Lincoln Electric 718114 User Manual

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User's Manual

Spirit II 150

High Current Density Plasma Cutting System
with Manual Gas Console (MGC)

718114 Rev D

This information shall not be provided to non-U.S. persons or transferred by any means to
any location outside the United States contrary to the requirements of the EAR.

Prologue Spirit II User’s Manual

Rev

ECO#

Author

Date

Description of Change

Added 100A/150A silver electrodes, replaced RHF with

to inlet gas pressure.

Deionization filter cartridge (500510) replaced sediment

clarify cabling requirements for various configurations.

Corrected contact ratings on page 3-19.

ground in Parts List.

Revision History

A - CAD 02/04/2013 Initial Release

B LAD0202 CAD 06/07/2013

C LAD0217 CAD 08/06/2013

D

LAD0228
LAD0223

CAD 08/28/2013

This documentation may not be copied, photocopied, reproduced, translated,

or reduced to any electronic medium or machine-readable format without

explicit written permission from Kaliburn.

FASTON is a trademark of the TE Connectivity Ltd family of companies.

Other logos, products and company names mentioned herein

may be trademarks of their respective owners.

© Copyright 2013 Kaliburn Inc.

4130 Carolina Commerce Parkway

ISC, corrected system interconnect diagrams, changed
rated inlet gas pressure to 115 psi, added 100 psi minimum

filter (300152). Parts list updated.
Expanded notes on System Interconnection diagrams to

Added pinouts to CII, FII, JII cables in Parts List.
Corrected part numbers for coolant/power leads and work

a Lincoln Electric Company

Ladson, SC 29456 USA

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.

ii

Spirit II User’s Manual Prologue

Table of Contents

Section 1: Safety

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

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

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

Toxic Fume Prevention ..................................................................................... 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

Manual Gas Console (MGC) Specifications ...................................................... 2-5

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

Impulse Start Console (ISC) Specifications ....................................................... 2-7

Torch and 2-Gang Manifold Specifications ........................................................ 2-8

5-Gang Manifold Specifications ......................................................................... 2-9

Airborne Noise Emissions ................................................................................. 2-10

Section 3: Installation

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

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

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

Power Supply Primary Power Connections ....................................................... 3-5

Power Supply Output Connections ................................................................... 3-7

ISC Control Cable and ISC Ground Connections .............................................. 3-9

Cooling System Connections ............................................................................ 3-9

Torch Leads to Impulse Start Console Connections ......................................... 3-11

Torch Leads to Torch Base Connections .......................................................... 3-13

Torch Gas Connections ..................................................................................... 3-14

Gas Supply Connections ................................................................................... 3-17

CAN Communication Connections .................................................................... 3-18

CNC Machine Interface Connections ................................................................ 3-19

Filling the Cooling System ................................................................................. 3-20

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iii

Prologue Spirit II User’s Manual

Section 4: Operation

Operating the Manual Gas Console (MGC) ...................................................... 4-1

Setting up to Cut ............................................................................................... 4-2

Setting up to Mark (Overrides Cut) .................................................................... 4-3

Verifying Input Gas Pressures ........................................................................... 4-3

Making a Cut or Mark ........................................................................................ 4-4

Piercing Thick Materials .................................................................................... 4-5

Moving Pierces and Edge Starts ....................................................................... 4-5

Cut Quality ........................................................................................................ 4-6

Checking Errors ................................................................................................ 4-7

Checking the Version and Serial Number ......................................................... 4-7

Changing the Language .................................................................................... 4-8

Adjusting the Screen Contrast ........................................................................... 4-8

Section 5: Torch Consumables and Cut Charts

Installing / Removing the Torch Head ............................................................... 5-1

Installing / Replacing Consumables .................................................................. 5-2

Maximizing Consumable Life ............................................................................ 5-3

Inspecting for Damage ...................................................................................... 5-4

Selecting Consumables ..................................................................................... 5-5

Cutting Charts ................................................................................................... 5-12

Section 6: Maintenance and Troubleshooting

Routine Maintenance ........................................................................................ 6-1

Replacing the Torch Coolant and Filter ............................................................. 6-4

Microprocessor (DSP) Status Indicators ........................................................... 6-5

Microprocessor (DSP) Sequence of Operation ................................................. 6-5

Error Codes ....................................................................................................... 6-7

General Troubleshooting ................................................................................... 6-9

Chopper Test Procedure ................................................................................... 6-11

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iv

Spirit II User’s Manual Prologue

Section 7: Parts List

Power Supply (300211 - 300219) ...................................................................... 7-1

Manual Gas Console (300600) ......................................................................... 7-5

Impulse Start Console (300500) ........................................................................ 7-7

Torch and Manifold Assemblies ........................................................................ 7-8

Shielded Torch Leads ....................................................................................... 7-9

CAN Communication Cable and Termination Plug ........................................... 7-9

Manifold Control Cables .................................................................................... 7-9

Gas Hose Package with MGC ........................................................................... 7-10

Coolant and Power Leads ................................................................................. 7-11

Work Ground Lead ............................................................................................ 7-11

Oxygen Supply Gas Hose (Optional) ................................................................ 7-12

Nitrogen Supply Gas Hose (Optional) ............................................................... 7-12

Air Supply Gas Hose (Optional) ........................................................................ 7-12

H17 Supply Gas Hose (Optional) ...................................................................... 7-12

"CII" Cable (for Optional External Inova) ........................................................... 7-13

"FII" Cable (for Optional Internal Inova) ............................................................. 7-14

"JII" Cable (for Optional Internal Inova) ............................................................. 7-15

Section 8: Internal Inova Console Option

Overview ........................................................................................................... 8-1

Plug Identification .............................................................................................. 8-1

Unique Interconnect Cables .............................................................................. 8-1

Grounding ......................................................................................................... 8-2

Parts List ........................................................................................................... 8-3

Appendix A: Electromagnetic Compatibility (EMC)

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

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

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

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

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v

Prologue Spirit II User’s Manual

Limited Warranty

KALIBURN expressly warrants that this product shall be free from defects in materials
and workmanship, under proper and normal use for the intended function of such
product, for a period of three (3) years for the Spirit II plasma power supply (includes the
cooling system and internally installed Inova option) and one (1) year for all other Spirit
II system component. This warranty does not apply to torch consumable parts.

The warranty period starts three (3) months after the product ships from the factory.

This product is intended for commercial use and is not intended for personal, family, or
household purposes. There are no warranties that extend beyond the express limited
warranty set forth immediately above. All other warranties, whether expressed, implied,
statutory or made herein or in any other communication, including any implied warranty
of merchantability, fitness for any particular purpose or non-infringement, are expressly
excluded.

This warranty will be considered void if the Spirit II system is operated with non-genuine
KALIBURN torch consumables, or if the equipment has been subjected to improper
installation, improper care or abnormal operation.

If this product or any component thereof is determined to be defective in materials or
workmanship, KALIBURN will repair or replace the defective component or product.
The buyer’s remedies are limited to the return of the product for repair or replacement of
any defective product or part at the sole discretion of KALIBURN. No freight charges of
any kind are covered under this warranty. All returned goods shall be at the buyer’s risk
and expense. In no event will KALIBURN be responsible for any special, incidental or
consequential damages or injury to the person or property of anyone by reason of any
defect in any equipment sold hereunder.

Returned Goods Procedure

KALIBURN utilizes a returned goods procedure that must be followed before returning
any items for repair, replacement, or restocking. This means that a returned goods
authorization number must be obtained prior to shipment to KALIBURN. It will be
necessary for the customer to provide a description, along with the part number and
serial number, if applicable, of the item to be returned. In no case will KALIBURN
accept a returned shipment without the proper returned goods authorization number.

For shipments inside the U.S., parts must be returned to KALIBURN within 30 days of
the invoice date to be considered for credit. For shipments outside the U.S., parts must
be returned within 60 days of the invoice date to be considered for credit.

Electromagnetic Compatibility (EMC)

The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit II plasma cutting systems are
manufactured to comply with the European standard EN 60974-10 (Electromagnetic
compatibility (EMC) – Product standard for arc welding equipment). Information about
the EMC standard EN 60974-10 can be found in Appendix A.

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vi

Spirit II User’s Manual Section 1: Safety

Ultraviolet Radiation Protection

Noise Protection

Section 1: Safety

General Precautions

Whereas plasma cutting has been used safely for years, it does require certain
precautions to ensure the safety of the operator and other people around the
equipment. The following safety information must be provided to each person who will
operate, observe, perform maintenance, or work in close proximity to this piece of
equipment.

Installation, operation, and repairs made to the Spirit system should only be performed
by qualified personnel. The system makes use of both A.C. and D.C. circuitry for
operation. Fatal shock hazard does exist. Exercise extreme caution while working
on the system.

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 provides protection
up to 400 amperes. All exposed skin areas should be covered with flame-retardant
clothing. The cutting area should also be prepared in such a way that ultraviolet light
does not reflect. Walls and other surfaces should be painted with dark colors to reduce
reflected light. Protective screens or curtains should be installed to protect additional
workers in the area from ultraviolet radiation.

The system generates high noise levels while cutting. Depending on the size of the
cutting area, distance from the cutting torch, and arc current cutting level, acceptable
noise levels may be exceeded. Proper ear protection should be used as defined by
local or national codes. See Section 2 for noise emission levels.

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

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1-1

Section 1: Safety Spirit II User’s Manual

Toxic Fume Prevention

Electric Shock Prevention

Care should be taken to ensure adequate ventilation in the cutting area. Some
materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the
cutting area. Also, some solvents decompose and form harmful gases when exposed
to ultraviolet radiation. These solvents should be removed from the area prior to cutting.
Galvanized metal can produce harmful gases during the cutting process. Ensure proper
ventilation and use breathing equipment when cutting these materials.

Certain metals coated with or containing lead, cadmium, zinc, beryllium, and mercury
produce harmful toxins. Do not cut these metals unless all people subjected to the
fumes wear proper air breathing equipment.

The Spirit system uses high open circuit voltages that can be fatal. Extreme care
should be used when operating or performing maintenance on the system. Only
qualified personnel should service 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
the operator. In addition, it should be sized according to local and national electrical
codes. Inspect the primary power cord frequently. Never operate the system if the
power cord is damaged in any way.

• Make sure the primary power ground wire is connected to the input power ground
stud on the power supply. Make sure the connection is securely tightened.

• Make sure the positive output (work ground) of the power supply is connected to a
bare metal area on the cutting table. A driven ground rod should be placed no
further than five feet from this connection. Make sure this ground point on the
cutting table is used as the star ground point for all other ground connections.

• Inspect the torch leads frequently. Never use the system if the leads are damaged
in any way.

• Do not stand in wet, damp areas when operating or performing maintenance on the
system.

• Wear insulated gloves and shoes while operating or performing maintenance on the
system.

• Make sure the system is switched off at the wall disconnect before servicing the
power supply or torch.

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.

1-2

Spirit II User’s Manual Section 1: Safety

Fire Prevention

Explosion Prevention

• Never change torch consumable parts unless the system is switched off at the wall
disconnect.

• Do not attempt to remove any parts from beneath the torch when cutting.
Remember that the workpiece forms the current path back to the power supply.

• Never bypass the safety interlock devices.

• Before removing any of the covers, switch the system off at the wall disconnect.

Wait at least five (5) minutes before removing any cover. This will give the
capacitors inside the unit time to discharge. See Section 6 for additional safety
precautions.

• Never operate the system without all of the covers in place. See Section 6 for
additional safety precautions.

• Preventive maintenance should be performed daily to avoid possible safety hazards.

When using the Spirit system, it is necessary to exercise good judgment. While cutting,
the arc produces sparks that could cause a fire if they fall 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 sure that the cutting area is properly ventilated when using oxygen as a cutting
gas.

The Spirit system uses compressed gases. Use proper techniques when handling
compressed gas cylinders and other compressed gas equipment. Observe the
following guidelines to protect against explosion:

• Never operate the system in the presence of explosive gases or other explosive
materials.

• Never cut pressurized cylinders or any closed container.

• When using a water table and cutting aluminum under water or with water touching

the underside of the aluminum plate, hydrogen gas is produced. This hydrogen gas
may collect under the plate and explode during the cutting process. Make sure the
water table is properly aerated to help prevent the accumulation of hydrogen gas.

• Handle all gas cylinders in accordance with safety standards published by the U.S.
Compressed Gas Association (CGA), American Welding Society (AWS), Canadian
Standards Association (CSA), or other local or national codes.

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.

1-3

Section 1: Safety Spirit II User’s Manual

Health Support Equipment

• Compressed gas cylinders should be maintained properly. Never attempt to use a
cylinder that is leaking, cracked, or has other signs of physical damage.

