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Automatic Gas Console

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2. Shield Cap Nozzle Electrode 277274 279489 279440 yellow o ring YY A 9 D ps Ly M LYS Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 279443 279160 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 150 190 135 250 300 450 3 8 JEE 145 140 275 400 1 2 110 300 500 20 82 58 75 135 155 5 8 460 95 350 600 3 4 65 150 400 800 160 1 07 175 35 200 i 1000 170 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 149 4955 3 3 6 3 300 8 10 3545 3 5 7 0 i 155 500 12 2995 7 4 20 82 58 75 3 4 3 9 16 160 2380 8 9 800 20 162 1575 3 9 4 1 10 2 1000 25 174 940 5 0 4 3 Marking Material Arc Travel Marking Initial Pierce Thickness cib Plasma Shield Postiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 120 250 6350 100 2 5 100 2 5 0 Use an arc transfe
3. Retaining Cap Swirl Ring 277154 277153 277142 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 080 130 250 050 150 100 080 1 8 135 160 070 175 3 16 145 80 100 200 200 25 80 25 79 085 1 4 150 50 060 250 300 3 8 155 40 075 275 400 090 1 2 162 30 115 300 500 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 2 129 6400 1 2 3 7 100 2 0 3 134 4420 1 7 4 3 5 145 1920 2 3 5 2 25 80 25 79 300 2 2 6 148 1440 1 7 6 1 10 156 975 2 0 7 0 500 2 3 12 160 820 2 6 7 4 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow Plasma Shield Postiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 135 250 6350 096 2 4 100 2 5 0 Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking Revised 10 22 2009 This information is subject to the controls of the Export Administration Regulations EAR
4. Stock Number scission eens a clacioee ee 280022 PL CTOM A sad cued cused ered e enheccdbee tated eae E 3 035 in 77 mm Widi ener nea nee ter Mente net meee tne ee Or anor aee ae 8 35 in 212 mm Depth since ceeccs lt tr cote tenets ee reat Ae os Steak 7 in 178 mm MY GIGI sess ac tacts deere E ETE 6 Ib 2 7 kg 6 180 157 327 8 3 250 6 4 I I i t AL 4 187 4 8 MOUNTING HOLES 1 180 30 A a 3 800 97 IEN OOO S38 7 0 178 D I wi 3 035 77 hI 8 350 212 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 7 Specifications Spirit275a User s Manual Rev K Airborne Noise Emissions The Spirit275a system generates high noise 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 Spirit275a when operating at 275 amps 145 arc volts The measurements were made with a sound level meter levels while cutting Distance From Torch A Weighted Sound Pre
5. ABERE SKASADARARKRSKNAKR ANAREN i 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 8 4 Parts List Spirit275a User s Manual Rev K Power Supply 3 of 4 Fy id 8 91011121514 ejet ojo Op m 1 This information is su
6. 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 8 9 Parts List Spirit275a User s Manual Rev K Remote High Frequency Console Assembly 205500 Item Number Part Number Quantity Description 1 715051 2 Coolant return fitting left hand 2 715050 1 Coolant supply fitting right hand 3 709227 1 Strain relief 5 709001 1 4 pin receptacle 6 707001 1 Line filter 7 706109 1 Transformer 5000V 20 mA 8 702069 1 Capacitor 15 kV 9 708057 1 Door interlock switch 10 500014 1 Spark gap assembly 11 740039 3 Spark gap electrode 12 505043 1 High frequency inductor 13 740072 1 Standoff 14 800041 1 Busbar 15 500505 1 RHF console p c board assembly 16 715021 1 Coolant supply fitting right hand 17 500503 1 Cathode manifold 18 205010 1 CTP sensor lead filter assembly 19 200287 1 Transformer insulating plate 22 500098 1 Ground cable D O8 T5 5 1 8 1 Q jj 2 e o
7. cccecceeeteeeeeeeeees 1315 Ib 596 kg Torch Cooling System Discharge pressure ssesseeeeeeeeeees 150 psi 10 2 bar Flow rate eenaa enaere E raaa eaa 1 gal min 3 8 liters min Coolant fluid assein a besies Propylene glycol deionized water Coolant tank capacity eeees 3 2 gal 12 liters I EE Oa E ae GSpirit275a 48 1 219 r i gt FSKALIBURN 39 991 i 32 5 826 H 43 1 092 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 Specifications Spirit275a User s Manual Rev K Automatic Gas Console Specifications Stock Number 2ivit cic sot hated h ce an aeeeee e 280002 PI IQM co bscxeb onde nicapieneeh a 9 in 229 mm AATA I Aa EE AS ESEE E E eecteet 25 in 635 mm PS Ui ccleaner ce aan 23 8 in 605 mm Weiger rae r pairie ees cess ks 110 Ib 50 kg Gas Supply Requirements Plasma gas types Mild Steel ccitentac tact eiieeii Oxygen or Air Stainless Steel 4 1 0 nceienedtecieea Air or H17 AlUMINU M eas s e aee eein Air Shield gas types Mild Steel lt coesione Oxygen or Air Stainless Steel ceeceeeceeeeeees Air or Nitrogen AUMIA Air or Nitrogen Preflow gas type c ccccccccecccecece
8. 2 1 Specifications Spirit275a User s Manual Rev K System Components The degree of protection provided by the Spirit275a system is IP21S and as such is intended only for indoor use It is not suitable for use in rain or snow The Spirit275a system is tested in accordance with CISPR 11 EMC classification Group 2 ISM Class A The Spirit275a consists of the following components Standard Components Power Supply Automatic Gas Console Remote High Frequency RHF Console RHF Console Control 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 Water and Power Leads Gas Hose Package Work Ground Lead System Manual Consumable Spare Parts Kit see Section 8 for details Optional Components Supply Gas Hoses see Section 8 for details Power Supply Specifications Stock Number 208 VAC ESO OOM Z est hd sect cht ha tonite etait fod arose 280410 230 VAC 30 GORZ 3 ccrccn saree eee bla eelee 280411 380 VAC 3 50 60HZ zp arctescuactessaictevadeacters eset eneeeaigaaaeattete 280414 415 VAC 3 50 60HZ vcd nities nee 280415 AGO VAC 30 GOMZ cated eiie e a Ea ee 280412 575 VAC SCP DOM Zara e i aa a aa 280413 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 loca
9. Operation Spirit275a User s Manual Rev K 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 Current A Time ms 30 490 50 390 70 300 100 300 150 175 200 195 260 175 275 175 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 pie
10. B D 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 8 10 Parts List Spirit275a User s Manual Rev K Torch and Manifold Assemblies Item Number Part Number Quantity 260214 277195 820134 279050 279150 279160 820209 500024 500018 280022 500740 279013 279113 279112 716012 277056 277086 277087 279061 aRWN ee ee ee 6 7 8 9 10 11 12 13 Not shown Not shown Not shown Not shown Not shown ee E E eT gt A E ee Ge ee Ce Description 2 gang manifold assembly includes bracket 2 gang manifold bracket Torch handle Torch Base Torch Head Copper Electrode Torch Head Silver Electrode O ring red O ring blue O ring red 5 gang manifold assembly Torch solenoid plasma hose O ring red indicator only not a seal O ring red O ring red O ring lubricant Nozzle removal tool Electrode removal tool driver Copper Electrode removal tool Silver Electrode removal tool This information is subject to the controls of the Export Administration Regulations EAR This inf
11. in mm msec All Thicknesses N A 28 25 N A 108 250 6350 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 275 7 0 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised10 22 2009 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 50 Operation Spirit275a User s Manual Rev K Mild Steel 200 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Electrode 277273 279489 279440 yellow o ring SY J Z A P Zz J Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 279443 279160 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 230 040 200 300 3 8 130 140 090 250 400 150 1 2 133 120 115 300 500 5 8 137 100 130 350 600 152 3 4 140 75 150 400 800 153 20 82 58 75 1 147 50 175 450 1000 455 1 25 155 25 240 50
12. Faulty microprocessor p c board Relay CR1 defective N OOA Incorrect torch consumables installed Incorrect gas pressure settings Check the control panel status LED s and troubleshoot accordingly 4 Check the spark gap assembly inside the RHF console for proper arcing after a start signal is applied Open the RHF door and pull up on the door interlock switch plunger to defeat the interlock If there is no spark skip to the next test No arc at the torch w N gt 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 7 9 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Problem Possible Cause 5 Check the automatic gas console messages screen and troubleshoot accordingly If the output voltage low error is present perform the chopper test in this section 6 Pilot arc transistor PAT is not operating properly Check the PAT LED s on the microprocessor p c board and PAT drive p c board Damaged or loose torch lead connections Shorted torch or torch leads Check the continuity between the Electrode lead and the Nozzle lead to make sure they are not shorted 9 Open torch or torch leads Check the continuity from the Electrode lead to the torch electrode a
13. Outer Cap Shield Cap 277149 Nozzle 277123 2 Electrode 277137 ae 4 A Torch Head Retaining Cap Swirl Ring 277154 277110 277142 279150 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 14 075 87 105 100 12 105 88 75 105 035 070 11 120 89 65 30 70 40 70 200 10 135 90 55 4410 3 16 94 50 040 080 300 i 1 4 100 40 060 125 400 115 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 2 2565 87 100 2 5 2080 9 1 8 2 7 3 30 70 40 70 88 1685 200 5 94 1235 1 0 2 1 2 8 400 6 98 1075 1 3 2 9 2 9 Marking Material Arc Travel Marking Initial Pierce Thickness Prefiow Plasma Shield Fostilow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 145 250 6350 147 3 7 100 2 5 0 Use an arc transfer height ignition height of 070 1 8 mm for cutting and 100
14. 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 46 Operation Spirit275a User s Manual Rev K Aluminum 100 Amps Air Plasma Nitrogen Shield Copper Electrode Q Outer Cap Shield Cap Nozzle 277284 2 Electrode 277282 LL Torch Head faa 3 7 Retaining Cap Swirl Ring 277154 277151 277283 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 158 105 155 250 300 095 3 8 25 94 26 93 162 90 180 275 400 098 1 2 165 70 195 300 500 100 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 158 2710 3 8 6 3 300 2 4 10 25 94 26 93 162 2210 4 6 7 0 500 2 5 12 165 1890 4 9 7 4 Marking Material Arc Travel Marking Initial Pierce Thickness prenow Pasma Shield Fostilow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 130
15. Work Ground Lead 1 Route one end of the 1 0AWG work ground lead through the middle 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 RHF Console Ground Connection Perform the following steps to connect the chassis of the RHF console to the cutting table See figure below 1 Connect one end of the RHF console ground lead to the ground stud on the RHF console 2 Connect the other end of the RHF console ground lead to chassis ground on the cutting table Make sure that good metal to metal contact is made This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provide
16. gang torch valve assembly Preflow Gas Hose Qi 1 Connect one end of the preflow hose to the preflow outlet on the rear of the AGC Note that the preflow hose fittings have left hand threads 2 Connect the other end of the preflow hose to the preflow inlet on the 5 gang torch valve assembly 5 Gang Manifold Control Cable Q2 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 G3 1 Connect the 2 gang manifold control cable plug marked P18 to the 2 gang manifold as shown 2 Connect the 2 gang manifold control cable plug labeled P13 to the connector labeled P13 on the rear of the power supply This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 12 Installation Spirit275a User s Manual Rev K MAXIMUM INPUT GAS PRESSURE 145 pel Hi7 NITROGEN OXYGEN N N N 15 NNN AN AY RW This information is subject t
17. psi psi volts ipm in in msec in 050 135 180 050 400 100 080 063 25 74 19 73 138 140 065 150 082 080 143 90 075 150 200 085 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 5 137 3870 1 5 2 5 150 2 1 25 74 19 73 2 0 142 2360 1 8 3 7 200 2 2 Marking Material F Arc Travel Marking Initial Pierce Thickness PreNow Plasma Shield Rooney Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 145 250 6350 147 3 7 100 2 5 0 Use an arc transfer height ignition height of 100 2 5 mm for cutting and 100 2 5 mm for marking Revised 10 21 2009 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 45 Operation Spirit275a User s Manual Rev K Aluminum 70 Amps Air Plasma Nitrogen Shield Copper Electrode Q Outer Cap Shield Cap 277150 Nozzle 277125 2 Electrode 277131 a 4 A Torch Head
18. 2 a 4 A Torch Head Retaining Cap Swirl Ring 277154 277151 277283 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 150 090 200 300 3 8 430 100 130 250 400 090 1 2 25 94 26 93 65 155 300 500 5 8 143 47 325 800 185 095 3 4 145 35 350 1000 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 3950 2 1 4 9 300 10 2405 3 3 6 5 2 3 130 500 12 25 94 26 93 1850 3 7 7 3 16 143 1180 8 3 4 7 1000 2 4 20 145 800 9 0 Marking Material Arc Travel Marking Initial Pierce Thickness Preniow Plasma shield Postiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 130 250 6350 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 1 Revised on 10 21 2009 This information is subject to the controls of the Export Administration Regulations EAR This infor
19. 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 gas hose to the marking outlet on the rear of the AGC 2 Connect the other end of the marking hose to the marking inlet on the 5 gang torch valve assembly 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 Installation Spirit275a User s Manual Rev K Postflow Gas Hose 1 Connect one end of the postflow hose to the postflow outlet on the rear of the AGC Note that the postflow hose fittings have left hand threads 2 Connect the other end of the postflow hose to the postflow inlet on the 5 gang torch valve assembly Plasma Gas Hose 1 Connect on end of the plasma hose to the plasma outlet on the rear of the AGC 2 Connect the other end of the plasma hose to the plasma inlet on the 2 gang torch valve assembly Shield Gas Hose 1 Connect one end of the shield hose to the shield outlet on the rear of the AGC 2 Connect the other end of the shield hose to the shield inlet on the 5
20. Part Number Length 200363 25 25 ft 7 6 m 200363 50 50 ft 15 2 m srac IT 5S E 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 8 16 Parts List Spirit275a User s Manual Rev K Power Supply Microprocessor P C Board Assembly 280275
21. TAC LED 12 MOTION LED 13 HOLD IN LED 14 HOLD OUT LED 15 MAN CONSOLE LED 16 5V uP PWR LED 17 12V uP PWR LED 18 ILK PWR LED 19 ANALOG PWR LED 20 GAS PWR LED 21 OVER CURRENT LED 22 ERROR LED 28 COMM PWR LED 29 15V LED 30 XMIT LED 31 RECV Indication Pilot Arc Relay Energized Main contactor CON1 energized CR3 and K1 relays energized Latch relay energized Coolant pump relay CR5 energized Three phase power satisfactory Power Supplied to ACG High frequency transformer TR5 energized Preflow gas valve 1 energized Plasma gas valve 2 energized Shield gas valve 3 energized Vent gas valve 4 energized Postflow gas valve 5 energized Marking gas valves 6 and 7 energized Plasma start signal applied to Spirit Chopper energized Pilot arc transistor energized Transferred arc established from torch to workpiece Motion relay energized Arc hold input enabled Power supply ready relay energized Not used 5V microprocessor power supply satisfactory 12V microprocessor power supply satisfactory 12V interlock power supply satisfactory 15V analog power satisfactory 24V gas solenoid power satisfactory Over current power down to reset Blinks on and off to display error codes 5V communication power supply satisfactory 15V analog power satisfactory Indicates serial transmission to AGC Indicates serial transmission from AGC This information is subject to the controls of the Export Admini
22. in mm msec All Thicknesses N A 28 25 N A 135 250 6350 096 2 4 100 2 5 0 Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking Revised 12 1 2009 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 34 Operation Spirit275a User s Manual Rev K Stainless Steel 70 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277150 277125 277131 a a j YN a Dp h NY Z of P MD _ Jf J Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277142 279150 Imperial Material p Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 10 135 132 120 060 150 200 oE 3 16 134 100 070 200 300 i 25 80 25 79 1 4 140 75 090 225 400 090 3 8 148 50 120 250 500 i Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Pos
23. loess fos fo e g elie feo J ii x 6 Des 22 2 amp as a paveTb GND cea BCED PR MN z o S hav ow w 33 lt a PL MAX p Sm Pi3 m v9 a LE seg TAF ap Ej 5 7 i REED PL MN i E E cbd os LeD Z 2 zb ZB ries a F K al ff Bie So p EO AUXI us vt weg z i l pm mek ae Tet ny g a TTT a T al nee BRRR i Nasal Goo on c39 ko Lol 4 L Hoa l 3 mee E a ig n m ml NEUT g fo q ET iar A bii 2 s re g T T pei Seo am Ox REE T_T Hien al a 4 g a FEF Gi a ein amp oH 38 uit E D9 ke TE WX 5 a 33g cele Lepes LED2S LED24 mlED23 LED LE F au 5 5 a 8 3 z mT e Wik g gH Le R 3 Me d i a i eta e Th ue E a amp ASHA mF F z ami ax P R w U36 OF z sT zuu ENABLE ba 4 L kenl id i i Rea S s4 H Bastele Ro Ea paz e Le EJ 3 s R Ey 5 iy j PREFLOW mi 55 1 d BRI T T ae Ey Paar IZ m GND Ts T Rw R 22 6 g i i us fe EJ 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 8 21 Parts List Spirit275a User s Manual Rev K Consumable Spare Parts Kit Part Number 280267 Part Number 277130 277137 277131 277132 277282 277133 277292 277291 277135 277270 277120
24. messages sequencing and errors The message screen should be the initial starting point when troubleshooting the system MESSAGES WAITING FOR START SIGNAL press M 10 ExT CURRENT MODE MESSAGES KALIBURN 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Viewing Cut Errors The Spirit has an error tracking system that keeps a record of certain faults that occur during operation These faults affect the consumable parts life and measures should be taken to prevent them from occurring To view the cut errors scroll down to the View Cut Errors selection on the maintenance screen and press ENT The cut errors screen will be displayed as shown The error tracking system keeps a record of the total number of pierces the number of errors and the error percentage Any time the consumables are changed the pierce counter should be reset to zero by pressing CLR When this occurs the data from the present count will move into the first previous errors position The data that was in the first previous errors position will move to the second previous errors position and so on PIERCES 22 ERRORS 9 PERCENT ERROR 41 1 PIERCES ER
25. mm m mm mm msec mm 6 143 3770 3 1 6 3 400 35 10 156 2825 4 8 7 0 600 A 12 25 75 50 67 162 2430 5 5 7 4 3 3 16 170 1630 8 3 3 4 6 4 1200 20 170 990 9 0 3 6 Marking Material Arc Travel Marking Initial Pierce Thickness Preniow Plasma shield Postiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 135 250 6350 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 Revised 12 01 2009 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 48 Operation Spirit275a User s Manual Rev K Aluminum 200 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap 277274 Q Outer Cap Nozzle 277289 2 Electrode 277291 a 4 A Torch Head Retaining Cap Swirl Ring 277154 277266 277143 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield
26. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 42 Operation Spirit275a User s Manual Rev K Stainless Steel 275 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Q Outer Cap Shield Cap 277263 Nozzle 277276 Electrode 277270 Y Torch Head Retaining Cap Swirl Ring 277154 277266 277258 279150 Imperial Material p Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 143 120 125 300 600 465 5 8 148 90 140 350 800 i 3 4 152 80 180 400 1200 20 93 70 83 170 1 0 165 55 210 450 1 25 175 35 250 350 1500 480 1 50 185 25 300 350 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 141 3220 3 1 7 3 600 42 16 148 2275 3 6 8 9 800 i 20 153 1940 4 7 10 3 20 93 70 83 4 3 25 164 1435 5 2 11 3 1500 32 175 880 6 4 8 9 46 38 184 640 7 5 8 9 i Marking Material Arc Travel M
27. terminal through the strain relief on the RHF console and connect it to the CTP sensor lead filter assembly RHF Console Control Cable 4 1 Connect the RHF console control cable plug labeled P16 to the connector labeled P16 on the rear of the power supply 2 Connect the RHF console control cable plug labeled P1 to the connector labeled P1 on the RHF console Power Supply Coolant Supply Hose 1 Connect one end of the power supply coolant supply hose to the coolant supply fitting on the rear of the power supply Note that the coolant supply fitting has right hand threads 2 Connect the other end of the power supply coolant supply hose to the coolant in fitting on the RHF console Note that the coolant in fitting has right hand threads This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 5 Installation Spirit275a User s Manual Rev K Power Supply Coolant Return Hose 1 Connect one end of the power supply coolant return hose to the coolant return fitting on the rear of the power supply Note that the coolant return fitting has left hand threads 2 Connect the other end of the power supply coolant return hose to the coolant out fitting on the RHF console Note that the coolant out fitting has left hand threads
28. 155 85 210 300 600 430 5 8 160 60 220 325 800 3 4 168 45 240 350 1200 135 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 144 3910 4 0 6 3 400 32 10 150 2805 4 7 7 0 600 l 12 25 75 70 67 153 2330 5 1 7 4 33 16 160 1510 5 6 8 3 800 l 20 170 1030 6 2 9 0 1200 3 4 Marking Material Arc Travel Marking Initial Pierce Thickness Prefiow Plasma Shield een Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 135 250 6350 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 Revised 12 01 2009 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 39 Operation Spirit275a User s Manual Rev K Stainless Steel 200 Amps H17 Plasma Nitrogen Shield Copper Electrode This gas combination gives the good cut quality and minimum dross levels Q Outer Cap Shield Cap 277274 Nozzle 277287 Electrode 277135 Y
29. 21 2009 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 25 Operation Spirit275a User s Manual Rev K Mild Steel 50 Amps Oxygen Plasma Oxygen or Air Shield Copper Electrode Shield Cap Nozzle Electrode 277115 277122 277131 J 3 m a SS Yy Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277140 277142 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in Cold Rolled Steel Oxygen Shield Swirl Ring 277140 12 105 123 70 120 100 075 11 120 25 74 12 73 126 60 125 135 200 078 10 135 128 50 135 Hot Rolled Steel Air Shield Swirl Ring 277142 14 075 200 100 075 12 105 106 190 100 135 125 180 25 74 19 73 200 080 10 135 110 170 110 3 16 113 105 440 200 300 085 1 4 117 75 i 225 400 087 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield P
