 03E8 msb 03 lsb E8 In this example the following string would be transmitted in order to set the pierce time to 1000mS for a power supply on net node 1 AA 01 FA 04 03 E8 0D For multiple power supply installations commands can be sent to all power supplies at the same time This is referred to as a global command To send a global command...

Page 117: ...ceives the cutting current all other parameters will be set to their default values Whenever the material type material thickness process or cutting current is changed new default values will be retrieved for all other parameters If a changed is desired cutting current must be sent last for the updated to occur To use non standard parameters first set the material type material thickness process a...

Page 118: ...mation Set Material Type 1 AA nn FA 01 00 0D 00 Mild Steel Hot Rolled 01 Stainless Steel 02 Aluminum 03 Other 04 Mild Steel Cold Rolled Set Thickness 2 AA nn FA 02 0D Thickness in mils inches x 1000 Valid Range 0 to 2000 Set Operating Current 3 AA nn FA 03 00 0D 01 30A 02 50A 03 70A 04 100A 05 150A 06 200A 0A 260A 0B 275A 0C 400A Set Cutting Pierce Time 4 AA nn FA 04 0D Cutting pierce time in ms V...

Page 119: ...ant word of the swirl ring part number Torch Swirl Ring Part Number lsw 21 AA nn FA 15 0D If requested in command 30 the AGC will transmit the least significant word of the swirl ring part number Torch Nozzle Part Number msw 22 AA nn FA 16 0D If requested in command 30 the AGC will transmit the most significant word of the nozzle part number Torch Nozzle Part Number lsw 23 AA nn FA 17 0D If reques...

Page 120: ...orch body part number lsw 18 Send electrode part number msw 19 Send electrode part number lsw 20 Send swirl ring part number msw 21 Send swirl ring part number lsw 22 Send nozzle part number msw 23 Send nozzle part number lsw 24 Send retaining cap part number msw 25 Send retaining cap part number lsw 26 Send shield cap part number msw 27 Send shield cap part number lsw 28 Send outer cap part numbe...

Page 121: ...fied within 8 seconds unit will power down Power Off 39 AA nn FA 27 00 01 0D Deenergizes power supply torch coolant pump and cooling fans Request System Status 40 AA nn FA 28 00 01 0D System status can only be requested after a Power On command 38 is transmitted The status is returned in the following form All bits 0 fault 1 ok LSB Bit 0 RHF Door LSB Bit 1 AC Power LSB Bit 2 Coolant Flow LSB Bit 3...

Page 122: ... the cutting conditions for the present material type and thickness Set Arc Off Delay Time 51 AA nn FA 33 0D Sets the delay time in mS between the reception of a stop signal and the extinction of the arc Valid Range 0 to 2000 mS Machine Type 52 AA nn FA 34 0D If requested in command 30 the AGC will transmit the machine type 153 Spirit150a 203 Spirit200a 273 Spirit275a 403 Spirit400a Set Marking Ar...

Page 123: ...the capacitors Failure of a capacitor can result in a sudden release of stored energy causing rupture of the capacitor case Routine Maintenance Note At minimum these checks should be performed on a monthly basis In excessively dirty environments or in heavy usage situations the checks should be performed more frequently Power Supply 1 Remove the left right front and rear panels of the power supply...

Page 124: ...ts to the remote high frequency console Also make sure the shield adapter is secured tightly to the high frequency console enclosure 3 Inspect the braided shield for nicks or cuts and replace if necessary 4 Remove the torch handle and verify that the connections at the torch base are tightened securely Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage ...

Page 125: ...er of the RHF console and verify that all leads and hoses are tightened securely Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened 2 Check the spark gap electrodes for signs of wear Replace electrodes that have rounded faces Use a clean feeler gauge and set the spark gap to 015 38 mm Work Ground 1 Verify that the work ground lead is s...

Page 126: ...rch head is installed onto the torch base 5 Using a funnel to collect the coolant unscrew the drain petcock on the bottom of the coolant reservoir Leave the funnel in place after the coolant drains out of the reservoir 6 Remove the torch coolant supply hose from the rear of the power supply Note that the coolant supply hose has right hand threads 7 Blow compressed air 100 psi maximum into the cool...

