This information is subject to the controls of the Export Administration Regulations [EAR].
RETURN TO MAIN MENU
User's Manual
Spirit II 275
High Current Density Plasma Cutting System
with Automatic Gas Console (AGC)
718115 Rev D
This information shall not be provided to non-U.S. persons or transferred by any means to
any location outside the United States contrary to the requirements of the EAR.
Page 2
Prologue Spirit II User’s Manual
Rev
ECO#
Author
Date
Description of Change
Added 100A/150A silver electrodes, replaced RHF with ISC,
added argon marking, corrected system interconnect
diagrams, changed rated inlet gas pressure to 115 psi,
(300152). Parts list updated.
Corrected Plasma Console icon description from hardware
error to warning message.
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
Ladson, SC 29456 USA
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ii
Page 3
Spirit II User’s Manual Prologue
Table of Contents
Section 1: Safety
General Precautions ......................................................................................... 1-1
Troubleshooting Serial Communication ............................................................ B-3
RS-422 Serial Commands ................................................................................ B-4
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v
Page 6
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.
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.
vi
Page 7
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
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-1
Page 8
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
Page 9
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.
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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.
1-3
Page 10
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.
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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.
1-4
Page 11
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
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
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-5
Page 12
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.
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.
1-6
Page 13
Spirit II User’s Manual Section 2: Specifications
Section 2: Specifications
System Description
The Spirit II 275 is a 275 amp microprocessor controlled, 100% duty cycle high current
density plasma cutting and marking system. It utilizes a precision, dual gas torch that is
capable of cutting mild steel up to 2" thick and stainless steel up to 1-1/2” thick.
The system contains a computer controlled automatic gas console with a touch screen
interface (plasma console). All cutting parameters are controlled through the plasma
console. Setting up a cut is as simple as selecting the material type, material thickness,
and process (cutting or marking). All gas types and pressures are set automatically.
The operator can easily view pictures and part numbers of the torch consumables.
Another screen shows the recommended cutting speed and torch height for making the
cut. These parameters can be transmitted to an X/Y machine controller or an arc
voltage control system via RS-422 serial communication. The RS-422 port also allows
for full control of the cutting parameters from an x/y machine controller. The system
keeps a detailed record of errors that may have occurred during the cutting sequence.
Additionally, systems utilizing the automatic gas console can use argon for marking,
which produces improved mark quality.
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. Eight nozzle sizes (30, 50,
70, 100, 150, 200, 260, and 275 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.
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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.
2-1
Page 14
Section 2: Specifications Spirit II User’s Manual
System Components
The Spirit II 275 System consists of the following components:
Standard Components
• Power Supply
• Automatic Gas Console
• Plasma Console (Touch Screen)
• CAN Cables
• CAN Termination Plug
• Impulse Start Console (ISC)
• ISC Control Cable
• ISC Ground Cable
• Torch and Handle Assembly
• Torch Lead Set
• 5-gang Manifold Assembly
• 5-gang Manifold Control Cable
• 2-gang Manifold Assembly
• 2-gang Manifold Control Cable
• 17 Inch Plasma 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
Page 15
Spirit II User’s Manual Section 2: Specifications
Input Current at
Maximum Output
208 VAC, 3Ø, 60Hz
300221
163 amps
220 VAC, 3Ø, 60Hz
300222
153 amps
240 VAC, 3Ø, 60Hz
300223
140 amps
380 VAC, 3Ø, 50/60Hz
300224
88 amps
400 VAC, 3Ø, 50/60Hz
300225
84 amps
415 VAC, 3Ø, 50/60Hz
300226
81 amps
440 VAC, 3Ø, 50/60Hz
300227
76 amps
480 VAC, 3Ø, 60Hz
300228
70 amps
600 VAC, 3Ø, 60Hz
300229
56 amps
38.4"
29.0" [737]
43.2" [1097]
Power Supply Specifications
Power Supply Description Part Number
Open Circuit Voltage ......................................... 325 VDC
Output Current (drooping characteristic) ........... 10 - 275 amps
Maximum Output Voltage ................................. 180 VDC
Coolant Tank Capacity ...................................... 3.2 gal (12 liters)
Weight (without coolant) ................................... 1270 lb (576 kg)
[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
Page 16
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.
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.
