Lincoln Electric 718118 User Manual

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User's Manual

Spirit II 400

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

718118 Rev D

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

Prologue Spirit II User’s Manual

Rev

ECO#

Author

Date

Description of Change

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

pressure.

clarify cabling requirements for various configurations.

Corrected contact ratings on page 3-19. Added pinouts to CII, FII, JII cables in Parts List.

Revision History

A - CAD 02/04/2013 Initial Release

B LAD0202 CAD 06/07/2013

C LAD0217 CAD 08/06/2013

D LAD0228 CAD 08/28/2013

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

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

explicit written permission from Kaliburn.

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

Other logos, products and company names mentioned herein

may be trademarks of their respective owners.

4130 Carolina Commerce Parkway

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

Deionization filter cartridge (500510) replaced sediment filter (300152). Parts list updated. Expanded notes on System Interconnection diagrams to

a Lincoln Electric Company

Ladson, SC 29456 USA

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

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

ii

Spirit II User’s Manual Prologue

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

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

Section 1: Safety Spirit II User’s Manual

Toxic Fume Prevention

Electric Shock Prevention

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

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

The Spirit system uses high open circuit voltages that can be fatal. Extreme care should be used when operating or performing maintenance on the system. Only qualified personnel should service the system. Observe the following guidelines to protect against electric shock:

• A wall-mounted disconnect switch should be installed and fused according to local and national electrical codes. The disconnect switch should be located as close as possible to the power supply so it can be turned off in case of an emergency.

• The primary power cord should have a 600 volt minimum rating in order to protect the operator. In addition, it should be sized according to local and national electrical codes. Inspect the primary power cord frequently. Never operate the system if the power cord is damaged in any way.

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

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

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

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

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

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

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

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

1-2

Spirit II User’s Manual Section 1: Safety

Fire Prevention

Explosion Prevention

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

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

• Never bypass the safety interlock devices.

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

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

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

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

When using the Spirit system, it is necessary to exercise good judgment. While cutting, the arc produces sparks that could cause a fire if they fall on flammable materials. Make sure that all flammable materials are a suitable distance away from the cutting area. All flammable liquids should be at least 40 feet away from the cutting area, preferably stored in a metal cabinet. Plasma cutting should never be attempted on containers that contain flammable materials. Make sure that fire extinguishers are readily accessible in the cutting area.

Make sure that the cutting area is properly ventilated when using oxygen as a cutting gas.

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

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

• Never cut pressurized cylinders or any closed container.

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

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

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

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

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

1-3

Section 1: Safety Spirit II User’s Manual

Health Support Equipment

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

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

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

• Never attempt to repair compressed gas cylinders.

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

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

momentarily prior to installing a regulator.

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

• Never use a compressed gas cylinder or pressure regulator for any purpose other than which it is intended.

• Never use a pressure regulator for any gas other than which it is intended.

• Never use a pressure regulator that is leaking or has other signs of physical

damage.

• Never use oxygen hoses and pressure regulators for any gas other than oxygen.

• Never use any gas hose that is leaking or has other signs of physical damage.

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

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

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

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

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

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

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

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

1-4

Spirit II User’s Manual Section 1: Safety

Safety Standards Booklet Index

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

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

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

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

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

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

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

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

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

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

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

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

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

33126.

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

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

10036.

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

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

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

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

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

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

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

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

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

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

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

Spirit II User’s Manual Section 2: Specifications

Section 2: Specifications

System Description

The Spirit II 400 is a 400 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 3" thick and stainless steel up to 1-1/2” thick.

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

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

The torch is water-cooled and consumables are machined to exacting dimensions and checked with the latest computerized measuring systems. Nine nozzle sizes (30, 50, 70, 100, 150, 200, 260, 275, and 400 amps) are available to produce excellent cut quality throughout the cutting range.

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

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

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

2-1

Section 2: Specifications Spirit II User’s Manual

System Components

The Spirit II 400 System consists of the following components:

Standard Components

• Power Supply

• Cooling System (includes torch coolant)

• Cooling System Control Cable

• Manual Gas Console

• CAN Cable

• CAN Termination Plug

• Impulse Start Console (ISC)

• ISC Control Cable

• ISC Ground Cable

• Torch and Handle Assembly

• Torch Lead Set

• 5-gang Manifold Assembly

• 5-gang Manifold Control Cable

• 2-gang Manifold Assembly

• 2-gang Manifold Control Cable

• 17 Inch Plasma Hose

• Coolant and Power Leads

• Gas Hose Package

• Work Ground Lead

• Spirit II User’s Manual

Optional Components

• Supply Gas Hoses

• Internal Inova Console

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.

2-2

Spirit II User’s Manual Section 2: Specifications

Input Current at

Maximum Output

220 VAC, 3Ø, 60Hz

300232

262 amps

240 VAC, 3Ø, 60Hz

300233

240 amps

380 VAC, 3Ø, 50/60Hz

300234

152 amps

400 VAC, 3Ø, 50/60Hz

300235

144 amps

415 VAC, 3Ø, 50/60Hz

300236

140 amps

440 VAC, 3Ø, 50/60Hz

300237

131 amps

480 VAC, 3Ø, 60Hz

300238

120 amps

600 VAC, 3Ø, 60Hz

300239

96 amps

34.2" [869]

49.5" [1257]

Power Supply Specifications

Power Supply Description Part Number

Open Circuit Voltage ......................................... 370 VDC

Output Current (drooping characteristic) ........... 10 - 400 amps

Maximum Output Voltage ................................. 200 VDC

Duty Cycle ........................................................ 100% @ 80 kW

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

Weight .................................... .......................... 1922 lb (872 kg)

39.9"

[1013]

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.

2-3

Section 2: Specifications Spirit II User’s Manual



 

36.0" [914]

23.0" [584]

15.8" [401]

Cooling System Specifications

Part Number ..................................................... 300275

Discharge pressure .......................................... 150 psi (10.2 bar)

Flow rate .......................................................... 2.1 gal/min (7.9 liters/min)

Coolant fluid ..................................................... Propylene glycol solution

Coolant tank capacity ....................................... 3.2 gal (12 liters)

Weight .............................................................. 141 lb (64 kg) (without coolant)

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

Spirit II User’s Manual Section 2: Specifications

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.

2-5

Section 2: Specifications Spirit II User’s Manual

12.4" [315]

12.0" [305]

13.7" [348]

10.9" [277]

7.0" [178]

(4) Ø .300 [7.6]

Manual Gas Console (MGC) Specifications

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

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

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

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

2-6

Spirit II User’s Manual Section 2: Specifications

Gas Supply Requirements

Plasma gas types:

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

Stainless Steel ............................................ Air, Nitrogen, or H17

Aluminum .................................................... Air or Nitrogen

Shield gas types:

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

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

Aluminum .................................................... Air or Nitrogen

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

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

Plasma gas flow rate (maximum):

Oxygen ........................................................ 78 scfh (2209 liters/hour)

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

H17 or Nitrogen ........................................... 106 scfh (3002 liters/hour)

Shield gas flow rate (maximum):

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

Air ................................................................ 258 scfh (7306 liters/hour)

Nitrogen ...................................................... 326 scfh (9231 liters/hour)

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

Marking gas flow rate (maximum) ..................... 89 scfh (2520 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.

2-7

Section 2: Specifications Spirit II User’s Manual



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



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



12.75" [324]

8.00" [203]

12.00" [305]

13.50" [343]

10.00" [254]

5.35" [136]

(4) Ø.312 [8]

Impulse Start Console (ISC) Specifications

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

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

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

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

2-8

Spirit II User’s Manual Section 2: Specifications









Torch Head

Torch Base

Torch Handle

1.99"

Alignment Indicator Attachment Ring

Manifold

Torch and 2-Gang Manifold Specifications

Part Number:

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

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

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

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

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

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

Max Weight:

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

3.38" [86]

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

[51]

1.87" [47]

5.08" [129]

(Slot)

Alignment Indicator (Circle)

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

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

2-9

Section 2: Specifications Spirit II User’s Manual



















4.20"

6.18" [157]

0.327" [8.3]

0.25" [6.4]

1.18" [30]

3.035" [77]

(4) 0.187" [4.8] Mounting Holes

5-Gang Manifold Specifications

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

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

3.80" [97]

[107]

8.35" [212]

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

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

2-10

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 400 amps, 205 arc volts. The measurements were made with a sound level meter.

Distance From Torch

meters above the

120 dB 115 dB

The maximum noise level is 131 dB at a distance of 3 inches (76.2 mm) from the torch while cutting at 400 amps, 205 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

Section 2: Specifications Spirit II User’s Manual

BLANK

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

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2-12

Spirit II User’s Manual Section 3: Installation

WARNING

when lifting.

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, pallet jack or crane. In order to prevent damaging the power supply when lifting with a forklift or pallet jack, the forks should be of adequate length to protrude on the far side of the power supply. If lifting with a sling (lifting straps), ensure the following:

• Sling and material handling equipment must comply with local and national laws and regulations. The personnel involved in the move must be properly trained and qualified to use such equipment.

