Lincoln Electric spirit II 150 Technical Manual Download Page 3

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Spirit II User’s Manual

Prologue

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.

iii

Table of Contents

Section 1: Safety

General Precautions ......................................................................................... 1-1

Ultraviolet Radiation Protection ......................................................................... 1-1

Noise Protection ................................................................................................ 1-1

Toxic Fume Prevention ..................................................................................... 1-2

Electric Shock Prevention ................................................................................. 1-2

Fire Prevention .................................................................................................. 1-3

Explosion Prevention......................................................................................... 1-3

Health Support Equipment ................................................................................ 1-4

Safety Standards Booklet Index ........................................................................ 1-5

Section 2: Specifications

System Description ........................................................................................... 2-1

System Components ......................................................................................... 2-2

Power Supply Specifications ............................................................................. 2-3

Torch Coolant Specifications ............................................................................. 2-4

Automatic Gas Console (AGC) Specifications .................................................. 2-5

Gas Supply Requirements ................................................................................ 2-6

Plasma Console Specifications ......................................................................... 2-7

Arc Starting Console (ASC) Specifications with RHF ........................................ 2-8

Arc Starting Console (ASC) Specifications with CleanStrike

™

.......................... 2-9

Torch and 2-Gang Manifold Specifications ........................................................ 2-10

5-Gang Manifold Specifications ......................................................................... 2-11

Airborne Noise Emissions ................................................................................. 2-12

Electromagnetic Compatibility (EMC) ................................................................ 2-12

Section 3: Installation

Initial Inspection ................................................................................................ 3-1

Component Placement ...................................................................................... 3-1

System Interconnection ..................................................................................... 3-2

Power Supply Primary Power Connections ....................................................... 3-7

Power Supply Output Connections ................................................................... 3-9

ASC Control Cable and ASC Ground Connections ........................................... 3-11

Cooling System Connections ............................................................................ 3-11

Torch Leads to Arc Starting Console Connections ............................................ 3-13

Torch Leads to Torch Base Connections .......................................................... 3-15

Torch Gas Connections ..................................................................................... 3-16

Gas Supply Connections ................................................................................... 3-19

Plasma Console Connections ........................................................................... 3-20

CAN Communication Connections .................................................................... 3-21

CNC Machine Interface Connections ................................................................ 3-22

Filling the Cooling System ................................................................................. 3-23

Summary of Contents for spirit II 150

Page 1: ...rements of the EAR Technical Manual SPIRIT II 150 Register your equipment http www burny com warranty Save for future reference Date Purchased Model Number Serial Number THELINCOLNELECTRICCOMPANY BK718113 Rev I Issue Date 01 SEP 2015 4130 Carolina Commerce Pkwy Ladson SC 29456 U S A Lincoln Global Inc All Rights Reserved Phone 1 843 695 4000 www lincolnelectric com Automatic Plasma Cutting System ...

Page 2: ... Added argon purity specification Added notes about torch handle vent hole Updated Chopper Test Procedure Clarified RS422 Parameter Control description F LAD0264 CAD 03 31 2014 Added BK prefix to all part numbers Added PCB Outline Dwgs and corrected electrode tool in Part List Corrected Remote On Off info in Installation section G LAD0276 LAD0199 LAD0284 LAD0288 CAD 09 18 2014 Clarified fuse break...

Page 3: ...omatic Gas Console AGC Specifications 2 5 Gas Supply Requirements 2 6 Plasma Console Specifications 2 7 Arc Starting Console ASC Specifications with RHF 2 8 Arc Starting Console ASC Specifications with CleanStrike 2 9 Torch and 2 Gang Manifold Specifications 2 10 5 Gang Manifold Specifications 2 11 Airborne Noise Emissions 2 12 Electromagnetic Compatibility EMC 2 12 Section 3 Installation Initial ...

Page 4: ...Settings 4 11 Restoring or Deleting Customized Settings 4 12 Configuration Tab 4 13 Advanced Config Tab 4 14 Network Settings Tab 4 15 Software Updates Tab 4 16 System Info Tab 4 18 Tools Tab Restart Plasma Console 4 18 Pressures Coolant Tab 4 19 RS422 Tab 4 20 Electrical Tab 4 21 Cut Info Tab 4 21 Power Supply Tab 4 23 Error Log Tab 4 23 Messages Tab 4 24 Section 5 Torch Consumables and Cutting C...

Page 5: ...Work Ground Lead 7 14 Oxygen Supply Gas Hose Optional 7 15 Nitrogen Supply Gas Hose Optional 7 15 Air Supply Gas Hose Optional 7 15 H17 Supply Gas Hose Optional 7 15 Argon Supply Gas Hose Optional 7 15 CII Cable for Optional External Inova 7 16 FII Cable for Optional Internal Inova 7 17 JII Cable for Optional Internal Inova 7 18 PCB Assemblies Component Reference Locations 7 19 Section 8 Internal ...

Page 6: ...ble de l usure des câbles ni des dom mages résultant de l usure des câbles suite à des courbures et à l abra sion L usager final est responsable de l inspection de routine des câbles pour vérifier qu ils ne présentent pas d usure éventuelle et pour y remédier avant la panne du câble 6 Tous les Produits Burny Kaliburn sont garantis par Burny Kaliburn et ne sont pas couverts par cette garantie Email...

Page 7: ...cise extreme caution while working on the system Ultraviolet Radiation Protection Plasma cutting produces ultraviolet radiation similar to a welding arc 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 pr...

Page 8: ... the system Observe the following guidelines to protect against electric shock A wall mounted disconnect switch should be installed and fused according to local and national electrical 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...

Page 9: ...all on flammable materials Make sure that all 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 ...

Page 10: ...d gas cylinder 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 H...

Page 11: ...tainers 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 Welding Society 550 NW LeJeune Road Miami FL 33126 7 ANSI Standard ...

Page 12: ...ciation 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 Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlingto...

Page 13: ...erial communication The RS 422 port also allows for full control of the cutting parameters from an x y machine controller The system keeps a detailed record of errors that may have occurred during the cutting sequence Additionally systems utilizing the automatic gas console can use argon for marking which produces improved mark quality The Spirit II system is available with an Arc Starting Console...

Page 14: ...mponents Standard Components Power Supply Automatic Gas Console Plasma Console Touch Screen CAN Cables CAN Termination Plug Arc Starting Console ASC with Remote High Frequency RHF or Arc Starting Console ASC with CleanStrike Technology ASC Control Cable ASC Ground Cable Torch and Handle Assembly Torch Lead Set 5 gang Manifold Assembly 5 gang Manifold Control Cable 2 gang Manifold Assembly 2 gang M...