2-4
Page 17
Spirit II User’s Manual Section 2: Specifications
12.4" [315]
12.0" [305]
13.7" [348]
7.0" [178]
Automatic Gas Console (AGC) Specifications
Part Number ..................................................... 300400
Weight .............................................................. 53 lb (24 kg)
(4) Ø .300 [7.6]
10.9" [277]
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.
Air or Nitrogen ............................................. 225 scfh (6371 liters/hour)
Preflow gas flow rate (maximum) ...................... 60 scfh (1699 liters/hour)
Marking gas flow rate (maximum) ..................... 79 scfh (2237 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
Page 19
Spirit II User’s Manual Section 2: Specifications
9.2" [234]
13.4" [340]
3.6" [91]
10.1" [257]
(4) Ø.180 [5]
Plasma Console Specifications
Part Number ..................................................... 300800
Weight .............................................................. 10 lb (4.5 kg)
3.2" [81]
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
Page 20
Section 2: Specifications Spirit II User’s Manual
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.
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.
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Page 22
Section 2: Specifications Spirit II User’s Manual
4.20"
3.80"
6.18" [157]
0.327" [8.3]
0.25" [6.4]
1.18" [30]
8.35" [212]
(4) 0.187" [4.8] Mounting Holes
5-Gang Manifold Specifications
Part Number .................................................... 300075
Weight .............................................................. 6 lb (2.7 kg)
[107]
[97]
3.035" [77]
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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Page 23
Spirit II User’s Manual Section 2: Specifications
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 275 amps, 145 arc volts. The measurements were made
with a sound level meter.
Distance From Torch
meters above the
110 dB 107 dB
The maximum noise level is 127 dB at a distance of 3 inches (76.2 mm) from the torch
while cutting at 275 amps, 145 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.
2-11
Page 24
Section 2: Specifications Spirit II User’s Manual
BLANK
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Page 25
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.
Automatic Gas Console (AGC)
The AGC is usually mounted on the gantry of the cutting machine. See Section 2 for
mounting dimensions.
Plasma Console
The plasma console 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 certain 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.
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3-1
Page 26
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.
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3-2
Page 27
Spirit II User’s Manual Section 3: Installation
Figure 1: Spirit II System with Automatic Gas Console and Internal Inova System
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3-3
Page 28
Section 3: Installation Spirit II User’s Manual
Figure 2: Spirit II System with Automatic Gas Console and External Inova System
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3-4
Page 29
Spirit II User’s Manual Section 3: Installation
Input Current
Output (amps)
Recommended
Size (amps)
208 VAC, 60Hz
163
200
220 VAC, 60Hz
153
200
240 VAC, 60Hz
140
175
380 VAC, 50/60Hz
88
110
400 VAC, 50/60Hz
84
100
415 VAC, 50/60Hz
81
100
440 VAC, 50/60Hz
76
100
480 VAC, 60Hz
70
90
600 VAC, 60Hz
56
70
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)
at 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.
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3-5
Page 30
Section 3: Installation Spirit II User’s Manual
Strain Relief
Disconnect Box
TB5 Connections
L1 (U)
TB5
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L1 L2 L3 Gnd
Figure 3: Power Supply Primary Connections
3-6
L2 (V)
L3 (W)
Ground
Connections
Page 31
Spirit II User’s Manual Section 3: Installation
1 2 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.
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3-7
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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
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3-8
Page 33
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.
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3-9
Page 34
Section 3: Installation Spirit II User’s Manual
Figure 5: Cooling System Connections
6 5 7 8 7
8
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3-10
Page 35
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.
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3-11
Page 36
Section 3: Installation Spirit II User’s Manual
15
13
14
12
11
Figure 6: Torch Leads to Impulse Start Console Connections
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3-12
Page 37
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
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3-13
Page 38
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 automatic gas
console, torch base, and manifold assemblies. See figure 8.
Note: When making hose connections, only tighten the brass fittings
enough to make gas seals. The fittings are subject to damage if over
tightened.
7.5 Foot Shield Gas Hose
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 17 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 Shield Gas Hose
1. Connect one end of the marking shield gas hose to the marking shield outlet
on the rear of the AGC.
2. Connect the other end of the marking shield gas hose to the marking shield
inlet on the 5-gang manifold.