• All power supply covers must be securely installed.

• Two slings are required. Each sling should pass through all three (3) structural

members on the bottom of the power supply. See sling access holes below.

• Lift slowly -not more than 8 in. (203 mm) high- to ensure even weight distribution.

• Move slowly to prevent uncontrollable acceleration/deceleration.

Falling equipment can cause injury.

• Lift only with

equipment of adequate lifting capacity.

• Be sure power

Sling Access Hole

supply is stable

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.

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

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

3-1

Section 3: Installation Spirit II User’s Manual

The power supply must be cleaned as often as necessary to prevent the accumulation of metallic dust inside the unit. See Section 2 for unit dimensions.

Manual Gas Console (MGC)

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

Impulse Start Console (ISC)

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

5-Gang Manifold

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

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.

Cooling System

The cooling system must be located within 8 feet (2.4 meters) of the plasma power supply. The surface on which the cooling system is located should have a grade of no greater than 10º to eliminate the risk of toppling over. See Section 2 for unit dimensions.

System Interconnection

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

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

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

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

3-2

Spirit II User’s Manual Section 3: Installation

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

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

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

3-3

Section 3: Installation Spirit II User’s Manual

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

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

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

3-4

Spirit II User’s Manual Section 3: Installation

Input Current

Output (amps)

Recommended

Size (amps)

220 VAC, 60Hz

262

350

240 VAC, 60Hz

240

300

380 VAC, 50/60Hz

152

200

400 VAC, 50/60Hz

144

175

415 VAC, 50/60Hz

140

175

440 VAC, 50/60Hz

131

175

480 VAC, 60Hz

120

150

600 VAC, 60Hz

96

125

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.

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

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

3-5

Section 3: Installation Spirit II User’s Manual

Strain Relief

Disconnect Box TB5 Connections

L1 (U)

L1 L2 L3 Gnd

TB5

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

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

Figure 3: Power Supply Primary Connections

3-6

L2 (V) L3 (W) Ground

Connections

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 #4/0AWG 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 #4/0AWG work ground lead through the bottom strain relief on the rear of the power supply and connect it to the work terminal.

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

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

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

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

3-7

Section 3: Installation Spirit II User’s Manual

4 1 3

2

1 2 3

Strain Relief

Figure 4: Power Supply Output Connections

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

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

3-8

Spirit II User’s Manual Section 3: Installation

10 5 6 7 8

9

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 power supply and 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 cooling system. 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 cooling system. 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.

Cooling System Control Cable

1. Connect the cooling system control cable plug labeled P14 to the connector labeled P14 on the rear of the power supply.

2. Connect the cooling system control cable plug labeled P1 to the connector labeled P1 on the cooling system.

Cooling System Ground Connection (Customer Supplied)

The Cooling System must be connected to protective earth ground in accordance

with national or local codes. The Cooling System receives its power from the plasma power supply and as such must be connected to the same protective ground as the plasma power supply.

Use a minimum of 8 AWG (10 mm2) wire connected from the cooling system

grounding stud to the plasma power supply protective earth ground. Note: the customer must supply grounding wire.

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

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

3-9

Section 3: Installation Spirit II User’s Manual

Figure 5: Cooling System Connections

7 8 10 9 6 5 7

8

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

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

3-10

Spirit II User’s Manual Section 3: Installation

11

12

13

14

15

Torch Leads to Impulse Start Console Connections

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

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

Braided Shield

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

2. Slide the threaded ring over the torch leads, thread it onto the brass shield connector, and tighten firmly. The shield connector should ground the braided shield to the case of the impulse start console in order to help reduce high frequency noise emission. Using an ohmmeter, measure for zero ohms between the braided shield and the ground stud located on the outside of the impulse start console.

Torch Electrode/Coolant Supply Lead

• Connect the torch electrode/coolant supply lead to the brass cathode manifold. Note that the torch electrode/coolant supply lead has right hand threads.

Torch Coolant Return Lead

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

Torch Nozzle Lead

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

Torch CTP Sensor Lead

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

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

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

3-11

Section 3: Installation Spirit II User’s Manual

15

13

14

12

11

Figure 6: Torch Leads to Impulse Start Console Connections

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

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3-12

Spirit II User’s Manual Section 3: Installation

18

19

18

19

17

16

17

16

17

18

19

Torch Leads to Torch Base Connections

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

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

Torch Lead through Torch Handle Installation

1. Route the torch leads through the torch handle. Note that the threaded end of the torch handle mates with the torch base.

Torch Electrode/Coolant Supply Lead

• Connect the torch electrode/coolant supply lead to the torch base as shown.

Torch Coolant Return Lead

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

Torch Nozzle Lead

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

Torch CTP Sensor Lead

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

Figure 7: Torch Leads to Torch Base Connections

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

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

3-13

Section 3: Installation Spirit II User’s Manual

20

21

22

23

Torch Gas Connections

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

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

7.5 Foot Shield Gas Hose

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

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

17 Inch Plasma Gas Hose

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

2. Thread the torch handle onto the torch base, being careful not to twist the torch leads and gas hoses when tightening the torch handle.

3. Tighten the base to the handle using a pin style adjustable spanner wrench (fits 2" diameter with ¼" diameter pin).

4. Attach the 2-gang manifold assembly to the torch handle. The top of the manifold bracket should be flush with the top of the torch handle.

5. Connect the other end of the 157 inch (432 mm) plasma gas hose to the plasma gas outlet on the 2-gang manifold.

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

6 Foot Preflow/Postflow/Marking Gas Hose

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

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

Marking Gas Hose

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

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

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

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

3-14

Spirit II User’s Manual Section 3: Installation

25

26

27

28

29

30

Postflow Gas Hose

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

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

Plasma Gas Hose

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

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

Shield Gas Hose

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

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

Preflow Gas Hose

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

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

5-Gang Manifold Control Cable

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

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

2-Gang Manifold Control Cable

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

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

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3-15

Section 3: Installation Spirit II User’s Manual

Manual Gas

25

22

26

27

23

25

22

21

30

GREEN

REAR

BLUE

27

21

20

28

26

20

28

29

23

BLUE

GREEN

RED

Console

RED

Figure 8: Torch Gas Connections

PORT

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3-16

Spirit II User’s Manual Section 3: Installation

31

32

33

34

32

34

31

33

Gas Supply Connections

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

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

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

Air Inlet (ISO 3821 hose color - black)

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

Oxygen Inlet (ISO 3821 hose color - blue)

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

Nitrogen Inlet (ISO 3821 hose color - black)

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

H17 Inlet (ISO 3821 hose color - red)

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

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

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

3-17

Section 3: Installation Spirit II User’s Manual

35

36

35

36

CAN Communication Connections

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

CAN Cable

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

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

CAN Termination Plug

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

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

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

3-18

Spirit II User’s Manual Section 3: Installation

CNC Machine Interface Connections

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

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

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

Arc Hold Input The power supply requires a contact closure between P8 pins 10 and 11 to inhibit arc starting even though a plasma start signal has been applied to the unit. When the contacts are opened, the arc is initiated. This feature is used to decrease cycle time by allowing pre-cut gas and contact sequencing to occur simultaneously with initial torch height positioning. The contacts should be rated for 24VDC - 7.3mA.

Motion Output The power supply provides a maintained contact closure output between P8 pins 12 and 14 as long as an arc is maintained between the torch and the workpiece. The motion contacts are rated for 24VDC – 10mA.

Remote On/Off Input The power supply requires a maintained contact closure between P8 pins 5 and 6 to energize the system from a remote location, provided that the OFF Button on the manual gas console is released. Opening the contacts deenergizes the system. If the remote on/off feature is not used, install a jumper between terminal block TB1 positions 7 and 8. The contacts should be rated for 24VAC – 10mA.

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

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

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

3-19

Section 3: Installation Spirit II User’s Manual

Filling the Cooling System

WARNING: Do not touch the fans inside the cooling system.

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 cover from the cooling system.

5. Ensure the coolant filter housing is tightened securely.

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

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

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

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

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

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

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

13. Remove primary power from the Spirit system.

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

15. Replace the cooling system cover and replace the coolant reservoir cap/level gauge.

16. End of procedure.

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

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

3-20

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

OFF Button

Section 4: Operation

Operating the Manual Gas Console (MGC)

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

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

Up/Down/Select Buttons

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

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

Display

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

Pressure Regulator Knobs

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

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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.

4-1

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

Push the OFF Button on the MGC to disable

Move the pointer to Current.

Move the pointer to Select Gas.

Move the pointer to Adjust Gas.

Move the pointer to a gas and then press

The system is now setup to cut.

Setting up to Cut

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

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

Cutting is displayed.

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

Press SELECT to cycle through the list until

Press SELECT.

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

Press SELECT.

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

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

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

4-2

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

Push the OFF Button on the MGC to disable

Press SELECT to cycle through the list until

cut.