30. 277118 277269 277276 277145 277144 277149 277115 277150 277286 277146 277117 277298 277274 277211 277263 277138 277140 277142 277283 277141 Quantity 3 3 5 Description Nozzle 200A Stainless H17 Nozzle 260A Stainless H17 Nozzle 275A Mild Steel Nozzle 275A Stainless Air 275A Aluminum Shield Cap 30A Mild Steel 30A Aluminum Shield Cap 30A Stainless Air Shield Cap 50A Stainless Air Shield Cap 50A Mild Steel Shield Cap 70A Mild Steel 70A Stainless 50 70A Aluminum Shield Cap 100A Mild Steel 100A Stainless Air 100A Aluminum Shield Cap 100A Stainless H17 Shield Cap 150A Mild Steel 150A Stainless Air 150A Aluminum Shield Cap 150A Stainless H17 Shield Cap 200A Mild Steel 200A Stainless 200A Aluminum Shield Cap 260A Stainless H17 Shield Cap 275A Mild Steel 275A Stainless Air 275A Aluminum Swirl Ring 30A Stainless Air Swirl Ring 30 50A Mild Steel 70A Stainless H17 30A Aluminum Swirl Ring 50 70A Mild Steel 50 70A Stainless Air 50 70A Aluminum Swirl Ring 100A Mild Steel 100A Stainless Air 100A Aluminum Swirl Ring 100A Stainless H17 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
31. 277121 277122 277123 277125 277124 277284 277126 277293 277289 Quantity 3 2 6 Description Electrode 30A Mild Steel 30A Aluminum Electrode 30 50A Stainless Air Electrode 50 70A Mild Steel 70A Stainless Air 50 70A Aluminum Electrode 70A Stainless H17 Electrode 100A Mild Steel 100A Stainless Air 100A Aluminum Electrode 100A Stainless H17 Electrode 150A Mild Steel 150A Stainless Air 150A Aluminum Electrode 200A Mild Steel 200A Stainless Air 200A Aluminum Electrode 150 200 260A Stainless H17 Electrode 275A Mild Steel 275A Stainless Air 275A Aluminum Nozzle 30A Mild Steel 30A Aluminum Nozzle 30A Stainless Air Nozzle 50A Mild Steel 50A Aluminum Nozzle 50A Stainless Air Nozzle 70A Mild Steel 70A Stainless Air 70A Aluminum Nozzle 70A Stainless H17 Nozzle 100A Mild Steel 100A Stainless Air 100A Aluminum Nozzle 100A Stainless H17 Nozzle 150A Mild Steel 150A Stainless Air 150A Aluminum Nozzle 200A Mild Steel 200A Stainless Air 200A Aluminum 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 8 22 Parts List Spirit275a User s Manual Rev K Part Number 277287
32. 277140 277154 277122 2771442 277131 279150 m S 50A Q 9 O 277154 277125 277142 Q 4 D 277283 277282 100A 9 6 277151 277154 277117 277152 277293 277139 277292 Q 150A 59 D 277289 277143 277291 277270 277154 Q 4 D 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 11 Operation Spirit275a User s Manual Rev K Mild Steel Silver Electrode Outer Shield Inner Nozzle Swirl Silver Torch Retaining Cap Cap Retaining Cap Ring Electrode Head 279440 277154 277274 277266 279489 279443 low oxtng 279160 277154 279469 279458 red o ring Q 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 12 Operation Spirit275a User s Manual Rev K Stainless Steel H17 Plasma Copper Electrode Outer Shield Inner Nozle Swirl Copper Retaining Cap Cap Retaining Cap Ring Electrode 277154 277150 277113 277124 277140 277132 277133 100A 277154 277298 277266
33. 277297 277139 277135 2791450 150A O C0077154 277274 277266 277287 277259 277135 279150 200A O OWD D 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 13 Operation Spirit275a User s Manual Rev K Stainless Steel Air or Nitrogen Plasma Copper Electrode Outer Shield Inner Nozzle Swirl Copper Retaining Cap Cap Retaining Cap Ring Electrode hae 277144 277110 277121 277138 277137 30A BEBE RTTAIO BTS BTA a 277137 279150 50A O BFF ap i aa BITES B 277131 279150 70A O BE BEBE BETAS a TER 277282 279150 100A O e a BTBOS BITS 277292 279150 150A meea apaya yaa aa aids 277291 279150 200A FFB ayaa pya ariaa riae eek 277270 279150 275A This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 14 Operation Spirit275a User s Manual Rev K Stainless Steel Air or Nitrogen Plasma Silver Electrode Outer Shield Inner Nozzle Swirl Silver Torch Retaining Cap Cap Retaining Cap Ring Electrode Head 279440 277154 277274 277266 279489 279443 alow octing 279160 N Thi
34. 280318 65 280318 70 280318 75 280318 80 280318 85 280318 90 280318 95 280318 100 Part Number CSA Systems 288318 10 288318 15 288318 20 288318 25 288318 30 288318 35 288318 40 288318 45 288318 50 288318 55 288318 60 288318 65 288318 70 288318 75 288318 80 288318 85 288318 90 288318 95 288318 100 10 7 m 16 8 m 18 3 m 65 ft 19 8 m 21 3 m 22 9 m eae m 95 ft 29 0 m 100 ft 30 5 m POWER SUPPLY O O STAR GROUND 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 8 15 Parts List Spirit275a User s Manual Rev K Oxygen Supply Gas Hose Optional A Part Number Length 200362 25 25 ft 7 6 m 200362 50 50 ft 15 2 m 54 BLUE Nitrogen Supply Gas Hose Optional Part Number Length 200365 25 25 ft 7 6 m 200365 50 50 ft 15 2 m m BLACK 54 Air Supply Gas Hose Optional srac fp Part Number Length 200364 25 25 ft 7 6 m 200364 50 50 ft 15 2 m BLACK gt CAME H17 Supply Gas Hose Optional RED i
35. 75 150 350 800 20 82 58 75 155 3 4 153 60 190 400 1200 1 0 158 40 210 450 160 1 25 170 20 250 350 1500 165 1 50 180 10 275 350 175 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 129 5220 1 8 4 9 400 aa 10 134 3655 1 9 6 5 l 600 12 138 3020 2 6 7 3 16 146 1890 3 8 8 9 800 3 9 20 82 58 75 20 153 1450 4 8 10 3 25 157 1050 5 2 11 3 4 1 1500 32 170 495 6 4 8 9 4 2 38 179 260 6 9 8 9 4 4 Marking Material F Arc Travel Marking Initial Pierce Thickness ROW Plasma Shield Rostow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 25 25 N A 120 250 6350 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 Edge start recommended Revised 12 01 2009 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 53 Operation Spirit275a User s Manual Rev K Aluminum 200 Amps Air Plasma Nitrogen Shield Silver Electrode
36. 8 23 Parts List Spirit275a User s Manual Rev K Part Number 277139 277143 277259 277258 277110 277153 277151 277152 277113 277266 277280 716012 500024 500018 820209 277056 277086 277087 260105 277154 Quantity 1 anana a PhO Description Swirl Ring 150A Mild Steel 150A Stainless 150A Aluminum 260A Stainless H17 Swirl Ring 200A Mild Steel 200A Stainless Air 200A Aluminum Swirl Ring 200A Stainless H17 Swirl Ring 275A Mild Steel 275A Stainless Air 275A Aluminum Inner Retaining Cap 30 50A Stainless Air Inner Retaining Cap 30 50 70A Mild Steel 70A Stainless Air 30 50 70A Aluminum Inner Retaining Cap 100A Mild Steel 100A Stainless Air 100A Aluminum 150A Mild Steel 1 2 and below Inner Retaining Cap 150A Mild Steel 5 8 and above 150A Stainless Air 150A Aluminum Inner Retaining Cap 70 100A Stainless H17 Inner Retaining Cap 150A Stainless H17 200 275A Mild Steel 200A Stainless 200 275A Aluminum 275A Stainless Air Inner Retaining Cap 260A Stainless H17 O ring Lubricant Torch O ring blue lower Torch O ring red middle Torch O ring black red upper Nozzle Removal Tool Electrode Removal Tool Driver Electrode Removal Tool Socket Swirl Ring Removal Tool Outer Retaining Cap This information is subject to the controls of the Export Administration Regulations EAR This
37. Cutting Travel Speed Save as User File 35 36 37 38 39 40 41 42 43 44 45 46 Hex String AA nn FA 22 00 0D AA nn FA 23 00 0D AA nn FA 24 00 0D AA nn FA 25 00 01 0D AA nn FA 26 00 01 OD AA nn FA 27 00 01 OD AA nn FA 28 00 01 OD AA nn FA 29 00 01 OD AA nn FA 2A OD AA nn FA 2B OD AA nn FA 2C 0D AA nn FA 2D 0D AA nn FA 2E 00 01 0D Additional Information If requested in command 30 the AGC will transmit the cutting chart version x 10 If requested in command 30 the AGC will transmit the number of pierces Range 0 to 9999 If requested in command 30 the AGC will transmit the number of pierce errors Range 0 to 9999 Resets number of pierces and errors to 0 Energizes power supply torch coolant pump and cooling fans If torch coolant flow switch not satisfied within 8 seconds unit will power down Deenergizes power supply torch coolant pump and cooling fans System status can only be requested after a Power On command 38 is transmitted The status is returned in the following form All bits O fault 1 0k LSB Bit 0 RHF Door LSB Bit 1 AC Power LSB Bit 2 Coolant Flow LSB Bit 3 Coolant Level LSB Bit 4 Coolant Temp LSB Bit 5 AGC status LSB Bit 6 Inlet Gas Pressures LSB Bit 7 Not used MSB Bit 0 Not used MSB Bit 1 Hydrogen Cutting Enabled Purges gas lines Sets cutting arc voltage in Volts x 100
38. F8 fuse AGC 2A 21 709076 4 F6 F7 F9 F11 fuse AGC 1 2A 22 709033 1 F5 fuse AGC 1A 23 280275 1 Microprocessor p c board assembly 24 709002 3 P8 P12 P13 14 socket receptacle 25 709001 1 P7 4 pin receptacle 26 709124 1 P16 9 socket receptacle 27 709061 2 F1A F1B fuse holder 28 709128 2 F1A F1B fuse FNM 6 25A 29 709060 1 Strain relief 30 500810 1 A C detect p c board assembly 31 200092 1 Coolant reservoir without fittings or cap Not shown 200292 1 Coolant reservoir assembly with fittings and cap 32 500518 1 Coolant reservoir cap level gauge 33 708062 1 LS1 coolant level switch 34 505024 1 TS1 Coolant temperature switch 35 500052 1 Pump motor 1 3hp 230V 50 60 Hz 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 8 1 Parts List Spirit275a User s Manual Rev K Item Number Part Number 36 500513 37 500511 38 708061 39 715084 40 708068 41 708059 42 500516 43 260250 44 260012 45 500509 46 500510 47 708117 48 500348 49 702076 50 708118 51 701165 52 500536 53 705011 54 709167 55 702075 56 277452 57 Contact factory 58 280130 59 709117 62 706036 63 706041 64 706042 65 706043 66 280003 67 708103 68 708104 69 708105 72 709190 73 709191 74 740106 75 704050 76 200204 77 715052 78
39. J KALIBURN HSpirit275a HIGH CURRENT DENSITY PLASMA CUTTING SYSTEM WITH AUTOMATIC GAS CONSOLE User s Manual Part Number 718085 Rev K 10 15 2012 This information is subject to the controls of the Export Administration REVISION 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 Spirit275a User s Manual Rev K REVISION HISTORY Rev ECO Author Date Description of Change As released 05 08 07 Changed location of coolant level switch o O D gt 05 23 07 Changed 30A mild steel preflow pressure from 30 to 35 psi m 1 07 02 07 Changed cutting charts to have separate metric and imperial versions Changed 575V control xfmr part number to 706205 10 15 07 Added PAR relay in series with surge injection circuit to schematic and parts list 10 21 09 Section Updates e Contents e Section 2 e Section 3 e Section 7 e Section 8 10 25 10 Section Updates e Contents e Section 3 e Section 4 e Section 5 e Section 6 e Section 7 e Appendix A e Appendix B deleted 05 10 2011 Section Updates e AGC Max Input Pressure change to 145 psi in 2 4 3 1 3 13 3 14 8 8 e AGC Fan added to drawings in 3 1 3 13 e Postflow label changed in 8 9 08 01 2012 e Section 1 added pointers to Section 7 e Section
40. KALIBURN 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 Automatic Gas Console Advanced Functions Software Updates The Automatic Gas Console has a floppy disk drive that is used to update the software as new revisions are released To access the floppy disk drive remove the floppy disk drive cover on the rear panel of the console The software update may either be installed on one floppy disk or two floppy disks Follow the instructions below for the appropriate update One Disk Update al 2 o Pror oi Remove primary power from the Spirit system Insert the floppy disk containing the software update into the floppy disk drive Apply primary power to the system and wait until the AGC Updated Successfully message appears Remove the floppy disk from the floppy disk drive Remove primary power from the system Reinstall the floppy disk drive cover Apply primary power to the system Two Disk Update 1 2 3 8 9 Remove primary power from the Spirit system Insert the first floppy disk containing the software update into the floppy disk drive Apply primary power to the system and wait until the AGC Updated Successfully message appears Remove the f
41. Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 150 190 135 250 300 450 3 8 455 145 140 275 400 i 1 2 110 300 500 20 82 58 75 135 155 5 8 460 95 350 600 3 4 65 150 400 800 160 1 0 175 35 200 1000 170 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 149 4955 3 3 6 3 300 TA 10 3545 3 5 7 0 155 500 12 2995 7 4 20 82 58 75 3 4 3 9 16 160 2380 8 9 800 20 162 1575 3 9 4 1 10 2 1000 25 174 940 5 0 4 3 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow Plasma Shield Postiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 120 250 6350 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 Edge start recommended Revised 10 21 2009 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 49 Operation Spirit275a User s Ma
42. Rev K Mild Steel 30 Amps Oxygen Plasma Oxygen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277130 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277140 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 20 036 120 105 080 100 062 18 048 121 97 090 16 060 125 78 110 065 14 075 35 85 6 84 126 65 105 200 i 12 105 127 55 11 120 129 50 070 120 125 300 10 135 131 40 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 120 2615 2 0 100 1 6 1 5 124 2020 2 6 2 8 1 7 2 35 85 6 84 1615 200 126 2 7 2 5 1455 18 3 128 1285 2 9 3 1 300 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow Plasma shied Postiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 145 250 6350 177 45 100 2 5 0 1 Revised on 10
43. Status LED s eeeeeeeeeeeeeeees 7 7 Troubleshooting Using the Automatic Gas Console Messages Screen 7 8 General Troubleshooting ccc sei oecieec idence eee 7 9 Chopper Test ProCedUne pesciamsartsetnacnsicientlers latatinetimrauteataces neticiscutnlbsetitettera 7 12 Section 8 Parts List POWER SUD DIY EPA EA AS EAE A E EE E E AE AE 8 1 A tomatie Gas CONSOIG srssroe edea a a a E EE e e a a a dave 8 7 Remote High Frequency Console 22 cc c cseccceccdeceeneeees epee ee eeeneededesedensseeercneeenee 8 10 Torch and Manifold Assemblies a5 icjesesceriecasnckwiasdscussccanes Qpacsaxenncenaeiaedetaunendeaubpseenenand 8 11 Shielded Torch LeadS soc tide casninwanisneaacnwdoahubeduaieco tient Nalwnnasy saceiadevbula bent eadeeatalymenenis 8 12 Gas hose Package vic Rene nie ee eS 8 13 Coolant and POWwsIHcLGads sess wicci vet ucee Ss desta ase eee 8 14 Wonk Ground Cable siscccice atest cnsad a e Ea a a leat a o meskes 8 15 Oxygen Supply Gas Hose Optional 00 0 2 cccccceeeeeeee cece eect eee eeeeeeeeaeeeeeeeeeeeeeeeeeeeeees 8 15 Nitrogen Supply Gas Hose Optional ccc cceeseceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaaaaaaaeees 8 16 Air Supply Gas Hose Optional 2 2 c c cc ce cceece cee eeeeecee cree ee eeeneedetesesenetecceceneeseeeeee 8 16 H17 Supply Gas Hose Optional io 4 13 24 cs cts cleave clclmade dias scredstlbet tier 8 16 Power Supply Microprocessor P C Board cceeceeeee
44. This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 4
45. This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 6 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Troubleshooting Using the Control Panel Status LED s If the Spirit system develops a problem first check the control panel status LED s If one or more of the LED s does not illuminate after the ON button is depressed use the status LED s to pinpoint the problem e RHF Door LED Extinguishes when the RHF door switch opens Check the RHF door switch and associated wiring e Gas Console LED Extinguishes when there is a problem with the gas console or when the unit is adjusting gas pressures Switch to the messages screen on the gas console to pinpoint the problem e 3 Phase Power LED Extinguishes when there is a problem with the three phase power being supplied to the chopper assembly Verify that the primary wall disconnect fuses are good and check the main transformer main contactor and A C Detect p c board for proper operation Also this LED should turn on immediately when the green ON button is pressed If not check P28 3 to P28 4 for 10 VDC first This should drop to 0 VDC when the ON button is pushed If not then check CR1 and associated wiring e Coolant Flow LED Extinguishes when there is a problem with the torch coolant system Check the coolant pump fuse F2 and
46. U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 3 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Altering Gas Pressures Normally the preflow gas and plasma gas pressures should not be changed The shield gas can be adjusted in small increments to fine tune a cut To alter the gas pressures use the arrow keys to scroll to the appropriate pressure setting The pressure setting should be highlighted as shown and the editing cursor should be blinking Use the numerical keypad to enter the desired operating pressure Use the CLR key to backspace if an error is made Press ENT when the correct value has been entered Note that all of the gases have minimum and maximum limits and cannot be programmed beyond these limits PREFLOW UBSTANCE MILD STEEL COLD GAS ALR HICKNESS 0 250 INCHES psi 029 0 URRENT 70 AMPS ROCESS CUTTING GAS OXYGEN ORCH PARTS cis 176 i i D lJ CUTTING PIERCE TIME 0200 ms GAS ALR MARKING PIERCE TIME 0000 ms psi 025 0 USE THE NUMERICAL KEYPAD TO ENTER PLASMA GAS PRESSURE CURRENT MODE PLASMA 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 4 A
47. Valid Range 5000 to 20000 Sets cutting height in mils inches 1000 Valid Range 0 to 999 Sets cutting pierce height in mils inches 1000 Valid Range 0 to 999 Sets cutting travel speed inches min displayed on the voltage screen Valid Range 0 to 999 Saves the present cutting conditions as a user file This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 7 Serial Communication Spirit275a User s Manual Rev K Command Hex String Additional Information Restore Factory 47 AAnnFA2F00010D Restores the factory cutting condition for Condition the present material type and thickness Cutting Condition 48 AA nn FA 30 00 0D If requested in command 30 the AGC Type will transmit whether the present cutting condition is a factory default setting or a custom user setting Note This is only valid when initially loading material type thickness and process 0 factory 1 custom Configure H17 49 AA nn FA 31 00 0D 0 Disable H17 cutting Cutting 1 Enable H17 cutting Reload Cutting 50 AAnnFA3200010D Reloads the cutting conditions for the Condition present material type and thickness Set Arc Off Delay 51 AA nn FA 33 OD Sets the delay time in mS between the Time reception of a stop signal and the ext
48. a z FLOW P20 N S fa Crp z C40 o MARK c73 t 2 T Jo 2 a p C DMARK Peki w 2 r 20 80D D na amp Lal FLO ik 6c 8 a u26 CAL o ose z amp Cocee m CK 6c VR4 c69 u35 g C 8 id a S TP9 FLT PRES afale f z zg o L 1 A 5 c19 Py O C pres fet a at Og e scm FLS avr 12A T G asv T Uh Tr TP10 CC pve 12a wy 064 w Lad Sa 8 2 Q FLF 24c B OR E cs Gag tae u A i ad Fi In ui4 7 CO RHF GND BR4 VR5 bes LW RESET 0 0 0 ae oo teP u36 FROG a8 D LED29 LEDI9 fi GAS Uo Wf 15V 5V 412P lst La PILOT N R P27 Swi oe Hev D La q F R54 DI g 1 B S 4 R55 Hx z tee GND fa B ce x era 1 86 FL34 an C65 Z 9 TP18 al Aux4C__ S AA CURR are fe 204 C FL29 T7 p Ma 9 ED luy La VOLT paci T 100A u37 RE U i Tresl so CD FLis Roa c56 c50 c39 Ed ce Ae Q p29 40A C FLI9 u38 u29 u22 Lito gt R0 F a 208 C FL20 B Rael ut2 TRA ca 5 My keal B BSSR ci4 TP2 TPM EE N w C rLat U4 rrr wo g trot g 8A CD FL2e es R20 4 L pate FLOW SJ acc a Ee fa e WM S Etg B an Lad Q CUR 2a C FLe4 le Ua R iy ret t R4 it debi 14 CD R6 4 F 4 F Ree o FL32 T P89 4 j Ret cs wie P27 P22 a i 4 H 4 H ROL ag Ree Wis rih R73 La u5 f tt oT 1 a c85 Pen Re C FEL 7 S s DUTY tReet 2 S C76 R76 d 4 i 583E H we T u43 1P13 Ocvale ER cie TP20 u1 C16 Cio c84 DUTY CYCLE L R77 u33 u28 U21 SDFPER ON OFF DUTY CYCLE SHIELD c59 LED16 iene Ke BYR START opto 3 PAR IS CrPe PAR Be gilt 5 K4 PWR CHOPPER opTo2 Z L lt P26 R7
49. in MILD STEEL COLD MENU CURRENT MODE STATUS 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 Operation Spirit275a User s Manual Rev K Setting up a Cut or Mark The automatic gas console makes it very simple to set up the machine Material type material thickness and process cutting or marking are the only parameters that must be set All other parameters are adjusted automatically Perform the following steps to enter the data See Section 5 for advanced functions of the automatic gas console Selecting Material Type From the status mode press the down arrow once to scroll down to substance or press Menu then Material The substance area should be highlighted as shown below and the substance type should be blinking To change the substance type press F3 as indicated by the help prompt Pressing F3 repeatedly will scroll through the list of possible substance choices The available substance types are as follows e Mild Steel Cold Rolled e Mild Steel Hot Rolled e Stainless Steel e Aluminum e Other PREFLOW SUBSTANCE MILD STEEL COLD GAS AIR THICKNESS 0 290 INCHES psi 025 0 CURRENT 70 AMPS PROCESS CUTTING TORCH PARTS GAS OXYGEN psi 0 6 0 CUTTING PIERCE TIME 02
50. information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 24 Electromagnetic Compatibility EMC Spirit275a User s Manual Rev K Appendix A Electromagnetic Compatibility EMC Background The 380V 50 60Hz and 415V 50 60Hz CE marked Spirit275a plasma cutting systems are manufactured to comply with the European standard EN 60974 10 Electromagnetic compatibility EMC Product standard for arc welding equipment The system has been tested in accordance with CISPR 11 EMC classification Group 2 ISM Class A The limits used in this standard are based on practical experience However the ability of plasma cutting equipment to work in a compatible manner with other radio and electronic systems is greatly influenced by the manner in which it is installed and used For this reason it is important that the plasma cutting equipment be installed and used in accordance with the information below if electromagnetic compatibility is to be achieved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installation and Use The user is responsible for installing and using the plasma cutting equipment according to the manufacturers instructions If electromagnetic disturbances are detected then it
51. initialization is simple Apply power wait until the automatic gas console AGC has finished booting then transmit the desired material type material thickness and optionally the process cutting or marking and the system will be ready for operation All other parameters will be set to their default values and may be changed at any time Transmitting Parameters to the Spirit System To transmit parameters to the Spirit convert the following hex strings to 8 bit binary arrays AA 10101010 and transmit them using a 9600 baud RS 422 serial communication port The port settings should have a start bit one stop bit and no parity A table can be found in this section that lists the RS 422 commands and their descriptions This table contains the necessary hex strings for sending different commands and parameters to the system For example to switch the material type from mild steel to stainless steel look up the command for setting material type in the table You will see the following table entry Command Hex String Additional Information Set Material Type 1 AAnnFA0100 0D 00 Mild Steel Hot Rolled 01 Stainless Steel 02 Aluminum 03 Other 04 Mild Steel Cold Rolled Note that spaces in the command string are shown for clarity only and should not be sent as part of the command A command string always begins with the value AA hex The nn is the net node communication node of the Spirit system that is to receive the c
52. ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 108 250 6350 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised 10 22 09 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 52 Operation Spirit275a User s Manual Rev K Stainless Steel 200 Amps Air Plasma Nitrogen Shield Silver Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277274 279489 279440 yellow o ring Outer Cap Retaining Cap 2 Torch Head Swirl Ring 277154 277266 279443 279160 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 130 200 200 400 070 150 3 8 133 150 250 500 1 2 140 110 115 300 600 152 5 8 146
53. m 280317 75 75 ft 22 9 m 280317 80 80 ft 24 4 m 280317 85 85 ft 25 9 m 280317 90 90 ft 27 4 m 280317 95 95 ft 29 0 m 280317 100 100 ft 30 5 m bee PREFLOW HOSE aa AGC 5 GANG MANIFOLD SHIELD HOSE AGC 0 5 GANG MANIFOLD PLASMA HOSE AGC 2 GANG MANIFOLD POSTFLOW HOSE AGC 1 CI 5 GANG MANIFOLD MARKING HOSE AGC 5 GANG MANIFOLD 7 5 FOOT SHIELD HOSE 5 GANG MANIFOLD TORCH a 6 FOOT PREFLOW POSTFLOW MARKING HOSE i 5 GANG MANIFOLD Ha HH 2 GANG MANIFOLD 2 GANG MANIFOLD CONTROL CABLE POWER SUPPLY 2 GANG MANIFOLD 5 GANG MANIFOLD CONTROL CABLE 5 GANG MANIFOLD 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 8 13 Parts List Spirit275a User s Manual Rev K Coolant and Power Leads Part Number Part Number anath Non CSA Systems CSA Systems eng n 280306 5 288306 5 5 ft 1 5 m 280306 10 288306 10 10 ft 3 0 m 280306 15 288306 15 15 ft 4 6 m
54. the United States contrary to the requirements of the EAR 5 10 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Viewing Actual Errors Once the error set is selected and the ENT key is pressed on the error selection screen the actual cut errors will be displayed as shown ACTUAL ERRORS SFERRED ARC NOT ESTABLISHED FORE UPSLOPE SFERRED ARC LOST B OFERRED ARC LOST D OFERRED ARC LOST D NOFERRED ARC LOST D E URING UPSLOPE URING CUT URING DOWNSLOPE PRESS ANY KEY TO RETURN TO THE ERROR MENU CURRENT MODE CUT ERRORS KALIBURN When any of the errors listed on the actual cut errors screen occur measures should be taken to avoid further errors The following is a description of the errors and possible causes e Transferred arc not established This error occurs when the arc fails to transfer to the workpiece It primarily causes nozzle damage and is typically due to a pierce height that is too high e Transferred arc lost before upslope This error occurs when the arc transfers to the workpiece but is lost immediately It primarily causes nozzle damage and is typically due to a pierce height that is too high e Transferred arc lost during upslope This error occurs when the arc transfers to the workpiece but is lost before steady state operation It primarily causes electrode damage and is typically due to a pierce time that is
55. the shield cap part number If requested in command 30 the AGC will transmit the least significant word of the shield cap part number If requested in command 30 the AGC will transmit the most significant word of the outer cap part number This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 5 Serial Communication Spirit275a User s Manual Rev K Command Hex String Additional Information Torch Outer Cap 29 AA nn FA 1D 0D If requested in command 30 the AGC Part Number Isw will transmit the least significant word of the outer cap part number Send Parameter 30 AA nn FA 1E 0D 01 Send material type 02 Send material thickness 03 Send current set point 04 Send cutting pierce time 05 Send preflow gas type 06 Send preflow pressure 07 Send plasma gas type 08 Send plasma gas pressure 09 Send shield gas type 10 Send shield gas pressure 15 Send cutting travel speed 16 Send torch body part number msw 17 Send torch body part number Isw 18 Send electrode part number msw 19 Send electrode part number Isw 20 Send swirl ring part number msw 21 Send swirl ring part number Isw 22 Send nozzle part number msw 23 Send nozzle part number Isw 24 Send retaining cap part number
56. 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 Installation Spirit275a User s Manual Rev K Initial Filling of the Torch Coolant Reservoir Note Never turn on the power supply before filling the torch coolant reservoir with the proper coolant solution When handling coolant it is recommended that you wear nitrile gloves and safety glasses 1 Remove the coolant reservoir cap and fill the reservoir with 2 gallons of coolant solution 2 Apply main power to the Spirit unit 3 Depress and hold the green ON button on the Spirit control panel 4 The coolant pump will begin pumping coolant fluid through the system The Coolant Flow LED will remain out until the coolant has filled the entire system and begins flowing back into the tank The coolant pump will turn off if the coolant level drops below the minimum level inside the reservoir If this happens add more coolant solution to the reservoir and return to Step 3 5 When the Coolant Flow LED illuminates release the green ON switch The Spirit system should remain energized and continue pumping coolant through the system 6 Locate the small red push button on top of the coolant filter deionization cartridge Depress and hold the button until no air is seen inside the clear filter housing 7 Fill the reservoir with coolant solution until the coolant gauge indicates full Coolant s
57. 0 i 1 5 165 17 300 350 1500 158 1 75 175 12 350 2 0 185 7 500 500 160 Metric Material i Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 6100 8 4 9 300 10 130 3480 2 3 6 5 3 8 500 12 132 3160 2 7 7 3 16 137 2515 3 3 8 9 800 20 141 1810 3 8 10 3 20 82 58 75 1000 3 9 25 146 1310 4 3 11 3 32 155 610 6 1 12 7 38 164 435 7 5 8 9 1500 4 0 45 175 295 9 2 9 2 50 183 195 12 2 12 2 4 1 Marking Material F Arc Travel Marking Initial Pierce Thickness Preflow Bigot shied Rostiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 120 250 6350 100 2 5 100 2 5 0 Edge start recommended Revised 12 01 09 Use an arc transfer height ignition height of 200 5 1 mm for cutting and 100 2 5 mm for marking 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 51 Operation Spirit275a User s Manual Rev K Mild Steel 275 Amps Oxygen Plasma Air Shield Silver Electrode Shield Cap Nozzle Elec
58. 00 ms GAS AIR MARKING PIERCE TIME 0000 ms psi 025 0 PRESS GEED 10 cuewce CURRENT MODE MATERIAL 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 Operation Spirit275a User s Manual Rev K Setting Material Thickness To set the material thickness use the down arrow to scroll down to Thickness The material thickness should be highlighted as shown below and the editing cursor should be blinking Use the numerical keypad to enter the material thickness Use the CLR key to backspace if an error is made Press the enter key when the correct value has been entered SUBSTANCE MILD STEEL COLD GAS AIR 0 250 INCHES psi 025 0 CURRENT 70 AMPS PROCESS CUTTING TORCH PARTS GAS OXYGEN psi 076 0 CUTTING PIERCE TIME 0200 ms GAS AIR MARKING PIERCE TIME 0000 ms psi 029 0 USE THE NUMERICAL KEYPAD TO ENTER THICKNESS CURRENT MODE THICKNESS 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 7 Operation Spirit275a User s Manual Rev K Selecting Pro
59. 2 5 mm for marking Revised 10 21 2009 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 33 Operation Spirit275a User s Manual Rev K Stainless Steel 70 Amps H17 Plasma Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277150 277124 277132 lm Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277113 277140 279150 Imperial Material A Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 16 35 60 36 60 135 80 100 200 300 090 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 5 35 60 36 60 135 2030 2 5 5 1 300 2 3 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow Plasma Shield poe Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm
60. 250 6350 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 Revised 02 23 2010 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 47 Operation Spirit275a User s Manual Rev K Aluminum 150 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap 277117 Q Outer Cap Nozzle 277293 2 Electrode 277292 a 4 A Torch Head Retaining Cap Swirl Ring 277154 277152 277139 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 145 130 250 400 125 3 8 155 115 185 275 500 i 1 2 25 75 50 67 165 90 230 300 600 130 5 8 65 325 800 135 170 250 3 4 45 350 1200 140 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts
61. 280306 20 288306 20 20 ft 6 1 m 280306 25 288306 25 25 ft 7 6 m 280306 30 288306 30 30 ft 9 1 m 280306 35 288306 35 35 ft 10 7 m 280306 40 288306 40 40 ft 12 2 m 280306 45 288806 45 45 ft 13 7 m 280306 50 288306 50 50 ft 15 2 m 280306 55 288306 55 55 ft 16 8 m 280306 60 288306 60 60 ft 18 3 m 280306 65 288306 65 65 ft 19 8 m 280306 70 288306 70 70 ft 21 3 m 280306 75 288306 75 75 ft 22 9 m 280306 80 288306 80 80 ft 24 4 m 280306 85 288306 85 85 ft 25 9 m 280306 90 288306 90 90 ft 27 4 m 280306 95 288306 95 95 ft 29 0 m 280306 100 288306 100 100 ft 30 5 m g a RHF CONSOLE CONTROL CABLE a p POWER SUPPLY de gt b F RHF CONSOLE F amp B e POWER SUPPLY ELECTRODE LEAD POWER SUPPLY O RHF CONSOLE eee neers POWER SUPPLY NOZZLE LEAD aE e EN POWER SUPPLY CTP SENSOR LEAD ECONS saath A POWER SUPPLY COOLANT RETURN HOSE E renee ails g POWER SUPPLY COOLANT SUPPLY HOSE f EEA 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 8 14 Parts List Spirit275a User s Manual Rev K Work Ground Cable Part Number Non CSA Systems 280318 10 280318 15 280318 20 280318 25 280318 30 280318 35 280318 40 280318 45 280318 50 280318 55 280318 60
62. 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 Spirit275a 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 Spirit275a User s Manual Rev K TABLE OF CONTENTS Section 1 Safety General Precautions cccsccessewlsacs Jatvaes saetvea he coseetseaasges ean cea tautgera see taenseeudetdawaneveaaabees 1 1 Ultraviolet Radiation Protection sseicesicaie asavescesk saivucdecalceaseasenseedacciaseasbesstemseeesa vend eds 1 1 Noise POLE CON ssicexahrk a scieih eit ce clee iacban ass ceaebariad E a ALi 1 1 Toxic Fume Prevention x sscere itsacktac hued cndann be nsteited rekesae snatetinteca honed tude tea sethzatara stented ithe 1 1 Electric Shock Prevention suicnscsii ne oa nasauud od miei oeinadee malas 1 2 FIRS a ASAINN O aE E wud cds EE E aoe 1 3 Explosion Preventiom enri eteen aeee e e
63. 5 500 i 12 124 2485 3 5 7 3 3 3 Retaining Cap 277152 16 127 1760 a6 8 3 1000 3 3 20 130 1340 i 9 0 3 4 25 20 74 45 67 133 1040 3 7 10 1 4500 32 145 625 5 1 8 9 3 6 38 154 385 5 6 8 9 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow Plasma nied ee Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 135 250 6350 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 Edge start recommended 1 Revised on 12 01 09 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 29 Operation Spirit275a User s Manual Rev K Mild Steel 200 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode 277274 277289 277291 Q Outer Cap YY Torch Head Retaining Cap Swirl Ring 277154 277266 277143 279150 Imperial Mater
64. 500526 500574 79 709228 80 709227 81 709231 82 500525 83 701141 Quantity B e MND Ao A A A BS SE B E SB SBD a ABAD BSB BAND e AB AB BS BS B B SB ABAD A Aa Description V band clamp Coolant pump 70 gph Solenoid valve 220 240VAC Check valve coolant return CR2 CR85 relay FS1 coolant flow switch Fan front panel Heat exchanger Shunt Coolant filter housing Coolant filter deionization cartridge CON main contactor Relay p c board assembly EMI filter 380 415 V units only CR3 PAR relay R7 R8 3 ohm pilot arc resistor PAT IGBT drive p c board assembly PAT IGBT TB5 30 power terminal block PAT IGBT filter capacitor I O p c board assembly Height control voltage divider p c board assembly Chopper assembly I O terminal block small TR8 transformer 241 4 36 TR4 TR7 transformer 241 3 12 TR5 transformer 241 4 12 TR3 transformer 241 6 12 Power supply 24VDC CR1 relay CR1 relay socket CR1 hold down clip TB6 terminal block marker 4 position TB6 terminal block 4 position Bulb power on switch LED lens green Fan 120V Drain petcock Fan guard large outside Fan guard small inside I O terminal block large Strain relief F2 fuse MDL 5A Fan heat exchanger front pane R9 2 ohm pilot arc resistor 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 trans
65. 7 added chopper warning e Section 8 updated drawing of power supply microprocessor board 10 15 2012 e Added Quick Disconnect Torch information throughout manual e Section 7 defective flow switch 25 blinks 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 4130 Carolina Commerce Parkway Ladson SC 29456 USA 843 695 4000 Phone 843 695 4001 Fax www kaliburn net 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 Spirit275a User s Manual Rev K 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 equipment for a period of one 1 year for the Spirit275a torch and leads and three 3 years for the Spirit275a power supply and automatic gas console 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 description on the face hereof All other warranties either expressed or implied including any implied warranty of merch
66. 9 J H q R67 CON Ss TPS piecav arre u42 R80 H 4 H R68 a CON PINI DN DFF Move7 MOV26 R3 4 F q F R69 Or LED10 TPL i OORT PWR PAT DPTOS E AVAG wor 3 18 IE tps brain SURGE Ik p 2AVAC MoT asvi eos SURGE PAR TT 5 PREFLOW LED READY COOLANT TAC CON READY j FLOW opTo4 5 SURGE PAT C opto rated S P8 LATCH TP40 LED20 LATCH PAT E GSV EEV A O GAS LEDI PUMP sev Ta 8 PWR MOTION drie z 3 PH avi GZ PUMP IS Atp7 3 PH asve wO oPTm2 Level LED13 PUMP AUX1 1 Gsv3 O are TP37 a ets oe es SHIELD PURRENT a HOLD OPTOS r aa PHA mee s I lt IS GSV4TP35 ata N OPP eae nUe FLOW LED oprais LEDER TEDS Aux2 2 SA4 TP34 ERROR READY TP23 GSV5 Gsv4 Gsv4 ppro7 s a eUxI t HFA GSV6 7 2 oe io AUXI S B ips H 2 1 ONSET siae anua a gi ees P23 TP36 oPTo14 CHOPPER CONSOLE l ean z GSV esv5 opTos 5 iE Z 5 KALIBURN AUX2 a 3 TP44 Ol BLANK PCB P N 280349 REV2 t Aux2 2 TP39 TP45 TP21 oPTois optus zg Vr i Gsv6 GSV6 GSV7 ae E 2 DCOM 5 MARKING o P38 H 2 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 8 17 Parts List Spirit275a User s Manual Rev K A C Detect P C Board Assembly 500810 uv U m e n gt gt nn mm WO T1 OTP5 O TP6 TPT O BLANK PCB P N 500809
67. A nn FA 12 OD AA nn FA 13 OD AA nn FA 14 0D AA nn FA 15 OD AA nn FA 16 OD AA nn FA 17 OD AA nn FA 18 OD AA nn FA 19 OD AA nn FA 1A OD AA nn FA 1B OD AA nn FA 1C 0D Additional Information If requested in command 30 the AGC will transmit the most significant word of the torch body part number If requested in command 30 the AGC will transmit the least significant word of the torch body part number If requested in command 30 the AGC will transmit the most significant word of the electrode part number If requested in command 30 the AGC will transmit the least significant word of the electrode part number If requested in command 30 the AGC will transmit the most significant word of the swirl ring part number If requested in command 30 the AGC will transmit the least significant word of the swirl ring part number If requested in command 30 the AGC will transmit the most significant word of the nozzle part number If requested in command 30 the AGC will transmit the least significant word of the nozzle part number If requested in command 30 the AGC will transmit the most significant word of the retaining cap part number If requested in command 30 the AGC will transmit the least significant word of the retaining cap part number If requested in command 30 the AGC will transmit the most significant word of
68. AY DETAIL MAXIMUM INPUT GAS PRESSURE 145 psl H17 MARKING MARKING POSTFLOW OUT PLASMA OUT NITROGEN IN OXYGEN AIR 678910 TS STSTSTSTSTS S Sfel SSSss sls sisis 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 8 8 Parts List Spirit275a User s Manual Rev K Automatic Gas Console 2 of 2 F EHS ae NADAXO LJ m Scl 0 MO144ud S L O E d O D 0 NO om Zz fal o fH cal 8 Bail ARREK 8 s 9 9 9 2 8 10 1112 1314 8 8 9 N uj o Sje 567 c i YWASY Id eg ze Ee 2 F tite harerereitsttalleserstetrestteal sk ERES PETAT i D PREFLOW SHIELD 0 150 PSI 0 150 PSI S G Li
69. DE DELAY 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Altering Gas Types Although the gas types should not normally be changed the procedure is given here anyway Note that the preflow gas cannot be changed To alter the gas types used for a particular cut use the arrows to scroll to the appropriate gas or press the Menu key then the Plasma Gas or Shielding Gas key The appropriate gas selection should be highlighted as shown and the present gas choice should be blinking Press F3 to scroll through the gas choices When the desired gas type is blinking press ENT to accept the gas type The plasma gas can be changed to air oxygen or H17 and the shield gas can be changed to air oxygen or nitrogen PREFLOW UBSTANCE MILD STEEL COLD GAS ALR HICKNESS 0 250 INCHES psi 029 0 URRENT 70 AMPS ROCESS CUTTING ORCH PARTS GAS OXYGEN psi 076 0 CUTTING PIERCE TIME 0200 ms GAS AIR MARKING PIERCE TIME 0000 ms psi 025 0 PRESS EB 10 chance CURRENT MODE PLASMA This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non
70. E E EEEE eE 1 3 Health Support Equipment cccccccccccscsceeeesseeeseeeeeeeeeeeeeeeeneeeeeaaeseasseeeeseeeeeeeseees 1 4 Safety Standards Booklet Index cccccc ccc cececeeeeeeceeeeeeeeeeneneeeseesseseeeseeneceneeeeees 1 5 Section 2 Specifications System Description eee BU olde eee 2 1 System Components 45s Seether detec en ee tee eg Ale ae 2 2 Power Supply Specifications cccccccececccccecceeeeeseeeeseeeeeeeeeeeeeeeeeeseeaeseeaaeseeeeees 2 2 Automatic Gas Console Specifications cccccccccccccceeeseeeeeeeeeeeeeeeeeeeeeeeeeaeeeaaeaees 2 4 Remote High Frequency Console Specifications cceeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 5 TORCHUS PECIICALIONS asc2eccipasacesoatsnotoa aa nee Lae alee ones 2 6 5 Gang Manifold Specifications 2 2 2 2 cece cece cece eeeeeeneenecnee esses eee ee eter etttteeeeeeeneeeeaea 2 7 Airborne Noise EMISSIONS wocscipeiareticeti rotie dines ati deenaaded acesrechatecend anita trennen 2 8 Section 3 Installation WPCA TVS FS CLIC acai esas ccs acaba eotec ea ins e a eE a nate cae edabe 3 1 System IMtSrCOMMeCCUON sessment eeg E ee aca ads 3 1 Power Supply Installation ccecccccccceecccceeceeeeeesseeseeeeeeeeeeeeeeeeseeeeeeeeeeagseeeseees 3 2 Remote High Frequency Installation cece eeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenaaaaaaas 3 2 5 Gang Manifold Installation ccccccee cece cece eee tence eaeaee sees settee eee eetttte
71. ENTER THE TIME DELAY BETWEEN THE RECEPTION OF A STOP SIGNAL AND THE EXTINCTION OF THE ARC PRESS ENT A RETURN TO THE MAINTENANCE MENU CURRENT MODE ARC OFF DELAY KAL I BURN This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 20 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Switching Between Cutting and Marking The Spirit system has the capability of plasma cutting and plasma marking with the same set of consumables The process cutting or marking can be set by the RS 422 serial interface by a hard signal on the CNC interface plug or locally at the automatic gas console To control how switching between processes is performed scroll down to the Cut Mark Cut selection on the Maintenance Screen and press enter The Cut Mark Cut Configuration screen will be displayed as shown Pressing F3 will toggle the cut mark cut configuration between hard signal RS 422 and local When the desired selection is highlighted press ENT CUT MARK CUT CONFIGURATION STATUS HARD SIGNAL USE THIS PARAMETER TO SPECIFY HON SHITCHING BETHEEN CUTTING AND MARKING 1S CONTROLLED PRESS M10 CHANGE CONFIGURATION PRESS AD 10 RETURN TO THE MAINTENANCE MENU CURRENT MODE CUT MARK CUT CONFIGURATION
72. NG PIERCE TIME 0000 ms psi 025 0 PRESS F io SAVE SETTING FOR 0 290 in MILD STEEL COLD CURRENT MODE STATUS Help Prompt 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 Operation Spirit275a User s Manual Rev K Automatic Gas Console Status Screen When the automatic gas console is in the status mode the status screen is displayed as shown The status screen displays all of the primary cutting or marking parameters To edit a parameter on the status screen the arrow keys can be used to scroll through the different parameters or the Menu key can be used as described previously Note that when the Menu key is pressed the Menu icon appears in the upper right hand corner of the screen as shown To return to the status mode from another mode press the Menu key then the Status key The status screen also displays the Please Wait icon while the gas pressures are being adjusted or when an error occurs with the gas system MATERIAL SUBSTANCE MILD STEEL COLD GAS AIR THICKNESS 0 250 INCHES psi 025 0 CURRENT 70 AMPS PROCESS CUTTING TORCH PARTS GAS OXYGEN psi 076 0 CUTTING PIERCE TIME 0200 ms GAS AIR MARKING PIERCE TIME 0000 ms psl 025 0 PRESS F3 D SAVE SETTING FOR 0 250
73. REPLACE REPAIR Lal MICROPROCESSOR CABLE P C BOARD REPLACE Lai CHOPPER peg ASSEMBLY 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 7 14 Parts List Spirit275a User s Manual Rev K Section 8 Parts List Power Supply Note See Figures Below Item Number Part Number Quantity Description 1 708088 1 Off switch red 2 708111 1 Off actuator red 3 708090 1 On switch green 4 708089 1 On actuator green illuminated 5 501163 2 Light housing 6 501164 2 Bulb 7 501162 1 White lens 8 501161 1 Red lens 12 707260 1 L1 inductor 13 500557 1 TR2 control transformer 208 230 460 V 60 Hz 706205 TR2 control transformer 575 V 60 Hz 500559 TR2 control transformer 380 415 V 50 60 Hz 14 706264 1 TR1 main transformer 208 V 60 Hz 3 706263 TR1 main transformer 230 V 60 Hz 30 706262 TR1 main transformer 380 V 50 60 Hz 30 706261 TR1 main transformer 415 V 50 60 Hz 30 706260 TR1 main transformer 460 V 60 Hz 30 706265 TR1 main transformer 575 V 60 Hz 30 15 709086 4 TB1 TB4 terminal block marker 14 position 16 709007 4 TB1 TB4 terminal block 14 position 17 709058 10 F2 F11 fuse holder 18 709012 1 F10 fuse AGC 3A fuse 19 709011 2 F3 F4 fuse AGC 5A 20 709059 1