Page 127: ...eflow gas valve 1 energized OPTO 11 LED PLASMA Plasma gas valve 2 energized OPTO 12 LED SHIELD Shield gas valve 3 energized OPTO 13 LED GSV4 Vent gas valve 4 energized OPTO 14 LED GSV5 Postflow gas valve 5 energized OPTO 15 LED MARKING Marking gas valves 6 and 7 energized LED 8 START Plasma start signal applied to Spirit LED 9 CHOPPER Chopper energized LED 10 PAT Pilot arc transistor energized LED...

Page 128: ... PWR LED 29 15V The following LED s should illuminate when the ON button is depressed OPTO 6 LED 3 PHASE OPTO 5 LED PUMP OPTO 4 LED LATCH The following LED s should illuminate in sequence after a start signal is received in the cutting mode LED 8 START OPTO 10 LED PREFLOW OPTO 12 LED SHIELD OPTO 3 LED SURGE OPTIONAL OPTO 2 LED CON OPTO 1 LED PAR LED 10 PAT LED 9 CHOPPER OPTO 9 LED HIGH FREQ LED 11...

Page 129: ...hase power being supplied to the chopper assembly Verify that the primary wall disconnect fuses are good and check the main transformer main contactor and A C Detect p c board for proper operation Also this LED should turn on immediately when the green ON button is pressed If not check P28 3 to P28 4 for 10 VDC first This should drop to 0 VDC when the ON button is pushed If not then check CR1 and ...

Page 130: ...rror code by blinking LED22 on and off to indicate that an error has occurred The number of blinks can be counted to determine which error has occurred The following chart lists the errors and the corresponding number of blinks LED22 Number of Blinks Error 1 No transferred arc TAC established 2 TAC lost before current slope up 3 TAC lost during current slope up 4 TAC lost while cutting 5 TAC lost ...

Page 131: ...erforming any tests Problem Possible Cause Front panel white A C power light will not illuminate 1 Primary disconnect fuse blown 2 Fuse F1A F1B or F4 blown 3 White light or associated wiring bad 4 Transformer TR2 or associated wiring bad Unit will not energize when the ON button is pressed 1 RHF door open 2 Low coolant level 3 Fuse F4 blown 4 Faulty ON switch or associated wiring The ON switch is ...

Page 132: ...lead to the large brass body of the torch No spark between the spark gap electrodes 1 Improper spark gap Set gap to 015 381 mm 2 Worn spark gap electrodes Clean electrodes with 600 grit sandpaper and regap Replace electrodes that have a rounded face 3 Bad high frequency transformer TR5 Check for signs of arcing 4 Check for 120VAC on the input side of filter FL1 inside the RHF console after a start...

Page 133: ...8 and P9 on the gas console I O p c board 3 Loose motorized regulator plugs Remove and reinstall the motor plugs and P4 P7 on the gas console I O p c board 4 Pressure regulator orifice clogged with dirt or debris Turn off primary power and turn motorized regulator screw all the way in by hand 5 Binding regulator Turn off primary power and turn all motorized regulators to their mid positions by han...

Page 134: ...ing flow chart can be found at the end of this section 1 Turn off all power to the Spirit power supply 2 Open the RHF console door and disconnect the black primary wires of the high frequency transformer from the 120 VAC line filter Close the RHF console door to activate the door interlock switch 3 Remove the front and left side panels from the power supply to expose the output terminal block and ...

Page 135: ...a start signal to the power supply and check the DC voltage between P2 4 ground and P2 5 signal on the chopper p c board This voltage should change from approximately 15 5 VDC to less than 1 VDC after the main contactor of the power supply is energized If 15 5 VDC is not present replace the chopper If no voltage change occurs check for approximately 15 5 VDC between P26 1 ground and P26 2 signal o...

Page 136: ...J This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 14 ...

Page 137: ...ransformer 230 V 60 Hz 3Ø TR1 main transformer 380 V 50 60 Hz 3Ø TR1 main transformer 415 V 50 60 Hz 3Ø TR1 main transformer 460 V 60 Hz 3Ø TR1 main transformer 575 V 60 Hz 3Ø 15 709086 4 TB1 TB4 terminal block marker 14 position 16 709007 4 TB1 TB4 terminal block 14 position 17 709058 10 F2 F11 fuse holder 18 709012 1 F10 fuse AGC 3A fuse 19 709011 2 F3 F4 fuse AGC 5A 20 709059 1 F8 fuse AGC 2A 2...