• All gas cylinders should be secured to a wall or rack to prevent accidental knock
over.

• If a compressed gas cylinder is not being used, replace the protective valve cover.

• Never attempt to repair compressed gas cylinders.

• Keep compressed gas cylinders away from intense heat, sparks, or flames.

• Clear the compressed gas cylinder connection point by opening the valve

momentarily prior to installing a regulator.

• Never lubricate compressed gas cylinder valves or pressure regulators with any type
of oil or grease.

• Never use a compressed 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.

The Spirit system creates electric and magnetic fields that may interfere with certain
types of health support equipment, such as pacemakers. Any person who uses a
pacemaker or similar item should consult a doctor before operating, observing,
maintaining, or servicing the system. Observe the following guidelines to minimize
exposure to these electric and magnetic fields:

• Stay as far away from the power supply, torch, torch leads, and impulse start
console as possible.

• Route the torch leads as close as possible to the work ground cable.

• Never place your body between the torch leads and work ground cable. Keep the

work ground cable and the torch leads on the same side of your body.

• Never stand in the center of a coiled up set of torch leads or work ground cable.

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.

1-4

Spirit II User’s Manual Section 1: Safety

Safety Standards Booklet Index

For further information concerning safety practices to be exercised with plasma arc
cutting equipment, please refer to the following publications:

1. AWS Standard AWN, Arc Welding and Cutting Noise, obtainable from the American

Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

2. AWS Standard C5.2, Recommended Practices for Plasma Arc Cutting, obtainable

from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

3. AWS Standard FSW, Fire Safety in Welding and Cutting, obtainable from the

American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

4. AWS Standard F4.1, Recommended Safe Practices for Preparation for Welding and

Cutting of Containers and Piping, obtainable from the American Welding Society,
550 NW LeJeune Road, Miami, FL 33126.

5. AWS Standard ULR, Ultraviolet Reflectance of Paint, obtainable from the American

Welding Society, 550 NW LeJeune Road, Miami, FL 33126.

6. AWS / ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes,

obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL

33126.

7. ANSI Standard Z41.1, Standard For Men’s Safety-Toe Footwear, obtainable from

the American National Standards Institute, 11 West 42nd Street, New York, NY

10036.

8. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding

Processes, obtainable from the American National Standards Institute, 11 West
42nd Street, New York, NY 10036.

9. ANSI Standard Z87.1, Safe Practices For Occupation and Educational Eye and

Face Protection, obtainable from the American National Standards Institute, 11
West 42nd Street, New York, NY 10036.

10. ANSI Standard Z88.2, Respiratory Protection, obtainable from the American

National Standards Institute, 11 West 42nd Street, New York, NY 10036.

11. OSHA Standard 29CFR 1910.252, Safety and Health Standards, obtainable from

the U.S. Government Printing Office, Washington, D.C. 20402.

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

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1-5

Section 1: Safety Spirit II User’s Manual

12. NFPA Standard 51, Oxygen - Fuel Gas Systems for Welding, Cutting, and Allied

Processes, obtainable from the National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.

13. NFPA Standard 51B, Cutting and Welding Processes, obtainable from the National

Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

14. NFPA Standard 70, National Electrical Code, obtainable from the National Fire

Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

15. CGA booklet P-1, Safe Handling of Compressed Gases in Containers, obtainable

from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202.

16. CGA booklet P-14, Accident Prevention in Oxygen-Rich and Oxygen-Deficient

Atmospheres, obtainable from the Compressed Gas Association, 1725 Jefferson
Davis Highway, Suite 1004, Arlington, VA 22202.

17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the

Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202.

18. CSA Standard W117.2, Safety in Welding, Cutting, and Allied Processes,

obtainable from Canadian Standards Association, 178 Rexdale Boulevard, Toronto,
Ontario M9W lR3, Canada.

19. Canadian Electrical Code Part 1, Safety Standard for Electrical Installations,

obtainable from the Canadian Standards Association, 178 Rexdale Boulevard,
Toronto, Ontario M9W 1R3, Canada.

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

1-6

Spirit II User’s Manual Section 2: Specifications

Section 2: Specifications

System Description

The Spirit II 150 is a 150 amp microprocessor controlled, 100% duty cycle high current
density plasma cutting and marking system. It utilizes a precision, dual gas torch that is
capable of cutting mild steel up to 1-1/2" thick and stainless steel up to 1” thick.

The system contains a manually controlled gas console, which also provides the
primary interface to the entire Spirit system.

For cutting mild steel, the system uses oxygen for the plasma gas and either oxygen or
air for the shielding gas. When cutting stainless steel or other non-ferrous materials, air
or H17 (17.5% hydrogen, 32.5% argon, 50% nitrogen) is used for the plasma gas and
either air or nitrogen is used for the shielding gas. Oxygen and nitrogen are used for
the preflow and postflow gases.

The torch is water-cooled and consumables are machined to exacting dimensions and
checked with the latest computerized measuring systems. Five nozzle sizes (30, 50,
70, 100, and 150 amps) are available to produce excellent cut quality throughout the
cutting range.

Each enclosure in the system is rated for IP21S sealing, which is intended for
indoor use only. The system is not suitable for use in rain or snow.

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.

2-1

Section 2: Specifications Spirit II User’s Manual

System Components

The Spirit II 150 System consists of the following components:

Standard Components

• Power Supply

• Manual Gas Console

• CAN Cable

• CAN Termination Plug

• Impulse Start Console (ISC)

• ISC Control Cable

• ISC Ground Cable

• Torch and Handle Assembly

• Torch Lead Set

• 5-gang Manifold Assembly

• 5-gang Manifold Control Cable

• 2-gang Manifold Assembly

• 2-gang Manifold Control Cable

• 17 Inch Plasma Hose

• Coolant and Power Leads

• Gas Hose Package

• Work Ground Lead

• Spirit II User’s Manual

Optional Components

• Supply Gas Hoses

• Internal Inova Console

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

2-2

Spirit II User’s Manual Section 2: Specifications

Input Current at

Maximum Output

208 VAC, 3Ø, 60Hz

300211

99 amps

220 VAC, 3Ø, 60Hz

300212

94 amps

240 VAC, 3Ø, 60Hz

300213

86 amps

380 VAC, 3Ø, 50/60Hz

300214

54 amps

400 VAC, 3Ø, 50/60Hz

300215

52 amps

415 VAC, 3Ø, 50/60Hz

300216

50 amps

440 VAC, 3Ø, 50/60Hz

300217

47 amps

480 VAC, 3Ø, 60Hz

300218

43 amps

600 VAC, 3Ø, 60Hz

300219

34 amps

29.0" [737]

43.2" [1097]

150

Power Supply Specifications

Power Supply Description Part Number

Open Circuit Voltage ......................................... 300 VDC

Output Current (drooping characteristic) ........... 10 - 150 amps

Maximum Output Voltage ................................. 170 VDC

Duty Cycle ........................................................ 100% @ 25.5 kW

Maximum Ambient Temperature ....................... 104° F (40° C)

Coolant Discharge Pressure ............................. 150 psi (10.2 bar)

Coolant Flow Rate ............................................ 1 gal/min (3.8 liters/min)

Coolant Fluid ..................................................... Propylene glycol solution

Coolant Tank Capacity ...................................... 3.2 gal (12 liters)

Weight (without coolant) ................................... 953 lb (432 kg)

38.4"
[975]

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

2-3

Section 2: Specifications Spirit II User’s Manual

Torch Coolant Specifications

Note: Refer to the supplier’s most current Material Safety Data Sheet for

information regarding safety, handling, and storage of torch coolant.

The Spirit system is shipped without torch coolant in the reservoir. Coolant
must be added before applying power to the system. Only use Kaliburn

approved torch coolant solution for optimal system performance as commercially
available antifreeze contains corrosion inhibitors that will damage the cooling
system. The standard coolant solution consists of 25% industrial grade
propylene glycol and provides freezing protection down to -13º C (9º F). The
standard solution can be ordered in one-gallon containers, PN 500695. For
operating temperatures below -13º C, a 50% solution of industrial grade
propylene glycol can be ordered in one-gallon containers, PN 500895, providing
protection down to -36º C (-33º F).

Failure to use the proper propylene glycol solution may result in cooling
system and/or torch damage.

The torch coolant should be flushed out of the Spirit system every six months
and replaced with new coolant. The coolant filter / deionization cartridge should
also be changed at the same time. See Section 6 for details.

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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

Spirit II User’s Manual Section 2: Specifications

12.4" [315]

12.0" [305]

13.7" [348]

10.9" [277]

7.0" [178]

(4) Ø .300 [7.6]

Manual Gas Console (MGC) Specifications

Part Number .................................................... 300600

Weight .............................................................. 50 lb (23 kg)

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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

Section 2: Specifications Spirit II User’s Manual

Gas Supply Requirements

Plasma gas types:

Mild Steel ..................................................... Oxygen

Stainless Steel ............................................ Air or H17

Aluminum .................................................... Air

Shield gas types:

Mild Steel ..................................................... Oxygen or Air

Stainless Steel ............................................. Air or Nitrogen

Aluminum .................................................... Nitrogen

Preflow gas type ............................................... Oxygen and Nitrogen

Marking gas type............................................... Nitrogen

Plasma gas flow rate (maximum):

Oxygen or Air ............................................... 67 scfh (1897 liters/hour)

H17 .............................................................. 75 scfh (2124 liters/hour)

Shield gas flow rate (maximum):

Oxygen ........................................................ 19 scfh (538 liters/hour)

Air or Nitrogen ............................................. 225 scfh (6371 liters/hour)

Preflow gas flow rate (maximum) ...................... 60 scfh (1699 liters/hour)

Marking gas flow rate (maximum) ..................... 67 scfh (1897 liters/hour)

Rated Inlet gas pressure ................................... 115 psi (7.9 bar)

Minimum Inlet gas pressure .............................. 110 psi (7.6 bar)

Maximum Inlet gas pressure ............................. 145 psi (10.0 bar)

Oxygen and nitrogen should be supplied with a purity of at least 99.5%.
H17 should be supplied with a purity of at least 99.995%.

A potential fire hazard exists when cutting with oxygen. KALIBURN recommends
that an exhaust ventilation system be used when cutting with oxygen. Flashback
arrestors must be supplied (unless they are not available for the chosen gases
and pressures) to prevent a possible fire from propagating back to the gas
supplies.

Ensure that oxygen lines remain free from contaminants such as oil and grease. The
mixture of such contaminants with oxygen presents an additional fire hazard.

Compressed air must be clean, dry, and oil-free and may be supplied from compressed
cylinders or from an air compressor. Be aware that shop air systems are prone to oil
and moisture contamination. If shop air is used, it must be cleaned to ISO 8573.1:
Class 1.4.1. Specify dry air when using compressed cylinders. Breathing quality air
contains moisture and must not be used.

3/8” (inside diameter) hoses are required for all inlet gas connections. Mating
connectors are supplied with the unit. Quick-connect fittings must not be used.

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.

2-6

Spirit II User’s Manual Section 2: Specifications















12.75" [324]

8.00" [203]

12.00" [305]

13.50" [343]

10.00" [254]

5.35" [136]

(4) Ø.312 [8]

Impulse Start Console (ISC) Specifications

Part Number ..................................................... 300500

Weight .............................................................. 22 lb (10 kg)

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.

2-7

Section 2: Specifications Spirit II User’s Manual









Torch Head

Torch Base

Torch Handle

1.99"

Alignment Indicator
Attachment Ring

Manifold

Torch and 2-Gang Manifold Specifications

Part Number:

2-Gang Manifold Assembly .................................................. 284214

Torch Handle (standard) ...................................................... 278001

Torch Handle (short) ............................................................ 278018

Torch Base........................................................................... 279000

Torch Head (Copper Electrode) ........................................... 279100

Torch Head (Silver Electrode) .............................................. 279060

Max Weight:

Manifold/Bracket, Handle (278001), Base and Head ........... 8.3 lbs (3.8 kg)

3.38" [86]

278001 = 9.46" [240]
278018 = 7.06" [179]

[51]

1.87" [47]

5.08" [129]

(Slot)

Alignment Indicator
(Circle)

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.

2-8

Spirit II User’s Manual Section 2: Specifications



















4.20"

6.18" [157]

0.327" [8.3]

0.25" [6.4]

1.18" [30]

3.035" [77]

(4) 0.187" [4.8] Mounting Holes

5-Gang Manifold Specifications

Part Number .................................................... 280022

Weight .............................................................. 6 lb (2.7 kg)

3.80"
[97]

[107]

8.35" [212]

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.