74. REV 0 ASSEMBLY P N 500810 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 8 18 Parts List Spirit275a User s Manual Rev K Relay P C Board Assembly 500348 HoH rr Z a K2 PRESSURE x mM 2 In Zz N a gt m Ld N lt N gt Lu a4 N xt mM 2 In Zz N a m O a x zZ lt m 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 8 19 Parts List Spirit275a User s Manual Rev K Power Supply I O P C Board Assembly 277452 1 4 7 A afl c4 3 6 9 B oo h L See od O ELECTRODE NOZZLE SHUNT POS WORK GROUND SHUNT NEG O O O O a C_D C D C a INNERLOGIC INC BLANK PCB P N 200351 REV 0 ASSEMBLY P N 200352 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 8 20 Parts List Spirit275a User s Ma
75. RORS 6 PERCENT ERROR 32 2 PIERCES ERRORS 12 PERCENT ERROR 1 3 PIERCES ERRORS 0 PERCENT ERROR 0 4 PIERCES ERRORS 0 PERCENT ERROR 0 I 3 PIERCES ERRORS O PERCENT ERROR 0 PRESS MES 10 VIEW ERRORS PRESS GT 10 RESET COUNT PRESS ANY OTHER KEY TO RETURN TO THE MAINTENANCE MENU CURRENT MODE CUT ERRORS KALIBURN 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Selecting an Error Set to View When the cut errors screen is being displayed press F3 to view the actual cut errors When F3 is pressed the error selection screen is displayed as shown Use the arrow keys to scroll to the error set that is to be viewed and press ENT I VIEW PRESENT ERRORS US ERRORS 1 US ERRORS 2 US ERRORS 3 US ERRORS 4 ERRORS 9 PRESS GA THEN GBB ro RETURN TO STATUS SCREEN PRESS ME 10 SELECT AN OPTION FROM THE MENU CURRENT MODE CUT ERRORS KALIBURN 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
76. To set the communication node number for the Spirit system scroll down to the Set Communication Node selection on the maintenance screen and press ENT The communication node selection screen will be displayed as shown Press F3 to scroll through the available node numbers When using an Inova torch height control system with the Spirit the communication node feature must be disabled To disable the communication node press F3 until disabled is displayed in the node number selection box When the desired selection is highlighted press ENT RS 422 SERIAL COMMUNICATION NODE NUMBER DISABLED SET THE NODE NUMBER TO DISABLED WHEN THE SPIRIT IS CONNECTED TO AN INOVA USING AN RS 422 COMMUNICATION CABLE PRESS QB O SELECT THE PROPER NODE NUMBER PRESS ENT A RETURN TO THE MAINTENANCE MENU CURRENT MODE COMMUNICATION NODE KAL I BURN 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Inova Parameter Transmit If an Inova arc voltage control system is not being used with the Spirit system the Inova Parameter Transmit feature must be disabled With the Inova Parameter Transmit feature set to automatic the Inova is automatica
77. Y Torch Head Retaining Cap Swirl Ring 277154 277266 277259 279150 Imperial Material p Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 156 80 195 250 500 450 1 2 148 75 130 300 600 i 5 8 37 68 85 68 155 60 190 350 800 J55 3 4 160 50 200 400 1200 i 1 0 170 35 240 450 1500 160 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 154 2010 4 7 6 5 600 3 8 12 149 1935 3 6 7 3 16 37 68 85 68 155 1515 4 8 8 9 800 39 20 161 1215 5 2 10 3 i 1500 25 169 915 6 0 11 3 4 1 Marking Material Arc Travel Marking Initial Pierce Thickness Prefiow Plasma Shield een Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 120 250 6350 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 Revised 12 01 2009 This information is subject to the controls of the Export Ad
78. aining Cap Swirl Ring Torch Head 277154 277280 277139 279150 Imperial Material p Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 145 85 160 250 500 490 1 2 142 80 140 300 600 5 8 145 65 185 350 800 40 63 70 63 195 3 4 150 55 225 400 1200 1 0 160 33 250 450 200 1500 1 25 170 26 280 350 205 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 144 2140 4 0 6 5 600 4 8 12 142 2060 3 7 7 3 16 145 1640 4 7 8 9 800 40 63 70 63 5 0 20 151 1315 5 8 10 3 25 159 875 6 3 11 3 1500 5 1 32 170 650 7 1 8 7 5 2 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow Pasma Shield poe Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 108 250 6350 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 Edge start recommended Revised 12 01 2009 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S
79. 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 4 Specifications Spirit275a User s Manual Rev K Remote High Frequency Console Specifications Stock Number s cic c eee chee 205500 PLT Ae deceit beatae dy veer S AEE ESA 5 35 in 136 mm Widi eee te eee ie ere ee eh eee Beare Renee Mir ney eRe eC 13 5 in 343 mm DG ptlisirceesacetce EE 10 in 25 mm MV GIGI erang sett ced acatee tenth E s 22 b 10 kg Spark gap distance 0 eeeeeeeeeeeeeeeeeeeeeeeeeeeees 015 in 381 mm _ 8 00 203 i a i i 4 312 8 mm p 12 75 324 12 00 305 13 50 343 ij e a 10 00 254 m ani 5 35 136 ooi POWER TEADS on m RABUN o This information is subject to the controls of the Export Administration Regulat
80. antability or fitness for any particular purpose are expressly excluded If this product or any component thereof is determined to be defective in manufacture KALIBURN will repair or replace the defective component or product The buyers remedies are limited to the return of the product for repair or replacement of any non conforming 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 Beyond this remedy KALIBURN will not 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 This warranty will be considered void if torches or torch consumables manufactured by anyone other than KALIBURN are incorporated into this product 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 stock 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
81. anual Rev K attempt to use a cylinder that is leaking cracked or has other signs of physical damage e All gas cylinders should be secured to a wall or rack to prevent accidental knock over e lf a compressed gas cylinder is not being used replace the protective valve cover e Never attempt to repair compressed gas cylinders e Keep compressed gas cylinders away from intense heat sparks or flames e Clear the compressed gas cylinder connection point by opening the valve momentarily prior to installing a regulator e Never lubricate compressed gas cylinder valves or pressure regulators with any type of oil or grease e Never use a compressed gas cylinder or pressure regulator for any purpose other than which it is intended e Never use a pressure regulator for any gas other than which it is intended e Never use a pressure regulator that is leaking or has other signs of physical damage e Never use oxygen hoses and pressure regulators for any gas other than oxygen e Never use any gas hose that is leaking or has other signs of physical damage Health Support Equipment The Spirit275a 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 Spirit system Observe the following guidelines to minimize exposure to these electr
82. any location outside the United States contrary to the requirements of the EAR 5 13 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Restoring Factory Default Cutting or Marking Conditions To restore a factory default cutting or marking condition scroll down to the Restore Factory Defaults selection on the maintenance screen and press ENT The restore screen will be displayed as shown Note that the present material type and thickness selected on the status screen will be automatically displayed on the restore screen Press ENT to restore the factory default setting for the material type and thickness displayed To change the material type press the F3 key To edit the material thickness use the arrow keys to scroll to Thickness and use the numerical keypad to enter the thickness To restore the factory default cutting and marking conditions for all user saved files press 1 then 2 then 3 as shown on the screen below To restore corrupted cutting or marking conditions press 7 then 8 then 9 as shown on the screen below SUBSTANCE MILD STEEL HOT THICKNESS 0 250 inches PROCESS CUTTING PRESS fH To RESTORE DEFAULTS FOR THE ABOVE SETTING PRESS FMB THEN MM THEN RMB TO RESTORE ALL DEFAULT SETTINGS IRG pi PRESS GEAR THEN MM THEN ER TO RESTORE CORRUPTED USER DATA PRESS BIB T0 CHANGE SUBSTANCE TYPE CURRENT MODE RESTORE DEFAULTS KAL I BURN This information is subje
83. arking Initial Pierce Thickness Preflow Pasma Shield poe Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 108 250 6350 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 Edge start recommended Revised 10 22 2009 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 43 Operation Spirit275a User s Manual Rev K Aluminum 30 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap 277145 Nozzle 277120 Electrode 277130 Torch Head Outer Cap Retaining Cap Swirl Ring 277154 277153 277140 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 040 150 100 100 065 050 30 92 20 90 135 120 030 063 90 150 200 070 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma S
84. aterial type Oxygen Inlet Qs ISO 3821 hose color blue e 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 e Nitrogen must be supplied to the unit at all times regardless of the cutting current or material type H17 Inlet 7 ISO 3821 hose color red e H17 must be supplied to the unit when stainless steel is being cut with H17 as the plasma gas See cutting charts in Section 4 for more information C Gd G MAXIMUM INPUT GAS PRESSURE 145 psi MARKING MARKING POSTFLOW PLASMA SHIELD PREFLOW PRESSURE OuT OUT Our UT QUT i ki EN li onae L E Oo O O PAra Tr ATATA TAT ATATA ATAT PAP D 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 15 Installation Spirit275a User s Manual Rev K CNC Machine Interface Connections Perform the following steps to properly interface the Spirit275a system with a CNC cutting machine See the system schematic for additional information Plasma Start Input e The Spirit275a requires a contact closure betwe
85. between P26 8 and P2 1 and between P26 7 and P2 2 Also check that these wires are not shorted to each other If the cable is OK connect P26 to the microprocessor p c board but leave P2 disconnected from the chopper With power applied give the power supply a start signal and check for approximately 10 VDC between P26 7 ground and P26 8 signal when the main contactor is energized If 10 VDC is not present replace the microprocessor p c board If 10 VDC is present turn all power off reconnect P2 to the chopper p c board and repeat the test for 10 VDC between P2 2 ground and P2 1 signal If 10 VDC is present and LED 7 is not illuminated replace the chopper 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 7 13 Maintenance and Troubleshooting Spirit275a User s Manual Rev K 3 PHASE POWER 2 FUSES CORRECT AS NECESSARY NO 3 PHASE AT CHOPPER CHECK CON1 AND WIRING YES 325 VDC YES AT CHOPPER OUTPUT CHOPPER OK NO CHECK FUSE F2 AND WIRING 120 VAC AT CHOPPER NO P2 4 5 NO VOLTAGE OK YES P26 1 2 VOLTAGE OK REPAIR ON OFF CABLE YES
86. bject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 5 Parts List Spirit275a User s Manual Rev K Power Supply 4 of 4 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 8 6 Parts List Spirit275a User s Manual Rev K Automatic Gas Console Assembly 280002 Note See Figures Below Item Number Part Number Quantity Not shown 16 17 18 19 20 31 Not shown 33 34 35 36 37 38 39 40 280005 501146 500860 710199 500861 706044 709003 700404 702037 709179 709192 505039 500021 505047 501145 708097 715097 260217 500867 500868 709007 709009 200082 500907 200083 501170 505041 280049 200288 280286 280001 708078 280007 260111 260109 260104 280030 280031 32 92 mm ASD SB Sm mom mm nn nr nn WU DAO Sa ama O ahY Aa aA a oa a Description AGC decal membrane sw
87. by blinking LED22 on and off to indicate that an error has occurred The number of blinks can be counted to determine which error has occurred The following chart lists the errors and the corresponding number of blinks LED22 Number of Error Blinks 1 No transferred arc TAC established 2 TAC lost before current slope up 3 TAC lost during current slope up 4 TAC lost while cutting 5 TAC lost during current slope down 6 Start signal applied prematurely 7 Start signal removed prematurely 8 Output voltage below 60V 9 Output voltage above 210V 10 Invalid current set point 11 Current feedback circuit open 12 TAC not established within 2 seconds 13 Arc hold timed out 14 Pilot arc not established 15 Low current during cut 16 TAC sensed when start signal applied 17 Faulty AC phase 18 Low torch coolant flow 19 Gas console error 20 RHF door switch open 21 Low torch coolant level 22 High torch coolant temperature 23 Main contactor shorted 24 AGC Fan not operational 25 Defective Flow Switch 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 7 8 Maintenance and Troubleshooting Spirit275a User s Manual Rev K General Troubleshooting The following chart lists general troubleshooting guidelines for the Spirit system when the sta
88. cation outside the United States contrary to the requirements of the EAR 5 17 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Viewing Serial Communications To view the serial communication between the Spirit and an external device scroll down to the View Serial Communication selection on the Maintenance screen and press enter The Serial Communication screen will be displayed as shown All incoming and outgoing data is displayed in decimal base 10 format Note that incoming data is appended to show an R before the data and outgoing transmissions are appended to show a T before the data Pressing F3 will toggle the display on and off and pressing CLR will clear the screen PRESS MJ 10 TOsGLE ON OFF R170 Ri R250 R38 ROO ROL R13 PRESS MED 10 CLEAR SCREEN press M 70 ExT SERIAL COMM ON CURRENT MODE SERIAL COMMUNICATION KAL I BURN 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Configuring Hydrogen Cutting When hydrogen cutting is enabled the H17 hydrogen mixture will automatically be selected as the plasma gas for certain material types and thicknesses To prevent th
89. ceeeeeeeeeeeeeeeseeeeeeeeeeeeeeees 8 17 AC Detect PC Board ea2 etitean cote ere ent en ee nal tel saben ole tt oer aie ad tea 8 18 Relay P O Board cca ate eo tee vena E tence ot aa E r mac pee sare ea aiaee E e ESETE 8 19 Power Supply I O P C Board cccccccccceceeeeeeeeeeeeeeeeeeeaeeeeeeasssseeeeesseeeeeeeeeeeeeeaees 8 20 Automatic Gas Console I O P C Board ccc ceeeeeeeeeeeeeceeeeeeeeeeeeeeeeeeteeeeeeeeeeaaaaaaas 8 21 Consumable Spare Parts Kit gah cehcsvohixs 322 sic pans ansacmasaasi epee endo Sev Sadia taadans a ieee 8 22 Appendix A Electromagnetic Compatibility EMC BACK GQFOUna 2s ccseaectacterasa ae E a E E A a A EG A 1 Installation ang WSC a ore oes hate Ae oO ees ee de ee de ek oe A 1 Assessment OL Ga stani Pte he ho eth et te Me ee ee eS A 2 Methods of Reducing Emissions 2 0220 6 ceeceeeeeeeeeeeeeeeteneeeneeeeeedeceeeneennnectenenees A 2 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 Safety Spirit275a User s Manual Rev K 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
90. ceneeeteeeeeenene Oxygen and Nitrogen Marking gas type eeeeeeeeeeeeeeeeeeetttteeeeees Nitrogen Plasma gas flow rate maximum Oxygen OF AIr coke cele i esetsi necra itha 67 scfh 1897 liters hour Pel LEE ited E E E E E E 75 scfh 2124 liters hour Shield gas flow rate maximum OXYGEN Ke eera eene enep ieee iee Ee 19 scfh 538 liters hour Air or Nitrogen seeren 225 scfh 6371 liters hour Preflow gas flow rate maximum 60 scfh 1699 liters hour Marking gas flow rate maximum 79 scfh 2237 liters hour Rated Inlet gas pressure cccccccseeeeseeeeeeeeees 120 psi 8 3 bar Maximum Inlet gas preSSUre 0ceeeeeeee eee 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
91. cess The Spirit system has the capability of plasma cutting and plasma marking with the same set of consumables The process cutting or marking can be set by the RS 422 serial interface by a hard signal on the CNC interface plug or locally at the automatic gas console See Section 5 Automatic Gas Console Advanced Functions for instructions on setting up how switching between cutting and marking is performed To set the operating process use the down arrow to scroll down to Process The process area should be highlighted as shown below and the process should be blinking To change the process press F3 as indicated by the help prompt Repeatedly pressing F3 will alternate between cutting and marking Press the enter key when the desired process has been selected At this point the default parameters are selected and adjusted automatically for the material type material thickness and process selected Note that the CNC machine can override the selected process unless the cut mark cut configuration is set to Local SUBSTANCE MILD STEEL COLD GAS AIR THICKNESS 0 250 INCHES psi 025 0 CURRENT 70 AMPS PROCESS CUTTING TORCH PARTS GAS OXYGEN psi 0 6 0 CUTTING PIERCE TIME 0200 ms GAS AIR MARKING PIERCE TIME 0000 ms psi 025 0 press Mj 10 cuewce CURRENT MODE PROCESS This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided t
92. ct to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 14 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Measurement System The Spirit system will operate using Imperial units or Metric units To change the units of operation scroll down to the Measurement System selection on the maintenance screen and press ENT The measurement system screen will be displayed as shown Press F3 to toggle the measurement system between Imperial and Metric When the desired selection is highlighted press ENT MEASUREMENT SYSTEM IMPERIAL PRESS F3 i CHANGE SYSTEM OF MEASUREMENT PRESS ENT A RETURN TO THE MAINTENANCE MENU CURRENT MODE MEASUREMENT SYSTEM KAL I BURN 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Communication Node When multiple Spirit systems are being used together on an RS 422 serial communication link each system must have a unique identification number node number to identify itself to the network
93. d 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 e 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 Spirit system if the power cord is damaged in any way e Make sure the primary power ground wire is connected to the input power ground stud on the Spirit power supply Make sure the connection is securely tightened e Make sure the positive output work ground of the Spirit 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 e Inspect the torch leads frequently Never use the system if the leads are damaged in any way e Do not stand in wet damp areas when operating or performing maintenance on the system e Wear insulated gloves and shoes while operating or performing maintenance on the system e Make sure the Spirit system is switched off at the wall disconnect before servicing the power supply or torch e Never change torch consumable parts unless the Spirit system is switched off at the wall disconnect T
94. d by any means to any location outside the United States contrary to the requirements of the EAR 5 12 Automatic Gas Console Advanced Function S Spirit275a User s Manual Rev K Pressure Diagnostics To enter the pressure diagnostics mode scroll down to the Pressure Diagnostics selection on the maintenance screen and press ENT The pressure diagnostics screen will be displayed as shown Pressing the Preflow Gas Plasma Gas and Shielding Gas buttons will toggle the corresponding valves between the off and on states Note that the preflow valve and the plasma valve cannot be on at the same time During a cutting or marking sequence the status of all valves will display N A PREFLOW 024 9 psi PLASMA 080 1 psi SHIELD 029 2 psi POSTFLON 079 3 psi MARKING 028 0 psi LE PREF LE PLAS LE SH press MB T0 T06 PRESS R TO 106 press A T0 T00 PRESS AT TO press R 10 To press jj 10 ker LE MARK RN TOT PRESSURE VALVE ST VALVE ST VALVE ST VALVE ST VALVE ST MA VALVE ON OFF G G G ELD VALVE ON OFF GLE POSTFLON VALVE ON OFF G U LOW VALVE ON OFF ING VALVE ON OFF HE MAINTENANCE MENU CURRENT MODE PRESSURE DIAGNOSTICS ATUS ATUS ATUS ATUS ATUS KALIBURN 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
95. d should be sized according to local and national codes Route the power cable through the lower strain relief on the rear of the power supply and connect it to the input terminal block TB5 as shown TB5 is located on the base of the power supply behind the left side cover Be sure to connect the primary ground cable to the ground stud on the input terminal block 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 Installation Spirit275a User s Manual Rev K G PEBE o Bes bep zef j TB5 Location Disconnect Box 5 Connections Strain Relief L1 U L2 V L3 W Ground W This informat
96. d to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 6 Installation Spirit275a User s Manual Rev K Ry iwi p D A LONO ONIO in Nae Ng Na 6 asesese SxS AN KOS XX tetty eso 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 Installation Spirit275a User s Manual Rev K Torch Leads to RHF Console Connections Perform the following steps to connect the torch leads to the RHF console See figure below 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 RHF 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 RHF console in order to help reduce high frequency noise emission Using an ohmm
97. e Gas Console status LED will illuminate 3 Once the Gas Console LED illuminates the unit is ready for cutting or marking Upon the reception of a cycle start signal the following sequence will take place Two second gas preflow High frequency starting circuit energized Pilot arc initiation Transferred arc cutting or marking arc established e Motion output relay energized 4 Upon removal of the cycle start signal the arc will be extinguished and the motion output relay will be deenergized 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 19 Operation Spirit275a User s Manual Rev K 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
98. e Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 16 138 115 105 200 300 100 1 4 28 67 46 67 140 100 125 225 400 405 3 8 152 65 180 250 500 i Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 5 138 2865 2 7 5 1 2 5 28 67 46 67 400 6 139 2625 3 0 5 5 2 7 Marking Material Arc Travel Marking Initial Pierce Thickness Prenlow Plasma Shield ron Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 130 250 6350 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 Revised 12 1 09 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 36 Operation Spirit275a User s Manual Rev K Stainless Steel 100 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross l