Page 15: ...0212 94 amps 240 VAC 3Ø 60Hz BK300213 86 amps 380 VAC 3Ø 50 60Hz BK300214 54 amps 400 VAC 3Ø 50 60Hz BK300215 52 amps 415 VAC 3Ø 50 60Hz BK300216 50 amps 440 VAC 3Ø 50 60Hz BK300217 47 amps 480 VAC 3Ø 60Hz BK300218 43 amps 600 VAC 3Ø 60Hz BK300219 34 amps Open Circuit Voltage 300 VDC Output Current drooping characteristic 10 150 amps Maximum Output Voltage 170 VDC Duty Cycle 100 25 5 kW Maximum Am...

Page 16: ...tion 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 BK500695 For operating temperatures below 13º C a 50 solution of ...

Page 17: ...egulations 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 5 Automatic Gas Console AGC Specifications Part Number BK300418 Weight 53 lbs 24 kg 12 4 315 12 0 305 13 7 348 10 9 277 7 0 178 4 Ø 300 7 6 ...

Page 18: ... 145 psi 10 0 bar Oxygen and nitrogen should be supplied with a purity of at least 99 5 H17 purity should be at least 99 995 Argon purity should be at least 99 99 All should be clean dry and oil free A potential fire hazard exists when cutting with oxygen It is recommended that an exhaust ventilation system be used when cutting with oxygen Flashback arrestors must be supplied unless they are not a...

Page 19: ...ration 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 7 Plasma Console Specifications Part Number BK300800 Weight 10 lbs 4 5 kg 9 2 234 13 4 340 3 6 91 3 2 81 10 1 257 4 Ø 180 5 ...

Page 20: ...means to any location outside the United States contrary to the requirements of the EAR 2 8 Arc Starting Console ASC Specifications with Remote High Frequency RHF Part Number BK300510 Weight 24 lbs 10 9 kg Spark gap distance 0 015 in 0 381 mm Note The Spirit II system requires either an ASC with RHF or an ASC with CleanStrike Technology but not both 12 75 324 8 00 203 12 00 305 13 50 343 10 00 254...

Page 21: ...nited States contrary to the requirements of the EAR 2 9 Arc Starting Console ASC Specifications with CleanStrike Technology Part Number BK300500 Weight 22 lbs 10 kg Note The Spirit II system requires either an ASC with RHF or an ASC with CleanStrike Technology but not both Systems containing an ASC with CleanStrike Technology are only recommended for use with downdraft cutting tables 12 75 324 8 ...

Page 22: ... EAR 2 10 Torch and 2 Gang Manifold Specifications Part Number 2 Gang Manifold Assembly BK284214 Torch Handle standard BK278001 Torch Handle short BK278018 Torch Base BK279000 Torch Head Copper Electrode BK279100 Torch Head Silver Electrode BK279060 Max Weight Manifold Bracket Handle BK278001 Base and Head 8 3 lbs 3 8 kg Torch Head 5 08 129 Torch Base 1 87 47 Torch Handle BK278001 9 46 240 BK27801...

Page 23: ...his 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 11 5 Gang Manifold Specifications Part Number BK300075 Weight 6 lbs 2 7 kg 4 20 107 3 80 97 6 18 157 0 327 8 3 0 25 6 4 1 18 30 8 35 212 3 035 77 4 0 187 4 8 Mounting Holes ...

Page 24: ...by local or national codes The following chart gives the noise levels generated by the system when operating at 150 amps 130 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound Pressure Level C Weighted Sound Pressure Level 1 meter horizontal 1 6 meters above the workpiece 97 dB 94 dB The maximum noise level is 121 dB at a distance of 3 inches 76 2 mm...

Page 25: ...nto and out of the power supply Maintain at least 24 inches of space on all sides of the unit The location should subject the power supply to the least amount of dust dirt moisture and corrosive vapors The surface on which the power supply is located should have a grade of no greater than 10º to eliminate the risk of toppling over The power supply must be cleaned as often as necessary to prevent t...

Page 26: ...oner of an arc voltage control height control capable of maintaining the cutting arc voltage within 1 arc volt The arc voltage must be adjustable in 1 arc volt increments The positioner must be rigid to ensure cut quality and a torch collision sensor is highly recommended See Section 2 for mounting dimensions System Interconnection The Spirit II system interconnection diagrams on the following pag...

Page 27: ...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 3 Figure 1a Spirit II System AGC Internal Inova ASC with RHF ...

Page 28: ...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 Figure 1b Spirit II System AGC External Inova ASC with RHF ...

Page 29: ...f 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 5 Figure 1c Spirit II System AGC Internal Inova ASC with CleanStrike Technology ...

Page 30: ...f 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 6 Figure 1d Spirit II System AGC External Inova ASC with CleanStrike Technology ...

Page 31: ...owed by local or national codes The main feed device breaker or fuse and any branch protection breaker or fuse upstream of the power supply must be sized to handle all branch loads for both steady state and inrush current 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 rec...

Page 32: ...trary to the requirements of the EAR 3 8 cover removed Be sure to connect the primary ground cable to the ground stud on the input terminal block Under no circumstances are the supply cables to be routed through the opening in the power supply cabinet without conduit or an appropriate strain relief as per local and national codes Strain Relief Disconnect Box Connections TB5 Connections L1 U L2 V L...

Page 33: ...llips head screw For systems that include ACS with CleanStrike Technology connect it to the angled bracket on the red standoff using the provided Phillips head screw Power Supply CTP Sensor Lead 1 Route the ring terminal end of the 14AWG power supply CTP sensor lead through the bushing on the rear of the power supply and connect it to the CTP terminal 2 Route the FASTON end of the power supply CTP...

Page 34: ...ions 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 10 ASC with RHF ASC with CleanStrike Technology 4 1 3 2 Strain Relief Strain Relief 1 3 2 Figure 4 Power Supply Output Connections Strain Relief 1 3 2 ...

Page 35: ...rting console 2 Connect the other end of the ASC ground cable to the star ground on the cutting table Make sure that good metal to metal contact is made Cooling System Connections Perform the following steps to connect the cooling system to the arc starting console See Figure 5 on the next page Coolant Supply Hose 1 Connect one end of the coolant supply hose to the coolant out fitting on the rear ...

Page 36: ... 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 12 ASC with RHF ASC with CleanStrike Technology Figure 5 Cooling System Connections 7 8 8 7 5 6 6 5 7 8 ...