2-9

Section 2: Specifications Spirit II User’s Manual

A-Weighted Sound

Pressure Level

C-Weighted Sound

Pressure Level

1 meter horizontal / 1.6

workpiece

Airborne Noise Emissions

The system generates high noise levels while cutting. Depending on the size of the
cutting area, distance from the cutting torch, and arc current cutting level, acceptable
noise levels may be exceeded. Proper ear protection should be used as defined by
local or national codes. The following chart gives the noise levels generated by the
system when operating at 150 amps, 130 arc volts. The measurements were made
with a sound level meter.

Distance From Torch

meters above the

97 dB 94 dB

The maximum noise level is 121 dB at a distance of 3 inches (76.2 mm) from the torch
while cutting at 150 amps, 130 arc volts.

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.

2-10

Spirit II User’s Manual Section 3: Installation

Section 3: Installation

Initial Inspection

All systems undergo full testing before being shipped from Kaliburn. In the unlikely
event that one of the components is defective or missing, please contact Kaliburn so a
replacement item can be sent. Also, Kaliburn has taken special care in packaging the
system. If the system was damaged during shipment, file a claim with the shipping
company, and then contact Kaliburn to order replacement parts.

Component Placement

Plasma Power Supply

The power supply should be lifted by a forklift or pallet jack. In order to prevent
damaging the power supply, the forks should be of adequate length to protrude on the
far side of the power supply. The proper location of the power supply will provide
dependable service and reduce periodic maintenance time. Choose a location that will
provide unrestricted air movement into 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 the accumulation of metallic dust inside the unit. See Section 2
for unit dimensions.

Manual Gas Console (MGC)

The MGC should be mounted near the CNC controller so that it is easy accessible by
the operator. See Section 2 for mounting dimensions.

Impulse Start Console (ISC)

The ISC should be mounted in a convenient location that is away from other electronic
control devices. The ISC offers significantly reduced emissions compared to traditional
high frequency, however, the high voltage pulse generated inside the unit may interfere
with the operation of sensitive control electronics. The ISC is usually mounted on the
gantry of the cutting machine or on the cutting table. See Section 2 for mounting
dimensions.

5-Gang Manifold

The 5-gang manifold assembly must be mounted within 6 feet (1.8 m) of the torch. See
Section 2 for mounting dimensions.

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

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3-1

Section 3: Installation Spirit II User’s Manual

2-Gang Manifold

The 2-gang manifold assembly must be mounted to the torch. See Section 2 for
mounting dimensions.

Torch

The torch must be installed on the positioner of an arc voltage control (height control)
capable of maintaining the cutting arc voltage within 1 arc volt. The arc voltage must be
adjustable in 1 arc volt increments. The positioner must be rigid to ensure cut quality
and a torch collision sensor is highly recommended. See Section 2 for mounting
dimensions.

System Interconnection

The Spirit II system interconnection diagrams on the following pages will assist in the
planning and installation of the system as well as identifying cables and hoses upon
receipt.

The optional Inova torch height control is also shown to assist with its connections,
whether as an external console or internal to the plasma power supply.

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.

3-2

Spirit II User’s Manual Section 3: Installation

Figure 1: Spirit II System with Manual Gas Console and Internal Inova System

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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

Section 3: Installation Spirit II User’s Manual

Figure 2: Spirit II System with Manual Gas Console and External Inova System

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

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

3-4

Spirit II User’s Manual Section 3: Installation

Input Current at

Output (amps)

Recommended

Size (amps)

208 VAC, 60Hz

99

125

220 VAC, 60Hz

94

125

240 VAC, 60Hz

86

110

380 VAC, 50/60Hz

54

65

400 VAC, 50/60Hz

52

65

415 VAC, 50/60Hz

50

60

440 VAC, 50/60Hz

47

60

480 VAC, 60Hz

43

60

600 VAC, 60Hz

34

45

Power Supply Primary Power Connections

** Before connecting primary power, check the data plate

on the power supply to verify the voltage required **

A primary disconnect switch, switching all ungrounded supply conductors, should be
provided for each Spirit system. The disconnect switch should be located as close as
possible to the power supply so it can be turned off quickly in case of an emergency.
The disconnect switch should be equipped with time delay fuses only. The
magnetic inrush current of the power supply will cause fast acting fuses to blow. The
disconnect switch should be sized according to local and national codes. The rating
must meet or exceed the continuous rating of the fuses used. See the following chart
for recommended fuse sizes:

3 Phase

Input Voltage (VAC)

Maximum

Time-Delay Fuse

Connection to the supply circuit can be by means of flexible supply cables or supply
cables through conduit to a permanent installation. The supply cables should have a
600 volt minimum rating and should be sized according to local and national codes.

Route flexible supply cables through the strain relief on the back of the power supply
and connect to the input terminal block TB5 as shown. For supply cables through
conduit, install the conduit in place of the strain relief and connect the associated supply
cables to the input terminal block TB5. See Figure 3 on the next page.

TB5 is located on the rear of the power supply and is accessible with the right-side
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.

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.

3-5

Section 3: Installation Spirit II User’s Manual

Strain Relief

Disconnect Box
TB5 Connections

L1 (U)

TB5

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.

L1 L2 L3 Gnd

Figure 3: Power Supply Primary Connections

L2 (V)
L3 (W)
Ground

Connections

3-6

Spirit II User’s Manual Section 3: Installation

2

1 3 4

Power Supply Output Connections

Perform the following steps to connect the output of the power supply to the impulse
start console and the work table. See Figure 4 on the next page.

Power Supply Electrode Lead

1. Route one end of the #1/0AWG power supply electrode lead through the upper
strain relief on the rear of the power supply and connect it to the electrode terminal.

2. Route the other end of the power supply electrode lead through the strain relief on
the impulse start console and connect it to the cathode manifold.

Power Supply Nozzle Lead

1. Route the larger ring terminal end of the #10AWG power supply nozzle lead through
the bushing on the rear of the power supply and connect it to the nozzle terminal.

2. Route the smaller ring terminal end of the power supply nozzle lead through the
strain relief on the impulse start console and connect it to the pilot terminal on the
printed circuit board.

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 sensor lead through the strain
relief on the impulse start console and connect it to the CTP sensor lead with
FASTON connector.

Work Ground Lead

1. Route one end of the #1/0AWG work ground lead through the bottom strain relief on
the rear of the power supply and connect it to the work terminal.

2. Connect the other end of the work ground lead to the star ground point on the cutting
table.

The star ground point is generally referred to as the common ground point on the
cutting table where all subsystems of the machine are grounded. This point is then
connected to a driven earth ground rod that should be as close as possible to the
star ground. The ground rod should have no other wires connected to it. The
ground rod should be at least 3/4 inches in diameter and should be driven into the
earth’s permanent moisture layer. The length of the ground rod varies from
installation to installation and should be installed according to local and national
codes. Refer to the National Electrical Code, Article 250, Section H, Ground
Electrode System for additional information.

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.

3-7

Section 3: Installation Spirit II User’s Manual

4 1 3

2

Strain Relief
1

2

3

Strain Relief

Figure 4: Power Supply Output Connections

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

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

3-8

Spirit II User’s Manual Section 3: Installation

5 6 7

8

ISC Control Cable and ISC Ground Connections

Perform the following steps to connect the ISC control cable and ISC ground. See
Figure 5 on the next page.

ISC Control Cable

1. Connect the ISC control cable plug labeled P16 to the connector labeled P16 on the
rear of the power supply.

2. Connect the ISC control cable plug labeled P1 to the connector labeled P1 on the
impulse start console.

ISC Ground Cable

1. Connect one end of the ISC ground cable to the ground stud on the impulse start
console.

2. Connect the other end of the ISC 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 impulse start 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 of
the power supply. Note that the coolant out fitting has right hand threads.

2. Connect the other end of the coolant supply hose to the coolant in fitting on the
impulse start console. Note that the coolant in fitting has right hand threads.

Coolant Return Hose

1. Connect one end of the coolant return hose to the coolant in fitting on the rear of the
power supply. Note that the coolant in fitting has left hand threads.

2. Connect the other end of the coolant return hose to the coolant out fitting on the
impulse start console. Note that the coolant out fitting has left hand threads.

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.

3-9

Section 3: Installation Spirit II User’s Manual

Figure 5: Cooling System Connections

6 5 7 8 7

8

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

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

3-10

Spirit II User’s Manual Section 3: Installation

11

12

13

14

15

Torch Leads to Impulse Start Console Connections

Perform the following steps to connect the torch leads to the impulse start console.
See Figure 6 on the next page.

Note: When making hose connections, only tighten the brass fittings enough to
make water or gas seals. The fittings are subject to damage if over tightened.

Braided Shield

1. Remove the threaded ring from the brass shield connector on the end of the braided
shield. Route the torch leads through the opening in the impulse start console and
push the shield connector through the hole until it is seated against the side of the
console.

2. Slide the threaded ring over the torch leads, thread it onto the brass shield
connector, and tighten firmly. The shield connector should ground the braided
shield to the case of the impulse start 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 impulse start 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 threads.

Torch Coolant Return Lead

• Connect the torch coolant return lead to the brass cathode manifold. Note that the
torch coolant return lead has left hand threads.

Torch Nozzle Lead

• Connect the torch nozzle lead to the angled bracket on the red standoff. Note that
the torch nozzle lead has right hand threads.

Torch CTP Sensor Lead

• Connect the #18AWG torch CTP sensor lead to the red standoff as shown.

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.

3-11

Section 3: Installation Spirit II User’s Manual

15

13

14

12

11

Figure 6: Torch Leads to Impulse Start Console Connections

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

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

3-12

Spirit II User’s Manual Section 3: Installation

18

19

18

19

17

16

17

16

16

17

18

19

Torch Leads to Torch Base Connections

Perform the following steps to connect the torch leads to the torch base.

Note: When making hose connections, only tighten the brass fittings
enough to make water or gas seals. The fittings are subject to damage if
over tightened. Also, use two wrenches when tightening the torch fittings
to avoid damaging the torch base.

Torch Lead through Torch Handle Installation

1. Route the torch leads through the torch handle. 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

• Connect the torch coolant return lead to the torch base as shown. Note that
the torch coolant return lead fitting has left hand threads.

Torch Nozzle Lead

• Connect the torch nozzle lead to the torch base as shown.

Torch CTP Sensor Lead

• Connect the torch CTP sensor lead to the torch base as shown.

Figure 7: Torch Leads to Torch Base Connections

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

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

3-13

Section 3: Installation Spirit II User’s Manual

20

21

22

23

Torch Gas Connections

Perform the following steps to connect the torch gas hoses to the manual gas
console, torch base, and manifold assemblies. See figure 8.

Note: When making hose connections, only tighten the brass fittings
enough to make gas seals. The fittings are subject to damage if over
tightened.

7.5 Foot Shield Gas Hose

1. Route one end of the 7.5 foot (2.3 m) shield gas hose through the torch
handle and connect to the shield gas fitting on the torch base.

2. Connect the other end of the 7.5 foot (2.3 m) shield gas hose to the shield
gas outlet on the 5-gang manifold.

17 Inch Plasma Gas Hose

1. Route one end of the 17 inch (432 mm) plasma gas hose through the torch
handle and connect to the plasma gas fitting on the torch base.

2. Thread the torch handle onto the 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 ¼" 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 14 inch (432 mm) plasma gas hose to the
plasma gas outlet on the 2-gang manifold.

6. Mount the torch handle/base/manifold to the positioner. Note the alignment
indicators on the torch base (slot) and torch head (circle). These aid in
aligning the quick-disconnect torch base and head and should be oriented so
they are clearly visible when the operator is changing heads.

6 Foot Preflow/Postflow/Marking Gas Hose

1. Connect one end of the 6 foot (1.8 m) preflow/postflow/marking gas hose to
the preflow/postflow/marking outlet on the 5-gang manifold.

2. Connect the other end of the 6 foot (1.8 m) preflow/postflow/marking gas
hose to the preflow/postflow/marking inlet on the 2-gang manifold.

Marking Gas Hose

1. Connect one end of the marking shield gas hose to the marking shield outlet
on the rear of the MGC.

2. Connect the other end of the marking shield gas hose to the marking shield
inlet on the 5-gang manifold.

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.

3-14

Spirit II User’s Manual Section 3: Installation

25

26

27

28

29

30

Postflow Gas Hose

1. Connect one end of the postflow hose to the postflow outlet on the rear of the
MGC. Note that the postflow hose fittings have left hand threads.

2. Connect the other end of the postflow hose to the postflow inlet on the 5-gang
manifold.

Plasma Gas Hose

1. Connect on end of the plasma hose to the plasma outlet on the rear of the
MGC.

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
MGC.

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
MGC. Note that the preflow hose fittings have left hand threads.