99. e on the Spirit system The system utilizes potentially fatal A C and D C voltages All maintenance should be performed with safety in mind Use extreme caution when working near the power conversion module i e chopper The large electrolytic capacitors store large amounts of energy even after power has been removed from the system Wait at least five minutes after turning off power and then use a voltmeter to verify that the capacitors are fully discharged before touching the power conversion module Capacitor failure can injure and or cause property damage If troubleshooting requires the system to be powered with the enclosure panels removed remain clear of the capacitors Failure of a capacitor can result in a sudden release of stored energy causing rupture of the capacitor case Routine Maintenance Note At minimum these checks should be performed on a monthly basis In excessively dirty environments or in heavy usage situations the checks should be performed more frequently Power Supply 1 2 NOOA Remove the left right front and rear panels of the power supply Using clean dry compressed air blow out all accumulated dust inside the power supply including dust on p c boards and fans Be sure to blow out the fan and heat exchanger at the rear of the unit In an excessively dirty environment blow out the unit on a weekly basis Verify that all torch lead and work ground connections are secure and free fr
100. e 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 Explosion Prevention The Spirit275a 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 e Never operate the Spirit system in the presence of explosive gases or other explosive materials e Never cut pressurized cylinders or any closed container e 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 e 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 e Compressed gas cylinders should be maintained properly Never 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 Safety Spirit275a User s M
101. e use of H17 hydrogen cutting must be disabled To disable hydrogen cutting scroll down to the Configure Hydrogen Cutting selection on the Maintenance Screen and press enter The Configure Hydrogen Cutting screen will be displayed as shown Pressing F3 will toggle the hydrogen cutting setting between enabled and disabled When the desired selection is highlighted press ENT HYDROGEN CUTTING STATUS DISABLED PRESS F3 D ENABLE DISABLE Hl CUTTING PRESS ENT A RETURN TO THE MAINTENANCE MENU CURRENT MODE CONFIGURE HYDROGEN CUTTING KAL I BURN 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Setting an Arc Off Delay In some instances such as when cutting thicker stainless steel materials it may be desirable to delay the extinction of the cutting arc after a stop signal is received To program an arc off delay scroll down to the Set Arc Off Delay selection on the Maintenance Screen and press enter The Set Arc Off Delay screen will be displayed as shown Use the keypad to enter the desired delay time in milliseconds The delay can be set from 0 to 2000 mS ARC OFF DELAY DELAY 0000 nS USE THE NUMERICAL KEYPAD TO
102. eeeeeeeeeeeeeeeeeeeeeeeeees 5 21 Software Updates sisi ces esatectics eed cecana aa ata ci settee aap case Asean Lanta aeons 5 22 Section 6 Serial Communication Initializing the Spirit System 2 2 cccccceeeseseeeseesseeeeeeeeeeeeeeeeeeeeeeeaaseesseeeeseeeeeeeeeeess 6 1 Transmitting Parameters to the Spirit System 2 0 00 cccceeee cette eee eeeeeeeeeeeeeaeaaaaaaeees 6 1 Communication Error Checking s 1 s65sc ceeeetndtanieediet en neti 6 2 Default Cutting Parameters 22 2 5 cesta ataelee ee atontetcneleetontt acetate eee 6 3 Troubleshooting Serial COMMUNICATION eee eeeeeeeeeeeeeeeeeeeeee eee eeteteeeeeeeeeaaaaaaaae 6 3 RS 422 Serial COMMANAS 25 ocsce sso eas ace eee ed adic wie Sag ae eh ete 6 4 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 Spirit275a User s Manual Rev K Section 7 Maintenance and Troubleshooting Routine Maintenance cccccessceeessseseeeeceeeeeeececeeceeeceaaeeaasseeeeseeeeeeeeeeeeeeeeeeeanaaees 7 1 Replacing the Torch Coolantec 2 32 cence nena Sei in eens 7 4 Micr pr cess r Status LED Sipocot i a eetan cabs a Sa Gas ont ra eraai Si n 7 5 Microprocessor Sequence of Operation ccccceccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaanaes 7 6 Troubleshooting Using the Control Panel
103. en 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 12VDC 10mA Plasma Cut Mark Input e The Spirit275a 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 12VDC 10mA Arc Hold Input e The Spirit275a 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 12VDC 10mA Motion Output e The Spirit275a 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 6A 125VAC 6A 110VDC 2A 30VDC Remote On Off Input e The Spirit275a requires a maintained contact closure between P8 pins 5 and 6 to energize the system from a remote location provided that the emergency stop button on the front panel is not activated Opening the contacts deenergizes the system If the remote on off feature is not used insta
104. eter measure for zero ohms between the braided shield and the ground stud located on the outside of the RHF console Torch Electrode Coolant Supply Lead e 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 AD e 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 e 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 13 e 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 8 Installation Spirit275a User s Manual Rev K O00 10 11 13 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 Installation Spirit275a User s Manual Rev K Torch Leads to Torch Base Connections Perform the following step
105. ety and Health Standards obtainable from the U S Government Printing Office Washington D C 20402 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 IR3 Canada 19 Canadian Electrical Code Part 1 Safety Standard for Electrical Installations obtainable from the Canadian Standards Association 178 Re
106. evels Shield Cap Nozzle Electrode 277284 277282 277286 Q YY EF Torch Head Outer Cap Retaining Cap Swirl Ring 277154 277151 277283 279150 Imperial Material p Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 141 100 135 225 400 092 3 8 25 94 35 93 147 80 170 250 500 095 1 2 154 55 210 300 600 i Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 140 2595 3 2 5 6 400 2 3 10 25 94 35 93 148 1935 4 4 6 5 600 2 4 12 152 1540 5 0 7 3 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow Eigen Snieg ree Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 130 250 6350 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 Revised 10 21 2009 This information is subject to the controls of the Export Administration Regulations EAR This informat
107. f 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 249 1 Safety in Welding Cutting and Allied Processes obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 7 ANSI Standard 241 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 249 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 287 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 288 2 Respiratory Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 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 Safety Spirit275a User s Manual Rev K 11 OSHA Standard 29CFR 1910 252 Saf
108. ferred by any means to any location outside the United States contrary to the requirements of the EAR 8 2 Parts List Spirit275a User s Manual Rev K Power Supply 1 of 4 3 5 5 1 4 6 6 2 4 7 8 5 Qr noor Qeucomos i Na BKALIBURN e R OFF ON POWER POWER Tea K Q roar reer iN o o o o INO 17X21 17O 17X24 17X21 FS 17 1 BRE ofe dace elelee Ojelelelelejelelelelejelelejo F4 119 F3 4 1234667 8 91011121314 XN8 o s TB2 fle ee eS eee eee eee 5 F2 Sis 9 s8 9 9 9 9 9 9 s ajo 781 s r Front panel fans not shown item numbers 42 and 82 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 8 3 Parts List Spirit275a User s Manual Rev K Power Supply 2 of 4 O O 12346567 8 9 1011121314 9 8 9 8 9 9 98 9 9 9 9 9 9 9le TBS Sle s 9 9 9 9 9 9 9 9 9 9 9 2M _
109. g arc transfers to the workpiece a motion signal ok to move signal is sent to the x y controller or torch height control When the motion signal is issued the x y controller or torch height control should position the torch to the correct pierce height The torch should remain at the pierce height until the Pierce Time has elapsed at which time the torch should be positioned at the correct cutting or marking height When cutting the Pierce Time should be adjusted so the arc fully penetrates the plate before the torch is moved to the cut height See Piercing Thick Materials in Section 4 When marking the Pierce Time is usually adjusted to zero To alter the Pierce Time use the arrow keys to scroll to Cutting Pierce Time or Marking Pierce Time The pierce time should be highlighted as shown and the editing cursor should be blinking Use the numerical keypad to enter the desired Pierce Time Note that the units are in milliseconds 1000 milliseconds 1 second Use the CLR key to backspace if an error is made When the correct value has been entered press ENT Note that the maximum allowable Pierce Time is 5000 milliseconds 5 seconds PREFLOW UBSTANCE MILD STEEL COLD GAS ALR HICKNESS 0 290 INCHES psi 029 0 URRENT 70 AMPS ROCESS CUTTING ORCH PARTS GAD OXYGEN psi 076 0 CUTTING PIERCE TIME 0200 ms GAS AIR MARKING PIERCE TIME 0000 ms psi 029 0 USE THE NUMERICAL KEYPAD TO ENTER DELAY TIME CURRENT MO
110. he United States contrary to the requirements of the EAR 3 17 Installation Spirit275a User s Manual Rev K Torch Coolant Requirements Note Refer to the supplier s most current Material Safety Data Sheet for information regarding safety handling and storage of torch coolant The Spirit275a 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 13 C 9 F The standard solution can be ordered in one gallon containers PN 500695 For operating temperatures below 13 C a 50 solution of industrial grade propylene glycol can be ordered in one gallon containers PN 500895 providing protection down to 36 C 33 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 water filter deionization cartridge should also be changed at the same time See Section 7 for details This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided
111. head uses cooling tube P N 277007 If replacement is required use tool P N 200109 If using a silver electrode the torch head uses cooling tube P N 279117 and cooling tube holder P N 279116 Remove the cooling tube holder using tool P N 277087 and inspect the o rings for damage Apply a small amount of o ring lubricant before re installing in the torch head 9 Wipe any excess o ring lubricant off of the torch base and head This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 2 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Remote High Frequency Console 1 Open the cover of the RHF console and verify that all leads and hoses are tightened securely Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened 2 Check the spark gap electrodes for signs of wear Replace electrodes that have rounded faces Use a clean feeler gauge and set the spark gap to 015 38 mm Work Ground 1 Verify that the work ground lead is securely fastened to the star ground on the cutting table and that the connection point is free from corrosion Use a wire brush to clean the connection point if necessary This information is subject to the controls of the Expor
112. hield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 3885 2 5 100 1 7 30 92 20 90 135 0 8 1 5 2520 3 4 200 1 8 Marking Material F Arc Travel Marking Initial Pierce Thickness PreNow Pasma Shield Roe Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 145 250 6350 177 4 5 100 2 5 0 Use an arc transfer height ignition height of 100 2 5 mm for cutting and 100 2 5 mm for marking Revised 12 01 2009 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 44 Operation Spirit275a User s Manual Rev K Aluminum 50 Amps Air Plasma Nitrogen Shield Copper Electrode Q Outer Cap Shield Cap 277150 Nozzle 277122 2 Electrode 277131 LL Torch Head Retaining Cap Swirl Ring 277154 277153 277142 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi
113. hield ROStMOw Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 135 250 6350 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 Revised 12 01 09 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 38 Operation Spirit275a User s Manual Rev K Stainless Steel 150 Amps Air Plasma Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Copper Electrode Shield Cap 277117 Q Nozzle 277293 2 Electrode 277292 Y J Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277139 279150 Imperial Material p Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 150 160 250 400 495 3 8 150 115 180 275 500 1 2 25 75 70 67
114. his 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 Safety Spirit275a User s Manual Rev K e 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 e Never bypass the safety interlock devices e Before removing any of the Spirit 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 7 for additional safety precautions e Never operate the Spirit system without all of the covers in place See Section 7 for additional safety precautions e Preventive maintenance should be performed daily to avoid possible safety hazards Fire Prevention When using the Spirit275a 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 Mak
115. hould be added to the system any time the level drops below half full 8 Check for coolant leaks at all hose connections inside the power supply RHF console and at the 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 3 19 Installation Spirit275a User s Manual Rev K BLANK PAGE 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 Operation Spirit275a User s Manual Rev K Section 4 Operation Power Supply Front Panel Controls All of the Spirit controls and status indicator lights are located on the front panel of the system as shown below This section describes the function of each control and indicator Power Off Button Deenergizes the Spirit system and turns off the cooling fans and coolant pump Power On Button Indicator 2 Energizes the Spirit system and turns on the cooling fans and coolant pump Also illuminates to show that the system is energized AC Power Indicator G Illuminates when 3 phase power is applied to the Spirit system DC Power Indicator Illuminates
116. ial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 8 35 110 190 150 100 100 080 3 16 113 130 200 200 25 80 79 1 4 40 116 120 110 225 300 085 3 8 122 75 140 250 400 i Metric Material A Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 3 35 109 4995 3 6 100 2 5 2 0 5 25 80 79 113 3265 5 1 40 300 6 115 3105 2 7 5 5 2 2 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow plasma Sneg ey Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 135 250 6350 096 2 4 100 2 5 0 1 Revised on 12 01 2009 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 27 Operation Spirit275a User s Manual Rev K Mild Steel 100 Amps Oxygen Plasma Air Shield Q Outer Cap Copper Electrode Shield Cap Nozzle Electrode 277284 277282 277286
117. ial F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 230 040 200 300 3 8 130 140 090 250 400 150 1 2 133 120 115 300 500 5 8 137 100 130 350 600 152 3 4 140 75 150 400 800 153 20 82 58 75 1 147 50 175 450 1000 455 1 25 155 25 240 500 i 1 5 165 17 300 350 1500 158 1 75 175 12 350 2 0 185 7 500 500 160 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 6100 8 4 9 300 10 130 3480 2 3 6 5 3 8 500 12 132 3160 2 7 7 3 16 137 2515 3 3 8 9 800 20 141 1810 3 8 10 3 20 82 58 75 1000 3 9 25 146 1310 4 3 11 3 32 155 610 6 1 12 7 38 164 435 7 5 8 9 1500 4 0 45 175 295 9 2 9 2 50 183 195 12 2 12 2 4 1 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow Plasma Snieg Postiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 120 250 6350 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 Edge start recommended Revised 12 01 09 This informat
118. ic and magnetic fields e Stay as far away from the Spirit power supply torch torch leads and remote high frequency console as possible e Route the torch leads as close as possible to the work ground cable e 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 e 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 Safety Spirit275a User s Manual Rev K 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 o
119. ignifies the end of the command The in the hex string is the MSB followed by the LSB of a type int The integer is the value used in the additional information column Thus the ig sometimes referred to as the additional information value In the example we wanted to transmit a Cutting Pierce Time of 1000 mS 1 second This value in hexadecimal would be 03E8 msb 03 Isb E8 In this example the following string would be transmitted in order to set the cutting pierce time to 1000mS for a power supply on net node 1 AA 01 FA 04 03 E8 0D For multiple power supply installations commands can be sent to all power supplies at the same time This is referred to as a global command To senda global command set the net node value to C8 hex 200 decimal In the example above the following string would be transmitted to set the Cutting Pierce Time to 1000mS for all power supplies connected on the network AA C8 FA 04 03 E8 0D Communication Error Checking With a single torch system all commands and parameters transmitted to the Spirit will be back transmitted in exactly the same form for error checking With a multiple torch system only the system with node focus will back transmit the commands The purpose of the node focus command 254 is to allow one Spirit system to use the transmission lines at a time If no node focus is set on initialization the first system to receive a command will receive node focus automatica
120. inction of the arc Valid Range 0 to 2000 mS Machine Type 52 AA nn FA 34 0D If requested in command 30 the AGC will transmit the machine type 153 Spirit150a 203 Spirit200a 273 Spirit275a 403 Spirit400a Set Marking Arc 53 AA nn FA 35 OD Sets marking arc voltage in Volts x 100 Voltage Valid Range 5000 to 20000 Set Marking Height 54 AA nn FA 36 OD Sets marking height in mils inches 1000 Valid Range 0 to 999 Set Marking Start 55 AA nn FA 37 OD Sets marking start height in mils inches Height 1000 Valid Range 0 to 999 Set Marking Travel 56 AA nn FA 38 OD Sets marking travel speed inches min Speed Valid Range 0 to 999 Set Marking Pierce 57 AA nn FA 39 OD Sets marking pierce time in ms Time Valid Range 0 to 9999 Configure 59 AA nn FA 3B 00 0D 0 Local at power supply Cut Mark Cut 1 Hard signal via interface plug 2 RS 422 Node Focus 254 AA C8 FAFE 00nn0D Sends a global command to all systems and sets the node focus to system nn This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 8 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Section 7 Maintenance and Troubleshooting WARNING Only qualified maintenance personnel should perform maintenanc
121. ion is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 4 Installation Spirit275a User s Manual Rev K Power Supply Output Connections Perform the following steps to connect the output of the power supply to the RHF console and the work table See figure below Power Supply Electrode Lead 1 Route one end of the 1 0AWG power supply electrode lead through the upper strain relief on the rear of the power supply and connect it to the electrode terminal 2 Route the other end of the power supply electrode lead through the strain relief on the RHF console and connect it to the cathode manifold Power Supply Nozzle Lead 2 1 Route one end of the 10AWG power supply nozzle lead through the upper strain relief on the rear of the power supply and connect it to the nozzle terminal 2 Route the other end of the power supply nozzle Lead through the strain relief on the RHF console and connect it to the pilot terminal on the RHF console printed circuit board Power Supply CTP Sensor Lead G 1 Route the end of the 14AWG power supply CTP sensor lead with the ring terminal through the middle strain relief on the rear of the power supply and connect it to the CTP terminal 2 Route the end of the power supply CTP sensor lead with the fast on
122. ion is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 30 Operation Spirit275a User s Manual Rev K Mild Steel 275 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode 277263 277269 277270 LL Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 277258 279150 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 125 140 300 500 139 165 5 8 105 135 325 600 3 4 138 90 120 350 800 170 1 144 65 160 400 1000 185 1 25 150 45 175 500 i 20 93 70 83 1 50 163 25 235 1 75 170 20 290 350 190 1500 2 00 180 15 350 2 25 185 13 375 375 260 2 50 190 9 385 385 275 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm
123. ion 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 37 Operation Spirit275a User s Manual Rev K Stainless Steel 150 Amps H17 Plasma Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Q Shield Cap 277298 Nozzle 277297 Electrode 277135 Y yj Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 277139 279150 Imperial Material A Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 95 250 250 400 438 3 8 75 150 275 500 l 1 2 25 81 75 81 165 60 165 300 600 140 5 8 50 185 325 800 l 3 4 40 250 350 1200 145 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 1845 3 8 7 0 3 4 600 12 155 1610 4 1 7 4 25 81 75 81 3 6 16 1260 4 7 8 3 800 20 167 940 6 9 9 0 1200 3 7 Marking Material Arc Travel Marking Initial Pierce Thickness Pretow Plasma s
124. ions EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 5 Specifications Spirit275a User s Manual Rev K Torch Specifications Stock Number 2 Gang Manifold Assembly 260214 Torch Mandl ccc tie hie Be neg 820134 Torch Base ereere deka debe keke 279050 Torch Head Copper Electrode ceee 279150 Torch Head Silver Electrode eeeeeee 279160 Weight Manifold Bracket Handle Base and Head 7 3 Ibs 3 3 kg Manifold 3 38 86 Torch Handle 9 20 234 ols alio 10 Torch Base 1 87 47 Alignment Indicator Slot C O OoOo o gt iL X D P a gt 3 o Zs Q Alignment Indicator Torch Head Small Circle 5 08 129 RRR X Xd RRRRNINRY ww D 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 2 6 Specifications Spirit275a User s Manual Rev K 5 Gang Manifold Specifications
125. itch AGC aluminum display panel AGC display window Aluminum standoff AGC EL display Transformer 241 7 16 Receptacle 9 position Filter bracket Filter Terminal block 10 position Terminal block marker 10 position Floppy disk drive Floppy disk drive cover Floppy disk drive cable Manifold Pressure switch 80 200 psi Transducer isolator Solenoid valve Motorized regulator assembly Motorized regulator assembly oxygen Terminal block 14 position Terminal block marker 14 position Solenoid valve assembly 3 gang Solenoid valve bracket Solenoid valve assembly 4 gang Power supply Video card upper p c board CPU middle p c board I O p c board assembly lower p c board Video card CPU I O p c board assembly Regulator Transducer 0 150 psi Pressure gauge 0 60 psi Proportional valve amplifier Proportional valve Power supply Fan Fan Guard 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 8 7 Parts List Spirit275a User s Manual Rev K Automatic Gas Console 1 of 2 SEE DETAIL BELOW MOTION DELAY G DELAY TINE 0200 ns Y TIE 0000 ns NESS ro sae serine FoR 0 PO Arara AAAA DISPL