Page 37: ...e of the arc starting 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 of the arc starting console Torch Electrode Coolant Supply Lead Connect the torch electrode coolant supply lead to the brass cathode manifold Note that the torch electrode coolant supply lead has right hand...

Page 38: ... 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 14 ASC with RHF ASC with CleanStrike Technology Figure 6 Torch Leads to Arc Starting Console Connections 15 12 14 13 11 15 13 12 14 11 ...

Page 39: ...ned Also use two wrenches when tightening the torch fittings to avoid damaging the torch base Torch Lead through Torch Handle Installation Route the torch leads through the torch handle Note that the threaded end of the torch handle mates with the torch base Torch Electrode Coolant Supply Lead Connect the torch electrode coolant supply lead to the torch base as shown Torch Coolant Return Lead Conn...

Page 40: ...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 Connect the other end of the 17 inch 432 mm plasma gas hos...

Page 41: ... outlet on the rear of the AGC 2 Connect the other end of the plasma hose to the plasma inlet on the 2 gang manifold 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 manifold Preflow Gas Hose 1 Connect one end of the preflow hose to the preflow outlet on the rear of the AGC ...

Page 42: ...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 3 18 Figure 8 Torch Gas Connections BLACK 25 22 26 27 24 23 22 21 30 RED GREEN REAR PORT REAR PORT BLUE 27 21 20 28 25 26 Automatic Gas Console 20 24 28 29 23 BLUE BLACK BLACK RED GREEN ...

Page 43: ...e 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 3821 hose color blue Oxygen must be supplied to the unit at all times unless stainless steel is being cut wit...

Page 44: ... communication cable See CAN Communication Connections for more details CAN Communications Insert the female end of the CAN communication cable or the CAN termination plug depending upon the connection scheme See CAN Communication Connections for more details RS 422 Communications Insert an RS 422 cable if necessary to connect to other devices RS 422 Communications Insert an RS 422 cable if necess...

Page 45: ...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 3 21 CAN Communication Connections Choose one of the schemes below to connect the Spirit system for CAN communications Both schemes require two CAN cables and a CAN termination plug ...

Page 46: ...imultaneously with initial torch height positioning The contacts should be rated for 24VDC 7 3mA Motion Output The power supply provides a maintained contact closure output between P8 pins 12 and 14 as long as an arc is maintained between the torch and the workpiece The motion contacts are rated for 24VDC 10mA Remote On Off Input The power supply requires a maintained contact closure between P8 pi...

Page 47: ...t 8 Apply primary power to the Spirit system and enable it by releasing turn right the OFF Button on the plasma console 9 On the plasma console press the Diagnostics navigation button to access the Pressures Coolant tab 10 Press the Fill Flush button to start the coolant pump circulating coolant through the system Note the Coolant Flow indicator press the Status navigation button will remain red u...

Page 48: ...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 States contrary to the requirements of the EAR 3 24 BLANK ...

Page 49: ...stem Release turn to the right to enable the system which can then be energized using the ON Button Touch Screen Turns on automatically when AC power is applied to the Spirit system Press the screen to operate as described below Navigation and ON Button Press the navigation buttons to access the various screens described in this section Change settings by simply pressing that part of the screen Na...

Page 50: ...icons at the top of the screen provide additional important information Messages and Icons Edge start is required The power supply is ON The power supply is OFF A valve is open Warning message see Error Log The system is cutting The system is marking Gas pressures are adjusting Setup Optimum Current pressures and gasses are set to the cutting chart defaults for the selected material and thickness ...

Page 51: ...omatically however these parameters can be customized See Customizing Cutting or Marking Settings for more information Select Material Type Press the Material Selection button and select the desired material from the list Choose cancel to return to the previously selected material Select Material Thickness Press the Thickness Selection button to choose from a list of predefined gauges and thicknes...

Page 52: ...he system the torch height control and the X Y controller must be configured properly To view the recommended cutting data press the Parameters navigation button See RS422 Parameter Control for more information on how to adjust these settings Viewing the Required Torch Parts Once the material and thickness have been selected the torch parts are determined automatically To see which consumables nee...

Page 53: ...icator Green when 3 phase power is satisfactory Red when there is a problem with main 3 phase power Gas Console Indicator Green when the automatic gas console is operational Red when there is a problem with the gas system Check the message screen for errors ASC Door Indicator Green when the arc starting console door is closed Red when the arc starting console door is open Coolant Temperature Indic...

Page 54: ...tual pressure reading will change Green for pressures at the set point Yellow for pressures not at the setpoint Press the Adjust button to automatically adjust the gas pressures A message at the top of the screen indicates the status of the regulators in the automatic gas console Pressure Regulators Adjusted Actual reading equals the Set Point The background color of the Actual reading will be Gre...

Page 55: ...ton on the Plasma Console 2 The AGC will purge the gas hoses and set the correct gas pressures automatically After the pressures have been set the Gas Console indicator on the Status Screen will change from red to green 3 Once the Gas Console indicator is green the system is ready for cutting or marking 4 When the system receives a start signal from the X Y controller the following sequence is ini...

Page 56: ...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 controller 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 controller motion delay time Movin...

Page 57: ...o cut a given 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 ...

Page 58: ...oint To alter the current set point from the default setting press the Current Amps button on the Material Screen and choose from the list of available values Note When marking is the selected process the current cannot be changed Altering Gas Types On the Material Screen press the Plasma or Shield button and select the desired gas type The plasma gas can be changed to Air Oxygen Nitrogen or H17 S...

Page 59: ...an be changed manually Press the corresponding data entry button and enter the desired value Once a value has been changed press the Manual Transmit button to send the value to the X Y machine or torch height control Saving Customized Settings If one of the default cutting or marking parameters was altered the new configuration can be saved for later use Press the Manage Custom Setups button on th...

Page 60: ...ry to the requirements of the EAR 4 12 Restoring or Deleting Customized Settings If a new setup configuration was saved for later use it can be restored at any time or deleted permanently from the list Press the Manage Custom Setups button on the Parameters Screen Press the left Prev or right Next arrow button to scroll through the list of existing custom setups The name of the selected setup will...

Page 61: ...r marking is changed or when the arc voltage pierce initial height or cutting marking height is changed on the Parameters Screen With the value set to Manual the parameters are transmitted using the Manual Transmit button on the Parameters Screen Choose Disable to prevent the system from sending RS422 communications Cut Mark Control The Spirit system has the capability of plasma cutting and plasma...