2. Connect the other end of the preflow hose to the preflow inlet on the 5-gang
manifold.

5-Gang Manifold Control Cable

1. Connect the 5-gang manifold control cable plug marked P15 to the 5-gang
manifold as shown.

2. Connect the 5-gang manifold control cable plug labeled P12 to the connector
labeled P12 on the rear of the power supply.

2-Gang Manifold Control Cable

1. Connect the 2-gang manifold control cable plug marked P18 to the 2-gang
manifold as shown.

2. Connect the 2-gang manifold control cable plug labeled P13 to the connector
labeled P13 on the rear of the power supply.

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.

3-15

Section 3: Installation Spirit II User’s Manual

Manual Gas

25

22

26

27

23

25

22

21

30

GREEN

REAR

REAR

BLUE

27

21

20

28

26

20

28

29

23

BLUE

GREEN

RED

Console

RED

Figure 8: Torch Gas Connections

PORT

PORT

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

3-16

Spirit II User’s Manual Section 3: Installation

32

34

31

33

31

32

33

34

Gas Supply Connections

Perform the following steps to connect the gas supply lines to the MGC. See Section 2
for gas supply requirements. Mating hose barbs and connectors are supplied with the
system and are sized for 3/8 inch inside diameter hose. Do not change the inlet gas

supply fittings to quick-connect fittings. Using quick-connect fittings to connect
and disconnect pressurized hoses may cause damage to the system.

Note: When making hose connections, only tighten the brass fittings enough to
make gas seals. The fittings are subject to damage if over tightened.

Air Inlet (ISO 3821 hose color - black)

• Air must be supplied to the unit at all times, regardless of the cutting current or
material type.

Oxygen Inlet (ISO 3821 hose color - blue)

• Oxygen must be supplied to the unit at all times, unless stainless steel is being cut
with H17 plasma.

Nitrogen Inlet (ISO 3821 hose color - black)

• Nitrogen must be supplied to the unit at all times, regardless of the cutting current or
material type.

H17 Inlet (ISO 3821 hose color - red)

• H17 must be supplied to the unit when stainless steel is being cut with H17 as the
plasma gas. See cutting charts in Section 5 for more information.

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.

3-17

Section 3: Installation Spirit II User’s Manual

35

36

35

35

36

CAN Communication Connections

Perform the following steps to connect the plasma power supply to the MGC.

CAN Cable

• Connect the male end of the CAN cable to the connector labeled P4 on the rear of
the plasma power supply.

• Connect the female end of the CAN cable to the top connector on the rear of the
MGC.

CAN Termination Plug

• If not already installed, connect the CAN termination plug to the bottom connector on
the rear of the MGC.

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.

3-18

Spirit II User’s Manual Section 3: Installation

CNC Machine Interface Connections

Perform the following steps to properly interface the Spirit system with a CNC cutting
machine. See the system schematic for additional information.

Plasma Start Input
The power supply requires a contact closure between P8 pins 3 and 4 to commence the
cutting or marking sequence. The sequence is terminated when the contacts are
opened. The contacts should be rated for 24VDC - 7.3mA.

Plasma Cut/Mark Input
The power supply requires a contact closure between P8 pins 1 and 2 to put the system
in plasma marking mode. Opening the contacts puts the system in cutting mode. The
operating mode should be selected prior to applying a start signal. The contacts should
be rated for 24VDC - 7.3mA.

Arc Hold Input
The power supply requires a contact closure between P8 pins 10 and 11 to inhibit arc
starting even though a plasma start signal has been applied to the unit. When the
contacts are opened, the arc is initiated. This feature is used to decrease cycle time by
allowing pre-cut gas and contact sequencing to occur simultaneously with initial torch
height positioning. The contacts should be rated for 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 pins 5 and 6 to
energize the system from a remote location, provided that the OFF Button on the
manual gas console is released. Opening the contacts deenergizes the system. If the
remote on/off feature is not used, install a jumper between terminal block TB1 positions
7 and 8. The contacts should be rated for 24VAC – 10mA.

Power Supply Ready Output
The power supply provides a maintained contact closure output between P8 pins 7 and
8 when the system is ready to cut or mark. The contacts are open during gas purge or
when an error occurs. The contacts are rated for 24VDC – 10mA.

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.

3-19

Section 3: Installation Spirit II User’s Manual

Filling the Cooling System

WARNING: Do not touch the fans inside the power supply.

Important: Never turn on the system when the coolant reservoir is empty.
Important: When handling coolant, wear nitrile gloves and safety glasses.
Important: Only use Kaliburn approved coolant. Commercially available

antifreeze contains corrosion inhibitors that will damage the cooling
system. See Section 2 for more information.

1. Remove primary power from the Spirit system.

2. Ensure the torch base and torch head (with consumables) are properly installed.

3. Ensure the coolant supply (in and out) hoses are properly installed.

4. Remove the coolant reservoir cap/level gauge and then remove the top, left and
right covers from the power supply.

5. Ensure the coolant filter housing is tightened securely.

6. Ensure the drain petcock on the bottom of the reservoir is tightened securely.

7. Fill the reservoir with approximately 2 ½ gallons of approved coolant.

8. Apply primary power to the Spirit system and enable it by releasing (turn right) the
OFF Button on the MGC.

9. On the MGC main menu, move the pointer to On. Press SELECT to start the
coolant pump circulating coolant through the system. Note: The coolant pump will
turn off automatically if the coolant level drops below the minimum level inside the
reservoir. If this happens, add more coolant.

10. With the coolant pump running, locate the small red push-button on top of the
coolant filter housing (beneath the reservoir). Press and hold the red button until no
air or bubbles are seen inside the filter housing. Dry any coolant that leaks out.

11. Check for coolant leaks at all hose connections, the ISC, and at the torch.

12. Push the OFF Button on the MGC to stop the coolant pump.

13. Remove primary power from the Spirit system.

14. Fill the reservoir with coolant until the coolant gauge indicates full.

15. Replace the power supply covers and replace the coolant reservoir cap/level gauge.

16. End of procedure.

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.

3-20

Spirit II User’s Manual Section 4: Operation with Manual Gas Console

OFF Button

Section 4: Operation

Operating the Manual Gas Console (MGC)

The Manual Gas Console (MGC) is the interface to the entire Spirit system when the
MGC is used instead of the Automatic Gas Console (AGC).

Push to disable the Spirit system.
Release (turn to the right) to enable
the system, which can then be
energized by choosing ON and then
SELECT.

Up/Down/Select Buttons

Press the up or down button to move
the pointer ( ) accordingly on the
display. These buttons are
represented as UP and DOWN
throughout this manual.

Press the select button to access
menu items or settings identified by
the pointer. This button is shown as
SELECT throughout this manual.

Display

The display turns on automatically
when AC power is applied to the
Spirit system. It displays the menu
tree, which is navigated using the
Up/Down/Select buttons and is used
to control the entire Spirit system.

Pressure Regulator Knobs

Turn to the left or right to adjust the
amount of output gas pressure for
PreFlow, PostFlow, Plasma and
Shield gases.

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

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

4-1

Section 4: Operation with Manual Gas Console Spirit II User’s Manual

Push the OFF Button on the MGC to disable

Move the pointer to Current.

Move the pointer to Select Gas.

Move the pointer to Adjust Gas.

Move the pointer to a gas and then press

The system is now setup to cut.

Setting up to Cut

The following procedure uses the information from the cutting charts in Section 5 to
prepare the system to cut. Press the UP or DOWN button on the MGC to move the
pointer through the menu as described below.

the system. On the main menu, move the
pointer to Setup. Press SELECT.

Cutting is displayed.

Press SELECT to cycle through the list until
the desired amperage is displayed.

Press SELECT to cycle through the list until

Press SELECT.

Press SELECT to choose the Plasma gas.
Move the pointer to Shield and press SELECT
to choose the shield gas. Move the pointer to
Return and press SELECT.

Press SELECT.

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.

SELECT to start the flow of that gas. Turn the
corresponding regulator knob on the MGC to
adjust the displayed pressure to match the
value in the cutting chart. Repeat for all other
gases. Move the pointer to Return and press
SELECT. Repeat to return to the main menu.

4-2

Spirit II User’s Manual Section 4: Operation with Manual Gas Console

Push the OFF Button on the MGC to disable

Press SELECT to cycle through the list until

cut.

On the main menu, move the pointer to

Verify that all connected gas pressures are at

Setting up to Mark (Overrides Cut)

The system will automatically switch between cutting and marking based upon
commands in the part program. However, all cutting commands in the part program can
be overridden with marking commands by simply changing the Process to Marking.

the system. On the main menu, move the
pointer to Setup. Press SELECT.

Marking is displayed. Move the pointer to
Return and press SELECT.

The system is now setup to mark instead of

Verifying Input Gas Pressures

For the system to work properly the input gas pressures must be within an acceptable
range. To check the input pressures, follow the steps below.

Input Gas. Press SELECT.

least 120psi. The maximum input gas pressure
is 145psi.

Press SELECT to return to the main menu.

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

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

4-3

Section 4: Operation with Manual Gas Console Spirit II User’s Manual

Release the OFF Button (turn to the right) on

The MGC will purge the gas hoses. The purge

deenergized.

Making a Cut or Mark

Once the process type, gas types and gas pressures have been set in the MGC; the
correct torch parts (consumables) installed; and the X/Y controller and torch height
control are properly configured; the system is ready to cut or mark.

the MGC. On the main menu, move the
pointer to On. Press SELECT.

icon ( ) is displayed during this process.

Once purging is complete, the ready icon ( )
is displayed. The system is now ready to cut or
mark.

When the system receives a start signal from
the X/Y controller, the following sequence is
initiated:

• Two second gas preflow

• Impulse start circuit energized

• Pilot arc initiation

• Transferred arc (cutting or marking arc)

established

• Motion output relay energized

When the start signal is removed, the arc is
extinguished and the motion output relay is

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

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

4-4

Spirit II User’s Manual Section 4: Operation with Manual Gas Console

Piercing Thick Materials

Care must be taken when piercing thick materials in order to prevent damage to the
shield cap and nozzle. As with all thicknesses, the pierce height must be set high
enough so the metal ejected while piercing does not come into contact with the shield
cap. Also, some of the material ejected during the pierce may adhere to the top side of
the plate and form a ring of solidified material around the pierce point.

Action must be taken so the torch does not move from the pierce height down to the
cutting height and come into contact with this solidified metal. The torch should not
move from the pierce height down to the cutting height until the X/Y 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.

Moving Pierces and Edge Starts

On very thick materials, an edge start or moving pierce may be required to prevent
damage to the torch consumables.

With a moving pierce, the X/Y machine should begin moving at approximately 5–10
inches/minute (125–250 mm/min) as soon as the arc transfers to the plate. After the arc
completely penetrates the plate, the torch should be positioned at the proper cutting
height and the X/Y machine speed should be increased to the correct level.

With an edge start the torch should be positioned at the edge of the material prior to
starting the arc.

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

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

4-5

Section 4: Operation with Manual Gas Console Spirit II User’s Manual

Cut Quality

Before the optimum cutting condition can be achieved on a particular material type and
thickness, the machine operator must have a thorough understanding of the cutting
characteristics of the Spirit system. When the cut quality is not satisfactory, the cutting
speed, torch height, or gas pressures may need to be adjusted in small increments until
the proper cutting condition is obtained. The following guidelines should be useful in
determining which cutting parameter to adjust.

Note: Before making any parameter changes, verify that the torch is square to
the workpiece. Also, it is essential to have the correct torch parts in place and to
ensure that they are in good condition. Check the electrode for excessive wear
and the nozzle and shield cap orifices for roundness. Also, check the parts for
any dents or distortions. Irregularities in the torch parts can cause cut quality
problems.

1. A positive cut angle (top dimension of piece smaller than the bottom dimension)
usually occurs when the torch standoff distance is too high, when cutting too fast, or
when excessive power is used to 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-speed dross is easily removed, while
high-speed dross usually requires grinding or chipping off. When using oxygen as
the shielding gas, bottom dross can sometimes be removed by increasing the shield
gas pressure. However, increasing the shield pressure too much can cause cut face
irregularities (see below). Bottom dross also occurs more frequently as the metal
heats up. As more pieces are cut out of a particular plate, the more likely they are to
form dross.

5. When using oxygen as a shielding gas, cut face irregularities usually indicate that
the shield gas pressure is too high or the torch standoff distance is too low.

6. A concave cut face usually indicates that the torch standoff distance is too low or the
shield gas pressure is too high. A convex cut face usually indicates that the torch
standoff distance is too high or the shield gas pressure is too low.