Page 138: ... CR3 PAR relay 51 701165 2 R7 R8 3 ohm pilot arc resistor 52 500536 1 PAT IGBT drive p c board assembly 53 705011 1 PAT IGBT 54 709167 1 TB5 3Ø power terminal block 55 702075 2 PAT IGBT filter capacitor 56 277452 1 I O p c board assembly 57 Contact factory 1 Height control voltage divider p c board assembly 58 282130 1 Chopper assembly 59 709117 1 I O terminal block small 62 706036 1 TR8 transform...

Page 139: ... of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 3 Power Supply 1 of 4 Front panel fans not shown item numbers 42 and 82 ...

Page 140: ...s subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 4 Power Supply 2 of 4 ...

Page 141: ...s subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 5 Power Supply 3 of 4 ...

Page 142: ...s subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 6 Power Supply 4 of 4 ...

Page 143: ...sition 14 505039 1 Floppy disk drive 15 500021 1 Floppy disk drive cover Not shown 505047 1 Floppy disk drive cable 16 501145 9 Manifold 17 708097 4 Pressure switch 80 200 psi 18 715097 6 Transducer isolator 19 260217 5 Solenoid valve 20 500867 3 Motorized regulator assembly 22 500868 1 Motorized regulator assembly oxygen 23 709007 1 Terminal block 14 position 24 709009 1 Terminal block marker 14 ...

Page 144: ...ject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 8 Automatic Gas Console 1 of 2 ...

Page 145: ...ject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 9 Automatic Gas Console 2 of 2 ...

Page 146: ...ant return fitting left hand 2 715050 1 Coolant supply fitting right hand 3 709227 1 Strain relief 5 709001 1 4 pin receptacle 6 707001 1 Line filter 7 706109 1 Transformer 5000V 20 mA 8 702069 1 Capacitor 15 kV 9 708057 1 Door interlock switch 10 500014 1 Spark gap assembly 11 740039 3 Spark gap electrode 12 505043 1 High frequency inductor 13 740072 1 Standoff 14 800041 1 Busbar 15 500505 1 RHF ...

Page 147: ...s bracket 2 277195 1 2 gang manifold bracket 3 820134 1 Torch handle 4 279050 1 Torch Base 5 279150 279160 1 Torch Head Copper Electrode Torch Head Silver Electrode 6 820209 1 O ring red 7 500024 1 O ring blue 8 500018 1 O ring red 9 280022 1 5 gang manifold assembly 10 500740 1 Torch solenoid plasma hose 11 279013 1 O ring red indicator only not a seal 12 279113 6 O ring red 13 279112 1 O ring re...

Page 148: ... non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 12 Shielded Torch Leads Part Number Length 200304 10 10 ft 3 0 m 200304 15 15 ft 4 6 m 200304 20 20 ft 6 1 m 200304 25 25 ft 7 6 m 200304 30 30 ft 9 1 m 200304 35 35 ft 10 7 m 200304 40 40 ft 12 2 m 200304 45 45 ft 13 7 m 200304 50 50 ft 15 2 m ...

Page 149: ...ary to the requirements of the EAR 8 13 Gas Hose Package Part Number Length 280317 20 20 ft 6 1 m 280317 25 25 ft 7 6 m 280317 30 30 ft 9 1 m 280317 35 35 ft 10 7 m 280317 40 40 ft 12 2 m 280317 45 45 ft 13 7 m 280317 50 50 ft 15 2 m 280317 55 55 ft 16 8 m 280317 60 60 ft 18 3 m 280317 65 65 ft 19 8 m 280317 70 70 ft 21 3 m 280317 75 75 ft 22 9 m 280317 80 80 ft 24 4 m 280317 85 85 ft 25 9 m 28031...