Page 62: ...number simply choose from node 1 through 8 When using an Inova torch height control system with the Spirit the communication node feature must be disabled To disable the communication node press the Disabled button Set CAN Domain Make sure the CAN domain is set to 1 All other selections are for future use Torch Selection Choose which type of Quick Disconnect head is being used The type of head cor...

Page 63: ... the requirements of the EAR 4 15 Network Settings Tab Press the Config navigation button followed by the Network Settings tab to access the screen described below To enable networking press the red exclamation graphic next to Network Disabled The graphic will change to a green check mark Enter the appropriate IP Address Subnet Mask and Gateway If DHCP is necessary press the red exclamation graphi...

Page 64: ...R 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 16 Software Updates Tab Press the Config navigation button followed by the Software Updates tab to update the Spirit system software See the next page for details on updating the software ...

Page 65: ...nto either port on the back of the Plasma Console 4 Turn the Plasma Console on 5 Allow the system to boot to the normal main screen and select Config from the Navigation Menu 6 Select the Software Updates tab 7 Using the arrows navigate to the software package to be installed Note that the system will overwrite the file without warning if steps aren t taken to rename the default Installer exe file...

Page 66: ...irements of the EAR 4 18 System Info Tab Press the Config navigation button followed by the System Info tab to access the screen described below This screen displays the hardware software and serial number for each of the components in the Spirit system Tools Tab Restart Plasma Console Press the Config navigation button followed by the Tools tab to access the screen described below This screen pro...

Page 67: ...Pressures Coolant Tab Press the Diagnostics navigation button followed by the Pressures Coolant tab to access the screen described below Pressing any of the Output Pressure buttons will cause the corresponding valve to open or close Note that the preflow valve and the plasma valve cannot be on at the same time During a cutting or marking sequence the status of all valves will display N A See the I...

Page 68: ... of the EAR 4 20 RS422 Tab Press the Diagnostics navigation button followed by the RS422 tab to access the screen described below Note that incoming data is appended to show an R before the data and outgoing transmissions are appended to show a T before the data Electrical Tab Press the Diagnostics navigation button followed by the Electrical tab to access the screen described below This diagnosti...

Page 69: ...eans to any location outside the United States contrary to the requirements of the EAR 4 21 Cut Info Tab Press the Diagnostics navigation button followed by the Cut Info tab to access the screen described below Press the Save to History button to add the Present Cut Errors to the History list for future reference This should be done each time consumables are changed Press any of the History button...

Page 70: ...This error occurs when the arc transfers to the workpiece but is lost before steady state operation It primarily causes electrode damage and is typically due to a pierce time that is too long or when cutting a given thickness with excessive current Transferred arc lost during cut This error occurs when the arc is lost during steady state operation It substantially shortens the electrode life and i...

Page 71: ...the United States contrary to the requirements of the EAR 4 23 Power Supply Tab Press the Diagnostics navigation button followed by the Power Supply tab to access the screen described below Error Log Tab Press the Diagnostics navigation button followed by the Error Log tab to access the screen described below Filters along the right side of the screen can be used to limit the data displayed based ...

Page 72: ...ersons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 24 Messages Tab Press the Diagnostics navigation button followed by the Messages tab to access the screen described below This screen displays all power supply and gas console messages sequencing and errors The message screen should be the initial starting point when troubleshooti...

Page 73: ...ime the torch head is connected to the torch base use a cotton swab to apply a small amount of o ring lubricant on each of the seven o rings on the top of the torch head Reminder do not use an excessive amount of o ring lubricant 2 Align the indicator on the torch head circle with the one on the torch base slot 3 Apply enough upward force to engage the threads while tightening the attachment ring ...

Page 74: ...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 5 2 YES NO To remove the torch head turn the attachment ring to the LEFT There is no gap between o ring and attachment ring Gap is visible between o ring and attachment ring O ring O ring Torch Base Torch Head ...

Page 75: ...onsumables do not use an excessive amount of o ring lubricant Also ensure that the lubricant is placed only on the o rings Excess lubricant can interfere with gas flow which can cause starting problems poor cut quality and short consumable life 1 Unthread the torch head from the torch base by turning the attachment ring to the LEFT Verify the torch base doesn t unthread from the torch handle 2 Rem...

Page 76: ...AR 5 4 YES NO 6 Use the swirl ring removal tool P N BK260105 to remove the swirl ring from the nozzle 7 Remove the electrode from the torch head using the appropriate tool All copper electrodes use socket P N BK277087 driver P N BK277086 All silver electrodes use P N BK279061 8 Inspect all consumables and o rings for damage and excess wear Replace with new consumables as necessary 9 Inspect the co...

Page 77: ...the gases and cutting 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...

Page 78: ...ged 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 nozzle Apply...

Page 79: ... of the EAR 5 7 Selecting Consumables Mild Steel Copper Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 30A BK284150 BK277115 BK277153 BK277122 BK277140 BK277142 BK277131 BK279100 50A BK284150 BK277150 BK277153 BK277125 BK277142 BK277131 BK279100 70A BK284150 BK277286 BK277151 ...

Page 80: ...sons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 8 Mild Steel Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode Torch Head BK284150 BK277286 BK277151 BK279484 BK279483 BK279410 brown o ring BK279060 100A BK284150 BK277117 BK277151 BK277152 BK279493 BK279439 BK279420 green o ring...

Page 81: ...ny means to any location outside the United States contrary to the requirements of the EAR 5 9 Stainless Steel H17 Plasma Copper Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head BK284150 BK277150 BK277113 BK277124 BK277140 BK277132 BK279100 70A BK284150 BK277146 BK277113 BK277126 BK277141 BK277133 BK279100 100A BK284150 BK277298 BK277266 BK...

Page 82: ...ements of the EAR 5 10 Stainless Steel Air or Nitrogen Plasma Copper Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head BK284150 BK277144 BK277110 BK277121 BK277138 BK277137 BK279100 30A BK284150 BK277149 BK277110 BK277123 BK277142 BK277137 BK279100 50A BK284150 BK277150 BK277153 BK277125 BK277142 BK277131 BK279100 70A BK284150 BK277286 BK277...

Page 83: ...ansferred by any means to any location outside the United States contrary to the requirements of the EAR 5 11 Stainless Steel Air or Nitrogen Plasma Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode Torch Head BK284150 BK277286 BK277151 BK279484 BK279483 BK279410 brown o ring BK279060 100A BK284150 BK277117 BK277152 BK279493 BK279439 BK279420 gr...

Page 84: ...y to the requirements of the EAR 5 12 Aluminum Copper Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 30A BK284150 BK277150 BK277153 BK277122 BK277142 BK277131 BK279100 50A BK284150 BK277150 BK277153 BK277125 BK277142 BK277131 BK279100 70A BK284150 BK277286 BK277151 BK277284 BK...