126. ition use the arrow keys to scroll off all selections on the status screen When none of the parameters are highlighted the Press F3 to Save Settings message will be displayed as shown Pressing F3 will cause the save confirmation window to pop up When this occurs press ENT to save the condition or press CLR to cancel the procedure Pressing ENT will save the settings for the particular material being cut and a User icon will appear in the upper right hand corner of the screen The User icon indicates that the parameters for the particular material being cut are not factory defaults but are user created The factory default condition can be restored as described later in this section PREFLOW UBSTANCE MILD STEEL COLD GAS ALR HICKNESS 0 290 INCHES psi 029 0 URRENT 70 AMPS ROCESS CUTTING ORCH PARTS GAD OXYGEN psi 076 0 CUTTING PIERCE TIME 0200 ms GAS AIR MARKING PIERCE TIME 0000 ms psi 029 0 PRESS F3 i SAVE SETTING FOR 0 250 in MILD STEEL COLD CURRENT MODE STATUS Gas Purge The gas lines can be purged at any time by pressing the Menu key then the Gas Purge key The gas pressures are also readjusted at this 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 6 A
127. l Rev K Section 4 Operation Power Supply Front Panel Controls cccccceccecceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeaaaeees 4 1 Automatic Gas Console Keypad cccceceeee cece eee eeeeeeeeeeeeeeeeaaaaeeeeeeeeeeeeeeeeeeeeeeeee 4 3 Automatic Gas Console Help Prompt cseceeeeeeeeseeeeeeeeeeeeeeeeeeeeeeessseeeeeeeess 4 4 Automatic Gas Console Status Screen eeeeeeeeeeeeeeeeeeeeeeeeeeeee eee eeeeteeeeeeeeenaea 4 5 Setting up a Cut or Mark ccccscsescsesecececceeeeeeneeeeeeeneeeedensntenensnecceceneneneceeeneeneneees 4 6 Torch Consumable Selecti n seccssecacceeeccx calc Paveeececneunceenendeiguaven se edetencceeeaneseesnenreeseines 4 11 Installing and Removing Torch ConSumables cccccecceeeeeeeeeeeeeteeeeeeeeennnneeaaaees 4 18 Makingvar C t or Mark cnc ereit cadet utente mag TAERE OEA Aa raae ite bes 4 19 Piercing Thick Malenial Se sccscrc utes attiew tara vitae reer renatka eea acu 4 20 CUR QUIIBY sa2e saat bela E EEEE ies eh aviary uch ys ed ote cade 4 21 Changing Consumable Parts sires csc ch c0 sz sce scteeceexceewicacvesvewserdseceareedett chet esveercaee es 4 22 Consumable LAG ceraint Mea eee Sih a Ri eae a iaa a aaeei E Gaee 4 23 CUTE Kear lge 8 ce nas ice tia la i acta E Aea hea lett nh tet ala ins Mats lies 4 24 Section 5 Automatic Gas Console Advanced Functions Altering the Current Set Point 2 22 0 cc ccscceeeeee cee eceee cece ee deneeeeenneeseedenenenneene
128. ld Steel 50 Amps Oxygen Oxygen or Air Page 4 26 Mild Steel 70 Amps Oxygen Air Page 4 27 Mild Steel 100 Amps Oxygen Air Page 4 28 Mild Steel 150 Amps Oxygen Air Page 4 29 Mild Steel 200 Amps Oxygen Air Page 4 30 Page 4 51 Mild Steel 275 Amps Oxygen Air Page 4 31 Page 4 52 Stainless Steel 30 Amps Air Air Page 4 32 Stainless Steel 50 Amps Air Nitrogen Page 4 33 Stainless Steel 70 Amps H17 Nitrogen Page 4 34 Stainless Steel 70 Amps Air Nitrogen Page 4 35 Stainless Steel 100 Amps H17 Nitrogen Page 4 36 Stainless Steel 100 Amps Air Nitrogen Page 4 37 Stainless Steel 150 Amps H17 Nitrogen Page 4 38 Stainless Steel 150 Amps Air Nitrogen Page 4 39 Stainless Steel 200 Amps H17 Nitrogen Page 4 40 Stainless Steel 200 Amps Air Nitrogen Page 4 41 Page 4 53 Stainless Steel 260 Amps H17 Nitrogen Page 4 42 Stainless Steel 275 Amps Air Nitrogen Page 4 43 Aluminum 30 Amps Air Nitrogen Page 4 44 Aluminum 50 Amps Air Nitrogen Page 4 45 Aluminum 70 Amps Air Nitrogen Page 4 46 Aluminum 100 Amps Air Nitrogen Page 4 47 Aluminum 150 Amps Air Nitrogen Page 4 48 Aluminum 200 Amps Air Nitrogen Page 4 49 Page 4 54 Aluminum 275 Amps Air Nitrogen Page 4 50 Page 4 55 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 24 Operation Spirit275a User s Manual
129. ll a jumper between terminal block TB1 positions 7 and 8 The contacts should be rated for 24VAC 115mA 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 16 Installation Spirit275a User s Manual Rev K Power Supply Ready Output e The Spirit275a 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 6A 125VAC 6A 110VDC 2A 30VDC RS 422 Serial Communication Link e An RS 422 serial communication link can be connected between the plug on the rear of the automatic gas console and a CNC machine or automatic height control system All process parameters can be controlled via the RS 422 communication link Also cutting or marking information such as_ initial height cutting or marking height recommended arc voltage and recommended travel speed can be transmitted from the automatic gas console to the CNC machine or height control See Section 6 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 t
130. ll control of the cutting parameters from an x y machine controller The gas console also tracks the number of cuts made with a particular set of consumables and keeps a detailed record of errors that may occur during the cutting sequence To aid in troubleshooting a message screen on the gas console displays all power supply and gas console sequencing All gas inlets and outlets are connected to the rear of the automatic gas console For cutting mild steel the Spirit275a 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 Spirit275a is technologically advanced to produce the highest quality cuts while maximizing consumable life The torch is water cooled and consumables are machined to exacting dimensions and checked with the latest computerized measuring systems Eight nozzle sizes 30 50 70 100 150 200 260 and 275 amps are available to produce excellent cut quality throughout the cutting range 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
131. lly Commands may be transmitted to systems without node focus but there will be no back transmission from those systems Also all parameters can be read at any time by transmitting a Send Parameter command 30 to the Spirit followed by the appropriate parameter to be read This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 2 Serial Communication Spirit275a User s Manual Rev K Default Cutting Parameters In order to initialize parameters on a spirit system an external device must communicate in sequence the material type material thickness process cutting or marking and the cutting current Once the Spirit system receives the cutting current all other parameters will be set to their default values Whenever the material type material thickness process or cutting current is changed new default values will be retrieved for all other parameters If a change is desired cutting current must be sent last for the update to occur To use non standard parameter first set the material type material thickness process and cutting current in sequence and then set the remaining parameter i e pierce time to the desired values Troubleshooting Serial Communication When troubleshooting serial communication with the Spiri
132. lly updated with the correct arc voltage pierce initial height and cutting marking height any time a new condition is loaded the process cutting or marking is changed or when the arc voltage pierce initial height or cutting marking height is changed on the Voltage screen With the Inova Parameter Transmit feature set to manual pressing F3 while the voltage screen is being displayed will automatically transmit the pierce initial height cutting marking height and arc voltage set points to the Inova To view the status of the Inova Parameter Transmit setting scroll down to the Inova Parameter Transmit selection on the maintenance screen and press ENT The Inova parameter transmit screen will be displayed as shown Pressing F3 will toggle the Inova Parameter Transmit setting between automatic manual and disabled When the desired selection is highlighted press ENT INOVA PARAMETER TRANSMIT STATUS AUTOMATIC IN AUTOMATIC MODE THE INOVA IS AUTOMATICALLY UPDATED WHEN THE PROCESS CHANGES OR WHEN A NEW CUT CONDITION IS LOADED IN MANUAL MODE THE INOVA IS UPDATED BY PRESSING F3 ON THE VOLTAGE SCREEN PRESS F3 D CHANGE THE CONFIGURATION PRESS ENT A RETURN TO THE MAINTENANCE MENU CURRENT MODE PARAMETER TRANSMIT KAL I BURN 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 lo
133. loppy disk from the floppy disk drive Remove primary power from the system wait five seconds then reapply primary power to the system Wait for the Please Insert Update Disk 2 message to appear Install the second floppy disk containing the software update into the floppy disk drive Press any key on the keypad Wait for the AGC Updated Successfully message to appear 10 Leave the second update disk in the floppy disk drive remove primary power from the system wait five seconds then reapply primary power 11 Wait for the AGC Updated Successfully message to appear 12 Remove the floppy disk from the floppy disk drive 13 Remove primary power from the system 14 Reinstall the floppy disk drive cover 15 Apply primary power to the 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 5 22 Spirit275a User s Manual Rev K Serial Communication Spirit275a User s Manual Rev K Section 6 Serial Communication Initializing the Spirit System The Spirit system uses an RS 422 serial communication port located on the rear of the automatic gas console to receive and respond to commands that are transmitted from an x y controller The communications ground is isolated to prevent ground loops System
134. lowing shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the plasma cutting equipment radio and television transmitters and receivers c computer and other control equipment d safety critical equipment e g guarding of industrial equipment the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may require additional protection measures h the time of day that plasma cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Plasma cutting equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed plasma cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected t
135. mation 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 28 Operation Spirit275a User s Manual Rev K Mild Steel 150 Amps Oxygen Plasma Air Shield Copper Electrode Q Outer Cap Electrode 277292 Nozzle 277293 Shield Cap 277117 Torch Head Retaining Cap Swirl Ring 277154 277151 277152 277139 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in Retaining Cap 277151 1 4 118 165 105 200 300 498 3 8 20 74 30 67 123 125 135 250 400 l 1 2 125 90 140 300 500 130 Retaining Cap 277152 5 8 127 70 440 325 600 130 3 4 130 55 l 350 1000 135 1 20 74 45 67 134 40 150 400 1 25 145 25 200 1500 140 350 1 5 155 15 225 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm Retaining Cap 277151 6 117 4305 2 6 4 9 300 32 10 20 74 30 67 123 3040 3 4 6
136. ments 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
137. ministration 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 40 Operation Spirit275a User s Manual Rev K Stainless Steel 200 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Nozzle 277289 Shield Cap 277274 Electrode 277291 M A 9 D H j S Y e J Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 277143 279150 Imperial Material p Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 130 200 200 400 070 150 3 8 133 150 250 500 1 2 140 110 115 300 600 152 5 8 146 75 150 350 800 20 82 58 75 155 3 4 153 60 190 400 1200 1 0 158 40 210 450 160 1 25 170 20 250 350 1500 165 1 50 180 10 275 350 175 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volt
138. msec mm 12 139 3290 3 6 7 4 500 re 16 436 2650 3 3 8 3 800 i 20 2190 3 1 9 0 4 3 1000 25 143 1690 4 0 10 1 re 32 150 1120 4 4 12 8 20 93 70 83 38 162 645 5 9 45 170 495 7 5 8 9 4 8 1500 50 178 395 8 7 55 183 345 9 2 9 2 6 6 60 187 285 9 6 9 6 6 9 Marking Material Arc Travel Marking Initial Pierce Thickness paw Plasma Shield ee Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 108 250 6350 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 300 7 6 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised 10 22 09 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 31 Operation Spirit275a User s Manual Rev K Stainless Steel 30 Amps Air Plasma Air Shield Q Outer Cap Copper Electrode Shield Cap Nozzle Electrode 277121 277137 277144 2 LL Torch Head Retaining Cap Swirl Ring 277154 277110 277138 279150 Imperial Material F Arc Tra
139. msw 25 Send retaining cap part number Isw 26 Send shield cap part number msw 27 Send shield cap part number Isw 28 Send outer cap part number msw 29 Send outer cap part number Isw 32 Send process select 33 Send software version 34 Send cutting chart version 35 Send number of pierces 36 Send number of pierce errors 42 Send cutting arc voltage 43 Send cutting height 44 Send cutting pierce height 48 Send cutting condition type 51 Send arc off delay time 52 Send machine type 53 Send marking arc voltage 54 Send marking height 55 Send marking start height 56 Send marking travel speed 57 Send marking pierce time 59 Send cut mark cut configuration Set Process 32 AA nn FA 20 00 OD 00 Cutting 01 Marking Software Version 33 AA nn FA 21 00 0D If requested in command 30 the AGC will transmit the software version x 10 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 6 Serial Communication Spirit275a User s Manual Rev K Command Cutting Chart Version Number of Pierces Number of Pierce Errors Reset Pierce Counter Power On Power Off Request System Status Purge Gases Set Cutting Arc Voltage Set Cutting Height Set Cutting Pierce Height Set
140. nd the Nozzle lead to the large brass body of the torch o N No spark between the spark gap 1 Improper spark gap Set gap to 015 electrodes 381 mm 2 Worn spark gap electrodes Clean electrodes with 600 grit sandpaper and regap Replace electrodes that have a rounded face 3 Bad high frequency transformer TR5 Check for signs of arcing 4 Check for 120VAC on the input side of filter FL1 inside the RHF console after a start signal has been given If 120V is not present check associated wiring back to the power supply The arc will not transfer to the workpiece Loose work ground connection Pierce height too high Incorrect damaged or worn consumables WON The gas console screen is blank 1 Blown gas console fuse F10 2 Loose cables inside the gas console Remove and reinstall all plugs on the interface p c board computer video board and display 3 Bad power supply inside gas console Check for all voltage LED s on the interface board and computer 4 Loose plug P17 on the bottom of the gas console Remove and reinstall the plug No response from the gas console 1 Loose keypad cable inside the gas keypad console Remove and reinstall the keypad 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 re
141. neeeeeeene 5 1 SEWING THE Pier CS VMS sesira teehee bee caotyeveyeiisdencdtv est E eee aea eaaa EEE EKSS 5 2 Altering Gas TY PCS kirek dic ae sad ania tei ridenad naan Wind oad oe a E E 5 3 Altering Gas Pressures scene seers Se ee sc eet attend ceae ennan ninne ass Mivauicateetes 5 4 Altering Arc Voltage Control and X Y Machine Parameters ecce 5 5 Saving a User Created Cutting or Marking Condition eeeeeeeeeeseesseeesererrrereen 5 6 Gas aU KO S Sides EPEE I EA A EEEE T T E EEA 5 6 Maintenance Screen wesc feat eet Saris cae eae ld wae ieaie iiith ennerien dne nternet ae 5 7 Viewing M SSages vies cee cient nee eee es 5 8 Viewing UE ETr rS idien e a EE ea ea esep ost aeea ete anter 5 9 Pressure Diagnostics cision hi Moe sand te Sodbeal enteri senede iniiai e ke eken eeren nenna 5 13 Restoring Factory Default Cutting or Marking Conditions eeeeeeeeeeeeeeeeeeeeen 5 14 M as rement Systemi sofon eieiei aeee Ke re eek at aaeei 5 15 Comm nication Node esinen ee a a A eee 5 16 Inova Parameter Transmit ceeeee cece eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee ee eeeeeesaaaaaaaaaaeeeeeees 5 17 Viewing Serial Communication 2 5 cccceeceeeeceee cece ceeeneesnesdeecceccdeceseceneeteeeseeeseeess 5 18 Configuring Hydrogen Cutting i0s0e oe ne neediness 5 19 DEMING ab AC OME Delay Tees cpsd obs ote is Seeder itendlen vote e eaa e aa cece ienest 5 20 Switching Between Cutting and Marking cceeeeee cece eect eeeeeeee
142. nistration 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 17 Operation Spirit275a User s Manual Rev K Installing and Removing Torch Consumables A Turn off the plasma power supply before continuing with this procedure 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 Note Do not over tighten the consumables Only tighten until the parts are seated properly 1 Unthread the quick disconnect torch head from the torch base by turning the attachment ring to the RIGHT 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 in the left image below Do not use a prying or bending motion as in the right image below CORRECT INCORRECT hal am i AVE 9 6 Use the swi
143. nters the preflow gas editing mode Menu Plasma Gas Enters the plasma gas editing mode Menu Shield Gas Enters the shield gas editing mode Menu Pierce Delay Enters the pierce time editing mode Menu Maint Enters the maintenance mode Menu Gas Purge Purges the cutting gases Menu Status Displays the main status screen Arrow Keys The Arrow keys are used to scroll up and down in order to edit or select a particular item 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 Operation Spirit275a User s Manual Rev K Function Keys The Function keys are used for various purposes in the editing and maintenance modes The help prompt instructs the user on the use of the Function keys Numerical Keys The Numerical keys are used for entering and editing parameters Automatic Gas Console Help Prompt Help prompts are displayed on the automatic gas console screen to assist the user Different screens may have more than one help prompt but the help prompts will always appear near the bottom of the screen PREFLOW SUBSTANCE MILD STEEL COLD GAS AIR THICKNESS 0 250 INCHES psi 025 0 CURRENT 70 AMPS PROCESS CUTTING TORCH PARTS GAS OXYGEN psi 0 6 0 CUTTING PIERCE TIME 0200 ms GAS AIR MARKI
144. nual Rev K Aluminum 275 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap 277263 Q Outer Cap Nozzle 277276 2 Electrode 277270 LL Torch Head Retaining Cap Swirl Ring 277154 277266 277258 279150 Imperial Material F Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 160 160 160 275 400 460 1 2 165 125 180 300 500 i 5 8 168 105 190 350 600 165 3 4 20 93 65 83 172 85 200 800 i 1 00 180 60 240 400 170 1 25 185 45 260 1000 1 50 190 25 270 180 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 160 3930 4 1 7 1 500 4 1 12 163 3375 4 4 7 4 16 168 2645 4 8 8 9 800 4 2 20 20 93 65 83 173 2055 5 3 25 179 1565 6 0 10 2 4 3 32 185 1120 6 6 1000 38 189 645 6 8 4 6 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow plasma snieg Pee Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm
145. nual Rev K Automatic Gas Console I O P C Board Assembly 200288 6ta ot Gs 09 21695 2709 z z9 2 1309 1091 ug a Bal Laem 229 Lidl 5 Lad s99 O59 969 Laven Ga PE Tl 14 es 14 Kod t fim seo DRC wa ECD aN 22AnWl mE IBAON Gar amm OZADL va ar Ol Std H ci of UE l am sl aR el amp ED g Gl ie ap j 5 EF g h a E R24 Move RE OHIO C O E aE sc K rae ae oe lz is 2 FOrO POA R33 i KOD 8 R medh Cre g pco R37 N a toate a 9 eer 3 88 Bb EC e g a oOo BE oo e E mea i Rie ry Lents F3 a a S a alt 32 yE OO ah oo 8 a E z z ECE Ne MIN v Pove Ha oni i E al E g E l BES we ws poo ss
146. o non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 8 Operation Spirit275a User s Manual Rev K Viewing Recommended Height Control and X Y Machine Settings Prior to making a cut or mark with the system the torch height control and the x y cutting machine must be configured properly To view the recommended cutting data press the Menu key then Voltage The voltage screen will be displayed as shown The x y machine speed should be set to the value shown Also the height control should be set to the proper pierce initial height cutting marking height and arc voltage Ifa KALIBURN Inova height control is being used simply press the F3 key to automatically transmit the parameters to the Inova Optionally the Spirit system can be set to automatically send the cutting marking parameters See Section 5 for information on configuring the Inova height control parameter transmit feature OUTPUT VOLTAGE 116 2 VOLTS PHASE 1 206 5 VOLTS DUTPUT CURRENT 70 1 AMPS PHASE 2 205 4 VOLTS PARAMETER TX STATUS AUTO PHASE 3 209 3 VOLTS MARKING ARC VOLTAGE 116 0 YOLTS ARC VOLTAGE 135 0 VOLTS PIERCE HEIGHT 0 125 INCHES START HEIGHT 0 100 INCHES CUTTING HEIGHT 0 110 INCHES MARKING HEIGHT 0 096 INCHES TRAVEL SPEED 120 IPM TRAVEL SPEED 250 IPM PRESS aM THEN Re 70 RETURN TO STATUS SCREEN CURRENT MODE VOLTAGE This information is subject t
147. o 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 Installation Spirit275a User s Manual Rev K Torch Head Connection Perform the following steps to connect the torch head to the torch base 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 small 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 LEFT to tighten 4 Keep tightening the attachment ring until it stops As shown below the attachment ring will NOT cover the o ring This is only a visual indicator no seal is created However there should be no gap between the attachment ring and the o ring During the tightening process after the initial install 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 sup
148. o 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 9 Operation Spirit275a User s Manual Rev K Viewing the Torch Parts Required Once the material substance and thickness have been chosen the default cutting parameters are selected and adjusted accordingly To display a pictorial view of the torch parts required to make the cut or mark scroll down to Torch Parts and press enter An example of the torch parts screen is displayed below TORCH PARTS SHIELD CAP NOZZLE ELECTRODE 277150 277125 277131 X OUTER CAP RETAINING CAP SMRL RING TORCH MAN BODY 277154 277153 277142 277000 Spirit275a PRESS ANY KEY TO RETURN TO THE STATUS SCREEN CURRENT MODE TORCH PARTS KAL I BURN 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 10 Operation Spirit275a User s Manual Rev K Torch Consumable Selection Mild Steel Copper Electrode Outer Shield Inner Nessie Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head 277154 277145 277153 277120 277140 277130 279150 I D 30A