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Page 39
Spirit II User’s Manual Section 3: Installation
24
25
26
27
28
29
30
Marking Plasma Gas Hose
1. Connect one end of the marking plasma gas hose to the marking plasma
outlet on the rear of the AGC.
2. Connect the other end of the marking plasma hose to the marking plasma
inlet on the 5-gang manifold.
Postflow Gas Hose
1. Connect one end of the postflow hose to the postflow outlet on the rear of the
AGC. Note that the postflow hose fittings have left hand threads.
2. 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
AGC.
2. Connect the other end of the plasma hose to the plasma inlet on the 2-gang
manifold.
Shield Gas Hose
1. Connect one end of the shield hose to the shield outlet on the rear of the
AGC.
2. Connect the other end of the shield hose to the shield inlet on the 5-gang
manifold.
Preflow Gas Hose
1. Connect one end of the preflow hose to the preflow outlet on the rear of the
AGC. 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.
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3-15
Page 40
Section 3: Installation Spirit II User’s Manual
BLACK
25
22
26
27
24
23
22
21
30
RED
GREEN
REAR
REAR
BLUE
27
21
20
28
25
26
Automatic Gas
20
24
28
29
23
BLUE
BLACK
BLACK
RED
GREEN
Console
Figure 8: Torch Gas Connections
PORT
PORT
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3-16
Page 41
Spirit II User’s Manual Section 3: Installation
31
32
33
34
35
32
34
31
33
35
Gas Supply Connections
Perform the following steps to connect the gas supply lines to the AGC. See Section 2
for gas supply requirements. Mating hose barbs and connectors are supplied with the
system and are sized for 3/8 inch inside diameter hose. Do not change the inlet gas
supply fittings to quick-connect fittings. Using quick-connect fittings to connect
and disconnect pressurized hoses may cause damage to the system.
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.
Argon Inlet
• Argon is optional and provides improved marking capabilities. If not used, this inlet
should be capped.
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3-17
Page 42
Section 3: Installation Spirit II User’s Manual
41
40
38
39
36
37
37
36
38
39
40
41
Plasma Console Connections
Perform the following steps to connect the plasma console to the Spirit system.
CAN Communications
• Insert the male end of the CAN communication cable. See "CAN Communication
Connections" for more details.
CAN Communications
• Insert the female end of the CAN communication cable or the CAN termination plug,
depending upon the connection scheme. See "CAN Communication Connections"
for more details.
RS-422 Communication
• Insert an RS-422 cable, if necessary, to connect to other devices.
RS-422 Communication
• Insert an RS-422 cable, if necessary, to connect to other devices.
USB
• Either USB port can be used to update the Spirit II software.
Ethernet
• No connection. For future development.
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3-18
Page 43
Spirit II User’s Manual Section 3: Installation
CAN Communication Connections
Choose one of the schemes below to connect the Spirit system for CAN
communications. Both schemes require two CAN cables and a CAN termination plug.
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3-19
Page 44
Section 3: Installation Spirit II User’s Manual
CNC Machine Interface Connections
Perform the following steps to properly interface the Spirit system with a CNC cutting
machine. See the system schematic for additional information.
Plasma Start Input
The power supply requires a contact closure between P8 pins 3 and 4 to commence the
cutting or marking sequence. The sequence is terminated when the contacts are
opened. The contacts should be rated for 24VDC - 7.3mA.
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
Plasma 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.
RS-422 Serial Communication Link
An RS-422 serial communication link can be connected between the plug on the rear of
the plasma console and a CNC machine or automatic height control system. All
process parameters can be controlled via the RS-422 communication link. Also, cutting
or marking information such as initial height, cutting or marking height, recommended
arc voltage, and recommended travel speed can be transmitted from the plasma
console to the CNC machine or height control. See Appendix B for additional serial
communication information.
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3-20
Page 45
Spirit II User’s Manual Section 3: Installation
Filling the Cooling System
WARNING: Do not touch the fans inside the power supply.
Important: Never turn on the system when the coolant reservoir is empty.
Important: When handling coolant, wear nitrile gloves and safety glasses.
Important: Only use Kaliburn approved coolant. Commercially available
antifreeze contains corrosion inhibitors that will damage the cooling
system. See Section 2 for more information.