Page 85: ...S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 13 Aluminum Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode Torch Head BK284150 BK277286 BK277151 BK279484 BK279483 BK279410 brown o ring BK279060 100A BK284150 BK277117 BK277152 BK279493 BK279439 BK279420 green o ring BK27...

Page 86: ...ex Material Current Plasma Gas Shield Gas Copper Electrode Silver Electrode Mild Steel 30 Amps Oxygen Oxygen Page 5 15 Mild Steel 50 Amps Oxygen Oxygen or Air Page 5 16 Mild Steel 70 Amps Oxygen Air Page 5 17 Mild Steel 100 Amps Oxygen Air Page 5 18 Page 5 33 Mild Steel 150 Amps Oxygen Air Page 5 19 Page 5 34 Stainless Steel 30 Amps Air Air Page 5 20 Stainless Steel 50 Amps Air Nitrogen Page 5 21 ...

Page 87: ...5 77 6 75 120 105 080 110 100 062 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 mm mm msec mm 1 35 77 6 75 120 2615 2 0 2 8 100 1 6 1 5 124 2020 2 6 200 1 7 2 126 161...

Page 88: ...Swirl Ring BK277142 14 075 25 74 19 72 106 200 100 135 100 075 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 psi psi volts mm m mm mm msec mm Cold Rolled Steel Oxygen Shield Swirl Ring BK277140 2 5 25 74...

Page 89: ...ipm in in msec in 1 8 25 76 35 74 110 190 100 150 100 080 3 16 40 113 130 200 200 1 4 116 120 110 225 300 085 3 8 122 75 140 250 400 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 mm 3 25 76 35 74 109 4995 2 5 3 6 100 2 0 5 40 113 3265 5 1 300 6 115 3105 2 7 5 5 2 2 Marki...

Page 90: ... 26 81 125 150 090 200 300 090 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 83 26 81 124 3950 2 1 4 9 300 2 3 10 130 2405 3 3 6 5 500 12 1850 3 7 7 3 16 143 1180 4 7 8 3 10...

Page 91: ...325 600 130 3 4 130 55 350 1000 135 1 134 40 150 400 1500 140 1 25 145 25 200 700 3000 1 50 155 15 225 350 1500 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 BK277151 6 20 71 30 69 117 4305 2 6 4 9 300 3 2 10 123 3040 3 4 6 5 500 12 124 2485 3 5 7 3 3 3 ...

Page 92: ...i psi psi psi volts ipm in in msec in 20 036 35 81 30 85 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 35 81 30 85 71 4855 0 6 1 3 100 1 7 1 5 73 3260 0 9 200 Marking For All Material T...

Page 93: ...075 25 66 40 67 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 25 66 40 67 87 2565 9 1 8 100 2 7 2 5 2080 3 88 1685 200 5 94 1235 1 0 2 1 400 2 8 6...

Page 94: ...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 65 30 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 65 30 60 135 2030 2 5 5 1 300 2 3 Marking...

Page 95: ...f Width ga in psi psi psi psi volts ipm in in msec in 10 135 25 76 25 76 132 120 060 150 200 085 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 3 25 76 25 76 131 3210 1 4 3 3 200 2 2 5 134 2445 ...

Page 96: ...eed Cutting Height Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 3 16 28 72 40 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 28 72 40 67 138 2865 2 7 5 1 ...

Page 97: ...Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 1 4 25 80 35 80 141 100 135 225 400 092 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 80 35 80 140 2595 3 2 5 6 400 2 3 10 148 1935 4 4 6 5 600 2 4...

Page 98: ... Time Kerf Width in psi psi psi psi volts ipm in in msec in 1 4 25 77 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 mm mm msec mm 10 25 77 75 81 155 1845 3 8 7 0 600 3 ...

Page 99: ...n in msec in 1 4 20 71 70 69 145 150 160 250 400 125 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 20 71 70 69 144 3910 4 0 6 3 400 3 2 10 150 2805 4 7 7 0 600 12 1...

Page 100: ...Kerf Width in psi psi psi psi volts ipm in in msec in 040 35 81 20 85 135 150 030 100 100 065 050 120 063 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 35 81 20 85 135 3885 0 8 2 5 100 1 7 1 5 2520 3 4 200 1 8 Marking For All Material Thicknesses Type...

Page 101: ... psi psi psi volts ipm in in msec in 050 25 66 19 67 135 180 050 100 100 080 063 138 140 065 150 082 080 143 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 66 19 67 137 3870 1 5 2 5 150 2 1 2 0 142 2360 1 8 3 7 200 2 2 Marking For All Material...

Page 102: ...0 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 76 25 76 129 6400 1 2 3 7 100 2 0 3 134 4420 1 7 4 3 5 145 1920 2 3 5 2 300 2 2 6 148 1440 1 7...

Page 103: ...si volts ipm in in msec in 1 4 25 80 26 80 158 105 155 250 300 095 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 80 26 80 158 2710 3 8 6 3 300 2 4 10 162 2210 4 6 7 0 500 2 5 12 165 1890 4 9 7 4 Marking For Al...

Page 104: ... 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 20 71 50 69 143 3770 3 1 6 3 400 3 2 10 156 2825 4 8 7 0 600 12 162 2430 5 5 7 4 3 3 16 170 1630 6 4 ...

Page 105: ...4 25 83 26 81 125 150 090 200 300 090 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 83 26 81 124 3950 2 1 4 9 300 2 3 10 130 2405 3 3 6 5 500 12 1850 3 7 7 3 16 143 1180 4 7...

Page 106: ...70 140 325 600 130 3 4 130 55 350 1000 135 1 134 40 150 400 1500 140 1 25 145 25 200 700 3000 1 50 155 15 225 350 1500 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 BK277151 6 20 71 30 69 117 4305 2 6 4 9 300 3 2 10 123 3040 3 4 6 5 500 12 124 2485 3 5 7...

Page 107: ... psi psi psi volts ipm in in msec in 1 4 25 80 35 80 141 100 135 225 400 092 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 80 35 80 140 2595 3 2 5 6 400 2 3 10 148 1935 4 4 6 5 600 2 4 12 152 1540 5 0 7 3 Marking ...

Page 108: ...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 20 71 70 69 144 3910 4 0 6 3 400 3 2 10 150 2805 4 7 7 0 600 12 153 2330 5 1 7 4 3 3 16 160 15...