On the main menu, move the pointer to

Verify that all connected gas pressures are at

Setting up to Mark (Overrides Cut)

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

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

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

The system is now setup to mark instead of

Verifying Input Gas Pressures

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

Input Gas. Press SELECT.

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

Press SELECT to return to the main menu.

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

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

4-3

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

Release the OFF Button (turn to the right) on

The MGC will purge the gas hoses. The purge

deenergized.

Making a Cut or Mark

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

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

icon ( ) is displayed during this process.

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

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

• Two second gas preflow

• Impulse start circuit energized

• Pilot arc initiation

• Transferred arc (cutting or marking arc)

established

• Motion output relay energized

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

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

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

4-4

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

Piercing Thick Materials

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

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

One way to accomplish this may be to program the pierce time on the torch height control system to a value that is longer than the X/Y controller motion delay time.

Moving Pierces and Edge Starts

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

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

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

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

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

4-5

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

Cut Quality

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

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

1. A positive cut angle (top dimension of piece smaller than the bottom dimension) usually occurs when the torch standoff distance is too high, when cutting too fast, or when excessive power is used to cut a given plate thickness.

2. A negative cut angle (top dimension of piece larger than the bottom dimension) usually occurs when the torch standoff distance is too low or when the cutting speed is too slow.

3. Top dross usually occurs when the torch standoff distance is too high.

4. Bottom dross usually occurs when the cutting speed is either too slow (slow-speed dross) or too fast (high-speed dross). Low-speed dross is easily removed, while high-speed dross usually requires grinding or chipping off. When using oxygen as the shielding gas, bottom dross can sometimes be removed by increasing the shield gas pressure. However, increasing the shield pressure too much can cause cut face irregularities (see below). Bottom dross also occurs more frequently as the metal heats up. As more pieces are cut out of a particular plate, the more likely they are to form dross.

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

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

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

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

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

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

4-6

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

On the main menu, move the pointer to Errors.

On the main menu, move the pointer to

Move the pointer to either Power Supply or

Review the necessary information.

SELECT to return to the main menu.

Checking Errors

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

Press SELECT.

(10) error codes.

See Section 6 in this manual for details on the

Press SELECT to cycle through the last ten

error codes.

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

Move the pointer to Return and press

SELECT to return to the main menu.

Checking the Version and Serial Number

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

Version. Press SELECT.

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

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

Gas Console. Press SELECT.

Press SELECT to return to the previous screen.

Move the pointer to Return and press

4-7

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

On the main menu, move the pointer to

Languages

Move the pointer to the desired language and

return to the main menu.

On the main menu, move the pointer to

Move the pointer to Contrast.

to return to the main menu.

Changing the Language

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

Configure. Press SELECT.

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

Press SELECT on

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

Adjusting the Screen Contrast

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

Configure. Press SELECT.

.

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

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

Press SELECT to cycle through the list of contrast settings.

Move the pointer to Return and press SELECT

4-8

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

YES

NO!

There is no

Gap is visible

O-ring

Torch Base

Section 5: Torch Consumables and Cutting Charts

Installing / Removing the Torch Head

WARNING: Remove primary power from the Spirit system!

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

2. Align the indicator on the torch head (circle) with the one on the torch base (slot).

3. Apply enough upward force to engage the threads while tightening the attachment ring. Turn the attachment ring to the RIGHT to tighten.

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

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

O-ring

Torch Head

gap between o-ring and attachment ring

between o-ring and attachment ring

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

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

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

5-1

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

YES

NO!

PULL

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:

• 400A copper electrodes use socket P/N 284052 & driver P/N 277086.

• All other copper electrodes use socket P/N 277087 & driver P/N 277086.

• All silver electrodes use P/N 279061.

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

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

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

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

5-2

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

Current (A)

Time (ms)

30

490

50

390

70

300

100

300

150

175

200

195

260

175

275

175

400

375

Maximizing Consumable Life

Use the following guidelines to maximize consumable parts life:

1. The Spirit system utilizes the latest advancement in technology for extending the life of the torch consumable parts. To maximize the life of the consumable parts, it is imperative that the shutdown procedure of the arc is carried out properly. The arc must be extinguished while it is still attached to the workpiece. A popping noise may be heard if the arc extinguishes abnormally. Note that holes are usually programmed without lead-outs to prevent loss of the arc during shutdown. There is a time delay between the reception of a stop signal and when the arc is extinguished. During this time, the gases and cutting current are changed to optimum values for extinguishing the arc. Ideally, the x/y machine controller should provide a plasma stop signal prior to the end of the cut path so the gases and current reach the shut off values at the same time that the part has been completely cut. The shut down times are different for each current and are given below.

Arc Shutdown Times

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

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

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

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

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

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

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

5-3

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

Part

Inspect For

Corrective Action

Outer Cap

Damaged o-ring

Replace shield cap

Center hole out of round

Damage o-ring

Replace retaining cap

Center hole out of round

Damaged o-rings

Replace nozzle

Damage

Damaged o-rings

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

Apply a thin film of o-ring lubricant

Replace retaining cap

Apply a thin film of o-ring lubricant

Replace nozzle

Apply a thin film of o-ring lubricant

Swirl Ring

Electrode

or

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

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

Clogged holes

Dry o-rings

Erosion or arcing

Dry o-rings

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

Apply a thin film of o-ring lubricant

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

Replace electrode

Apply a thin film of o-ring lubricant

5-4

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

Retaining Cap

Cap

Retaining Cap

Ring

Electrode

Head

284150

277145

277153

277120

277140

277130

279100

284150

277115

277153

277122

277140/

277142

277131

279100

284150

277117

277151/

277152

277293

277139

277292

279100

284150

284123

284121

284125

284122

284124

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

400A

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

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

284150

284123

284121

284125

279422

279460

(black o-ring)

279060

Mild Steel

Silver Electrode

Nozzle

100A

150A

200A

275A

279410

(brown o-ring)

279420

(green o-ring)

(red o-ring)

400A

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

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

5-6

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

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Copper

Electrode

Torch

Head

284150

277150

277113

277124

277140

277132

279100

284150

277146

277113

277126

277141

277133

279100

284150

277298

277266

277297

277139

277135

279100

284150

277274

277266

277287

277259

277135

279100

284150

277211

277280

277118

277139

277135

279100

284150

284155

284156

284158

284122

284159

279100

Stainless Steel - H17 Plasma

Copper Electrode

70A

100A

150A

200A

Nozzle

260A

400A

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

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

5-7

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

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Copper

Electrode

Torch

Head

284150

277144

277110

277121

277138

277137

279100

284150

277149

277110

277123

277142

277137

279100

284150

277150

277153

277125

277142

277131

279100

284150

277286

277151

277284

277283

277282

279100

284150

277117

277152

277293

277139

277292

279100

284150

277274

277266

277289

277143

277291

279100

284150

277263

277266

277276

277258

277270

279100

284150

284155

284156

284157

284122

284159

279100

Stainless Steel - Air or Nitrogen Plasma

Copper Electrode

Nozzle

30A

50A

70A

100A

150A

200A

275A

400A

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

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

5-8

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

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Silver

Electrode

Torch

Head

284150

277286

277151

279484

279483

279060

284150

277117

277152

279493

279439

279420

(green o-ring)

279060

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

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

284150

284155

284156

284158

284122

284159

279100

Aluminum

Copper Electrode

30A

50A

70A

100A

Nozzle

150A

200A

275A

400A

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

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

5-10

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

Outer

Retaining Cap

Shield

Cap

Inner

Retaining Cap

Swirl

Ring

Silver

Electrode

Torch

Head

284150

277286

277151

279484

279483

279060

284150

277117

277152

279493

279439

279420

(green o-ring)