1. Remove primary power from the Spirit system.
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 plasma console.
9. On the plasma console, press the Diagnostics navigation button to access the
Pressures/Coolant tab.
10. Press the Fill/Flush button to start the coolant pump circulating coolant through the
system. Note: the Coolant Flow indicator (press the Status navigation button) will
remain red until the coolant has filled the entire system and begins flowing back into
the tank. 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. If
the Fill/Flush button is not available (grayed out), release (turn right) the OFF Button.
11. 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.
12. Check for coolant leaks at all hose connections, the ISC, and at the torch.
13. Once the flow rate has stabilized (see Diagnostics > Pressures/Coolant tab), press
the Fill/Flush button again to stop the coolant pump.
14. Remove primary power from the Spirit system.
15. Fill the reservoir with coolant until the coolant gauge indicates full.
16. Replace the power supply covers and replace the coolant reservoir cap/level gauge.
17. End of procedure.
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3-21
Page 46
Section 3: Installation Spirit II User’s Manual
BLANK
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3-22
Page 47
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Navigation Buttons
The system is ON; cooling fans
Press to turn
The system is OFF, but enabled
.
Section 4: Operation
Operating the Plasma Console
The Plasma Console is the touch screen interface to the entire Spirit system when the
Automatic Gas Console (AGC) is used instead of the Manual Gas Console (MGC).
OFF Button
Push to disable the Spirit system.
Release (turn to the right) to enable
the system, which can then be
energized using the ON Button.
Touch Screen
Turns on automatically when AC
power is applied to the Spirit system.
Press the screen to operate as
described below.
Navigation and ON Button
Press the navigation buttons to access the various screens described in this section.
Change settings by simply pressing that part of the screen.
Press to access the desired screen.
ON Button
Press to energize the system (the
OFF Button must be released first).
This button also indicates three
different system conditions:
and coolant pump are running.
The system is OFF.
the system ON.
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4-1
(OFF Button has been released)
Press to turn the system ON.
Page 48
Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
Messages and Icons
selected material and thickness.
been made but not yet saved.
been saved as a custom setup.
Important Messages and Icons
Messages and icons at the top of the screen provide additional important information.
Edge start is required
The power supply is ON
The power supply is OFF
A valve is open
Warning message - see Error Log
The system is cutting
The system is marking
Gas pressures are adjusting
Setup: Optimum
Current, pressures and gasses are set
to the cutting chart defaults for the
Setup: Custom - Not Saved
Changes to cutting chart defaults have
Setup: Custom - Saved
Changes to cutting chart defaults have
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4-2
Page 49
Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Select Material Type
Select Material Thickness
Select Cut or Mark (Process)
configuration is set to Local.
Setting up to Cut or Mark
Press the Material navigation button to setup a cut or mark. Material type, material
thickness, and process (cut or mark) are the only parameters that must be selected. All
other parameters are adjusted automatically; however, these parameters can be
customized. See Customizing Cutting or Marking Settings for more information.
Press the Material Selection button
and select the desired material from
the list. Choose cancel to return to
the previously selected material.
Press the Thickness Selection button
to choose from a list of predefined
gauges and thicknesses or press the
data entry button ( ) to manually
enter a thickness.
Press Cut or Mark to select the
desired process and the default gases
will be displayed.
The selected process will have a light
blue background.
Note: The X/Y controller can
automatically override the selected
process unless the cut/mark/cut
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
Verifying Important Parameters
Prior to making a cut or mark with the system, the torch height control and the X/Y
controller must be configured properly. To view the recommended cutting data, press
the Parameters navigation button.
See RS422 Parameter Control for more information on how to adjust these settings.
Viewing the Required Torch Parts
Once the material and thickness have been selected, the torch parts are determined
automatically. To see which consumables need to be built up in the torch head, press
the View Torch Parts button on the Material screen. Press Cancel to return to the
Material screen.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
DC Power Indicator
when the coolant level inside the
the coolant flow is restricted.
Checking System Status
To view the system status indicators, press the Status navigation button.
Each indicator will be either Green or Red.
ISC Door
Green when the main contactor has
been energized and D.C. current is
flowing through the torch. Red when no
D.C. current is flowing.
3 Phase Power Indicator
Green when 3 phase power is
satisfactory. Red when there is a
problem with main 3 phase power.