149. o the plasma power source so that good electrical contact is maintained between the conduit and the plasma power source enclosure Maintenance of the Plasma Cutting Equipment The plasma cutting equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the plasma cutting equipment is in operation The plasma cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 2 Electromagnetic Compatibility EMC Spirit275a User s Manual Rev K Plasma Cutting Cables The plasma cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could recei
150. om corrosion Verify that the primary three phase A C voltage connections are tight Verify that all p c board connectors are installed securely Verify that the rear panel cable connectors are installed securely Verify that the automatic gas console connector is installed securely to the plug on the bottom of the gas console Check the torch coolant filter deionization cartridge at the rear of the power supply and replace if dirty Flush the cooling system every six months and replace the coolant and coolant filter deionization cartridge This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 1 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Automatic Gas Console 1 Remove the cover of the automatic gas console 2 Using clean dry compressed air blow out all accumulated dust inside the unit In an excessively dirty environment blow out the unit on a weekly basis 3 Verify that all p c board connectors are installed securely 4 Verify that all gas hose connectors are tight and that there are no leaks Only tighten the gas fittings enough to make a gas seal The fittings are subject to damage if over tightened 5 Inspect all gas hoses to ensure no damage exists Immediately
151. ommand The net node value of a system is set via the Set Communication Node selection on the maintenance screen See Section 5 for detailed information on setting the net node The value FA hex is the Spirit identifier The value 01 hex is the value that signifies the Set Material Type command The value OD hex is the end of command character In the above example the following hex string would need to be transmitted to switch the material type to stainless steel for a Spirit system on node 1 AA 01 FA 01 00 01 OD This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 1 Serial Communication Spirit275a User s Manual Rev K To send a parameter the parameter value needs to be sent as part of the command For example to send a desired cutting pierce time of 1000 milliseconds to the system look up the Set Cutting Pierce Time command in the command table You will see the following table entry Command Hex String Additional Information Set Pierce Time 4 AAnnFA04 0D Time in mS seconds 1000 Valid range 0 to 5000 Once again AA hex signifies the start of the command nn is the net node of the power supply and FA hex is the Spirit identifier The value 04 hex signifies the Set Cutting Pierce Time command and OD hex s
152. or goes out leave the unit energized until it illuminates Automatic Gas Console Display 6 Shows all of the power supply and gas console settings errors and sequencing Automatic Gas Console Keypad O Operator interface to automatic gas 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 4 2 Operation Spirit275a User s Manual Rev K Automatic Gas Console Keypad All cutting information is entered on the keypad of the automatic gas console as shown below This section provides a description of each key and its function MATERIAL VOLTAGE Q PLASMA SHIELDING GAS GAS Menu Key The Menu key is used to select the bottom portion of a split level key When the Menu key is pressed a menu icon will appear in the upper right hand corner of the screen Pressing the Menu key again will clear the icon and return to the previous mode Pressing a split level key while the menu icon is visible will enter the specified mode The following is a list and description of menu key functions Menu Material Enters the material editing mode Menu Current Enters the current editing mode Menu Voltage Displays the voltage screen Menu Preflow Gas E
153. ormation shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 11 Parts List Spirit275a User s Manual Rev K Shielded Torch Leads Part Number Length 280304 10 10 ft 3 0 m 280304 15 15 ft 4 6 m 280304 20 20 ft 6 1 m 280304 25 25 ft 7 6 m 280304 30 30 ft 9 1 m 280304 35 35 ft 10 7 m 280304 40 40 ft 12 2 m 280304 45 45 ft 13 7 m 280304 50 50 ft 15 2 m 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 8 12 Parts List Spirit275a User s Manual Rev K Gas Hose Package Part Number Length 280317 20 20 ft 6 1 m 280317 25 25 ft 7 6 m 280317 30 30 ft 9 1 m 280317 35 35 ft 10 7 m 280317 40 40 ft 12 2 m 280317 45 45 ft 13 7 m 280317 50 50 ft 15 2 m 280317 55 55 ft 16 8 m 280317 60 60 ft 18 3 m 280317 65 65 ft 19 8 m 280317 70 70 ft 21 3
154. ostflow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm Cold Rolled Steel Oxygen Shield Swirl Ring 277140 2 5 121 1895 2 9 100 1 9 25 74 12 73 3 4 3 125 1555 3 1 200 2 0 Hot Rolled Steel Air Shield Swirl Ring 277142 2 5 4885 100 1 9 106 2 5 3 4 3 4660 200 2 0 25 74 19 73 5 113 2555 5 1 3 6 400 2 2 6 116 2075 5 5 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow plasma Shield Posto Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 145 250 6350 147 3 7 100 2 5 0 1 Revised 10 21 2009 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 26 Operation Spirit275a User s Manual Rev K Mild Steel 70 Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode 277125 277131 277150 a D Q Outer Cap Torch Head Retaining Cap Swirl Ring 277154 277153 277142 279150 Imper
155. ply remove the torch head and inspect the o rings for damage CORRECT INCORRECT Correct Incorrect P Thereisno i Gap is visible gap between between O o ringand o ring and O attachment attachment ring 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 3 14 Installation Spirit275a User s Manual Rev K Automatic Gas Console Input Connections Perform the following steps to connect the gas supply lines to the automatic gas console 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 e Air must be supplied to the unit at all times regardless of the cutting current or m
156. quirements of the EAR 7 10 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Problem Possible Cause Gas pressures will not adjust 1 Wrong consumables installed in torch properly 2 Loose pressure transducer cable Remove and reinstall P8 and P9 on the gas console I O p c board 3 Loose motorized regulator plugs Remove and reinstall the motor plugs and P4 P7 on the gas console I O p c board 4 Pressure regulator orifice clogged with dirt or debris Turn off primary power and turn motorized regulator screw all the way in by hand 5 Binding regulator Turn off primary power and turn all motorized regulators to their mid positions by hand 6 Loose shield valve plug Remove and reinstall P3 on the gas console I O p c board Low pressure error 1 Supply gas pressure s less than 120 psi 2 Faulty pressure switch or associated wiring inside gas console Pressure error during cut 1 Supply gas pressure s fluctuating during cut 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 7 11 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Chopper Test Procedure WARNING Only qualified maintenance personnel should perform the chopper test procedure The system utilizes poten
157. r height ignition height of 250 6 4 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised 10 21 2009 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 54 Operation Spirit275a User s Manual Rev K Aluminum 275 Amps Air Plasma Nitrogen Shield Silver Electrode Shield Cap 277263 Nozzle 279469 2 Electrode 279450 red o ring nant be _ 4 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 279458 279160 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 8 160 160 160 275 400 160 1 2 165 125 180 300 500 5 8 168 105 190 350 600 465 3 4 20 93 65 83 172 85 200 800 i 1 00 180 60 240 400 170 1 25 185 45 260 1000 1 50 190 25 270 180 Metric Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postflow voltage Speed Heigh
158. rce height that is too high will cause the pilot arc time to be excessively long and will cause nozzle damage Never fire the torch in the air Nozzle damage will occur 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 the error tracking feature on the automatic gas console to keep track of cut errors See Section 5 for information on the error tracking feature O 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 23 Operation Spirit275a User s Manual Rev K 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 increased as the electrode wears in order to maintain the correct cutting height Cutting Chart Index Also remember that the arc voltage must be Copper Silver Mild Steel 30 Amps Oxygen Oxygen Page 4 25 Mi
159. re below 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 5foot 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 15 Inch Plasma Gas Hose 1 Route one end of the 15 inch 380 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 1 4 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 Mount the torch handle base manifold to the positioner Note the alignment indicators on the torch base slot and torch head small 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 Connect the other end of the 15 inch 380 mm plasma gas hose to the plasma gas outlet on the 2 gang manifold 6 Foot Preflow Postflow Marking Gas Hose 1
160. replace any damaged gas hoses Torch Torch Leads and Gas Hoses 1 Verify that all torch lead and gas hose connections are tight and that there are no gas or water leaks Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened 2 Verify that the braided shield of the torch leads is fastened securely to the brass shield adapter that connects to the remote high frequency console Also make sure the shield adapter is secured tightly to the high frequency console enclosure 3 Inspect the braided shield for nicks or cuts and replace if necessary 4 Remove the torch handle and verify that the connections at the torch base are tightened securely Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened 5 Make sure the torch lead insulating sleeves are positioned to properly cover the brass torch fittings at the rear of the torch base 6 Inspect the outer sleeve on the torch base s electrode coolant supply lead If nicks cuts or holes are found replace the torch base 7 Remove the torch consumables from the torch head and inspect all o rings Replace any o rings with cuts nicks abrasions or any other signs of wear Faulty o rings may cause gas or water leaks which will affect cut quality 8 With the electrode removed inspect the cooling tube in the torch head for damage If using a copper electrode the torch
161. rl ring removal tool P N 260105 to remove the swirl ring from the nozzle This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 18 Operation Spirit275a User s Manual Rev K 7 If using a copper electrode use the tool P N 277087 to remove the electrode from the torch head If using a silver electrode use the tool P N 279061 to remove the silver electrode from the torch head 8 Inspect all consumables and o rings for damage and excess wear Exchange for new consumables as necessary 9 Inspect the cooling tube in the torch head for damage See Section 7 Maintenance and Troubleshooting if replacement is necessary Making a Cut or Mark Once the material type thickness and process have been entered the correct torch parts are installed and the x y machine and height control systems have been properly configured perform the following steps to cut or mark with the system 1 Depress and hold the Power On button until the Coolant Flow status LED illuminates If the Coolant Flow led fails to illuminate after 10 seconds see the maintenance section for possible solutions 2 The automatic gas console will purge the gas hoses and set the correct gas pressures automatically After the pressures have been set correctly th
162. rmation is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 2 Installation Spirit275a User s Manual Rev K Primary Power Connection Before connecting primary power check the data plate to verify the voltage required by the Spirit power supply A primary disconnect switch switching all ungrounded supply conductors should be provided for each Spirit power supply 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 Current Recommended Input Voltage at Maximum Output Time Delay Fuse VAC amps Size amps 208V 60Hz 147 200 230V 60Hz 133 190 380V 50 60Hz 81 125 415V 50 60Hz 74 100 460V 60Hz 67 95 575V 60Hz 53 75 Use a Type SO power cable to connect the primary power to the Spirit power supply The power cable should have a 600 volt minimum rating an
163. s mm m mm mm msec mm 6 129 5220 1 8 4 9 400 8 10 134 3655 1 9 6 5 i 600 12 138 3020 2 6 7 3 16 146 1890 3 8 8 9 800 3 9 20 82 58 75 20 153 1450 4 8 10 3 25 157 1050 5 2 11 3 4 1 1500 32 170 495 6 4 8 9 4 2 38 179 260 6 9 8 9 4 4 Marking Material Arc Travel Marking Initial Pierce Thickness PERION Rasma Shielg Rostnow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 25 25 N A 120 250 6350 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 Edge start recommended Revised 12 01 2009 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 41 Operation Spirit275a User s Manual Rev K Stainless Steel 260 Amps H17 Plasma Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277211 277118 277135 a lf g NN A y 9 DO Outer Cap Ret
164. s See Section 2 for noise emission levels Toxic Fume 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 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 Safety Spirit275a User s Manual Rev K 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 Electric Shock Prevention The Spirit275a 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 Spirit system Observe the following guidelines to protect against electric shock e A wall mounted disconnect switch should be installed and fuse
165. s and excess o ring lubricant and clean as necessary Part Inspect For Corrective Action Dents cracks Replace outer cap Center hole out of round Dents Scratches Dry o ring Damaged o ring Replace shield cap Replace shield cap Apply a thin film of o ring lubricant Replace shield cap Retaining Cap Center hole out of round Dents cracks Dry o ring Damage o ring Replace retaining cap Replace retaining cap Apply a thin film of o ring lubricant Replace retaining cap Nozzle D Center hole out of round Erosion or arcing Dry o rings Damaged o rings Replace nozzle Replace nozzle Apply a thin film of o ring lubricant Replace nozzle Swirl Ring OJ Damage Clogged holes Dry o rings Damaged o rings Replace swirl ring Blow out with compressed air Replace swirl ring if clogs can t be removed Apply a thin film of o ring lubricant Replace swirl ring Electrode Pit depth Erosion or arcing Dry o rings Damaged o rings Replace electrode if center pit depth is greater than 040 1 mm Replace electrode Apply a thin film of o ring lubricant Replace electrode 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 22
166. s information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 15 Operation Spirit275a User s Manual Rev K Aluminum Copper Electrode Outer Shield Inner Nozzle Swirl Copper Retaining Cap Cap Retaining Cap Ring Electrode 277154 277145 277153 277120 277140 277130 Q 4I D 277131 50A E 277154 2771450 277153 277125 277142 277131 279150 70A 9 Ss asa STRSBE iat a aris TRIES i 100A 9 O OWD D ieee 277154 2771147 277152 277293 277139 277292 279150 150A 9 P ea aria e RTC CTs a 200A 9 277258 277270 275A 5 D 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 16 Operation Spirit275a User s Manual Rev K Aluminum Silver Electrode Outer Shield Inner Nozzle Swirl Silver Torch Retaining Cap Cap Retaining Cap Ring Electrode Head 279440 277154 277274 277266 279489 279443 yellow o ring 279160 200A 9 Op 279450 277154 279469 279458 red o ring 279160 275A 9 OD This information is subject to the controls of the Export Admi
167. s 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 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 e Connect the torch electrode coolant supply lead to the torch base as shown Torch Coolant Return Lead AD e 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 e Connect the torch nozzle lead to the torch base as shown Torch CTP Sensor Lead 13 e Connect the torch CTP sensor lead to the torch base 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 10 Installation Spirit275a User s Manual Rev K Torch Gas Connections Perform the following steps to connect the torch gas hoses to the automatic gas console torch base and torch valve assemblies See figu
168. 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 21 Operation Spirit275a User s Manual Rev K Changing Consumable Parts 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 debri
169. shall be the responsibility of the user of the plasma cutting equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the plasma cutting circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the plasma power source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer troublesome Note The plasma cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel plasma cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC 974 13 Arc welding equipment Installation and use This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 1 Electromagnetic Compatibility EMC Spirit275a User s Manual Rev K Assessment of Area Before installing plasma cutting equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The fol
170. si x 10 Pressure Valid Range 0 to 1200 Set Plasma Gas 7 AAnnFA07 00 0D 00 Oxygen Type 02 Air 04 H17 Set Plasma 8 AA nn FA 08 0D Plasma psi x 10 Pressure Valid Range 0 to 1200 Set Shield Gas Type 9 AA nn FA 09 00 OD 00 Oxygen 01 Nitrogen 02 Air Set Shield Pressure 10 AAnnFAOA OD Shield psi x 10 Valid Range 0 to 1200 Cutting Travel 15 AA nn FA OF OD If requested in command 30 the AGC Speed will transmit the cutting travel speed in inches per minute Range 0 to 999 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 4 Serial Communication Spirit275a User s Manual Rev K Command Torch Body Part Number msw Torch Body Part Number Isw Torch Electrode Part Number msw Torch Electrode Part Number Isw Torch Swirl Ring Part Number msw Torch Swirl Ring Part Number Isw Torch Nozzle Part Number msw Torch Nozzle Part Number Isw Torch Retaining Cap Part Number msw Torch Retaining Cap Part Number Isw Torch Shield Cap Part Number msw Torch Shield Cap Part Number Isw Torch Outer Cap Part Number msw IF 17 18 19 20 22 23 24 25 26 27 28 Hex String AA nn FA 10 OD AA nn FA 11 OD A
171. so shown to assist in its hookup i SPIRIT POWER SUPPLY WITH AGC Q a a i a a a 000 A mY a mW i ce 5 GANG MANIFOLD gt aa af 3 2 G INOVA POSITIONER C D L DL gt 4 5 GANG MANIFOLD CONTROL CABLE 2 GANG MANIFOLD CONTROL CABLE TORCH LEADS T POWER LEADS RHF CONSOLE E 66 BO i Gee ee ii COOLANT HOSES STAR WORK GROUND LEAD GROUND WORKPIECE 3 POWER INPUT RHF CONSOLE CONTROL CABLE INOVA REMOTE 2 a INOVA INOVA resonances ms ke CONTROL _E CABLE gt CCABLE CONSOLE B CABLE 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 3 1 Installation Spirit275a User s Manual Rev K Power Supply Installation The Spirit power supply should be lifted by a forklift or pallet jack In order to prevent damaging the power supply the forks should be of adequate length to protrude on the far side of the power supply The proper location of the power supply will provide dependable service and reduce periodic maintenance time Choose a location that will provide unrestricted air movement into and out of the power supply Maintain a
172. sole Advanced Functions This section describes how to operate the Spirit system when non standard cutting or marking conditions are desired Instructions are also given on how to access the various maintenance modes of the system Altering the Current Set Point To alter the current set point from the default setting use the arrow keys to scroll to Current Set Point or press the Menu key then the Current key The current setting should be highlighted as shown and the set point should be blinking Press F3 to scroll through the available current choices The current can only be set to values of 30 50 70 100 150 200 260 or 275 amps when cutting When marking the current cannot be changed Once the desired value is blinking press ENT PREFLOW SUBSTANCE MILD STEEL COLD GAS ALR THICKNESS 0 200 INCHES psi 025 0 CURRENT 70 PROCESS CUTTING TORCH PARTS GAS OXYGEN psi 076 0 CUTTING PIERCE TIME 0200 ms GAS AIR MARKING PIERCE TIME 0000 ns psi 025 0 PRESS Mj 10 cHance CURRENT MODE CURRENT 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Setting the Pierce Time After the Spirit cutting or markin
173. ssor PCB 9 If 325 VDC is not present at the output terminal block leave the jumper wire installed between P28 7 amp P28 8 ILK1 Check the chopper status LED s when a start signal is applied a LED s 4 amp 5 off go to step 10 b LED s 4 amp 5 on LED 6 off go to step 11 c LED s 4 amp 5 on LED 6 on LED 7 off go to step 12 d Only LED 4 or LED 5 on not both replace chopper e All LED s on replace chopper 10 Check the 120 VAC supply to the chopper between P1 1 and P1 3 on the chopper p c board If 120 V is present replace the chopper If 120 V is not present check fuse F3 and associated wiring 11 Apply a start signal to the power supply and check the DC voltage between P2 4 ground and P2 5 signal on the chopper p c board This voltage should change from approximately 15 5 VDC to less than 1 VDC after the main contactor of the power supply is energized If 15 5 VDC is not present replace the chopper If no voltage change occurs check for approximately 15 5 VDC between P26 1 ground and P26 2 signal on the microprocessor p c board If 15 5 VDC is not present check continuity between P26 on the microprocessor p c board and P2 on the chopper p c board If 15 5 VDC is present at the microprocessor p c board replace the microprocessor 12 Turn off primary power to the power supply Disconnect P2 from the chopper p c board and P26 from the microprocessor p c board Check continuity
174. ssure Level C Weighted Sound Pressure Level 1 meter horizontal 1 6 meters above the workpiece 110 dB 107 dB The maximum noise level is 127 dB at a distance of 3 inches 76 2 mm from the torch while cutting at 275 amps 145 arc volts This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 8 Installation Spirit275a User s Manual Rev K Section 3 Installation Initial Inspection All systems undergo full testing before being shipped from KALIBURN In the unlikely event that one of your components is defective or missing please contact KALIBURN so a replacement item can be sent to you Also KALIBURN has taken special care in packaging your Spirit275a system If your system was damaged during shipment you will have to file a claim with the shipping company Next it will be necessary to contact KALIBURN so replacement parts can be ordered If you need additional assistance please contact KALIBURN System Interconnection The Spirit275a system interconnection diagram shown below will assist you in identifying cables and hoses upon receipt of your system Electrical cables are marked with the appropriate plug number or letter and can be identified on the diagram The Inova arc voltage control is al