279060

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

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

Copper

Electrode

Silver

Electrode

Mild Steel

30 Amps

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 5-43

Mild Steel

150 Amps

Oxygen

Air

Page 5-17

Page 5-44

Mild Steel

200 Amps

Oxygen

Air

Page 5-18

Page 5-45

Mild Steel

275 Amps

Oxygen

Air

Page 5-19

Page 5-46

Mild Steel

400 Amps

Oxygen

Air

Page 5-20

Page 5-47

Stainless Steel

30 Amps

Air

Page 5-21

Stainless Steel

50 Amps

Air

Nitrogen

Page 5-22

Stainless Steel

70 Amps

H17

Nitrogen

Page 5-23

Stainless Steel

70 Amps

Air

Nitrogen

Page 5-24

Stainless Steel

100 Amps

H17

Nitrogen

Page 5-25

Stainless Steel

100 Amps

Air

Nitrogen

Page 5-26

Page 5-48

Stainless Steel

150 Amps

H17

Nitrogen

Page 5-27

Stainless Steel

150 Amps

Air

Nitrogen

Page 5-28

Page 5-49

Stainless Steel

200 Amps

H17

Nitrogen

Page 5-29

Stainless Steel

200 Amps

Air

Nitrogen

Page 5-30

Page 5-50

Stainless Steel

260 Amps

H17

Nitrogen

Page 5-31

Stainless Steel

275 Amps

Air

Nitrogen

Page 5-32

Stainless Steel

400 Amps

H17

Nitrogen

Page 5-33

Stainless Steel

400 Amps

Nitrogen

Air

Page 5-34

Aluminum

30 Amps

Air

Nitrogen

Page 5-35

Aluminum

50 Amps

Air

Nitrogen

Page 5-36

Aluminum

70 Amps

Air

Nitrogen

Page 5-37

Aluminum

100 Amps

Air

Nitrogen

Page 5-38

Page 5-51

Aluminum

150 Amps

Air

Nitrogen

Page 5-39

Page 5-52

Aluminum

200 Amps

Air

Nitrogen

Page 5-40

Page 5-53

Aluminum

275 Amps

Air

Nitrogen

Page 5-41

Page 5-54

Aluminum

400 Amps

Nitrogen

Air

Page 5-42

Cutting Charts

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

Cutting Chart Index

Material Current Plasma Gas Shield Gas

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

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

5-12

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

277145

277120

277130

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277140 279100

Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

20 .036

18 .048 121 97 .090

16 .060 125 78

14 .075 126 65

12 .105 127 55

11 .120 129 50

10 .135 131 40

Preflow Plasma Shield Postflow

35 77 6 75

Arc

Voltage

120 105 .080

Travel Speed

Cutting

Height

.105 200

.120 .125 300

Pierce Height

.110

Pierce

Time

100 .062

Metric*

Material

Thickness

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

1

1.5 124 2020 2.6

2

2.5 1455

3 128 1285 2.9 3.1 300

Preflow Plasma Shield Postflow

35 77 6 75

Arc

Voltage

120 2615 2.0

126

Travel Speed

1615

Cutting

Height

2.7

Pierce Height

2.8

Pierce

Time

100 1.6

200

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel

Speed

Marking

Height

Initial

Height

Kerf

Width

.065

.070

Kerf

Width

1.7

1.8

Pierce

Time

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

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

5-13

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

277115

277122

277131

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277140 / 277142

279100

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

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

Preflow Plasma Shield Postflow

Cold-Rolled Steel – Oxygen Shield – Swirl Ring 277140

12 .105

11 .120 126 60 .125

10 .135 128 50 .135

25 74 12 72

Hot-Rolled Steel – Air Shield – Swirl Ring 277142

14 .075

12 .105 190

.125 180

10 .135 110 170 .110

3/16 113 105

1/4 117 75 .225 400 .087

25 74 19 72

Arc

Voltage

123 70 .120

106

Travel Speed

200

Cutting

Height

.100

.140

Pierce Height

.135

.200 300 .085

Pierce

Time

100 .075

200 .078

100 .075

200 .080

Metric*

Material

Thickness

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

Preflow Plasma Shield Postflow

Arc

Voltage

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Kerf

Width

Kerf

Width

Cold-Rolled Steel – Oxygen Shield – Swirl Ring 277140

2.5

3 125 1555 3.1 200 2.0

25 74 12 72

121 1895 2.9

3.4

100 1.9

Hot-Rolled Steel – Air Shield – Swirl Ring 277142

2.5

3 4660 200 2.0

5 113 2555

6 116 2075 5.5

25 74 19 72

106

4885

2.5 3.4

3.6

5.1

100 1.9

400 2.2

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Pierce

Time

5-14

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

277150

277125

277131

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277142 279100

Mild Steel - 70 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/8

3/16

1/4 116 120 .110 .225 300

3/8 122 75 .140 .250 400

Preflow Plasma Shield Postflow

35

25 76

40

Metric*

Material

Thickness

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

3

5

6 115 3105 2.7 5.5 2.2

Preflow Plasma Shield Postflow

35

25 76

40

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

74

Height

.100

Height

2.5

Pierce Height

.150 100

Pierce Height

Marking

Height

Arc

Voltage

110 190

113 130 .200 200

Arc

Voltage

109 4995

113 3265 5.1

Arc

Voltage

Travel Speed

Cutting

Pierce

Time

Pierce

Time

3.6 100

300

Initial

Height

Kerf

Width

.080

.085

Kerf

Width

2.0

Pierce

Time

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

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

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

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

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

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

5-15

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

277286

277284

277282

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

277283 279100

Mild Steel - 100 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/4

3/8

1/2 65 .155 .300 500

5/8 143 47

3/4 145 35 .350 1000

Preflow Plasma Shield Postflow

25 83 26 81

Metric*

Material

Thickness

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

6

10

12 1850 3.7 7.3

16 143 1180

20 145 800 9.0

Preflow Plasma Shield Postflow

25 83 26 81

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

.185

4.7

Pierce Height

.325 800

Pierce Height

Marking

Height

Arc

Voltage

125 150 .090 .200 300

130

Arc

Voltage

124 3950 2.1 4.9 300

130

Arc

Voltage

Travel Speed

100 .130 .250 400

Travel Speed

2405 3.3 6.5

Cutting

Height

Cutting

Height

Travel Speed

8.3

Pierce

Time

Pierce

Time

500

1000 2.4

Initial

Height

Kerf

Width

.090

.095

Kerf

Width

2.3

Pierce

Time

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

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

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

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

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

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

5-16

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

277117

277293

277292

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

277151 / 277152

277139 279100

Mild Steel - 150 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/4

3/8 123 125 .135 .250 400

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

5/8

3/4 130 55 .350 1000 .135

1 134 40 .150 .400

1.25 *** 145 25 .200 .350

1.50 *** 155 15 .225 .350

Preflow Plasma Shield Postflow

Retaining Cap 277151

20 71 30 69

Retaining Cap 277152

20 71 45 69

Metric*

Material

Thickness

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

6

10 123 3040 3.4 6.5

12 124 2485 3.5 7.3 3.3

16

20 130 1340 9.0

25 133 1040 3.7 10.1

32 *** 145 625 5.1 8.9

38 *** 154 385 5.6 8.9

Preflow Plasma Shield Postflow

Retaining Cap 277151

20 71 30 69

Retaining Cap 277152

20 71 45 69

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

.140

3.6

Pierce Height

.325 600 .130

Pierce Height

8.3 1000 3.3

Marking

Height

Arc

Voltage

118 165 .105 .200 300

127 70

Arc

Voltage

117 4305 2.6 4.9 300

127 1760

Arc

Voltage

Travel Speed

Cutting

Height

Cutting

Height

Pierce

Time

1500 .140

Pierce

Time

500

1500

Initial

Height

Kerf

Width

.125

Kerf

Width

3.2

3.4

3.6

Pierce

Time

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

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

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

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

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

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

5-17

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

277274

277289

277291

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

277266

277143 279100

Mild Steel - 200 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/4

3/8 130 140 .090 .250 400

1/2 133 120 .115 .300 500

5/8 137 100 .130 .350 600 .152

3/4 140 75 .150 .400 800 .153

1 147 50 .175 .450 1000

1.25 155 25 .240 .500

1.50 *** 165 17 .300

1.75 *** 175 12 .350

2.00 *** 185 7 .500 .500 .160

Preflow Plasma Shield Postflow

20 74 58 72

Arc

Voltage

125 230 .040 .200 300

Travel Speed

Cutting

Height

Pierce Height

.350 158

Pierce

Time

1500

Metric*

Material

Thickness

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

6

10 130 3480 2.3 6.5

12 132 3160 2.7 7.3

16 137 2515 3.3 8.9 800

20 141 1810 3.8 10.3

25 146 1310 4.3 11.3

32 155 610 6.1 12.7

38 *** 164 435 7.5 8.9

45 *** 175 295 9.2 9.2

50 *** 183 195 12.2 12.2 4.1

Preflow Plasma Shield Postflow

20 74 58 72

Arc

Voltage

124 6100 .8 4.9 300

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

500

1000

1500

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

Nitrogen Nitrogen N/A 25 25 N/A 120 250 6350 .100 2.5 .100 2.5 0

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

* Use an arc transfer height (ignition height) of .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

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

277263

277269

277270

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

277266

277258 279100

Mild Steel - 275 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/2

5/8 105 .135 .325 600

3/4 138 90 .120 .350 800 .170

1 144 65 .160 .400 1000

1.25 150 45 .175 .500

1.50 *** 163 25 .235

1.75 *** 170 20 .290

2.00 *** 180 15 .350

2.25 *** 185 13 .375 .375 .260

2.50 *** 190 9 .385 .385 .275

Preflow Plasma Shield Postflow

20 81 70 79

Arc

Voltage

139

Travel Speed

125 .140 .300 500

Cutting

Height

Pierce Height

.350 .190

Pierce

Time

1500

Metric*

Material

Thickness

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

12

16

20 2190 3.1 9.0

25 143 1690 4.0 10.1

32 150 1120 4.4 12.8

38 *** 162 645 5.9

45 *** 170 495 7.5

50 *** 178 395 8.7

55 *** 183 345 9.2 9.2 6.6

60 *** 187 285 9.6 9.6 6.9

Preflow Plasma Shield Postflow

20 81 70 79

Arc

Voltage

139 3290 3.6 7.4 500

138

Travel Speed

2650 3.3 8.3 800

Cutting

Height

Pierce Height

8.9 4.8

Pierce

Time

1000

1500

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

Nitrogen Nitrogen N/A 25 25 N/A 108 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 54 100 2540 .120 3.0 .100 2.5 0