Gas Console Indicator
Green when the automatic gas console
is operational. Red when there is a
problem with the gas system. Check
the message screen for errors.
ISC Door Indicator
Green when the impulse start console
door is closed. Red when the impulse
start console door is open.
Coolant Temperature Indicator
Green when the torch coolant
temperature is satisfactory. Red when
the coolant temperature is too hot. If
this indicator turns Red, leave the
system on until it turns Green again.
Coolant Level Indicator
Green
reservoir is satisfactory. Red when
coolant must be added.
Coolant Flow Indicator
Green when the coolant flow through
the system is satisfactory. Red when
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
A message at the top of the screen
Purging Pressure Regulators
Press the Purge navigation button to access the screen described below.
The background color of the actual pressure reading will change;
• Green for pressures at the set point
• Yellow for pressures not at the setpoint
Press the Adjust button to automatically adjust the gas pressures.
indicates the status of the regulators
in the automatic gas console:
Pressure Regulators Adjusted
Actual reading equals the Set Point.
The background color of the Actual
reading will be Green.
Regulators Need Adjusted
Actual pressures do not equal the Set
Point; the background color of the
Actual reading will be Yellow. Press
the Adjust button.
Pressure Regulators Adjusting
The system is in the process of
adjusting the pressures to reach the
Set Point.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Making a Cut or Mark
Once the material type, material thickness, and process have been selected; the correct
torch parts (consumables) installed; and the X/Y controller and torch height control are
properly configured; the system is ready to cut or mark.
1. Release the OFF Button (turn to the right) and then press the ON Button on the
Plasma Console.
2. The AGC will purge the gas hoses and set the correct gas pressures automatically.
After the pressures have been set, the Gas Console indicator on the Status Screen
will change from red to green.
3. Once the Gas Console indicator is green, the system is ready for cutting or marking.
4. When the system receives a start signal from the X/Y controller, the following
sequence is 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 deenergized.
Check the troubleshooting section if any indicators in this procedure fail to change from
red to green after 10 seconds.
Note: The DC Power indicator will only turn green while cutting.
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
Piercing Thick Materials
Care must be taken when piercing thick materials in order to prevent damage to the
shield cap and nozzle. As with all thicknesses, the pierce height must be set high
enough so the metal ejected while piercing does not come into contact with the shield
cap. 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 edge start required icon ( ) will appear at the top of the
screen – the torch should be positioned at the edge of the material prior to starting the
arc.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Cut Quality
Before the optimum cutting condition can be achieved on a particular material type and
thickness, the machine operator must have a thorough understanding of the cutting
characteristics of the Spirit system. When the cut quality is not satisfactory, the cutting
speed, torch height, or gas pressures may need to be adjusted in small increments until
the proper cutting condition is obtained. 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.
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
Altering the Current Set Point
Altering Gas Types
can be changed to Air,
Altering Gas Pressures
gas pressures should not be changed.
gas can be adjusted in small
Customizing Cutting or Marking Settings
Changes to any of these factory default settings will cause the Setup message at the
top of the screen to change from Setup: Optimum to Setup: Custom - Not Saved. See
the next section to save custom settings.
To alter the current set point from the
default setting, press the Current
(Amps) button on the Material Screen
and choose from the list of available
values.
Note: When marking is the selected
process, the current cannot be
changed.
On the Material Screen, press the
Plasma or Shield button and select the
desired gas type.
The plasma gas
Oxygen, Nitrogen, or H17. Shield gas
can be changed to Air, Oxygen, or
Nitrogen.
Preflow gas cannot be changed.
Normally, the preflow gas and plasma
The shield
increments to fine-tune a cut. Use the
data entry button to enter a desired
pressure. Note that all of the gases
have minimum and maximum limits
and cannot be programmed beyond
these limits.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Altering Important Parameters
data entry button and enter the desired
Once a value has been changed, press
to send the
height control.
Press the Manage Custom Setups
Press the Save button and enter a
With the RS422 Parameter Control set
to Manual, certain values on the
Parameters Screen can be changed
manually. Press the corresponding
value.
the Manual Transmit button
value to the X/Y machine or torch
Saving Customized Settings
If one of the default cutting or marking parameters was altered, the new configuration
can be saved for later use.
button on the Parameters Screen.
name using the on-screen keyboard.