Page 109: ...i psi psi volts ipm in in msec in 1 4 25 80 26 80 158 105 155 250 300 095 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 80 26 80 158 2710 3 8 6 3 300 2 4 10 162 2210 4 6 7 0 500 2 5 12 165 1890 4 9 7 4 Marking...

Page 110: ... 69 145 145 130 250 400 125 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 20 71 50 69 143 3770 3 1 6 3 400 3 2 10 156 2825 4 8 7 0 600 12 162 2430 5 5 7 4 3 3 16 170 16...

Page 111: ...quires the system to be powered with the enclosure panels removed remain clear of 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 frequen...

Page 112: ...rch Torch Leads and Gas Hoses 1 Verify that all torch lead and gas hose connections are tight and that there are no gas or water leaks Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened 2 Verify that the braided shield of the torch leads is fastened securely to the brass shield adapter that connects to the arc starting console Also mak...

Page 113: ...7087 driver P N BK277086 and inspect the o rings for damage Apply a small amount of o ring lubricant before re installing in the torch head 9 Wipe any excess o ring lubricant off of the torch base and head Arc Starting Console ASC 1 Open the cover door of the arc starting console and verify that all leads and hoses are tightened securely Only tighten the fittings enough to make a water or gas seal...

Page 114: ...move the top left and right covers from the power supply 6 Connect a 3 8 ID hose and bucket to the drain petcock on the bottom of the reservoir Unscrew the petcock to drain the reservoir Leave the hose and bucket in place after the coolant drains out 7 Remove the coolant supply hose coolant out from the rear of the power supply Note that the coolant supply hose has right hand threads Be prepared f...

Page 115: ...LASMA START Plasma start signal applied to Spirit D37 ARC HOLD Arc hold input enabled D38 MARKING Marking input enabled D39 CORNER Corner current input enabled D40 EOFF Off button disengaged D41 MOTION Motion output signal activated D42 PLASMA READY Power supply ready output signal activated D43 PAT Pilot arc transistor energized D48 RMT ON OFF Remote On Off input enabled D50 ASC DOOR ASC door is ...

Page 116: ...en the OFF Button is released D40 OFF Button The following DSP Indicators should illuminate when the ON Button is activated Opto U21 Motor Solenoid Opto U19 Solenoid not used Opto U26 Fan D42 Plasma Ready The following DSP Indicators should illuminate when a START signal is applied begin cut cycle D36 Start Opto U27 Preflow Opto U29 Shield Opto U24 Surge only over 100 amps Opto U23 Contactor D24 P...

Page 117: ...ant temperature is high 10290 GC Quiet Lost CAN communication with Gas Console 10300 PC Quiet Lost CAN communication with Plasma Console 10320 FCC Invalid Using default current remove start 10330 PAC Invalid Pilot Arc Current invalid 10340 AH IHS Timeout Arc Hold for Initial Height Sense has timed out 10350 PAT Not Established Pilot Arc Current not established within 2 seconds 10360 TAC Not Establ...

Page 118: ...w Adjust Could not adjust Postflow Gas 20140 Marking Adjust Could not adjust Marking Gas Automatic Gas Console 20160 N2 Mix Adjust Could not adjust N2 Mix Gas 20170 O2 Mix Adjust Could not adjust O2 Mix Gas 20200 O2 Low O2 Input Pressure is low 20210 N2 Low N2 Input Pressure is low 20220 Argon Low Argon Input Pressure is low 20230 O2N2 Low Air Input Pressure is low 20240 H17 Low H17 Input Pressure...

Page 119: ...out or the associated wiring is bad 4 Control Transformer or associated wiring bad Power Supply will not energize when the ON Button is pressed 1 ASC door open 2 Low coolant level 3 Fuse is blown F1 F6 4 Faulty OFF Button or associated wiring 5 Off Relay faulty Power supply will not stay on when the ON Button is pressed 1 Faulty DSP board 2 Off Relay faulty No arc at the torch 1 Incorrect torch co...

Page 120: ...on but the touch screen doesn t work 1 Cycle primary power to the Spirit system Gas pressures will not adjust properly 1 Wrong consumables installed in torch 2 Loose pressure transducer cable on PC board in the AGC 3 Check connectors on the AGC valve associated with the malfunction Low pressure error 1 Supply gas pressure s less than 120 psi Pressure error during cut 1 Supply gas pressure s fluctu...

Page 121: ...e power conversion module Capacitor failure can injure and or cause property damage If troubleshooting requires the system to be powered with the enclosure panels removed remain clear of the capacitors Failure of a capacitor can result in a sudden release of stored energy causing rupture of the capacitor case IMPORTANT Depending upon the system there are one two or three chopper assemblies in the ...

Page 122: ...he Spirit system 7 Release the OFF Button on the Plasma Controller or Manual Gas Console to enable the system Press or SELECT the ON Button to energize the system After the gases set prepare to apply a start signal to the unit 8 With a start signal applied check the three phase voltage input to each chopper at the diode bridge terminals three screws on the left side of each chopper Refer to TABLE ...

Page 123: ...pirit II 150 Amp 208 300 N A N A N A N A 10 If the proper DC voltage is not present at the output terminal block check the 200 amp fuse F9 chopper 1 fuse F10 chopper 2 or fuse F11 chopper 3 located on the bottom right of the output bus bars If the fuse is open replace chopper and fuse 11 If the fuse s is good check if the chopper PWM LED illuminates when a start signal is applied a check D24 on th...

Page 124: ...m the Spirit system Check cable continuity between the chopper PCB and DSP PCB Use a digital voltmeter set up to read resistance ohms and make the following measurements Chopper 1 J1 1 to DSP J7 1 Chopper 1 J1 2 to DSP J7 2 Chopper 1 J1 3 to DSP J7 3 Chopper 1 J1 5 to DSP J7 4 Chopper 2 J1 1 to DSP J8 1 Chopper 2 J1 2 to DSP J8 2 Chopper 2 J1 3 to DSP J8 3 Chopper 2 J1 5 to DSP J8 4 Chopper 3 J1 1...

Page 125: ...er Supply BK300211 BK300219 Right Side View Item Part Number Quantity Description 4 BK707155 1 L1 Inductor 5 BK706409 BK706410 1 T2 Control Transformer 200 480 V 60 Hz T2 Control Transformer 600 V 60 Hz 6 BK706405 BK706501 1 T1 Main Transformer 200 480 V 60 Hz 3Ø T1 Main Transformer 600 V 60 Hz 3Ø 15 BK709105 1 Strain Relief 30 BK708121 1 CON 1 Contactor 31 BK702076 1 EMI Filter 380 415 V units on...