7. Note that different material compositions have an effect on dross formation.

8. If the material is not being completely severed, the likely causes are that the cutting
current is too low, the travel speed is too high, the gas pressures are incorrect, the
incorrect gas types are selected, the incorrect consumables are installed in the
torch, or the consumables are worn.

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

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

4-6

Spirit II User’s Manual Section 4: Operation with Manual Gas Console

On the main menu, move the pointer to Errors.

On the main menu, move the pointer to

Move the pointer to either Power Supply or

Review the necessary information.

SELECT to return to the main menu.

Checking Errors

The last ten (10) system errors are available through the MGC as described below.

Press SELECT.

(10) error codes.

See Section 6 in this manual for details on the

Press SELECT to cycle through the last ten

error codes.

Simultaneously pressing DOWN and SELECT
will erase all ten error codes.

Move the pointer to Return and press

SELECT to return to the main menu.

Checking the Version and Serial Number

The hardware version, software version and serial number for the Power Supply and
Gas Console can be displayed as described below.

Version. Press SELECT.

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.

Gas Console. Press SELECT.

Press SELECT to return to the previous
screen.

Move the pointer to Return and press

4-7

Section 4: Operation with Manual Gas Console Spirit II User’s Manual

On the main menu, move the pointer to

Languages

Move the pointer to the desired language and

return to the main menu.

On the main menu, move the pointer to

Move the pointer to Contrast.

to return to the main menu.

Changing the Language

The language displayed on the MGC can be changed as described below.

Configure. Press SELECT.

then press SELECT. The display changes
immediately to the selected language.

Press SELECT on

Move the pointer to Return and press SELECT
to return to the previous screen. Repeat to

Adjusting the Screen Contrast

The contrast of the display on the MGC can be adjusted as described below.

Configure. Press SELECT.

.

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.

Press SELECT to cycle through the list of
contrast settings.

Move the pointer to Return and press SELECT

4-8

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

YES

NO!

There is no

Gap is visible

O-ring

Torch Base

Section 5: Torch Consumables and Cutting Charts

Installing / Removing the Torch Head

WARNING: Remove primary power from the Spirit system!

1. Each time the torch head is connected to the torch base, use a cotton swab to apply
a small amount of o-ring lubricant on each of the seven o-rings on the top of the
torch head. Reminder: do not use an excessive amount of o-ring lubricant.

2. 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. Turn the attachment ring to the RIGHT to tighten.

4. Keep tightening the attachment ring until it stops. There should be no gap between
the attachment ring and the o-ring on the torch base.

During this process, a small amount of coolant will collect in the torch head.
It is normal for this coolant to discharge between the o-ring on the torch base and
the attachment ring while the system is being pressurized. If coolant continues to
discharge after the system is pressurized, turn off the plasma power supply, remove
the torch head and inspect the o-rings for damage.

O-ring

Torch Head

gap between
o-ring and
attachment
ring

between
o-ring and
attachment
ring

To remove the torch head, turn the attachment ring to the LEFT.

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.

5-1

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

YES

NO!

PULL

PULL

Installing / Replacing Consumables

WARNING: Remove primary power from the Spirit system!

Note: When installing the consumables, do not use an excessive amount
of o-ring lubricant. Also ensure that the lubricant is placed only on the
o-rings. Excess lubricant can interfere with gas flow, which can cause
starting problems, poor cut quality, and short consumable life.

1. 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. Remove the outer retaining cap from the torch head.

3. Remove the inner retaining cap from the torch head.

4. Separate the shield cap from either the inner retaining cap or the outer
retaining cap.

5. Use the nozzle removal tool (P/N 277056) to remove the nozzle from the
torch head. To do this, insert the tool into the groove on the nozzle and hold
the tool/nozzle in the palm of your hand. Pull both hands apart using a linear
motion as shown in the left image below. Do not use a prying or bending
motion as shown in the right image below.

OR

6. Use the swirl ring removal tool (P/N 260105) 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 277087 & driver P/N 277086.

• All silver electrodes use P/N 279061.

8. Inspect all consumables and o-rings for damage and excess wear. Replace
with new consumables as necessary.

9. Inspect the cooling tube in the torch head for damage. See Section 6
Maintenance and Troubleshooting if replacement is necessary.

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.

5-2

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Current (A)

Time (ms)

30

490

50

390

70

300

100

300

150

175

Maximizing Consumable Life

Use the following guidelines to maximize consumable parts life:

1. The Spirit system utilizes the latest advancement in technology for extending the life
of the torch consumable parts. To maximize the life of the consumable parts, it is
imperative that the shutdown procedure of the arc is carried out properly. The arc
must be extinguished while it is still attached to the workpiece. A popping
noise may be heard if the arc extinguishes abnormally. Note that holes are usually
programmed without lead-outs to prevent loss of the arc during shutdown. There is
a time delay between the reception of a stop signal and when the arc is
extinguished. During this time, 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

2. Use the recommended pierce height given in the cutting charts. A pierce height that
is too low will allow molten metal that is ejected during the piercing process to
damage the shield cap and nozzle. A pierce height that is too high will cause the
pilot arc time to be excessively long and will cause nozzle damage. See “Piercing
Thick Materials” in Section 4.

3. Never fire the torch in the air. Nozzle damage will occur.

4. Make sure the torch does not touch the plate while cutting. Shield cap and nozzle
damage will result.

5. Use a chain cut when possible. Starting and stopping the torch is more detrimental
to the consumables than making a continuous cut.

6. Always use error tracking on the plasma console to keep track of cut errors. See
Section 4 for information on error tracking.

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.

5-3

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Part

Inspect For

Corrective Action

Outer Cap

Damaged o-ring

Replace shield cap

Center hole out of round

Damage o-ring

Replace retaining cap

Replace retaining cap

Center hole out of round

Damaged o-rings

Replace nozzle

Replace nozzle

Damage

Damaged o-rings

Replace swirl ring

Replace swirl ring

Pit depth

Damaged o-rings

Replace electrode if center pit depth is

Replace electrode

Inspecting for Damage

When the cut quality is not satisfactory, use the following guidelines for
determining which consumable parts need to be changed. Inspect all parts for
dirt, debris, and excess o-ring lubricant and clean as necessary.

Shield Cap

Retaining Cap

Nozzle

Dents, cracks

Center hole out of round

Dents, Scratches

Dry o-ring

Dents, cracks

Dry o-ring

Erosion or arcing

Dry o-rings

Replace outer cap

Replace shield cap

Replace shield cap

Apply a thin film of o-ring lubricant

Replace retaining cap

Apply a thin film of o-ring lubricant

Replace nozzle

Apply a thin film of o-ring lubricant

Swirl Ring

Electrode

or

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.

Clogged holes

Dry o-rings

Erosion or arcing

Dry o-rings

Blow out with compressed air. Replace
swirl ring if clogs can’t be removed.

Apply a thin film of o-ring lubricant

greater than 0.040” (1 mm) for copper
electrode or 0.098" (2.5mm) for silver.

Replace electrode

Apply a thin film of o-ring lubricant

5-4

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Retaining Cap

Cap

Retaining Cap

Ring

Electrode

Head

284150

277145

277153

277120

277140

277130

279100

284150

277115

277153

277122

277140/

277142

277131

279100

284150

277117

277151/

277152

277293

277139

277292

279100

Selecting Consumables

Mild Steel

Copper Electrode

Outer

Shield

Inner

Nozzle

Swirl

Copper

Torch

30A

50A

70A

100A

150A

284150 277150 277153 277125 277142 277131 279100

284150 277286 277151 277284 277283 277282 279100

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.

5-5

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Silver

Electrode

Torch

Head

284150

277286

277151

279484

279483

279060

284150

277117

277151/

277152

279493

279439

279060

Mild Steel

Silver Electrode

Nozzle

100A

150A

279410

(brown o-ring)

279420

(green o-ring)

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.

5-6

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Copper

Electrode

Torch

Head

284150

277150

277113

277124

277140

277132

279100

284150

277146

277113

277126

277141

277133

279100

284150

277298

277266

277297

277139

277135

279100

Stainless Steel - H17 Plasma

Copper Electrode

70A

100A

150A

Nozzle

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.

5-7

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Copper

Electrode

Torch

Head

284150

277144

277110

277121

277138

277137

279100

284150

277149

277110

277123

277142

277137

279100

284150

277150

277153

277125

277142

277131

279100

284150

277286

277151

277284

277283

277282

279100

284150

277117

277152

277293

277139

277292

279100

Stainless Steel - Air or Nitrogen Plasma

Copper Electrode

Nozzle

30A

50A

70A

100A

150A

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.

5-8

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Silver

Electrode

Torch

Head

284150

277286

277151

279484

279483

279060

284150

277117

277152

279493

279439

279420

(green o-ring)

279060

Stainless Steel - Air or Nitrogen Plasma

Silver Electrode

Nozzle

100A

150A

279410

(brown o-ring)

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.

5-9

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Copper

Electrode

Torch

Head

284150

277145

277153

277120

277140

277130

279100

284150

277150

277153

277122

277142

277131

279100

284150

277150

277153

277125

277142

277131

279100

284150

277286

277151

277284

277283

277282

279100

284150

277117

277152

277293

277139

277292

279100

Aluminum

Copper Electrode

30A

50A

70A

100A

Nozzle

150A

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.

5-10

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Silver

Electrode

Torch

Head

284150

277286

277151

279484

279483

279060

284150

277117

277152

279493

279439

279420

(green o-ring)

279060

Aluminum

Silver Electrode

100A

150A

Nozzle

279410

(brown o-ring)

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.

5-11

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

Copper

Electrode

Silver

Electrode

Mild Steel

30 Amps

Oxygen

Oxygen

Page 5-13

Mild Steel

50 Amps

Oxygen

Oxygen or Air

Page 5-14

Mild Steel

70 Amps

Oxygen

Air

Page 5-15

Mild Steel

100 Amps

Oxygen

Air

Page 5-16

Page 5-31

Mild Steel

150 Amps

Oxygen

Air

Page 5-17

Page 5-32

Stainless Steel

30 Amps

Air

Air

Page 5-18

Stainless Steel

50 Amps

Air

Nitrogen

Page 5-19

Stainless Steel

70 Amps

H17

Nitrogen

Page 5-20

Stainless Steel

70 Amps

Air

Nitrogen

Page 5-21

Stainless Steel

100 Amps

H17

Nitrogen

Page 5-22

Stainless Steel

100 Amps

Air

Nitrogen

Page 5-23

Page 5-33

Stainless Steel

150 Amps

H17

Nitrogen

Page 5-24

Stainless Steel

150 Amps

Air

Nitrogen

Page 5-25

Page 5-34

Aluminum

30 Amps

Air

Nitrogen

Page 5-26

Aluminum

50 Amps

Air

Nitrogen

Page 5-27

Aluminum

70 Amps

Air

Nitrogen

Page 5-28

Aluminum

100 Amps

Air

Nitrogen

Page 5-29

Page 5-35

Aluminum

150 Amps

Air

Nitrogen

Page 5-30

Page 5-36

Cutting Charts

The cutting charts shown on the following pages are intended to give the
operator the best starting point to use when making a cut on a particular material
type and thickness. Small adjustments may have to be made to achieve the best
cut. Also, remember that the arc voltage must be increased as the electrode
wears in order to maintain the correct cutting height.

Cutting Chart Index

Material Current Plasma Gas Shield Gas

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.

5-12

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

277145

277120

277130

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277140 279100

Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(ga) (in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

20 .036

18 .048 121 97 .090

16 .060 125 78

14 .075 126 65

12 .105 127 55

11 .120 129 50

10 .135 131 40

Preflow Plasma Shield Postflow

35 77 6 75

Arc

Voltage

120 105 .080

Travel
Speed

Cutting

Height

.105 200

.120 .125 300

Pierce
Height

.110

Pierce

Time

100 .062

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

1

1.5 124 2020 2.6

2

2.5 1455

3 128 1285 2.9 3.1 300

Preflow Plasma Shield Postflow

35 77 6 75

Arc

Voltage

120 2615 2.0

126

Travel
Speed

1615

Cutting

Height

2.7

Pierce
Height

2.8

Pierce

Time

100 1.6

200

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 145 250 6350 .177 4.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 66 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .100” (2.5 mm) for cutting and marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Kerf

Width

.065

.070

Kerf

Width

1.7

1.8

Pierce

Time

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.