This name is added to the list of
existing custom setup files and can be
accessed again by scrolling through
the list using the left (Prev) or right
(Next) arrow buttons.
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
Press the Manage Custom Setups
Press the left (Prev) or right (Next)
When the desired setup is displayed,
Restoring or Deleting Customized Settings
If a new setup configuration was saved for later use, it can be restored at any time or
deleted permanently from the list.
button on the Parameters Screen.
arrow button to scroll through the list of
existing custom setups. The name of
the selected setup will appear under
Setup Name.
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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.
press the Restore or Delete button.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Configuration Tab
Press the Config navigation button followed by the Configuration tab to access the
screen described below.
RS422 Parameter Control
Controls how the Spirit communicates with the X/Y controller and height control system.
If an Inova arc voltage control system is not being used with the Spirit system, RS422
Parameter Control must be disabled. With the RS422 Parameter Control set to
automatic, the Inova is automatically updated with the correct arc voltage, pierce (initial)
height, and cutting (marking) height any time a new condition is loaded, the process
(cutting or marking) is changed, or when the arc voltage, pierce (initial) height, or cutting
(marking) height is changed on the Parameters Screen.
With the Inova Parameter Transmit feature set to manual, the voltage screen is being
displayed will automatically transmit the pierce (initial) height, cutting (marking) height,
and arc voltage set points to the Inova.
Cut/Mark Control
The Spirit system has the capability of plasma cutting and plasma marking with
the same set of consumables. The process (cutting or marking) can be set by
the RS-422 serial interface (COMM), by a hard signal (Hard Wire) on the CNC
interface plug, or locally (Local) through the plasma console.
Hydrogen Cutting (H17)
When hydrogen cutting is enabled, the H17 hydrogen mixture will automatically
be selected as the plasma gas for certain material types and thicknesses. To
prevent the use of H17, hydrogen cutting must be disabled.
Units of Measure
The Spirit system will display Imperial units or Metric units. Press to select.
Language
Press to select the desired language.
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
Advanced Config Tab
Press the Config navigation button followed by the Advanced Config tab to access the
screen described below.
Set RS422 Node
When multiple Spirit systems are being used together on an RS-422 serial
communication link, each system must have a unique identification number (node
number) to identify itself to the network. To set the communication node number,
simply choose from node 1 through 8.
When using an Inova torch height control system with the Spirit, the communication
node feature must be disabled. To disable the communication node, press the Disabled
button.
Set CAN Domain
Make sure the CAN domain is set to 1. All other selections are for future use.
Allow Error Suppression
Press Enable to allow error suppression. Press Disable to stop error suppression.
Arc Off Delay
In some instances, such as when cutting thicker stainless steel materials, it may
be desirable to delay the extinction of the cutting arc after a stop signal is
received. To program an arc off delay, press the data entry button ( ) and enter
the desired delay time in milliseconds. The delay can be set from 0 to 2000 mS.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Network Settings Tab
Press the Config navigation button followed by the Network Settings tab to access the
screen described below.
To enable networking, press the red exclamation graphic next to Network
Disabled. The graphic will change to a green check mark. Enter the appropriate
IP Address, Subnet Mask, and Gateway.
If DHCP is necessary, press the red exclamation graphic next to DHCP Disabled.
The graphic will change to a green check mark. Enter the required information.
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
Software Updates Tab
Press the Config navigation button followed by the Software Updates tab to update the
Spirit system software.
See the next page for details on updating the software.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Updating the Software
1. Copy the file Installer.exe onto a USB thumbdrive. This file will be emailed or an ftp
address will be provided for download.
2. Turn the Plasma Console off.
3. Insert the USB thumbdrive into either port on the back of the Plasma Console.
4. Turn the Plasma Console on.
5. Allow the system to boot to the normal main screen and select “Config” from the
Navigation Menu.
6. Select the “Software Updates” tab.
7. Using the arrows, navigate to the software package to be installed. Note that the
system will overwrite the file without warning if steps aren’t taken to rename the
default Installer.exe file. If you wish to maintain older software updates, you may
wish to rename the file to something like Installer mm/dd/yy_Installer.exe
8. Select the Install button.
9. At this point the Plasma Console will shut itself down and run the installer package.
10. To complete the install follow the onscreen instructions.
11. For the most basic installation, a new screen will be shown and simply clicking Install
will perform the update. In the event of a software upgrade to the Gas Console
and/or the Power Supply, further actions will be required. Again, follow the onscreen
instructions to complete the install.