* 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

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

284123

284125

284124

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

284121

284122 279100

Material

Thickness

Arc

Voltage

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Kerf

Width

5/8

135

.350

600

.155

1

150

85

.160

.500

1000

.180

1.75

162

40

.260

.800

3000

.200

2.25 ***

170

20

.280

.350

1000

.235

3.00 ***

195 8 .350

.350

2000

.250

Thickness

Voltage

Speed

Height

Time

Width

16

3405

3.3

8.9

800

3.9

25

149

2200

4.0

12.5

4.6

32

155

1500

4.4

15.3

1500

45

162

995

6.6

20.5

3000

5.1

55 ***

168

620

6.9

11.9

1000

6.0

60 ***

175

450

7.2

1300

70 ***

185

300

8.3

Mild Steel - 400 Amps - Oxygen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

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

1/2

3/4 110 .400 800 .160

1.25 155 60 .175 .600 1500

1.5 160 50 .225 .700 2000

2.00 165 33 .270 1.00 4500 .210

2.50 *** 182 15 .300 .350 1300 .245

2.75 *** 185 12 .325 .350 1500 .245

Metric*

Material

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

12

20 2700 3.4 10.5

Preflow Plasma Shield Postflow

30 79 70 76

Preflow Plasma Shield Postflow

.130

Pierce

1000

140 160 .140 .300 500 .150

145

Arc

138 4205 3.6 7.3 500 3.8

145

Travel

Cutting

.190

Kerf

4.1

38 159 1275 5.6 17.7 2000

30 79 70 76

50 164 860 6.8 25.4 4500 5.3

65 *** 182 365 7.7 1500

75 *** 193 220 8.7

8.9 2000 6.4

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

Nitrogen Nitrogen N/A 25 25 N/A 112 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 53 100 2540 .120 3.0 .100 2.5 0

* 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)

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

4.8

6.2

Pierce

Time

5-20

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

277144

277121

277137

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277110

277138 279100

Stainless Steel - 30 Amps - Air Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

20 .036

18 .048 165

16 .060 74 125

14 .075 75 90 .025 .070

Preflow Plasma Shield Postflow

35 81 30 85

Arc

Voltage

71

Travel Speed

200 .020

Cutting

Height

.035

Pierce Height

.050

Pierce

Time

100 .065

200

Metric*

Material

Thickness

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

1

1.5 73 3260 0.9 200

Preflow Plasma Shield Postflow

35 81 30 85

Arc

Voltage

71 4855 0.6

Travel Speed

Cutting

Height

Pierce Height

1.3

Pierce

Time

100

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

.068

Kerf

Width

1.7

Pierce

Time

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

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

5-21

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

277149

277123

277137

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277110

277142 279100

Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

14 .075

12 .105 88 75

11 .120 89 65

10 .135 90 55

3/16 94 50 .040 .080 300

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

Preflow Plasma Shield Postflow

25 66 40 67

Arc

Voltage

87 105

Travel Speed

Cutting

Height

.035 .070

Pierce Height

Pierce

Time

100

200

Metric*

Material

Thickness

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

2

2.5 2080

3 88 1685 200

5 94 1235 1.0 2.1

6 98 1075 1.3 2.9 2.9

Preflow Plasma Shield Postflow

25 66 40 67

Arc

Voltage

87

Travel Speed

2565

Cutting

Height

.9 1.8

Pierce Height

Pierce

Time

100

400

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

.105

.110

Kerf

Width

2.7

2.8

Pierce

Time

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

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

5-22

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

277150

277124

277132

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277113

277140 279100

Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

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

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

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

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

Preflow Plasma Shield Postflow

Arc

Voltage

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Metric*

Material

Thickness

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

5 35 65 30 60 135 2030 2.5 5.1 300 2.3

Preflow Plasma Shield Postflow

Arc

Voltage

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

Kerf

Width

Pierce

Time

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

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

5-23

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

Shield Cap

Nozzle

Electrode

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277142 279100

Stainless Steel - 70 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

277150 277125 277131

Imperial*

Material

Thickness

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

10 .135

3/16 134 100 .070 .200 300

1/4 140 75 .090 .225 400

3/8 148 50 .120 .250 500

Preflow Plasma Shield Postflow

25 76 25 76

Arc

Voltage

132 120 .060 .150 200

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Metric*

Material

Thickness

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

3

5 134 2445 1.8 5.1

6 138 2050 2.1 5.5 2.3

Preflow Plasma Shield Postflow

25 76 25 76

Arc

Voltage

131 3210 1.4 3.3 200

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

400

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

.085

.090

Kerf

Width

2.2

Pierce

Time

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

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

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

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

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

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

5-24

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

277146

277126

277133

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277113

277141 279100

Stainless Steel - 100 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

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

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

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

3/16

1/4 140 100 .125 .225 400

3/8 152 65 .180 .250 500

Preflow Plasma Shield Postflow

28 72 40 67

Arc

Voltage

138 115 .105 .200 300 .100

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Metric*

Material

Thickness

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

5

6 139 2625 3.0 5.5 2.7

Preflow Plasma Shield Postflow

28 72 40 67

Arc

Voltage

138 2865 2.7 5.1

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

400

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

.105

Kerf

Width

2.5

Pierce

Time

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

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

5-25

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

Shield Cap

Nozzle

Electrode

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

277283 279100

Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

277286 277284 277282

Imperial*

Material

Thickness

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

1/4

3/8 147 80 .170 .250 500

1/2 154 55 .210 .300 600

Preflow Plasma Shield Postflow

25 80 35 80

Metric*

Material

Thickness

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

6

10 148 1935 4.4 6.5

12 152 1540 5.0 7.3

Preflow Plasma Shield Postflow

25 80 35 80

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Height

Pierce Height

Marking

Height

Pierce

Time

Pierce

Time

600 2.4

Initial

Height

Arc

Voltage

141 100 .135 .225 400 .092

Arc

Voltage

140 2595 3.2 5.6 400 2.3

Arc

Voltage

Travel Speed

Cutting

Kerf

Width

.095

Kerf

Width

Pierce

Time

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

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

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

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

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

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

5-26

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

277298

277297

277135

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277266

277139 279100

Stainless Steel - 150 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

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

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

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/4

3/8 75 .150 .275 500

1/2 60 .165 .300 600

5/8 50 .185 .325 800

3/4 40 .250 .350 1200 .145

Preflow Plasma Shield Postflow

25 77 75 81 165

Metric*

Material

Thickness

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

10

12 1610 4.1 7.4

16 1260 4.7 8.3 800

20 167 940 6.9 9.0 1200 3.7

Preflow Plasma Shield Postflow

25 77 75 81

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

Arc

Voltage

155

Arc

Voltage

Height

Pierce

Height

Pierce Height

Marking

Height

Travel

Speed

95 .250 .250 400

Travel Speed

1845 3.8 7.0

Cutting

Height

Travel Speed

Pierce

Time

Pierce

Time

600

Initial

Height

Kerf

Width

.135

.140

Kerf

Width

3.4

3.6

Pierce

Time

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

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

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

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

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

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

5-27

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

Shield Cap

Nozzle

Electrode

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277152

277139 279100

Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

277117 277293 277292

Imperial*

Material

Thickness

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

1/4

3/8 150 115 .180 .275 500

1/2 155 85 .210 .300 600

5/8 160 60 .220 .325 800

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

Preflow Plasma Shield Postflow

20 71 70 69

Metric*

Material

Thickness

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

6

10 150 2805 4.7 7.0

12 153 2330 5.1 7.4

16 160 1510 5.6 8.3 800

20 170 1030 6.2 9.0 1200 3.4

Preflow Plasma Shield Postflow

20 71 70 69

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Height

Pierce Height

Pierce

Height

Marking

Height

Arc

Voltage

145 150 .160 .250 400

Arc

Voltage

144 3910 4.0 6.3 400

Arc

Voltage

Travel Speed

Travel

Speed

Travel Speed

Cutting

Height

Cutting

Pierce

Time

Pierce

Time

600

Initial

Height

Kerf

Width

.125

.130

Kerf

Width

3.2

3.3

Pierce

Time

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

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

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

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

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

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

5-28

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

277274

277287

277135

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277266

277259 279100

Stainless Steel - 200 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

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

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

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

3/8

1/2 148 75 .130 .300 600

5/8 155 60 .190 .350 800

3/4 160 50 .200 .400 1200

1.0 170 35 .240 .450 1500 .160

Preflow Plasma Shield Postflow

37 72 79 68

Metric*

Material

Thickness

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

10

12 149 1935 3.6 7.3

16 155 1515 4.8 8.9 800

20 161 1215 5.2 10.3

25 169 915 6.0 11.3 4.1

Preflow Plasma Shield Postflow

37 72 79 68

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

156 80 .195 .250 500

Arc

Voltage

154 2010 4.7 6.5

Arc

Voltage

Travel Speed

Cutting

Height

Cutting

Height

Pierce Height

Marking

Height

Pierce

Time

Pierce

Time

600 3.8

1500

Initial

Height

Width

Kerf

.150

.155

Kerf

3.9

Pierce

Time

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

Nitrogen Nitrogen N/A 25 25 N/A 120 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 72 100 2540 .120 3.0 .100 2.5 0