5-13

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277115

277122

277131

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277140 / 277142

279100

Mild Steel - 50 amps - Oxygen Plasma / Oxygen or Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(ga) (in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

Preflow Plasma Shield Postflow

Cold-Rolled Steel – Oxygen Shield – Swirl Ring 277140

12 .105

11 .120 126 60 .125

10 .135 128 50 .135

25 74 12 72

Hot-Rolled Steel – Air Shield – Swirl Ring 277142

14 .075

12 .105 190

.125 180

10 .135 110 170 .110

3/16 113 105

1/4 117 75 .225 400 .087

25 74 19 72

Arc

Voltage

123 70 .120

106

Travel
Speed

200

Cutting

Height

.100

.140

Pierce
Height

.135

.135

.200 300 .085

Pierce

Time

100 .075

200 .078

100 .075

200 .080

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

Preflow Plasma Shield Postflow

Arc

Voltage

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Kerf

Width

Kerf

Width

Cold-Rolled Steel – Oxygen Shield – Swirl Ring 277140

2.5

3 125 1555 3.1 200 2.0

25 74 12 72

121 1895 2.9

3.4

100 1.9

Hot-Rolled Steel – Air Shield – Swirl Ring 277142

2.5

3 4660 200 2.0

5 113 2555

6 116 2075 5.5

25 74 19 72

106

4885

2.5 3.4

3.6

5.1

100 1.9

400 2.2

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 145 250 6350 .147 3.7 .100 2.5 0

Argon** Air** N/A 50 25 N/A 71 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .135” (3.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

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.

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Pierce

Time

5-14

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

277150

277125

277131

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277142 279100

Mild Steel - 70 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/8

3/16

1/4 116 120 .110 .225 300

3/8 122 75 .140 .250 400

Preflow Plasma Shield Postflow

35

25 76

40

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

3

5

6 115 3105 2.7 5.5 2.2

Preflow Plasma Shield Postflow

35

25 76

40

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

74

74

.100

2.5

Pierce
Height

.150 100

Pierce
Height

Marking

Height

Arc

Voltage

110 190

113 130 .200 200

Arc

Voltage

109 4995

113 3265 5.1

Arc

Voltage

Travel
Speed

Travel
Speed

Travel
Speed

Cutting

Height

Cutting

Height

Pierce

Time

Pierce

Time

3.6 100

300

Initial

Height

Kerf

Width

.080

.085

Kerf

Width

2.0

Pierce

Time

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .096 2.4 .100 2.5 0

Argon** Air** N/A 50 25 N/A 62 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .150” (3.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

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.

5-15

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277286

277284

277282

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

277283 279100

Mild Steel - 100 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8

1/2 65 .155 .300 500

5/8 143 47

3/4 145 35 .350 1000

Preflow Plasma Shield Postflow

25 83 26 81

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10

12 1850 3.7 7.3

16 143 1180

20 145 800 9.0

Preflow Plasma Shield Postflow

25 83 26 81

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

.185

4.7

Pierce
Height

.325 800

Pierce
Height

Marking

Height

Arc

Voltage

125 150 .090 .200 300

130

Arc

Voltage

124 3950 2.1 4.9 300

130

Arc

Voltage

Travel
Speed

100 .130 .250 400

Travel
Speed

2405 3.3 6.5

Cutting

Height

Cutting

Height

Travel
Speed

8.3

Pierce

Time

Pierce

Time

500

1000 2.4

Initial

Height

Kerf

Width

.090

.095

Kerf

Width

2.3

Pierce

Time

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 130 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 60 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

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.

5-16

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

277117

277293

277292

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

277151 / 277152

277139 279100

Mild Steel - 150 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 123 125 .135 .250 400

1/2 125 90 .140 .300 500 .130

5/8

3/4 130 55 .350 1000 .135

1 134 40 .150 .400

1.25 *** 145 25 .200 .350

1.50 *** 155 15 .225 .350

Preflow Plasma Shield Postflow

Retaining Cap 277151

20 71 30 69

Retaining Cap 277152

20 71 45 69

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 123 3040 3.4 6.5

12 124 2485 3.5 7.3 3.3

16

20 130 1340 9.0

25 133 1040 3.7 10.1

32 *** 145 625 5.1 8.9

38 *** 154 385 5.6 8.9

Preflow Plasma Shield Postflow

Retaining Cap 277151

20 71 30 69

Retaining Cap 277152

20 71 45 69

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

.140

3.6

Pierce
Height

.325 600 .130

Pierce
Height

8.3 1000 3.3

Marking

Height

Arc

Voltage

118 165 .105 .200 300

127 70

Arc

Voltage

117 4305 2.6 4.9 300

127 1760

Arc

Voltage

Travel
Speed

Travel
Speed

Travel
Speed

Cutting

Height

Cutting

Height

Pierce

Time

1500 .140

Pierce

Time

500

1500

Initial

Height

Kerf

Width

.125

Kerf

Width

3.2

3.4

3.6

Pierce

Time

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 61 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)

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.

5-17

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277144

277121

277137

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277110

277138 279100

Stainless Steel - 30 Amps - Air Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(ga) (in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

20 .036

18 .048 165

16 .060 74 125

14 .075 75 90 .025 .070

Preflow Plasma Shield Postflow

35 81 30 85

Arc

Voltage

71

Travel
Speed

200 .020

Cutting

Height

.035

Pierce
Height

.050

Pierce

Time

100 .065

200

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

1

1.5 73 3260 0.9 200

Preflow Plasma Shield Postflow

35 81 30 85

Arc

Voltage

71 4855 0.6

Travel
Speed

Cutting

Height

Pierce
Height

1.3

Pierce

Time

100

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 145 250 6350 .177 4.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 55 100 2540 .140 3.6 .100 2.5 0

* Use an arc transfer height (ignition height) of .050” (1.3 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

.068

Kerf

Width

1.7

Pierce

Time

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.

5-18

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

277149

277123

277137

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277110

277142 279100

Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(ga) (in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

14 .075

12 .105 88 75

11 .120 89 65

10 .135 90 55

3/16 94 50 .040 .080 300

1/4 100 40 .060 .125 400 .115

Preflow Plasma Shield Postflow

25 66 40 67

Arc

Voltage

87 105

Travel
Speed

Cutting

Height

.035 .070

Pierce
Height

Pierce

Time

100

200

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

2

2.5 2080

3 88 1685 200

5 94 1235 1.0 2.1

6 98 1075 1.3 2.9 2.9

Preflow Plasma Shield Postflow

25 66 40 67

Arc

Voltage

87

Travel
Speed

2565

Cutting

Height

.9 1.8

Pierce
Height

Pierce

Time

100

400

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 145 250 6350 .147 3.7 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 65 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .070” (1.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

.105

.110

Kerf

Width

2.7

2.8

Pierce

Time

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.

5-19

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277150

277124

277132

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277113

277140 279100

Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)

This gas combination gives the best cut quality and minimum dross levels

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

3/16 35 65 30 60 135 80 .100 .200 300 .090

Preflow Plasma Shield Postflow

Arc

Voltage

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Metric*

Material

Thickness

(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

Preflow Plasma Shield Postflow

Arc

Voltage

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .096 2.4 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 80 100 2540 .130 3.3 .100 2.5 0

* Use an arc transfer height (ignition height) of .150” (3.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

Kerf

Width

Pierce

Time

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.

5-20

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Shield Cap

Nozzle

Electrode

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277142 279100

Stainless Steel - 70 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

277150 277125 277131

Imperial*

Material

Thickness

(ga) (in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

10 .135

3/16 134 100 .070 .200 300

1/4 140 75 .090 .225 400

3/8 148 50 .120 .250 500

Preflow Plasma Shield Postflow

25 76 25 76

Arc

Voltage

132 120 .060 .150 200

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

3

5 134 2445 1.8 5.1

6 138 2050 2.1 5.5 2.3

Preflow Plasma Shield Postflow

25 76 25 76

Arc

Voltage

131 3210 1.4 3.3 200

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

400

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

.085

.090

Kerf

Width

2.2

Pierce

Time

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .096 2.4 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 65 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .150” (3.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

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.

5-21

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277146

277126

277133

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277113

277141 279100

Stainless Steel - 100 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)

This gas combination gives the best cut quality and minimum dross levels

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

3/16

1/4 140 100 .125 .225 400

3/8 152 65 .180 .250 500

Preflow Plasma Shield Postflow

28 72 40 67

Arc

Voltage

138 115 .105 .200 300 .100

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

5

6 139 2625 3.0 5.5 2.7

Preflow Plasma Shield Postflow

28 72 40 67

Arc

Voltage

138 2865 2.7 5.1

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

400

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 130 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 80 100 2540 .110 2.8 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

.105

Kerf

Width

2.5

Pierce

Time

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.

5-22

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Shield Cap

Nozzle

Electrode

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

277283 279100

Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

277286 277284 277282

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 147 80 .170 .250 500

1/2 154 55 .210 .300 600

Preflow Plasma Shield Postflow

25 80 35 80

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 148 1935 4.4 6.5

12 152 1540 5.0 7.3

Preflow Plasma Shield Postflow

25 80 35 80

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

141 100 .135 .225 400 .092

Arc

Voltage

140 2595 3.2 5.6 400 2.3

Arc

Voltage

Travel
Speed

Travel
Speed

Travel
Speed

Cutting

Height

Cutting

Height

Pierce
Height

Pierce
Height

Marking

Height

Pierce

Time

Pierce

Time

600 2.4

Initial

Height

Kerf

Width

.095

Kerf

Width

Pierce

Time

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 130 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 68 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

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.

5-23

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277298

277297

277135

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277266

277139 279100

Stainless Steel - 150 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)

This gas combination gives the best cut quality and minimum dross levels

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 75 .150 .275 500

1/2 60 .165 .300 600

5/8 50 .185 .325 800

3/4 40 .250 .350 1200 .145

Preflow Plasma Shield Postflow

25 77 75 81 165

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

10

12 1610 4.1 7.4

16 1260 4.7 8.3 800

20 167 940 6.9 9.0 1200 3.7

Preflow Plasma Shield Postflow

25 77 75 81

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

Arc

Voltage

155

Arc

Voltage

Travel
Speed

95 .250 .250 400

Travel
Speed

1845 3.8 7.0

Cutting

Height

Cutting

Height

Travel
Speed

Pierce

Height

Pierce
Height

Marking

Height

Pierce

Time

Pierce

Time

600

Initial

Height

Kerf

Width

.135

.140

Kerf

Width

3.4

3.6

Pierce

Time

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 81 100 2540 .140 3.6 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

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.

5-24

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

Shield Cap

Nozzle

Electrode

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277152

277139 279100

Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

277117 277293 277292

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 150 115 .180 .275 500

1/2 155 85 .210 .300 600

5/8 160 60 .220 .325 800

3/4 168 45 .240 .350 1200 .135

Preflow Plasma Shield Postflow

20 71 70 69

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 150 2805 4.7 7.0

12 153 2330 5.1 7.4

16 160 1510 5.6 8.3 800

20 170 1030 6.2 9.0 1200 3.4

Preflow Plasma Shield Postflow

20 71 70 69

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

145 150 .160 .250 400

Arc

Voltage

144 3910 4.0 6.3 400

Arc

Voltage

Travel
Speed

Travel
Speed

Travel
Speed

Cutting

Height

Cutting

Height

Pierce
Height

Pierce

Height

Marking

Height

Pierce

Time

Pierce

Time

600

Initial

Height

Kerf

Width

.125

.130

Kerf

Width

3.2

3.3

Pierce

Time

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 65 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

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.

5-25

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277145

277120

277130

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277140 279100

Aluminum - 30 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

.040

.050 120

.063 90 .150 200 .070

Preflow Plasma Shield Postflow

35 81 20 85 135

Arc

Voltage

Travel
Speed

150

Cutting

Height

.030

Pierce
Height

.100 100 .065

Pierce

Time

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

1

1.5 2520 3.4 200 1.8

Preflow Plasma Shield Postflow

35 81 20 85 135

Arc

Voltage

Travel
Speed

3885

Cutting

Height

0.8

Pierce
Height

2.5 100 1.7

Pierce

Time

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 145 250 6350 .177 4.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 75 100 2540 .120 3.0 .100 2.5 0

* Use an arc transfer height (ignition height) of .100” (2.5 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

Kerf

Width

Pierce

Time

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.

5-26

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

277150

277122

277131

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277142 279100

Aluminum - 50 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

.050

.063 138 140 .065 150 .082

.080 143 90 .075 .150 200 .085

Preflow Plasma Shield Postflow

25 66 19 67

Arc

Voltage

135 180 .050

Travel
Speed

Cutting

Height

Pierce
Height

.100

Pierce

Time

100 .080

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

1.5

2.0 142 2360 1.8 3.7 200 2.2

Preflow Plasma Shield Postflow

25 66 19 67

Arc

Voltage

137 3870 1.5 2.5 150 2.1

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 145 250 6350 .147 3.7 .100 2.5 0

Argon** Air** N/A 50 25 N/A 77 100 2540 .120 3.0 .100 2.5 0

* Use an arc transfer height (ignition height) of .100” (2.5 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

Kerf

Width

Pierce

Time

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.