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
System Info Tab
Press the Config navigation button followed by the System Info tab to access the screen
described below.
This screen displays the hardware, software and serial number for each of the
components in the Spirit system.
Tools Tab (Restart Plasma Console)
Press the Config navigation button followed by the Tools tab to access the screen
described below.
This screen provides an on-screen calculator and buttons to restart the plasma
console (Restart Computer) and to Close Program.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Pressures/Coolant Tab
Press the Diagnostics navigation button followed by the Pressures/Coolant tab to
access the screen described below.
Pressing any of the Output Pressure buttons will cause the corresponding valve
to open or close. Note that the preflow valve and the plasma valve cannot be on
at the same time. During a cutting or marking sequence, the status of all valves
will display N/A.
See the Installation Section to initially fill the system with coolant. See the
Maintenance Section for the procedure to refill or flush coolant.
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
RS422 Tab
Press the Diagnostics navigation button followed by the RS422 tab to access the screen
described below.
Note that incoming data is appended to show an “R” before the data and
outgoing transmissions are appended to show a “T” before the data.
Electrical Tab
Press the Diagnostics navigation button followed by the Electrical tab to access the
screen described below.
This diagnostic screen displays important parameters for the Power Supply and Gas
Console that may be useful during troubleshooting.
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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.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Cut Info Tab
Press the Diagnostics navigation button followed by the Cut Info tab to access the
screen described below.
Press the Save to History button to add the Present Cut Errors to the History list for
future reference. This should be done each time consumables are changed.
Press any of the History buttons (1 through 5) to display the saved details.
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
When any of the following errors occur, measures should be taken to avoid further
errors. The following is a description of the errors and possible causes:
•Transferred arc not established
This error occurs when the arc fails to transfer to the workpiece. It primarily causes
nozzle damage and is typically due to a pierce height that is too high.
•Transferred arc lost before upslope
This error occurs when the arc transfers to the workpiece but is lost immediately. It
primarily causes nozzle damage and is typically due to a pierce height that is too
high.
•Transferred arc lost during upslope
This error occurs when the arc transfers to the workpiece but is lost before steady
state operation. It primarily causes electrode damage and is typically due to a pierce
time that is too long or when cutting a given thickness with excessive current.
•Transferred arc lost during cut
This error occurs when the arc is lost during steady state operation. It substantially
shortens the electrode life and is typically due to a torch standoff distance that is too
high or a travel speed that is to slow.
•Transferred arc lost during downslope
This error occurs when the arc is lost after a stop signal is received but before the
current downslope completes. It substantially shortens the electrode life and is
typically due to an incorrect lead-out or when cutting a given material thickness with
excessive current. When cutting small pieces that tend to drop into the table after
being cut, there should be a very short lead out or none at all. On thicker materials,
the arc is sometimes lost when crossing the kerf during the lead out. It is critical
that the lead-outs be fine tuned so the arc is not lost before downslope is
complete.
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Spirit II User’s Manual Section 4: Operation with Automatic Gas Console
Power Supply Tab
Press the Diagnostics navigation button followed by the Power Supply tab to access the
screen described below.
Error Log Tab
Press the Diagnostics navigation button followed by the Error Log tab to access the
screen described below.
Filters along the right side of the screen can be used to limit the data displayed
based upon Error #, Date, or Severity. Press the Clear button to remove all
filters.
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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.
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Section 4: Operation with Automatic Gas Console Spirit II User’s Manual
Messages Tab
Press the Diagnostics navigation button followed by the Messages tab to access the
screen described below.
This screen displays all power supply and gas console messages, sequencing,
and errors. The message screen should be the initial starting point when
troubleshooting the system.
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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.
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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.
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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
200
195
260
175
275
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.