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

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

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

5-29

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

Shield Cap

Nozzle

Electrode

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277266

277143 279100

Stainless Steel - 200 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

277274 277289 277291

Imperial*

Material

Thickness

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

1/4

3/8 133 150 .250 500

1/2 140 110 .115 .300 600 .152

5/8 146 75 .150 .350 800

3/4 153 60 .190 .400 1200

1.0 158 40 .210 .450

1.25 *** 170 20 .250 .350 .165

1.50 *** 180 10 .275 .350 .175

Preflow Plasma Shield Postflow

20 74 58 72

Metric*

Material

Thickness

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

6

10 134 3655 1.9 6.5

12 138 3020 2.6 7.3

16 146 1890 3.8 8.9 800

20 153 1450 4.8 10.3

25 157 1050 5.2 11.3 4.1

32 *** 170 495 6.4 8.9 4.2

38 *** 179 260 6.9 8.9 4.4

Preflow Plasma Shield Postflow

20 74 58 72

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

.070

Height

Pierce Height

.200 400

Pierce

Height

Marking

Height

Arc

Voltage

130 200

Arc

Voltage

129 5220 1.8 4.9 400

Arc

Voltage

Travel Speed

Travel

Speed

Travel Speed

Cutting

Height

Cutting

Pierce

Time

1500

Pierce

Time

600

1500

Initial

Height

Kerf

Width

.150

.155

.160

Kerf

Width

3.8

3.9

Pierce

Time

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

Nitrogen Nitrogen N/A 25 25 N/A 120 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 70 100 2540 .100 2.5 .100 2.5 0

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

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

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

5-30

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

277211

277118

277135

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277280

277139 279100

Stainless Steel - 260 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

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

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

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

3/8

1/2 142 80 .140 .300 600

5/8 145 65 .185 .350 800

3/4 150 55 .225 .400 1200

1.0 160 33 .250 .450

1.25 *** 170 26 .280 .350 .205

Preflow Plasma Shield Postflow

40 63 64 63

Metric*

Material

Thickness

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

10

12 142 2060 3.7 7.3

16 145 1640 4.7 8.9 800

20 151 1315 5.8 10.3

25 159 875 6.3 11.3 5.1

32 *** 170 650 7.1 8.7 5.2

Preflow Plasma Shield Postflow

40 63 64 63

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

145 85 .160 .250 500

Arc

Voltage

144 2140 4.0 6.5

Arc

Voltage

Travel Speed

Cutting

Height

Cutting

Height

Pierce Height

Marking

Height

Pierce

Time

1500

Pierce

Time

600 4.8

1500

Initial

Height

Width

Kerf

Width

.190

.195

.200

Kerf

5.0

Pierce

Time

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

Nitrogen Nitrogen N/A 25 25 N/A 108 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 75 100 2540 .160 4.1 .100 2.5 0

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

5-31

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

Shield Cap

Nozzle

Electrode

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277266

277258 279100

Stainless Steel - 275 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

277263 277276 277270

Imperial*

Material

Thickness

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

1/2

5/8 148 90 .140 .350 800

3/4 152 80 .180 .400 1200

1.0 165 55 .210 .450

1.25 *** 175 35 .250 .350

1.50 *** 185 25 .300 .350

Preflow Plasma Shield Postflow

20 73 70 75

Metric*

Material

Thickness

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

12

16 148 2275 3.6 8.9 800

20 153 1940 4.7 10.3

25 164 1435 5.2 11.3

32 *** 175 880 6.4 8.9

38 *** 184 640 7.5 8.9

Preflow Plasma Shield Postflow

20 73 70 75

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

143 120 .125 .300 600

Arc

Voltage

141 3220 3.1 7.3 600

Arc

Voltage

Travel Speed

Cutting

Height

Cutting

Height

Pierce Height

Marking

Height

Pierce

Time

1500

Pierce

Time

1500

Initial

Height

Kerf

Width

.165

.170

.180

Kerf

Width

4.2

4.3

4.6

Pierce

Time

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

Nitrogen Nitrogen N/A 25 25 N/A 108 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 55 100 2540 .130 3.3 .100 2.5 0

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

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

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

5-32

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

284155

284158

284159

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

284156

284122 279100

Stainless Steel - 400 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode

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

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

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/2

5/8 90 .180 .350 800 .175

3/4 75 .170 .400 1200

1 170 50 .185 .500 1500

1.25 175 40 .210 .700 2000

1.5 185 30 .270 .800 2500 .225

1.75 *** 193 23 .300

2.00 *** 200 18 .350 .250

Preflow Plasma Shield Postflow

30 80 82 96

Metric*

Material

Thickness

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

12

16 2270 4.5 8.9 800 4.4

20 1810 4.3 10.5

25 169 1310 4.6 12.5

32 175 1005 5.3 18.0 2000

38 184 765 6.8 20.2 2500 5.7

45 *** 193 570 7.6 7.8

50 *** 199 470 8.7 8.9 6.4

Preflow Plasma Shield Postflow

30 80 82 96

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

165

Arc

Voltage

165

Arc

Voltage

Travel Speed

105 .190 .300 600 .165

Travel Speed

2750 4.8 7.3 600 4.2

Cutting

Height

Cutting

Height

Travel Speed

Pierce Height

.350 1500

Pierce Height

Marking

Height

Pierce

Time

Pierce

Time

1500

Initial

Height

Kerf

Width

.200

.235

Kerf

Width

5.1

6.0

Pierce

Time

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

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

Argon** Nitrogen** N/A 50 25 N/A 68 100 2540 .160 4.1 .100 2.5 0

* 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)

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

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

5-33

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

Shield Cap

Nozzle

Electrode

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

284156

284122 279100

Stainless Steel - 400 Amps - Nitrogen Plasma / Air Shield

Copper Electrode

This gas combination gives medium cut quality and minimum dross levels

284155 284157 284159

Imperial*

Material

Thickness

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

1/2

5/8 170 110 .170 .350 800

3/4 165 90 .150 .400 1200

1 170 65 .150 .500 1500

1.25 175 45 .160 .700 2000

1.5 180 35 .170 .800 2500

1.75 *** 190 25 .190 .350

2.00 *** 205 15 .210 .350

Preflow Plasma Shield Postflow

30 85 63 96

Metric*

Material

Thickness

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

12

16 169 2775 4.2 8.9 800

20 165 2190

25 169 1690 12.5

32 175 1120 4.1 18.0 2000

38 179 895 4.2 20.2 2500

45 *** 190 610 4.8 7.8

50 *** 203 410 5.2 8.9

Preflow Plasma Shield Postflow

30 85 63 96

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

3.8

Pierce Height

10.5

Marking

Height

Arc

Voltage

175 130 .210 .300 600

Arc

Voltage

176 3415 5.5 7.3 600

Arc

Voltage

Travel Speed

Travel

Speed

Cutting

Height

Cutting

Height

Pierce

Time

1500

Pierce

Time

1500

Initial

Height

Kerf

Width

.165

.200

.205

Kerf

Width

4.2

5.1

5.2

Pierce

Time

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

Nitrogen Nitrogen N/A 25 25 N/A 107 250 6350 .100 2.5 .100 2.5 0

Argon** Nitrogen** N/A 50 25 N/A 71 100 2540 .160 4.1 .100 2.5 0

* 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)