Page 126: ...1 1 PAT IGBT 34 BK702075 2 PAT IGBT Filter Capacitor 36 BK300108 1 Printed Circuit Board PCB Power Supply Output I O 37 BK301200 1 Optional Printed Circuit Board PCB Voltage Divider 39 BK709378 1 I O Terminal Block small 40 BK280003 2 Power Supply 24VDC 43 BK708105 2 Relay Hold Down Clip 44 BK200204 1 Fan 4 7 46 BK709379 1 I O Terminal Block large 47 BK709227 2 Strain Relief 50 BK284029 2 Current ...

Page 127: ...2 BK501164 1 Bulb 3 BK501162 1 White Lens 5 BK706409 BK706410 1 T2 Control Transformer 200 480 V 60 Hz T2 Control Transformer 600 V 60 Hz 7 BK709359 1 F3 Fuse 5A Slow Blow 8 BK709358 1 F4 Fuse 5A Medium Blow 9 BK709358 1 F5 Fuse 5A Medium Blow 10 BK709360 1 F6 Fuse 6 3A 13 BK709061 2 F1A F1B Fuse Holder 14 BK709128 2 F1A F1B Fuse FNM 6 25A 18 BK500518 1 Coolant Reservoir Cap Level Gauge 38 BK30025...

Page 128: ... Reservoir without Fittings or Cap 18 BK500518 1 Coolant Reservoir Cap Level Gauge 19 BK300135 1 Coolant Level Switch 20 BK505024 1 Coolant Temperature Switch 21 BK500052 1 Coolant Pump Motor 1 3hp 230V 50 60 Hz 22 BK500513 1 V Band Clamp 23 BK300192 1 Coolant Pump 70 gph 24 BK708061 1 Solenoid Valve 220 240VAC 25 BK715118 1 Check Valve Coolant Return 26 BK300134 1 Coolant Flow Sensor 27 BK260250 ...

Page 129: ...rogen Regulator Valve 5 BK300415 1 Nitrogen Regulator Valve Amplifier Programmed 6 BK260109 1 Oxygen Regulator Valve 7 BK300415 1 Oxygen Regulator Valve Amplifier Programmed 8 BK260109 1 Marking Plasma Regulator Valve 9 BK300415 1 Marking Plasma Regulator Valve Amplifier Programmed 10 BK260109 1 Shield Regulator Valve 11 BK300415 1 Shield Regulator Valve Amplifier Programmed 12 BK260109 1 Preflow ...

Page 130: ... 1 BK300412 1 Power Supply 24VDC 8 3A 2 BK300301 AGC 1 Printed Circuit Board PCB Gas Console DSP 3 BK280030 1 Fan 24VDC 10 BK260109 1 Shield Regulator Valve 11 BK300415 1 Shield Regulator Valve Amplifier Programmed 12 BK260109 1 Preflow Regulator Valve 13 BK300415 1 Preflow Regulator Valve Amplifier Programmed 14 BK260109 1 Plasma Regulator Valve 15 BK300415 1 Plasma Regulator Valve Amplifier Prog...

Page 131: ...ption 1 BK300412 1 Power Supply 24VDC 8 3A 2 BK300301 AGC 1 Printed Circuit Board PCB Gas Console DSP 3 BK280030 1 Fan 24VDC 4 BK260109 1 Nitrogen Regulator Valve 5 BK300415 1 Nitrogen Regulator Valve Amplifier Programmed 6 BK260109 1 Oxygen Regulator Valve 7 BK300415 1 Oxygen Regulator Valve Amplifier Programmed 8 BK260109 1 Marking Plasma Regulator Valve 9 BK300415 1 Marking Plasma Regulator Val...

Page 132: ...r transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 8 Plasma Console BK300800 Item Part Number Quantity Description 1 BK300712 1 Power Supply 12VDC 2 BK300701 1 Printed Circuit Board PCB RS422 Isolation 3 BK300706 1 Printed Circuit Board PCB Computer 4 BK300707 1 10 4 LCD Touchscreen 5 BK708111 1 Switch Pushbutton OFF Button 4 5 1 3 2 ...

Page 133: ...0 1 Coolant supply fitting right hand 3 BK709227 1 Strain relief 5 BK709001 1 4 pin receptacle 6 BK707001 1 Line filter 7 BK706109 1 Transformer 5000V 20 mA 8 BK702069 1 Capacitor 15 kV 9 BK708057 1 Door interlock switch 10 BK500014 1 Spark gap assembly 11 BK740039 3 Spark gap electrode 12 BK505043 1 High frequency inductor 13 BK740072 2 Standoff 14 BK800041 1 Busbar 15 BK500505 1 Printed Circuit ...

Page 134: ... the requirements of the EAR 7 10 Arc Starting Console BK300500 with CleanStrike Technology Item Part Number Quantity Description 1 BK715051 2 Coolant Return Fitting left hand 2 BK715050 1 Coolant Supply Fitting right hand 3 BK715021 1 Coolant Supply Fitting right hand 4 BK709001 1 4 pin Receptacle 5 BK708057 1 Door Interlock Switch 6 BK500503 1 Cathode Manifold 7 BK300506 1 Printed Circuit Board ...

Page 135: ...279000 1 Torch Base 5 BK279100 BK279060 1 Torch Head Copper Electrode Torch Head Silver Electrode 6 BK820209 1 O ring red 7 BK500024 1 O ring blue 8 BK500018 1 O ring red 9 BK279013 1 O ring red indicator only not a seal 10 BK279112 2 O ring red 11 BK279113 6 O ring red 12 BK284039 1 17 Torch Solenoid Plasma Hose 13 BK300075 1 5 Gang Manifold for Automatic Gas Console Not shown BK716012 1 O ring L...

Page 136: ...Number Length BK284304 XX Where XX is the length in feet 4 10 ft lengths available in 1 ft increments 15 150 ft lengths available in 5 ft increments CAN Communication Cable and Termination Plug Item Part Number Length CAN Termination Plug BK300408 N A CAN Cable BK300177 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Manifold Control Cables Item Part Number Length...

Page 137: ...rmation 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 13 Gas Hose Package with AGC Part Number Length BK300080 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Custom lengths are available Contact factory ...

Page 138: ...es contrary to the requirements of the EAR 7 14 Coolant and Power Leads Part Number Non CSA Systems Part Number CSA Systems Length BK300306 XX BK388306 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Work Ground Lead Part Number Non CSA Systems Part Number CSA Systems Length BK300318 XX BK388318 XX Where XX is the length in feet 10 100 ft lengths available in 5 ft...