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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
Page 75
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
284150 277274 277266 277289 277143 277291 279100
200A
275A
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
284150 277263 277266 277269 277258 277270 279100
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
Page 76
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
284150
277274
277266
279489
279443
279440
(yellow o-ring)
279060
284150
277263
277266
279469
279458
279450
279060
Mild Steel
Silver Electrode
Nozzle
100A
150A
200A
275A
279410
(brown o-ring)
279420
(green o-ring)
(red 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
Page 77
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
284150
277274
277266
277287
277259
277135
279100
284150
277211
277280
277118
277139
277135
279100
Stainless Steel - H17 Plasma
Copper Electrode
70A
100A
150A
200A
Nozzle
260A
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
Page 78
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
284150
277274
277266
277289
277143
277291
279100
284150
277263
277266
277276
277258
277270
279100
Stainless Steel - Air or Nitrogen Plasma
Copper Electrode
Nozzle
30A
50A
70A
100A
150A
200A
275A
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
Page 79
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
279440
Stainless Steel - Air or Nitrogen Plasma
Silver Electrode
Nozzle
100A
150A
200A
284150 277274 277266 279489 279443
279410
(brown o-ring)
(yellow o-ring)
279060
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
Page 80
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
284150
277274
277266
277289
277143
277291
279100
284150
277263
277266
277276
277258
277270
279100
Aluminum
Copper Electrode
30A
50A
70A
100A
Nozzle
150A
200A
275A
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
Page 81
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
284150
277274
277266
279489
279443
279440
279060
284150
277263
277266
279469
279458
279450
(red o-ring)
279060
Aluminum
Silver Electrode
100A
150A
200A
275A
Nozzle
279410
(brown o-ring)
(yellow 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
Page 82
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 5-39
Mild Steel
150 Amps
Oxygen
Air
Page 5-17
Page 5-40
Mild Steel
200 Amps
Oxygen
Air
Page 5-18
Page 5-41
Mild Steel
275 Amps
Oxygen
Air
Page 5-19
Page 5-42
Stainless Steel
30 Amps
Air
Air
Page 5-20
Stainless Steel
50 Amps
Air
Nitrogen
Page 5-21
Stainless Steel
70 Amps
H17
Nitrogen
Page 5-22
Stainless Steel
70 Amps
Air
Nitrogen
Page 5-23
Stainless Steel
100 Amps
H17
Nitrogen
Page 5-24
Stainless Steel
100 Amps
Air
Nitrogen
Page 5-25
Page 5-43
Stainless Steel
150 Amps
H17
Nitrogen
Page 5-26
Stainless Steel
150 Amps
Air
Nitrogen
Page 5-27
Page 5-44
Stainless Steel
200 Amps
H17
Nitrogen
Page 5-28
Stainless Steel
200 Amps
Air
Nitrogen
Page 5-29
Page 5-45
Stainless Steel
260 Amps
H17
Nitrogen
Page 5-30
Stainless Steel
275 Amps
Air
Nitrogen
Page 5-31
Aluminum
30 Amps
Air
Nitrogen
Page 5-32
Aluminum
50 Amps
Air
Nitrogen
Page 5-33
Aluminum
70 Amps
Air
Nitrogen
Page 5-34
Aluminum
100 Amps
Air
Nitrogen
Page 5-35
Page 5-46
Aluminum
150 Amps
Air
Nitrogen
Page 5-36
Page 5-47
Aluminum
200 Amps
Air
Nitrogen
Page 5-37
Page 5-48
Aluminum
275 Amps
Air
Nitrogen
Page 5-38
Page 5-49
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
Page 83
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
* 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
Page 84
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
* 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
Page 85
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
* 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
Page 86
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual
* 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
Page 87
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
* 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
Page 88
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual
* 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)
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Kerf
Width
.150
.155
Kerf
Width
3.8
3.9
4.0
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
Page 89
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
* Use an arc transfer height (ignition height) of .300” (7.6 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)
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Kerf
Width
.165
.185
Kerf
Width
4.2
4.3
4.7
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.
5-19
Page 90
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
* 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.
5-20
Page 91
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
* 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.
5-21
Page 92
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual
* 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.
5-22
Page 93
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
* 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.
5-23
Page 94
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual
* 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.
5-24
Page 95
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
* 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
Page 96
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual
* 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.
5-26
Page 97
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
* 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.
5-27
Page 98
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual
* 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.
5-28
Page 99
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
* 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.
5-29
Page 100
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual
* 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.
*** 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.
5-30
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