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

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

5-34

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

277145

277120

277130

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277140 279100

Aluminum - 30 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

.040

.050 120

.063 90 .150 200 .070

Preflow Plasma Shield Postflow

35 81 20 85 135

Arc

Voltage

Travel Speed

150

Cutting

Height

.030

Pierce Height

.100 100 .065

Pierce

Time

Metric*

Material

Thickness

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

1

1.5 2520 3.4 200 1.8

Preflow Plasma Shield Postflow

35 81 20 85 135

Arc

Voltage

Travel Speed

3885

Cutting

Height

0.8

Pierce Height

2.5 100 1.7

Pierce

Time

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

Kerf

Width

Pierce

Time

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

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

5-35

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

277150

277122

277131

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277142 279100

Aluminum - 50 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

.050

.063 138 140 .065 150 .082

.080 143 90 .075 .150 200 .085

Preflow Plasma Shield Postflow

25 66 19 67

Arc

Voltage

135 180 .050

Travel Speed

Cutting

Height

Pierce Height

.100

Pierce

Time

100 .080

Metric*

Material

Thickness

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

1.5

2.0 142 2360 1.8 3.7 200 2.2

Preflow Plasma Shield Postflow

25 66 19 67

Arc

Voltage

137 3870 1.5 2.5 150 2.1

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

Kerf

Width

Pierce

Time

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

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

5-36

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

277150

277125

277131

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277153

277142 279100

Aluminum - 70 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

.080

1/8 135 160 .070 .175

3/16 145 80 .100 .200 200

1/4 150 50 .060 .250 300

3/8 155 40 .075 .275 400

1/2 162 30 .115 .300 500

Preflow Plasma Shield Postflow

25 76 25 76

Arc

Voltage

130 250 .050 .150

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

100 .080

Metric*

Material

Thickness

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

2

3 134 4420 1.7 4.3

5 145 1920 2.3 5.2

6 148 1440 1.7 6.1

10 156 975 2.0 7.0

12 160 820 2.6 7.4

Preflow Plasma Shield Postflow

25 76 25 76

Arc

Voltage

129 6400 1.2 3.7

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

100 2.0

300 2.2

500 2.3

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

.085

.090

Kerf

Width

Pierce

Time

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

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

5-37

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

277286

277284

277282

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

277283 279100

Aluminum - 100 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/4

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

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

Preflow Plasma Shield Postflow

25 80 26 80

Arc

Voltage

158 105 .155 .250 300 .095

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Metric*

Material

Thickness

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

6

10 162 2210 4.6 7.0

12 165 1890 4.9 7.4

Preflow Plasma Shield Postflow

25 80 26 80

Arc

Voltage

158 2710 3.8 6.3 300 2.4

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

500 2.5

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

Kerf

Width

Pierce

Time

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

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

5-38

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

277117

277293

277292

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277152

277139 279100

Aluminum - 150 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/4

3/8 155 115 .185 .275 500

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

5/8

3/4 45 .350 1200 .140

Preflow Plasma Shield Postflow

20 71 50 69

Arc

Voltage

145 145 .130 .250 400

170

Travel Speed

65

Cutting

Height

.250

Pierce Height

.325 800 .135

Pierce

Time

Metric*

Material

Thickness

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

6

10 156 2825 4.8 7.0

12 162 2430 5.5 7.4 3.3

16 170 1630

20 170 990 9.0 3.6

Preflow Plasma Shield Postflow

20 71 50 69

Arc

Voltage

143 3770 3.1 6.3 400

Travel Speed

Cutting

Height

6.4

Pierce Height

8.3

Pierce

Time

600

1200

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

.125

Kerf

Width

3.2

3.4

Pierce

Time

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

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

5-39

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

277274

277289

277291

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277266

277143 279100

Aluminum - 200 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/4

3/8

1/2 110

5/8

3/4 65 .150

1.0 *** 175 35 .200 1000 .170

Preflow Plasma Shield Postflow

20 74 58 72

Arc

Voltage

150 190 .135 .250 300

155

160

Travel Speed

145 .140 .275 400

95 .350 600

Cutting

Height

.135

Pierce Height

.300 500

.400

Pierce

Time

800 .160

Metric*

Material

Thickness

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

6

10

12 2995

16 160 2380 8.9 800

20 162 1575 3.9

25 *** 174 940 5.0 4.3

Preflow Plasma Shield Postflow

20 74 58 72

Arc

Voltage

149 4955 3.3 6.3 300

155

Travel Speed

3545 3.5 7.0

Cutting

Height

3.4

Pierce Height

7.4

10.2 1000

Pierce

Time

500

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

Nitrogen Nitrogen N/A 25 25 N/A 120 250 6350 .100 2.5 .100 2.5 0

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

* Use an arc transfer height (ignition height) of .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)

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

.150

.155

Kerf

Width

3.8

3.9

4.1

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.

5-40

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

277263

277276

277270

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

277266

277258 279100

Aluminum - 275 Amps - Air Plasma / Nitrogen Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

3/8

1/2 165 125 .180 .300 500

5/8 168 105 .190 .350 600

3/4 172 85 .200

1.00 *** 180 60 .240

1.25 *** 185 45 .260

1.50 *** 190 25 .270 .180

Preflow Plasma Shield Postflow

20 73 65 75

Arc

Voltage

160 160 .160 .275 400

Travel Speed

Cutting

Height

Pierce Height

.400

Pierce

Time

800

1000

Metric*

Material

Thickness

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

10

12 163 3375 4.4 7.4

16 168 2645 4.8 8.9

20 173 2055 5.3

25 *** 179 1565 6.0

32 *** 185 1120 6.6

38 *** 189 645 6.8 4.6

Preflow Plasma Shield Postflow

20 73 65 75

Arc

Voltage

160 3930 4.1 7.1

Travel Speed

Cutting

Height

Pierce Height

10.2

Pierce

Time

500 4.1

800 4.2

1000

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

Nitrogen Nitrogen N/A 25 25 N/A 108 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 56 100 2540 .120 3.0 .100 2.5 0

* Use an arc transfer height (ignition height) of .275” (7.0 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

.160

.165

.170

Kerf

Width

4.3

Pierce

Time

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

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

5-41

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

284155

284157

284159

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

284156

284122 279100

Aluminum - 400 Amps - Nitrogen Plasma / Air Shield

Copper Electrode

Shield Cap Nozzle Electrode

Imperial*

Material

Thickness

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

1/2

5/8 180 125 .190 .400 700 .205

3/4 185 100 .205 .500 800

1 190 75 .215 .600 1200

1.25 200 55 .220 .700 1500 .225

1.5 205 35 .225 .800 2000 .240

Preflow Plasma Shield Postflow

30 85 63 96

Arc

Voltage

175 150 .170 .300 600 .200

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Metric*

Material

Thickness

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

12

16 180 3150 4.8 10.3 800 5.2

20 185 2445 5.2 13.0

25 189 1945 5.4 15.0

32 200 1375 5.6 17.9 1500 5.7

38 204 895 5.6 20.2 2000 6.1

Preflow Plasma Shield Postflow

30 85 63 96

Arc

Voltage

173 3950 4.1 7.0 600 5.1

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

1200 5.3

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

Nitrogen Nitrogen N/A 25 25 N/A 106 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 75 100 2540 .140 3.6 .100 2.5 0

* 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. (Revised 04/26/2013)

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

.210

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.

5-42

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

277286

279484

279410

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

279483 279060

Mild Steel - 100 Amps - Oxygen Plasma / Air Shield

Silver Electrode

Shield Cap Nozzle Electrode

(brown o-ring)

Imperial*

Material

Thickness

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

1/4

3/8

1/2 65 .155 .300 500

5/8 143 47

3/4 145 35 .350 1000

Preflow Plasma Shield Postflow

25 83 26 81

Metric*

Material

Thickness

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

6

10

12 1850 3.7 7.3

16 143 1180

20 145 800 9.0

Preflow Plasma Shield Postflow

25 83 26 81

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Cutting

Height

.185

Cutting

Height

4.7

Pierce Height

.325 800

Pierce Height

Marking

Height

Arc

Voltage

125 150 .090 .200 300

130

Arc

Voltage

124 3950 2.1 4.9 300

130

Arc

Voltage

Travel Speed

100 .130 .250 400

Travel Speed

2405 3.3 6.5

Travel Speed

8.3

Pierce

Time

Pierce

Time

500

1000 2.4

Initial

Height

Kerf

Width

.090

.095

Kerf

Width

2.3

Pierce

Time

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

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

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

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

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

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

5-43

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

277117

279493

279420

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

284150

277151 / 277152

279439 279060

Mild Steel - 150 Amps - Oxygen Plasma / Air Shield

Silver Electrode

Shield Cap Nozzle Electrode

(green o-ring)

Imperial*

Material

Thickness

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

1/4

3/8 123 125 .135 .250 400

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

5/8

3/4 130 55 .350 1000 .135

1 134 40 .150 .400

1.25 *** 145 25 .200 .350

1.50 *** 155 15 .225 .350

Preflow Plasma Shield Postflow

Retaining Cap 277151

20 71 30 69

Retaining Cap 277152

20 71 45 69

Metric*

Material

Thickness

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

6

10 123 3040 3.4 6.5

12 124 2485 3.5 7.3 3.3

16

20 130 1340 9.0

25 133 1040 3.7 10.1

32 *** 145 625 5.1 8.9

38 *** 154 385 5.6 8.9

Preflow Plasma Shield Postflow

Retaining Cap 277151

20 71 30 69

Retaining Cap 277152

20 71 45 69

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Cutting

Height

.140

Cutting

Height

3.6

Pierce Height

.325 600 .130

Pierce Height

8.3 1000 3.3

Marking

Height

Arc

Voltage

118 165 .105 .200 300

127 70

Arc

Voltage

117 4305 2.6 4.9 300

127 1760

Arc

Voltage

Travel Speed

Pierce

Time

1500 .140

Pierce

Time

500

1500

Initial

Height

Kerf

Width

.125

Kerf

Width

3.2

3.4

3.6

Pierce

Time

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

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

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

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

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

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

5-44

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

277274

279489

279440

(yellow o-ring)