Page 150: ...306 10 288306 10 10 ft 3 0 m 280306 15 288306 15 15 ft 4 6 m 280306 20 288306 20 20 ft 6 1 m 280306 25 288306 25 25 ft 7 6 m 280306 30 288306 30 30 ft 9 1 m 280306 35 288306 35 35 ft 10 7 m 280306 40 288306 40 40 ft 12 2 m 280306 45 288806 45 45 ft 13 7 m 280306 50 288306 50 50 ft 15 2 m 280306 55 288306 55 55 ft 16 8 m 280306 60 288306 60 60 ft 18 3 m 280306 65 288306 65 65 ft 19 8 m 280306 70 28...

Page 151: ...0 ft 3 0 m 280318 15 288318 15 15 ft 4 6 m 280318 20 288318 20 20 ft 6 1 m 280318 25 288318 25 25 ft 7 6 m 280318 30 288318 30 30 ft 9 1 m 280318 35 288318 35 35 ft 10 7 m 280318 40 288318 40 40 ft 12 2 m 280318 45 288318 45 45 ft 13 7 m 280318 50 288318 50 50 ft 15 2 m 280318 55 288318 55 55 ft 16 8 m 280318 60 288318 60 60 ft 18 3 m 280318 65 288318 65 65 ft 19 8 m 280318 70 288318 70 70 ft 21 3...

Page 152: ...trary to the requirements of the EAR 8 16 Oxygen Supply Gas Hose Optional Part Number Length 200362 25 25 ft 7 6 m 200362 50 50 ft 15 2 m Nitrogen Supply Gas Hose Optional Part Number Length 200365 25 25 ft 7 6 m 200365 50 50 ft 15 2 m Air Supply Gas Hose Optional Part Number Length 200364 25 25 ft 7 6 m 200364 50 50 ft 15 2 m H17 Supply Gas Hose Optional Part Number Length 200363 25 25 ft 7 6 m 2...

Page 153: ...ontrols of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 17 Power Supply Microprocessor P C Board Assembly 282275 ...

Page 154: ... to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 18 A C Detect P C Board Assembly 500810 ...

Page 155: ...ct to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 19 Relay P C Board Assembly 500348 ...

Page 156: ... the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 20 Power Supply I O P C Board Assembly 277452 ...

Page 157: ...controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 21 Automatic Gas Console I O P C Board Assembly 200288 ...

Page 158: ...lectrode 100A Mild Steel 100A Stainless Air 100A Aluminum 277133 2 Electrode 100A Stainless H17 277292 3 Electrode 150A Mild Steel 150A Stainless Air 150A Aluminum 277291 3 Electrode 200A Mild Steel 200A Stainless Air 200A Aluminum 277135 2 Electrode 150 200 Stainless H17 277120 5 Nozzle 30A Mild Steel 30A Aluminum 277121 3 Nozzle 30A Stainless Air 277122 5 Nozzle 50A Mild Steel 50A Aluminum 27712...

Page 159: ...Stainless Air 100A Aluminum 277146 3 Shield Cap 100A Stainless H17 277117 3 Shield Cap 150A Mild Steel 150A Stainless Air 150A Aluminum 277298 3 Shield Cap 150A Stainless H17 277274 3 Shield Cap 200A Mild Steel 200A Stainless 200A Aluminum 277138 1 Swirl Ring 30A Stainless Air 277140 1 Swirl Ring 30 50A Mild Steel 70A Stainless H17 30A Aluminum 277142 1 Swirl Ring 50 70A Mild Steel 50 70A Stainles...

Page 160: ...ainless Air 100A Aluminum 150A Mild Steel 1 2 and below 277152 1 Inner Retaining Cap 150A Mild Steel 5 8 and above 150A Stainless Air 150A Aluminum 277113 1 Inner Retaining Cap 70 100A Stainless H17 277266 1 Inner Retaining Cap 150A Stainless H17 200A Mild Steel 200A Stainless 200A Aluminum 716012 1 O ring Lubricant 500024 2 Torch O ring blue lower 500018 2 Torch O ring red middle 820209 2 Torch O...

Page 161: ...ieved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installation and Use The user is responsible for installing and using the plasma cutting equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the ...

Page 162: ... surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Plasma cutting equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take ...

Page 163: ...e The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing...

Page 164: ...is information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 4 BLANK PAGE ...

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