Kaliburn Spirit200a User Manual Download Page 6

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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.

Section 7 Maintenance and Troubleshooting

Routine Maintenance .............................................................................................. 7-1

Replacing the Torch Coolant .................................................................................. 7-4

Microprocessor Status LED’s .................................................................................. 7-5

Microprocessor Sequence of Operation ................................................................. 7-6

Troubleshooting Using the Control Panel Status LED’s ......................................... 7-7

Troubleshooting Using the Automatic Gas Console Messages Screen ................. 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 (Optional) .............................................................................. 8-16

H17 Supply Gas Hose (Optional) ............................................................................ 8-16

Power Supply Microprocessor P.C. Board .............................................................. 8-17

A.C. Detect P.C. Board ........................................................................................... 8-18

Relay P.C. Board .................................................................................................... 8-19

Power Supply I/O P.C. Board ................................................................................. 8-20

Automatic Gas Console I/O P.C. Board .................................................................. 8-21

Consumable Spare Parts Kit ................................................................................... 8-22

Appendix A Electromagnetic Compatibility (EMC)

Background ............................................................................................................. A-1

Installation and Use ................................................................................................ A-1

Assessment of Area ................................................................................................ A-2

Methods of Reducing Emissions ............................................................................. A-2

Summary of Contents for Spirit200a

Page 1: ...r 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 b...

Page 2: ...tion 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 Inpu...

Page 3: ...nder 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...

Page 4: ...ponents 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 Airbor...

Page 5: ...omatic 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 Para...

Page 6: ...en 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 Shi...

Page 7: ...c 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...

Page 8: ...ical 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...

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 s...

Page 10: ...r 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 ot...

Page 11: ...ed 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 Reflec...

Page 12: ...ectrical 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 Compre...

Page 13: ...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...

Page 14: ...s 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 C...

Page 15: ...3 60Hz 282411 380 VAC 3 50 60Hz 282413 415 VAC 3 50 60Hz 282414 460 VAC 3 60Hz 282412 575 VAC 3 60Hz 282415 Input Current at Maximum Output 208 VAC 3 60Hz 115 amps 230 VAC 3 60Hz 104 amps 380 VAC 3 50...

Page 16: ...ormation 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 press...

Page 17: ...s 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...

Page 18: ...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 6 Remote High Frequency Console Speci...

Page 19: ...nited 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 Torc...

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 Manif...

Page 21: ...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 follo...

Page 22: ...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 Sta...

Page 23: ...act 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...

Page 24: ...er than 10 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 dim...

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...

Page 26: ...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 State...

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 Rout...

Page 28: ...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 i...

Page 29: ...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 Unite...

Page 30: ...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 sh...

Page 31: ...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 Unite...

Page 32: ...ittings 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...

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 d...

Page 34: ...ly 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 Pr...

Page 35: ...rmation 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...

Page 36: ...ply 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 t...

Page 37: ...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...

Page 38: ...e 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 cy...

Page 39: ...mmunication 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 paramet...

Page 40: ...ant 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 industri...

Page 41: ...oolant 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 pu...

Page 42: ...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 Stat...

Page 43: ...luminates 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 energi...

Page 44: ...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 sa...

Page 45: ...u 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 t...

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 o...

Page 47: ...een 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 differen...

Page 48: ...ters 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...

Page 49: ...de 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 b...

Page 50: ...atic 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...

Page 51: ...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 t...

Page 52: ...ocation 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 parameter...

Page 53: ...AR 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 27713...

Page 54: ...hall 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 C...

Page 55: ...on 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 Electr...

Page 56: ...f 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 2771...

Page 57: ...ovided 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 Out...

Page 58: ...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 27915...

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 Ca...

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 attach...

Page 61: ...n 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 ho...

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...

Page 63: ...late 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 dro...

Page 64: ...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 Repla...

Page 65: ...g 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...

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...

Page 67: ...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 12...

Page 68: ...3 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...

Page 69: ...ge 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 0...

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...

Page 71: ...0 500 130 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 Shie...

Page 72: ...0 130 350 600 152 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 Sh...

Page 73: ...ight 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 Mater...

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...

Page 75: ...ial 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...

Page 76: ...peed 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...

Page 77: ...ostflow 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...

Page 78: ...oltage 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...

Page 79: ...e 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 18...

Page 80: ...rce 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...

Page 81: ...eight 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...

Page 82: ...0 200 070 200 400 150 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 Met...

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 Preflo...

Page 84: ...ght 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...

Page 85: ...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 Pref...

Page 86: ...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 Preflo...

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...

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 Shiel...

Page 89: ...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 Pl...

Page 90: ...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 Preflo...

Page 91: ...sec 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 Plasm...

Page 92: ...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...

Page 93: ...en 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 s...

Page 94: ...main 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...

Page 95: ...rmally 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 pre...

Page 96: ...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 pre...

Page 97: ...ansferred 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 cuttin...

Page 98: ...oll 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 wi...

Page 99: ...y 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...

Page 100: ...e 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 selecti...

Page 101: ...ect 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 Th...

Page 102: ...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 bein...

Page 103: ...shed 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 Th...

Page 104: ...or 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...

Page 105: ...ts 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...

Page 106: ...tenance 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 restor...

Page 107: ...on 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...

Page 108: ...nk 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 No...

Page 109: ...e 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 chan...

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 Se...

Page 111: ...rogen 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 c...

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...

Page 113: ...s 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 pl...

Page 114: ...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 t...

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 h...

Page 116: ...e 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...

Page 117: ...eives 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 retrie...

Page 118: ...ation 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 Va...

Page 119: ...nt 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...

Page 120: ...rch 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 Sen...

Page 121: ...ied 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...

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 a...

Page 123: ...he 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 mon...

Page 124: ...s 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 necess...

Page 125: ...r 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 Chec...

Page 126: ...ch 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...

Page 127: ...flow 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 val...

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...

Page 129: ...ase 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...

Page 130: ...ror 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 corr...

Page 131: ...rforming 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 Tran...

Page 132: ...ead 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 r...

Page 133: ...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 dir...

Page 134: ...ng 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 transform...

Page 135: ...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...

Page 136: ...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...

Page 137: ...transformer 230 V 60 Hz 3 TR1 main transformer 380 V 50 60 Hz 3 TR1 main transformer 415 V 50 60 Hz 3 TR1 main transformer 460 V 60 Hz 3 TR1 main transformer 575 V 60 Hz 3 15 709086 4 TB1 TB4 terminal...

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 3 power terminal block 55 702075 2 PAT IGBT filter capacitor...

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 requirement...

Page 140: ...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 co...

Page 141: ...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 co...

Page 142: ...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 co...

Page 143: ...ition 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 is...

Page 144: ...ect 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 contrar...

Page 145: ...ect 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 contrar...

Page 146: ...nt 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 Capac...

Page 147: ...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 r...

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...

Page 149: ...ry 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...

Page 150: ...06 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 2...

Page 151: ...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...

Page 152: ...rary 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...

Page 153: ...ntrols 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 requ...

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...

Page 155: ...t 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...

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 th...

Page 157: ...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 req...

Page 158: ...ectrode 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 20...

Page 159: ...tainless 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 M...

Page 160: ...inless 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 27...

Page 161: ...eved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installatio...

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...

Page 163: ...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...

Page 164: ...s 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...

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