5-27

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277150

277125

277131

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277142 279100

Aluminum - 70 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

.080

1/8 135 160 .070 .175

3/16 145 80 .100 .200 200

1/4 150 50 .060 .250 300

3/8 155 40 .075 .275 400

1/2 162 30 .115 .300 500

Preflow Plasma Shield Postflow

25 76 25 76

Arc

Voltage

130 250 .050 .150

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

100 .080

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

2

3 134 4420 1.7 4.3

5 145 1920 2.3 5.2

6 148 1440 1.7 6.1

10 156 975 2.0 7.0

12 160 820 2.6 7.4

Preflow Plasma Shield Postflow

25 76 25 76

Arc

Voltage

129 6400 1.2 3.7

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

100 2.0

300 2.2

500 2.3

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .096 2.4 .100 2.5 0

Argon** Air** N/A 50 25 N/A 69 100 2540 .120 3.0 .100 2.5 0

* Use an arc transfer height (ignition height) of .150” (3.8 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

.085

.090

Kerf

Width

Pierce

Time

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.

5-28

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

277286

277284

277282

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

277283 279100

Aluminum - 100 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 162 90 .180 .275 400 .098

1/2 165 70 .195 .300 500 .100

Preflow Plasma Shield Postflow

25 80 26 80

Arc

Voltage

158 105 .155 .250 300 .095

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 162 2210 4.6 7.0

12 165 1890 4.9 7.4

Preflow Plasma Shield Postflow

25 80 26 80

Arc

Voltage

158 2710 3.8 6.3 300 2.4

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

500 2.5

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 130 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 71 100 2540 .120 3.0 .100 2.5 0

* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

Kerf

Width

Pierce

Time

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.

5-29

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277117

277293

277292

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277152

277139 279100

Aluminum - 150 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 155 115 .185 .275 500

1/2 165 90 .230 .300 600 .130

5/8

3/4 45 .350 1200 .140

Preflow Plasma Shield Postflow

20 71 50 69

Arc

Voltage

145 145 .130 .250 400

170

Travel
Speed

65

Cutting

Height

.250

Pierce
Height

.325 800 .135

Pierce

Time

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 156 2825 4.8 7.0

12 162 2430 5.5 7.4 3.3

16 170 1630

20 170 990 9.0 3.6

Preflow Plasma Shield Postflow

20 71 50 69

Arc

Voltage

143 3770 3.1 6.3 400

Travel
Speed

Cutting

Height

6.4

Pierce
Height

8.3

Pierce

Time

600

1200

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 69 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

.125

Kerf

Width

3.2

3.4

Pierce

Time

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.

5-30

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

277286

279484

279410

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

279483 279060

Mild Steel - 100 Amps - Oxygen Plasma / Air Shield

Silver Electrode

Shield Cap Nozzle Electrode

(brown o-ring)

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8

1/2 65 .155 .300 500

5/8 143 47

3/4 145 35 .350 1000

Preflow Plasma Shield Postflow

25 83 26 81

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10

12 1850 3.7 7.3

16 143 1180

20 145 800 9.0

Preflow Plasma Shield Postflow

25 83 26 81

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Cutting

Height

.185

Cutting

Height

4.7

Pierce
Height

.325 800

Pierce
Height

Marking

Height

Arc

Voltage

125 150 .090 .200 300

130

Arc

Voltage

124 3950 2.1 4.9 300

130

Arc

Voltage

Travel
Speed

100 .130 .250 400

Travel
Speed

2405 3.3 6.5

Travel
Speed

8.3

Pierce

Time

Pierce

Time

500

1000 2.4

Initial

Height

Kerf

Width

.090

.095

Kerf

Width

2.3

Pierce

Time

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 130 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 60 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

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.

5-31

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277117

279493

279420

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

277151 / 277152

279439 279060

Mild Steel - 150 Amps - Oxygen Plasma / Air Shield

Silver Electrode

Shield Cap Nozzle Electrode

(green o-ring)

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 123 125 .135 .250 400

1/2 125 90 .140 .300 500 .130

5/8

3/4 130 55 .350 1000 .135

1 134 40 .150 .400

1.25 *** 145 25 .200 .350

1.50 *** 155 15 .225 .350

Preflow Plasma Shield Postflow

Retaining Cap 277151

20 71 30 69

Retaining Cap 277152

20 71 45 69

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 123 3040 3.4 6.5

12 124 2485 3.5 7.3 3.3

16

20 130 1340 9.0

25 133 1040 3.7 10.1

32 *** 145 625 5.1 8.9

38 *** 154 385 5.6 8.9

Preflow Plasma Shield Postflow

Retaining Cap 277151

20 71 30 69

Retaining Cap 277152

20 71 45 69

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Cutting

Height

.140

Cutting

Height

3.6

Pierce
Height

.325 600 .130

Pierce
Height

8.3 1000 3.3

Marking

Height

Arc

Voltage

118 165 .105 .200 300

127 70

Arc

Voltage

117 4305 2.6 4.9 300

127 1760

Arc

Voltage

Travel
Speed

Travel
Speed

Travel
Speed

Pierce

Time

1500 .140

Pierce

Time

500

1500

Initial

Height

Kerf

Width

.125

Kerf

Width

3.2

3.4

3.6

Pierce

Time

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 61 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
*** Edge start recommended.
(Revised 04/26/2013)

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.

5-32

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

277286

279484

279410

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

279483 279060

Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield

Silver Electrode

Shield Cap Nozzle Electrode

(brown o-ring)

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 147 80 .170 .250 500

1/2 154 55 .210 .300 600

Preflow Plasma Shield Postflow

25 80 35 80

Arc

Voltage

141 100 .135 .225 400 .092

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 148 1935 4.4 6.5

12 152 1540 5.0 7.3

Preflow Plasma Shield Postflow

25 80 35 80

Arc

Voltage

140 2595 3.2 5.6 400 2.3

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

600 2.4

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 130 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 68 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

.095

Kerf

Width

Pierce

Time

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.

5-33

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277117

279493

279420

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277152

279439 279060

Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield

Silver Electrode

Shield Cap Nozzle Electrode

(green o-ring)

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 150 115 .180 .275 500

1/2 155 85 .210 .300 600

5/8 160 60 .220 .325 800

3/4 168 45 .240 .350 1200 .135

Preflow Plasma Shield Postflow

20 71 70 69

Arc

Voltage

145 150 .160 .250 400

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 150 2805 4.7 7.0

12 153 2330 5.1 7.4

16 160 1510 5.6 8.3 800

20 170 1030 6.2 9.0 1200 3.4

Preflow Plasma Shield Postflow

20 71 70 69

Arc

Voltage

144 3910 4.0 6.3 400

Travel
Speed

Cutting

Height

Pierce

Height

Pierce

Time

600

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 65 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .200” (5.1 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

.125

.130

Kerf

Width

3.2

3.3

Pierce

Time

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.

5-34

Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts

277286

279484

279410

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

279483 279060

Aluminum - 100 Amps - Air Plasma / Nitrogen Shield

Silver Electrode

Shield Cap Nozzle Electrode

(brown o-ring)

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 162 90 .180 .275 400 .098

1/2 165 70 .195 .300 500 .100

Preflow Plasma Shield Postflow

25 80 26 80

Arc

Voltage

158 105 .155 .250 300 .095

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 162 2210 4.6 7.0

12 165 1890 4.9 7.4

Preflow Plasma Shield Postflow

25 80 26 80

Arc

Voltage

158 2710 3.8 6.3 300 2.4

Travel
Speed

Cutting

Height

Pierce
Height

Pierce

Time

500 2.5

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 130 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 71 100 2540 .120 3.0 .100 2.5 0

* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

Kerf

Width

Pierce

Time

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.

5-35

Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual

277117

279493

279420

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277152

279439 279060

Aluminum - 150 Amps - Air Plasma / Nitrogen Shield

Silver Electrode

Shield Cap Nozzle Electrode

(green o-ring)

Imperial*

Material

Thickness

(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)

1/4

3/8 155 115 .185 .275 500

1/2 165 90 .230 .300 600 .130

5/8

3/4 45 .350 1200 .140

Preflow Plasma Shield Postflow

20 71 50 69

Arc

Voltage

145 145 .130 .250 400

170

Travel
Speed

65

Cutting

Height

.250

Pierce
Height

.325 800 .135

Pierce

Time

Metric*

Material

Thickness

(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)

6

10 156 2825 4.8 7.0

12 162 2430 5.5 7.4 3.3

16 170 1630

20 170 990 9.0 3.6

Preflow Plasma Shield Postflow

20 71 50 69

Arc

Voltage

143 3770 3.1 6.3 400

Travel
Speed

Cutting

Height

6.4

Pierce
Height

8.3

Pierce

Time

600

1200

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)

Nitrogen Nitrogen N/A 25 25 N/A 135 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 69 100 2540 .100 2.5 .100 2.5 0

* Use an arc transfer height (ignition height) of .250” (6.4 mm) for cutting and .100” (2.5 mm) for marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)

Arc

Voltage

Travel
Speed

Marking

Height

Initial

Height

Kerf

Width

.125

Kerf

Width

3.2

3.4

Pierce

Time

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.

5-36

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

Section 6: Maintenance & Troubleshooting

WARNING: Only qualified maintenance personnel should perform
maintenance on the Spirit system.

The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance
should be performed with safety in mind.

Use extreme caution when working near the power conversion module (i.e.,
chopper). The large electrolytic capacitors store large amounts of energy
even after power has been removed from the system. Wait at least five
minutes after turning off power, and then use a voltmeter to verify that the
capacitors are fully discharged before touching the 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.

Routine Maintenance

Note: At minimum, these checks should be performed on a monthly basis. In
excessively dirty environments or in heavy usage situations, the checks
should be performed more frequently.

Power Supply

1. Remove the left, right, and top covers on the power supply.

2. Using clean, dry, compressed air, blow out all accumulated dust, including dust on
PC boards and fans. Be sure to blow out the fan and heat exchanger at the rear of
the unit. In an excessively dirty environment, blow out the unit on a weekly basis.

3. Verify the ground and primary three phase A.C. voltage connections are tight.

4. Verify all PC board connectors are installed securely.

5. Verify all rear cable connectors are installed securely.

6. Verify the electrode lead and work ground lead are secure and free from corrosion.

7. Check the torch coolant filter / deionization cartridge at the rear of the power supply
and replace if dirty.

8. Flush the cooling system every six months and replace the coolant and coolant filter
/ deionization cartridge.

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

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

6-1

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

Manual Gas Console (MGC)

1. Remove the cover of the manual gas console. Using clean, dry, compressed air,
blow out all accumulated dust inside the unit. In an excessively dirty environment,
blow out the unit on a weekly basis.

2. Verify that all PC board connectors are installed securely.

3. Verify that all gas hose connectors are tight and that there are no leaks. Only

tighten the gas fittings enough to make a gas seal. The fittings are subject to
damage if over tightened.

4. Inspect all gas hoses to ensure no damage exists. Immediately replace any
damaged gas hoses.

Torch, 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 impulse start console. Also, make sure the
shield adapter is secured tightly to the impulse start console enclosure.

3. Inspect the braided shield for nicks or cuts and replace if necessary.

4. Remove the torch handle and verify that the connections at the torch base are
tightened securely. Only tighten the fittings enough to make a water or gas
seal. The fittings are subject to damage if over tightened.

5. Make sure the torch lead insulating sleeves are positioned to properly cover the
brass torch fittings at the torch base.

6. Inspect the outer sleeve on the torch base's electrode/coolant supply lead. If
nicks, cuts or holes are found, replace the torch base.

7. Remove the torch consumables from the torch head and inspect all o-rings.
Replace any o-rings with cuts, nicks, abrasions, or any other signs of wear.
Faulty o-rings may cause gas or water leaks, which will affect cut quality.

8. With the electrode removed, inspect the cooling tube in the torch head for
damage.

If using the copper electrode, the torch head uses cooling tube P/N 277007. If
replacement is required, use tool P/N 200109.

If using the silver electrode, the torch head uses cooling tube holder assembly
P/N 279216. Remove this using the tool (socket P/N 277087 & driver P/N

277086) and inspect the o-rings for damage. 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.

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

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

6-2

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

Impulse Start Console (ISC)

1. Open the cover (door) of the impulse start 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.

Work Ground

1. Verify that the work ground lead is securely fastened to the star ground on the
cutting table, and that the connection point is free from corrosion. Use a wire brush
to clean the connection point if necessary.