Page 139: ...25 ft increments Nitrogen Supply Gas Hose Optional Part Number Length BK200365 XX Where XX is the length in feet 25 100 ft lengths available in 25 ft increments Air Supply Gas Hose Optional Part Number Length BK200364 XX Where XX is the length in feet 25 100 ft lengths available in 25 ft increments H17 Supply Gas Hose Optional Part Number Length BK200363 XX Where XX is the length in feet 25 100 ft...

Page 140: ...d by any means to any location outside the United States contrary to the requirements of the EAR 7 16 CII Cable for Optional External Inova Part Number Length BK300902 XX Where XX is the length in feet 5 150 ft lengths available in 5 ft increments STRAIN RELIEF BK709015 CABLE BK711001 STRAIN RELIEF BK709025 PLUG BK709364 PLUG BK709016 BK709018 SOCKET BK709018 SOCKET BK709019 KEY BK709365 PIN BK709...

Page 141: ...to any location outside the United States contrary to the requirements of the EAR 7 17 FII Cable for Optional Internal Inova Part Number Length BK300903 XX Where XX is the length in feet 5 150 ft lengths available in 5 ft increments STRAIN RELIEF BK709021 CABLE BK711002 STRAIN RELIEF BK709025 PLUG BK709095 PLUG BK709364 BK709365 PINS BK709365 PINS BK709018 SOCKET BK709018 SOCKET BK709018 SOCKET BK...

Page 142: ...d by any means to any location outside the United States contrary to the requirements of the EAR 7 18 JII Cable for Optional Internal Inova Part Number Length BK300904 XX Where XX is the length in feet 5 50 ft lengths available in 5 ft increments STRAIN RELIEF BK709021 STRAIN RELIEF BK709025 CABLE BK711049 PLUG BK709364 PLUG BK709020 BK709018 SOCKET BK709018 SOCKET BK709019 KEY BK709365 PIN BK7093...

Page 143: ... 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 19 PCB Assemblies Component Reference Locations Power Supply Microprocessor DSP BK300101 Quadrant 1 J17 J13 U37 RHF U36 Impulse Start U35 U34 U32 Marking U31 Postflow U30 Vent U29 Shield J20 J22 J19 PCB Quadrant Map 1 3 4 2 ...

Page 144: ...tion 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 20 Power Supply Microprocessor DSP BK300101 Quadrant 2 J15 U28 Plasma U27 Preflow U19 Solenoid not used U21 Mtr Sol U22 PAR U24 Surge U26 Fan U23 Con J16 J12 J14 J1 PCB Quadrant Map 1 3 4 2 ...

Page 145: ...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 21 Power Supply Microprocessor DSP BK300101 Quadrant 3 J18 J11 J3 PCB Quadrant Map 1 3 4 2 ...

Page 146: ...inistration 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 22 PCB Quadrant Map Power Supply Microprocessor DSP BK300101 Quadrant 4 J3 J4 2 J4 1 J10 J7 J8 J9 J21 1 3 4 2 ...

Page 147: ...bject 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 23 Power Supply Output BK300108 ...

Page 148: ...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 contrary to the requirements of the EAR 7 24 Power Supply A C Detect BK300112 ...

Page 149: ...port 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 25 Gas Console Microprocessor DSP BK300301 AGC Quadrant 1 PCB Quadrant Map 1 3 4 2 J25 J19 J4 ...

Page 150: ...ort 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 26 Gas Console Microprocessor DSP BK300301 AGC Quadrant 2 J6 PCB Quadrant Map 1 3 4 2 J5 J31 J28 ...

Page 151: ... 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 27 Gas Console Microprocessor DSP BK300301 AGC Quadrant 3 J19 PCB Quadrant Map 1 3 4 2 J20 J21 J17 J13 ...

Page 152: ...port 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 28 PCB Quadrant Map Gas Console Microprocessor DSP BK300301 AGC Quadrant 4 J13 1 3 4 2 J9 J18 ...

Page 153: ...bject 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 29 Chopper Gate Driver BK300106 ...

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 7 30 Plasma Console RS422 Isolation BK300701 ...

Page 155: ...nova console See the standard Inova manual for all other Inova information Plug Identification Connections for the internal Inova console option are distinguished from other connections on the back of the power supply by the addition of the letter I before the plug number The function of each plug e g IP1 is the same as the corresponding plug found on the external Inova console e g P1 Spirit II 15...

Page 156: ...y to the requirements of the EAR 8 2 Grounding The internal Inova console must be connected to the same protective earth ground as the plasma power supply and in accordance with national or local codes The figures below describe two methods Use a minimum of 8AWG 10 mm2 wire Note the customer must supply the ground cable Direct to star ground Spirit II 150 275 Spirit II 400 Jumper to the work groun...

Page 157: ...ntrary to the requirements of the EAR 8 3 Parts List Item Part Number Quantity Description 1 BK110200 1 Printed Circuit Board PCB Microprocessor 2 BK110705 1 Printed Circuit Board PCB Power Distribution 3 BK110900 1 Printed Circuit Board PCB H Bridge 4 BK706003 1 Transformer 5 BK709360 1 F7 Fuse 6 3A 6 BK709370 1 F8 Fuse 3A 7 BK301200 1 Printed Circuit Board PCB Voltage Divider 8 BK709276 1 Power ...

Page 158: ... 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 Location in Spirit II 150 275 Continued 8 7 ...

Page 159: ...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 5 Location in Spirit II 400 1 5 6 3 4 2 F7 F8 pos A pos B ...

Page 160: ...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 8 6 Location in Spirit II 400 Continued 7 8 ...

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: ... 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 additional precautions such as filtering of the mains supply Consideration should be give...

Page 163: ...thing 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 of the workpiece increasing the risk of injury to users or damage to other ele...

Page 164: ...l 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 A 4 BLANK ...

Page 165: ... 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 table You will see the following table entry Command Hex String Additional Information Se...

Page 166: ... 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 set the net node value to C8 hex 200 decimal In the example above the following ...

Page 167: ...t system receives 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 thicknes...

Page 168: ...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 169: ... 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 system 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 system will transmit the most significant word of the nozzle part number Torch Nozzle Part Number lsw 23 AA nn FA 17 0D If req...

Page 170: ... torch 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 num...

Page 171: ...t satisfied 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 ASC Door LSB Bit 1 AC Power LSB Bit 2 Coolant Flow LS...

Page 172: ...ds 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 system will transmit the machine type 153 Spirit150a 203 Spirit200a 273 Spirit275a 403 Spirit400a Set Marki...

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