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

Mild Steel - 200 Amps - Oxygen Plasma / Air Shield

Silver Electrode

Shield Cap Nozzle Electrode

284150 277266 279443 279060

Imperial*

Material

Thickness

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

1/4

3/8 130 140 .090 .250 400

1/2 133 120 .115 .300 500

5/8 137 100 .130 .350 600 .152

3/4 140 75 .150 .400 800 .153

1 147 50 .175 .450 1000

1.25 155 25 .240 .500

1.50 *** 165 17 .300

1.75 *** 175 12 .350

2.00 *** 185 7 .500 .500 .160

Preflow Plasma Shield Postflow

20 74 58 72

Arc

Voltage

125 230 .040 .200 300

Travel Speed

Cutting

Height

Pierce Height

.350 158

Metric*

Material

Thickness

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

6

10 130 3480 2.3 6.5

12 132 3160 2.7 7.3

16 137 2515 3.3 8.9 800

20 141 1810 3.8 10.3

25 146 1310 4.3 11.3

32 155 610 6.1 12.7

38 *** 164 435 7.5 8.9

45 *** 175 295 9.2 9.2

50 *** 183 195 12.2 12.2 4.1

Preflow Plasma Shield Postflow

20 74 58 72

Arc

Voltage

124 6100 .8 4.9 300

Travel Speed

Cutting

Height

Pierce Height

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Arc

Voltage

Travel Speed

Marking

Height

Pierce

Time

1500

Pierce

Time

500

1000

1500

Initial

Height

Kerf

Width

.150

.155

Kerf

Width

3.8

3.9

4.0

Pierce

Time

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

Nitrogen Nitrogen N/A 25 25 N/A 120 250 6350 .100 2.5 .100 2.5 0

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

* Use an arc transfer height (ignition height) of .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.

5-45

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

277263

279469

279450

(red o-ring)

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

Mild Steel - 275 Amps - Oxygen Plasma / Air Shield

Silver Electrode

Shield Cap Nozzle Electrode

284150 277266 279458 279060

Imperial*

Material

Thickness

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

1/2

5/8 105 .135 .325 600

3/4 138 90 .120 .350 800 .170

1 144 65 .160 .400 1000

1.25 150 45 .175 .500

1.50 *** 163 25 .235

1.75 *** 170 20 .290

2.00 *** 180 15 .350

2.25 *** 185 13 .375 .375 .260

2.50 *** 190 9 .385 .385 .275

Preflow Plasma Shield Postflow

20 81 70 79

Metric*

Material

Thickness

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

12

16

20 2190 3.1 9.0

25 143 1690 4.0 10.1

32 150 1120 4.4 12.8

38 *** 162 645 5.9

45 *** 170 495 7.5

50 *** 178 395 8.7

55 *** 183 345 9.2 9.2 6.6

60 *** 187 285 9.6 9.6 6.9

Preflow Plasma Shield Postflow

20 81 70 79

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

Cutting

Height

Cutting

Height

Pierce Height

.350 .190

Pierce Height

Marking

Height

Arc

Voltage

139

Arc

Voltage

139 3290 3.6 7.4 500

138

Arc

Voltage

Travel Speed

125 .140 .300 500

Travel Speed

2650 3.3 8.3 800

Travel Speed

Pierce

Time

1500

Pierce

Time

1000

8.9 4.8 1500

Initial

Height

Kerf

Width

.165

.185

Kerf

Width

4.2

4.3

4.7

Pierce

Time

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

Nitrogen Nitrogen N/A 25 25 N/A 108 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 54 100 2540 .120 3.0 .100 2.5 0

* 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)

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.

5-46

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

284123

284125

279460

(black o-ring)

Outer Cap

Retaining Cap

Swirl Ring

Torch Head

Material

Thickness

Arc

Voltage

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Kerf

Width

1/2

140

160

.140

.300

500

.150

3/4

110

.400

800

.160

1.5

160

50

.225

.700

2000

2.00

165

33

.270

1.00

4500

.210

2.75 ***

185

12

.325

.350

1500

.245

Material

Thickness

Arc

Voltage

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Kerf

Width

12

138

4205

3.6

7.3

500

3.8

20

2700

3.4

10.5

4.1

25

149

2200

4.0

12.5

4.6

38

159

1275

5.6

17.7

2000

50

164

860

6.8

25.4

4500

5.3

55 ***

168

620

6.9

11.9

1000

6.0

65 ***

182

365

7.7

1500

75 ***

193

220

8.7

Mild Steel - 400 Amps - Oxygen Plasma / Air Shield

Silver Electrode

Shield Cap Nozzle Electrode

284150 284121 279422 279060

Imperial*

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

5/8

1 150 85 .160 .500 1000 .180

1.25 155 60 .175 .600 1500

1.75 162 40 .260 .800 3000 .200

2.25 *** 170 20 .280 .350 1000 .235

2.50 *** 182 15 .300 .350 1300 .245

3.00 *** 195 8 .350 .350 2000 .250

Metric*

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

Preflow Plasma Shield Postflow

30 79 70 76

Preflow Plasma Shield Postflow

.130

.350 600 .155

.190

145

135

16

32 155 1500 4.4 15.3 1500

45 162 995 6.6 20.5 3000 5.1

60 *** 175 450 7.2

70 *** 185 300 8.3

30 79 70 76

145

3405 3.3 8.9 800 3.9

1000

1300

8.9 2000 6.4

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

Nitrogen Nitrogen N/A 25 25 N/A 112 250 6350 .100 2.5 .100 2.5 0

Argon** Air** N/A 50 25 N/A 53 100 2540 .120 3.0 .100 2.5 0

* 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

4.8

6.2

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.

5-47

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

277286

279484

279410

Outer Cap

Retaining Cap

Swirl Ring Torch Head

284150

277151

279483 279060

Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield

Silver Electrode

Shield Cap Nozzle Electrode

(brown o-ring)

Imperial*

Material

Thickness

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

1/4

3/8 147 80 .170 .250 500

1/2 154 55 .210 .300 600

Preflow Plasma Shield Postflow

25 80 35 80

Arc

Voltage

141 100 .135 .225 400 .092

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

Metric*

Material

Thickness

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

6

10 148 1935 4.4 6.5

12 152 1540 5.0 7.3

Preflow Plasma Shield Postflow

25 80 35 80

Arc

Voltage

140 2595 3.2 5.6 400 2.3

Travel Speed

Cutting

Height

Pierce Height

Pierce

Time

600 2.4

Marking* – For All Material Thicknesses

Type of Gas Preflow Plasma Shield Postflow

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

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

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

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

Arc

Voltage

Travel Speed

Marking

Height

Initial

Height

Kerf

Width

.095

Kerf

Width

Pierce

Time

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

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

5-48

Lincoln Electric 718118 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Revision History

Table of Contents

Limited Warranty

Returned Goods Procedure

Electromagnetic Compatibility (EMC)

Ultraviolet Radiation Protection

Noise Protection

Section 1: Safety

General Precautions

Toxic Fume Prevention

Electric Shock Prevention

Fire Prevention

Explosion Prevention

Health Support Equipment

Safety Standards Booklet Index

Section 2: Specifications

System Description

System Components

Power Supply Specifications

Cooling System Specifications

Torch Coolant Specifications

Manual Gas Console (MGC) Specifications

Gas Supply Requirements

Impulse Start Console (ISC) Specifications

Torch and 2-Gang Manifold Specifications

5-Gang Manifold Specifications

Airborne Noise Emissions

Section 3: Installation

Initial Inspection

Component Placement

System Interconnection

Power Supply Primary Power Connections

Power Supply Output Connections

ISC Control Cable and ISC Ground Connections

Cooling System Connections

Torch Leads to Impulse Start Console Connections

Torch Leads to Torch Base Connections

Torch Gas Connections

Gas Supply Connections

CAN Communication Connections

CNC Machine Interface Connections

Filling the Cooling System

Section 4: Operation

Operating the Manual Gas Console (MGC)

Setting up to Cut

Setting up to Mark (Overrides Cut)

Verifying Input Gas Pressures

Making a Cut or Mark

Piercing Thick Materials

Moving Pierces and Edge Starts

Cut Quality

Checking Errors

Checking the Version and Serial Number

Changing the Language

Adjusting the Screen Contrast

Section 5: Torch Consumables and Cutting Charts

Installing / Removing the Torch Head

Installing / Replacing Consumables

Maximizing Consumable Life

Inspecting for Damage

Selecting Consumables

Cutting Charts