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

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

6-3

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

Replacing the Torch Coolant and Filter

WARNING: Do not touch the fans inside the power supply.

Important: Never turn on the system when the coolant reservoir is empty.
Important: When handling coolant, wear nitrile gloves and safety glasses.
Important: Only use Kaliburn approved coolant. Commercially available

antifreeze contains corrosion inhibitors that will damage the cooling
system. See Section 2 for more information.

The torch coolant should be flushed out of the system every six months and replaced
with new coolant. Replace the coolant filter / deionization cartridge at the same time.

1. Remove primary power from the Spirit system.

2. Ensure the torch base and torch head (with consumables) are properly installed.

3. Ensure the coolant supply (in and out) hoses are properly installed.

4. Remove the coolant reservoir cap/level gauge.

5. Remove 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 for some
coolant to escape from the fitting on the power supply and from the supply hose.

8. Blow compressed air (100 psi maximum) into the coolant supply hose. This will force
the remaining coolant from the torch, torch leads, and supply hose into the reservoir
and out of the drain petcock. Continue until coolant stops flowing into the bucket.

9. Tighten the drain petcock and remove the hose and bucket.

10. Protect the area beneath the coolant filter housing as coolant will leak during this
step. Unscrew the coolant filter housing and remove it from the power supply. Use
caution as the housing will be full of coolant. Install a new coolant filter / deionization
cartridge and replace the coolant filter housing. Remove the protective material and
dry any leaked coolant.

11. Reconnect the coolant supply hose on the rear of the power supply.

12. Follow all of the steps in "Filling the Cooling System" in Section 3 of this manual to
complete this procedure.

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

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

6-4

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

Microprocessor (DSP) Status Indicators

The microprocessor DSP board controls all of the functions of the Spirit power
supply. It contains diagnostic LEDs and OPTO LEDs which aid in
troubleshooting the system. These indicators illuminate when a particular event
occurs. Illuminated LEDs indicate the following:

LED Indication

D7 – RS232 OUT Isolated Serial transmission
D10 – RS232 T1 OUT Serial transmission
D11 – CAN RXD CAN transmission
D12 – CAN TXD CAN transmission
D24 – PWM Chopper(s) energized
D33 – COOLANT LEVEL Coolant reservoir level is sufficient
D36 – PLASMA 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 – ISC DOOR ISC door is closed
D77 – 3.3V uP PWR 3.3V Microprocessor power
D78 – 1.8V uP PWR 1.8V Microprocessor power

OPTO U21 – MTR/SOL Coolant pump relay CR5 energized (Pump On)
OPTO U22 – PAR Pilot arc relay energized
OPTO U23 – CON DC power output (main contactor energized)
OPTO U24 – SURGE CR3 and K1 (I/O PCB) relays energized
OPTO U26 – FAN Fans energized
OPTO U27 – PREFLOW Preflow gas valve 1 energized
OPTO U28 – PLASMA Plasma gas valve 2 energized
OPTO U29 – SHIELD Shield gas valve 3 energized
OPTO U30 – VENT Vent gas valve 4 energized
OPTO U31 – POSTFLOW Postflow gas valve 5 energized
OPTO U32 – MARKING Marking gas valves 6 and 7 energized
OPTO U34 – IMPULSE START Impulse start circuit energized
OPTO U37 – RHF HF transformer energized

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

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

6-5

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

Microprocessor (DSP) Sequence of Operation

The following DSP Indicators should illuminate after primary power is applied:

 D77 3.3V Supply
 D78 1.8V Supply
 D50 ISC (Door)
 D33 Coolant Level
 D37 Arc Hold (if INOVA is being used)
 D10 RS232 T1 Out (Blinking)
 D11 CAN RXD (Dim Flashing)
 D12 CAN TXD (Dim Flashing)

The following DSP Indicators should illuminate when the OFF Button is released:

 D40 OFF Button

The following DSP Indicators should illuminate when the ON Button is activated:

 U21 Opto Motor / Solenoid
 U19 Opto Solenoid (not used)
 U26 Opto Fan
 D42 Plasma Ready

The following DSP Indicators should illuminate when a START signal is applied (begin
cut cycle):

 D36 Start
 U27 Opto Preflow
 U29 Opto Shield
 U24 Opto Surge (only over 100 amps)
 U23 Opto Contactor
 D24 PWM (Chopper ON)
 U22 Opto Pilot Arc Relay ON
 D43 PAT ON (Blinks during a START)
 U34 Opto ISC (Blinks during a START)

The following DSP Indicators should illuminate with an arc transfer:

 U31 Opto Postflow
 U28 Opto Plasma
 D41 Motion

The following LEDs should turn OFF after the Motion Indicator turns ON:

 U34 Opto ISC
 U27 Opto Preflow
 D43 PAT

When the START signal is removed, OPTO U30 (Vent) will illuminate. It will then go out
with the rest of the cut cycle indicators.

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

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

6-6

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

Power Supply

Code

Short Description

Long Description

10121

ISC Door

ISC Door is open

10138

Stop Pressed (Off Button)

OFF Button on Plasma Console or Manual Gas
Console is pressed.

10140

Phase R

Transformer Secondary phase voltage is low

10150

Phase Y

Transformer Secondary phase voltage is low

10160

Phase B

Transformer Secondary phase voltage is low

10161

CON1

Main Contactor failed to open

10170

Coolant Level

Coolant Level is low

10180

Coolant Flow Low

Coolant flow is low

10190

Coolant Flow High

Coolant flow is high

10220

Coolant Temperature High

The coolant temperature is high

10290

GC Quiet

Lost CAN communication with Gas Console

10300

PC Quiet

Lost CAN communication with Plasma Console

10320

FCC Invalid

Final Cut Current invalid

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 Established

Transferred Arc Current not established within 2
seconds

10370

Current Unbalanced

Current is not balanced between chopper
assemblies (275A and 400A systems)

10380

TAC Lost 1

Transferred Arc lost during TAC hold time

10390

TAC Lost 2

Transferred Arc lost during Upslope

10400

TAC Lost 3

Transferred Arc lost during Cutting

10410

TAC Lost 4

Transferred Arc lost during Downslope

10420

FCC Unreached

Did not achieve final cut current

10430

Output Over Current

Chopper has exceeded its maximum rated current

10432

Output Over Current TZ

Instantaneous Over Current detected

10440

Output Over Voltage

Maximum Cutting Voltage has been exceeded.

10450

Start Premature Removal

Start Signal removed prior to completion of upslope

10461

Chopper1 Temp

Chopper 1 maximum operating temperature
exceeded

10462

Chopper2 Temp

Chopper 2 maximum operating temperature
exceeded

10463

Chopper3 Temp

Chopper 3 maximum operating temperature
exceeded

Error Codes

The following is a comprehensive list of error codes for the Spirit system. When the system
uses a Manual Gas Console, only the numeric error code is displayed. When an Automatic
Gas Console is used, the text description is also displayed.

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

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

6-7

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

Gas Console

Code

Short Description

Long Description

20100

Plasma Adjust

Could not adjust Plasma Gas

20110

Shield Adjust

Could not adjust Shield Gas

20120

Preflow Adjust

Could not adjust Preflow Gas

20130

Postflow 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 is low

20250

O2 High

O2 Input Pressure is high

20260

N2 High

N2 Input Pressure is high

20270

Argon High

Argon Input Pressure is high

20280

O2N2 High

Air Input Pressure is high

20290

H17 High

H17 Input Pressure is high

20300

PS Quiet

Lost CAN communication with Power Supply

20310

PC Quiet

Lost CAN communication with Plasma Controller

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

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

6-8

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

Problem

Possible Cause

Power Supply will not

1. ISC door open.

Power supply will not stay on

1. Faulty DSP board.

No arc at the torch

1. Incorrect torch consumables installed.

The arc will not transfer to

1. Loose work ground connection.

General Troubleshooting

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

Power supply indicator
(white light) will not
illuminate

energize after choosing ON
and then SELECT on the
MGC.

after choosing ON and then
SELECT on the MGC.

1. Primary disconnect fuse blown.

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

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

4. Control Transformer or associated wiring bad.

2. Low coolant level.

3. Fuse is blown (F1-F6).

4. Faulty OFF Button or associated wiring.

5. Off Relay faulty.

2. Off Relay faulty.

2. Incorrect gas pressure settings.

3. Pilot arc transistor (PAT) is not operating properly.
Check the PAT LED (D43) on the DSP
microprocessor board.

4. Damaged or loose torch lead connections.

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

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

the workpiece

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.

2. Pierce height too high.

3. Incorrect, damaged, or worn consumables.

6-9

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

Problem

Possible Cause

Primary power has been

1. Check power/communications CAN cable

The manual gas console

1. Cycle primary power to the Spirit system.

Gas pressures will not adjust

1. Wrong consumables installed in torch.

Low pressure error

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

Pressure error during cut

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

applied to the system, but
the manual gas console
screen is blank

connection on back of manual gas console.

2. Check for blown DIN rail fuse.

3. Check for 120v on pins of power/communications
CAN cable at back of the manual gas console.

screen is on, but the screen
doesn't work

properly

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

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

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

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

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

6-10

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

Chopper Test Procedure

WARNING: Only qualified maintenance personnel should perform the chopper
test procedure. The system utilizes potentially fatal A.C. and D.C. voltages. All
maintenance should be performed with safety in mind.

Use extreme caution when working near the power conversion module (i.e.,
chopper). The large electrolytic capacitors store large amounts of energy even
after power has been removed from the system. Wait at least five minutes after
turning off power, and then use a voltmeter to verify that the capacitors are fully
discharged before touching the 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 power supply. The following steps must be performed on each
chopper with the other chopper(s) disabled. To disable a chopper, remove the
plug from J1 on the chopper PCB (see drawing on next page).

1. Remove primary power from the Spirit system.

2. Open the impulse start console door and disconnect the black primary wires of the
high frequency transformer from the 120 VAC line filter. Close the impulse start
console door to activate the door interlock switch.

3. Remove the top, left, and right side covers from the power supply to expose the DSP
PCB, input and output terminal blocks and chopper(s).

4. Remove the Electrode, Work and Nozzle leads from the output terminal block, which
is located on the left side of the unit.

5. Ensure the torch head (with a full set of consumables) is properly installed onto the
torch base.

6. Apply primary power to the 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.

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

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

TABLE 1

Chopper 1

Chopper 2

Chopper 3

3 Phase

OCV

3 Phase

OCV

3 Phase

OCV

Spirit II

400 Amp

Spirit II

150 Amp

Diode Bridge Terminals

Chopper PCB

8. With a start signal applied, check the three phase voltage input to each chopper at
the diode bridge terminals (three screws on the left side of each chopper). Refer to
TABLE 1 for the proper three phase AC voltage.

Note that the system will only energize for approximately two seconds each

time a start signal is applied.

If the voltage is not present, check for primary voltage on the main contactor
(CON 1) and on the primary side of the power transformer.

J1 Plug

Top View of Chopper

9. With a start signal applied, check for the proper DC voltage (refer to TABLE 1) at the
output terminal block between Electrode and Work.

If the proper DC voltage is present, the chopper is working properly.

Spirit II

275 Amp

AC

255 370 255 370 255 370

225 325 225 325 N/A N/A

208 300 N/A N/A N/A N/A

(DC)

AC

(DC)

AC

(DC)

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

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

6-12

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

10. If the proper DC voltage is not present at the output terminal block, check the 200
amp fuse F9 (chopper 1), fuse F10 (chopper 2) or fuse F11 (chopper 3) located on
the bottom right of the output bus bars.

If the fuse is open, replace chopper and fuse.

11. If the fuse(s) is good, check if the chopper PWM LED illuminates when a start signal
is applied:

a) check D24 on the DSP PCB – If D24 doesn’t illuminate, replace DSP PCB.

b) check D2 on the chopper PCB – If D2 doesn’t illuminate, go to step 12.

12. Check PCB power to the chopper from the DSP:

a) Push the OFF Button.

b) Disconnect the J1 plug from the chopper PCB.

c) Leave the OFF Button pushed in.

d) With a digital voltmeter, measure the following voltages on the J1 plug:

J1-5 (ground) to J1-1 +15vdc Supply
J1-5 (ground) to J1-2 +5vdc Supply
J1-5 (ground) to J1-3 +5vdc (PWM Signal)

If ALL of the voltages are present, replace chopper. If any of the voltages are not
present, go to step 13:

13. Remove primary power from 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 to DSP J9-1
Chopper (3) J1-2 to DSP J9-2
Chopper (3) J1-3 to DSP J9-3
Chopper (3) J1-5 to DSP J9-4

If ALL of the continuity readings are good, replace DSP PCB.

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

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

6-13

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

BLANK

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

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

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