175. stration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 5 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Microprocessor Sequence of Operation The following LED s should illuminate after primary power is applied OPTO 8 LED Aux 2 LED 16 5V uP PWR LED 17 12V uP PWR LED 18 ILK PWR LED 19 ANALOG PWR LED 20 GAS PWR LED 28 COMM PWR LED 29 15V The following LED s should illuminate when the ON button is depressed e OPTO 6 LED 3 PHASE e OPTO 5 LED PUMP e OPTO 4 LED LATCH The following LED s should illuminate in sequence after a start signal is received in the cutting mode LED 8 START OPTO 10 LED PREFLOW OPTO 12 LED SHIELD OPTO 3 LED SURGE OPTIONAL OPTO 2 LED CON OPTO 1 LED PAR LED 10 PAT LED 9 CHOPPER OPTO 9 LED HIGH FREQ LED 11 TAC OPTO 11 LED PLASMA OPTO 14 LED GSV5 LED 12 MOTION After a transferred cutting arc is established the following LED s will go out e OPTO 9 LED HIGH FREQ e OPTO 10 LED PREFLOW e LED 10 PAT When the start signal is removed OPTO 11 LED PLASMA will extinguish and OPTO 13 LED GSV4 will illuminate and then go out with the rest of the cut cycle LED s This information is subject to the controls of the Export Administration Regulations EAR
176. t Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 160 3930 4 1 7 1 500 4 1 12 163 3375 4 4 7 4 16 168 2645 4 8 8 9 800 4 2 20 20 93 65 83 173 2055 5 3 25 179 1565 6 0 10 2 4 3 32 185 1120 6 6 1000 38 189 645 6 8 4 6 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow Rasma Shield Postiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 108 250 6350 100 2 5 100 2 5 0 Use an arc transfer height ignition height of 275 7 0 mm for cutting and 100 2 5 mm for marking Edge start recommended Revised10 22 2009 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 55 Operation Spirit275a User s Manual Rev K BLANK PAGE 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 56 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Section 5 Automatic Gas Con
177. t Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 3 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Replacing the Torch Coolant The torch coolant should be flushed out of the system every six months and replaced with new coolant The following procedure should be used to prevent damage to the cooling system Note When handling coolant it is recommended that you wear nitrile gloves and safety glasses 1 Remove primary power to the system 2 Remove the rear cover of the power supply to expose the cooling system 3 Remove the coolant reservoir cap level gauge 4 Make sure that consumables are properly installed in the torch head and that the torch head is installed on the torch base 5 Using a funnel to collect the coolant unscrew the drain petcock on the bottom of the coolant reservoir Leave the funnel in place after the coolant drains out of the reservoir 6 Remove the torch coolant supply hose from the rear of the power supply Note that the coolant supply hose has right hand threads 7 Blow compressed air 100 psi maximum into the coolant supply hose This will clear the coolant out of the torch torch leads and heat exchanger Note that the coolant will be forced into the reservoir and will drain out of the drain petcock 8 Unscrew
178. t 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 10 to eliminate the risk of toppling over The power supply must be cleaned as often as necessary to prevent the accumulation of metallic dust inside the unit See Section 2 for power supply dimensions Remote High Frequency Console Installation The remote high frequency RHF console should be mounted in a convenient location that is away from other electronic control devices The high voltage high frequency signal generated inside the unit can interfere with the operation of certain control systems The RHF console is usually mounted on the gantry of the cutting machine or on the cutting table See Section 2 for RHF console mounting dimensions 5 Gang Manifold Installation The 5 gang manifold assembly must be mounted within 6 feet 1 8 m of the torch See Section 2 for 5 gang manifold mounting dimensions Torch Installation The Spirit275a torch must be installed on the positioner of an arc voltage 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 torch mounting dimensions This info
179. t system switch to the View Serial Communication Screen to view incoming and outgoing data See Section 5 for information on the Serial Communication Screen This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 3 Serial Communication Spirit275a User s Manual Rev K Note RS 422 Serial Commands In the following commands nn represents the net node of the power supply that is to receive the command To send a global command to all power supplies in a network configuration nn should be set to C8 hex 200 decimal The in the hex string is the MSB followed by the LSB of a type int The integer is the value found in the additional information column Command Hex String Additional Information Set Material Type 1 AAnnFA01 00 0D 00 Mild Steel Hot Rolled 01 Stainless Steel 02 Aluminum 03 Other 04 Mild Steel Cold Rolled Set Thickness 2 AAnnFA02 0D Thickness in mils inches x 1000 Valid Range 0 to 2000 Set Operating 3 AAnnFA03 00 OD 01 30A Current 02 50A 03 70A 04 100A 05 150A 06 200A OA 260A OB 275A OC 400A Set Cutting Pierce 4 AAnnFA 04 0D Cutting pierce time in ms Time Valid Range 0 to 9999 Set Preflow 6 AAnn FA 06 0D Preflow p
180. tfow Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 3 131 3210 1 4 3 3 200 22 5 25 80 25 79 134 2445 1 8 5 1 400 s 6 138 2050 2 1 5 5 2 3 Marking Material Arc Travel Marking Initial Pierce Thickness Preflow plasma Shield Postniow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 25 N A 135 250 6350 096 2 4 100 2 5 0 Use an arc transfer height ignition height of 150 3 8 mm for cutting and 100 2 5 mm for marking Revised 10 22 2009 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 35 Spirit275a User s Manual Rev K Operation Stainless Steel 100 Amps H17 Plasma Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277146 277126 277133 9 a a SS Lp Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277113 277141 279150 Imperial Material p Arc Travel Cutting Pierce Pierc
181. the cutting height until the x y machine 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 machine motion delay time 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 20 Operation Spirit275a User s Manual Rev K 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 incre
182. the lower portion of the coolant filter housing and remove the coolant filter deionization cartridge Replace with a new filter 9 Reconnect the coolant supply hose 10 Refer to Section 3 for the remaining steps required for Filling the Torch Coolant Reservoir Only use Kaliburn approved torch coolant solution Commercially available antifreeze contains corrosion inhibitors that will damage the cooling system See Section 3 for more information on Torch Coolant Requirements 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 7 4 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Microprocessor Status LED s The microprocessor p c board controls all of the functions of the Spirit system It has diagnostic LED s which aid in troubleshooting the system The LED s illuminate when a particular event occurs Illuminated LED s indicate the following LED OPTO 1 LED PAR OPTO 2 LED CON OPTO 3 LED SURGE OPTO 4 LED LATCH OPTO 5 LED PUMP OPTO 6 LED 3 PHASE OPTO 8 LED Aux 2 OPTO 9 LED HIGH FREQ OPTO 10 LED PREFLOW OPTO 11 LED PLASMA OPTO 12 LED SHIELD OPTO 13 LED GSV4 OPTO 14 LED GSV5 OPTO 15 LED MARKING LED 8 START LED 9 CHOPPER LED 10 PAT LED 11
183. tially fatal A C and D C voltages All maintenance should be performed with safety in mind Use extreme caution when working near the power conversion module i e chopper The large electrolytic capacitors store large amounts of energy even after power has been removed from the system Wait at least five minutes after turning off power and then use a voltmeter to verify that the capacitors are fully discharged before touching the power conversion module Capacitor failure can injure and or cause property damage If troubleshooting requires the system to be powered with the enclosure panels removed remain clear of the capacitors Failure of a capacitor can result in a sudden release of stored energy causing rupture of the capacitor case Note A chopper troubleshooting flow chart can be found at the end of this section 1 Turn off all power to the Spirit power supply 2 Open the RHF console door and disconnect the black primary wires of the high frequency transformer from the 120 VAC line filter Close the RHF console door to activate the door interlock switch 3 Remove the front and left side panels from the power supply to expose the output terminal block and the microprocessor p c board 4 Remove the Electrode and Nozzle leads from the bottom connections of the output terminal block 59 amp 79 page 8 5 5 Apply three phase power to the unit and check the primary power on the input terminal block TB5 6 Depress the ON bu
184. tion outside the United States contrary to the requirements of the EAR 2 2 Specifications Spirit275a User s Manual Rev K Input Current at Maximum Output 208 VAC 3 OMI Z e oeeo eap eee eea araara eas uke 147 amps 230 VAC 30 GONZ aae SEN E nna maee 133 amps 380 VAC 3 50 60 HZ sssssssnsnsssssssnenessssrrrnrnesserrrnnnsssern n 81 amps 415 VAC 3 50 60HZ ssssssesssissnssessnrnnnerennrrnnnnsrnnnnrnnerenne 74 amps AGO VAC 30 60H Zunea alee eee rues 67 amps 575 VAC 3 60HZ iscsi esol taco Sedan ieee 53 amps Open Circuit Voltage 0 0 0 ee eeeeeeeeeeeeeeeeeeeeeeees 325 VDC Output Current drooping characteristic 10 275 amps Maximum Output Voltage n 180 VDC DULY CY CIE a G2 meet oie Sant etel el lent alg Stele 100 41 3 kW Maximum Ambient Temperature ee 104 F 40 C Dimensions AYATA TO 1 ui sates ces see ce cles Dies cee 32 5 in 826 mm Height including AGC eee 48 in 1219 mm DOpihinsectietteti ee ae goede ae 43 in 1092 mm Weight including AGC
185. 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 Spirit275a system should only be performed by qualified personnel The Spirit 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 Ultraviolet Radiation Protection Plasma cutting produces ultraviolet radiation similar to a welding arc This ultraviolet radiation can cause skin and eye burns For this reason it is essential that proper protection be worn The eyes are best protected by using safety glasses or a welding helmet with an AWS No 12 shade or ISO 4850 No 13 shade which 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 Noise Protection The Spirit275a 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 code
186. too long or when cutting a given thickness with excessive current e Transferred arc lost during cut This error occurs when the arc is lost during steady state operation It substantially shortens the electrode life and is typically due to a torch standoff distance that is too high or a travel speed that is to slow 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K e Transferred arc lost during downslope This error occurs when the arc is lost after a stop signal is received but before the current downslope completes It substantially shortens the electrode life and is typically due to an incorrect lead out or when cutting a given material thickness with excessive current When cutting small pieces that tend to drop into the table after being cut there should be a very short lead out or none at all On thicker materials the arc is sometimes lost when crossing the kerf during the lead out It is critical that the lead outs be fine tuned so the arc is not lost before downslope is complete 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 transferre
187. trode 277263 279469 279450 red o ring Outer Cap Retaining Cap Swirl Ring 277154 277266 279458 279160 Imperial Material Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow j Plasma Shield Postflow Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 2 125 140 300 500 139 165 5 8 105 135 325 600 3 4 138 90 120 350 800 170 1 144 65 160 400 1000 485 1 25 150 45 175 500 i 20 93 70 83 1 50 163 25 235 1 75 170 20 290 350 190 1500 2 00 180 15 350 2 25 185 13 375 375 260 2 50 190 9 385 385 275 Metric Material i Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 12 139 3290 3 6 7 4 500 42 16 136 2650 3 3 8 3 800 20 2190 3 1 9 0 4 3 1000 25 143 1690 4 0 10 1 4 32 150 1120 4 4 12 8 i 20 93 70 83 38 162 645 5 9 45 170 495 7 5 8 9 4 8 1500 50 178 395 8 7 55 183 345 9 2 9 2 6 6 60 187 285 9 6 9 6 6 9 Marking Material F Arc Travel Marking Initial Pierce Thickness Preflow Bigot shied Rostiow Voltage Speed Height Height Time ga in mm psi psi psi psi volts
188. tteeeeeeeeaeea 3 2 Toreh MS CAN OMA crsse sg cs axes econ cece E a a sxcadeesncasis ht e ender e E a eE 3 2 Primary Power Connection aric 28 ie 53 etd ieee Be dea td es en tad ea 3 3 Power Supply Output Connections 0 c cece ccc cc cece eeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeaaeenenseeees 3 5 RHF Console Ground Connection s45 lt sacavwnseeuciarcsateesteneravacueidtend ne eeicueates ena 3 6 Torch Leads to RHF Console Connections ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 3 8 Torch Leads to Torch Base Connections ccccceccccececeeeeeneeeeeeeeeeeeeeeeeeeeeeeeeaeeeaea 3 10 Porch Gas Connections sarskesincradncseeanmaded avatars oad aaee E dnd 3 11 PORCH ME AM Connection eae e a E a a dante tvel name 3 14 Automatic Gas Console Input Connections ccceeeeeeeeeeeeeeeeeeeaaeeeeeeeeeeeeees 3 15 CNC Machine Interface Connections cccceeeeeeeeeeeeeeeeeeeeeeeeceeeeeeeeeeereeeeeeeees 3 16 Torch Coolant REQUIFEMOENS acct cued cadaiwer owes svaced ecadess siiser oot cud Sududunsisoxewedad otedencetecteds 3 18 Initial Filling of the Torch Coolant ReServol ceeeeeeeeeeneeeeeeeeeeeeeeeeeeeeeeeetees 3 19 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 Spirit275a User s Manua
189. tton to energize the Spirit system and then apply a start signal to the unit Note that the unit will only energize for approximately two seconds each time a start signal is applied When making the following readings be sure the red DC Power light is illuminated on the front control panel of the unit After applying the start signal check the three phase voltage input to the chopper at the diode bridge terminals three right side screws on the chopper assembly for 225 VAC If the voltage is not present check for primary voltage on the main contactor CON and on the primary side of the power transformer 7 With a start signal applied check for 325 VDC at the Spirit output terminal block between Electrode and Work If 325 VDC is present the chopper is working properly 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 7 12 Maintenance and Troubleshooting Spirit275a User s Manual Rev K 8 If 325 VDC is not present at the output terminal block install a jumper wire between P28 7 amp P28 8 ILK1 With a start signal applied check for 325 VDC at the Spirit output terminal block between Electrode and Work If 325 VDC is present the chopper is working properly Check the I O PCB HV Output and its wiring to the Microproce
190. tus LED s or the automatic gas console messages screen do not give any insight to the particular problem being experienced Please contact KALIBURN technical support for any issues not covered in this section Before any tests are performed make sure that all system fuses are good The primary system fuse F1 is located on the rear panel of the unit All of the control fuses are located behind the front panel of the unit beside the microprocessor p c board The automatic gas console fuse is located behind the right side panel of the system Also check all of the voltage LED s on the system p c boards before performing any tests Problem Possible Cause Front panel white A C power light 1 Primary disconnect fuse blown will not illuminate 2 Fuse F1A F1B or F4 blown 3 White light or associated wiring bad 4 Transformer TR2 or associated wiring bad Unit will not energize when the ON button is pressed 1 RHF door open 2 Low coolant level 3 Fuse F4 blown 4 Faulty ON switch or associated wiring The ON switch is normally open 5 Faulty OFF switch or associated wiring The OFF switch is normally closed 6 Relay CR1 coil open Power supply will not stay on when 1 Check the control panel status LED s and the front panel ON button is troubleshoot accordingly pressed and released Check the gas console messages screen and troubleshoot accordingly Faulty latch relay on relay p c board Faulty relay p c board
191. utomatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Altering Arc Voltage Control and X Y Machine Parameters If the pierce initial height cutting marking height arc voltage or x y machine speed must be altered to achieve the desired cut quality switch to the voltage screen use the arrow keys to scroll to the desired parameter and edit the parameter using the keypad OUTPUT VOLTAGE 116 2 VOLTS PHASE 1 206 5 VOLTS OUTPUT CURRENT 70 1 AMPS PHASE 2 205 4 VOLTS PARAMETER TX STATUS AUTO PHASE 3 209 3 VOLTS MARKING ARC VOLTAGE 116 0 VOLTS ARC VOLTAGE 135 0 VOLTS PIERCE HEIGHT 0 125 INCHES START HEIGHT 0 100 INCHES CUTTING HEIGHT 0 110 INCHES MARKING HEIGHT 0 096 INCHES TRAVEL SPEED 120 IPM TRAVEL SPEED 250 IPM Paess QAM Then E 10 RETURN TO STATUS SCREEN CURRENT MODE VOLTAGE KAL I BURN This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 5 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Saving a User Created Cutting or Marking Condition If one of the default cutting or marking parameters must be altered to achieve the desired quality the new condition can be saved for later use To save a user created cutting or marking cond
192. utomatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Maintenance Screen To display the maintenance screen press the Menu key then the Maint key The maintenance screen will be displayed as shown From the maintenance screen use the arrow keys to scroll up or down to highlight a selection and press the Ent key to enter the desired maintenance mode The different maintenance modes are described below VIEW MESSAGES SET COMMUNICATION NODE VIEW CUT ERRORS INOVA PARAMETER TRANSMIT ESTORE FACTORY DEFAULTS VIEW SERIAL COMMUNICATION ESERVED SET ARC OFF DELAY R PRESSURE DIAGNOSTICS CONFIGURE HYDROGEN CUTTING R MEASUREMENT SYSTEM CUT MARK CUT CONFIGURATION PRESS ISMN THEN MBM T0 RETURN TO STATUS SCREEN PRESS ENT A SELECT AN OPTION FROM THE MENU CURRENT MODE MAINTENANCE 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 Automatic Gas Console Advanced Functions Spirit275a User s Manual Rev K Viewing Messages To view status messages from the Spirit power supply and automatic gas console scroll down to the View Messages selection on the maintenance screen and press ENT The message screen will be displayed as shown The message screen displays all power supply and gas console
193. ve a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 3 Electromagnetic Compatibility EMC Spirit275a User s Manual Rev K BLANK PAGE
194. vel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 20 036 200 020 71 100 065 18 048 165 30 80 30 80 035 050 16 060 74 125 260 068 14 075 75 90 025 070 Metric Material A Arc Travel Cutting Pierce Pierce Kerf Thickness Preflow Plasma Shield Postfow voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 71 4855 0 6 100 30 80 30 80 1 3 1 7 1 5 73 3260 0 9 200 Marking Material Arc Travel Marking Initial Pierce Thickness prenow Pasma Shield Fostilow Voltage Speed Height Height Time ga in mm psi psi psi psi volts ipm mm min in mm in mm msec All Thicknesses N A 28 28 N A 145 250 6350 177 45 100 2 5 0 Use an arc transfer height ignition height of 050 1 3 mm for cutting and 100 2 5 mm for marking Revised 12 1 2009 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 32 Operation Spirit275a User s Manual Rev K Stainless Steel 50 Amps Air Plasma Nitrogen Shield Copper Electrode Q
195. verify that 230VAC is present between TB3 13 and TB3 14 Also check for clogs in the coolant leads and coolant filter deionization cartridge e Coolant Level LED Extinguishes when the coolant level in the tank has dropped below the required minimum level Add more coolant to clear the error e Coolant Temperature LED Extinguishes when the coolant temperature has risen above the maximum operating temperature Ensure that the heat exchanger fan is running and that the heat exchanger is free from dust Blow out the heat exchanger and fan with clean dry oil free compressed air Leave the unit running until the LED illuminates 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 7 7 Maintenance and Troubleshooting Spirit275a User s Manual Rev K Troubleshooting Using the Automatic Gas Console Messages Screen If all of the status LED s are illuminated but the Spirit system still has a problem switch to the messages screen on the automatic gas console see Section 5 for specific instructions on switching to the messages mode The gas console may display information that is useful in pinpointing the problem While the automatic gas console is displaying an error message the power supply microprocessor displays an error code
196. when the main contactor has been energized and D C current is flowing through the torch Status Indicators G e RHF Door Indicator Illuminates when the RHF console door is closed securely Remains extinguished when the RHF console door is open e Gas Console Indicator Illuminates when the automatic gas console is operational Remains extinguished when there is a problem with the gas system Check the message screen on the automatic gas console for errors e 3 Phase Power Indicator Illuminates when 3 phase power is satisfactory Remains extinguished when there is a problem with main 3 phase power to the system e Coolant Flow Indicator Illuminates when the coolant flow through the system is satisfactory Remains extinguished when the coolant flow through the system is restricted This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 1 Operation Spirit275a User s Manual Rev K e Coolant Level Indicator Illuminates when the coolant level inside the reservoir is satisfactory Remains extinguished when coolant must be added to the system e Coolant Temperature Indicator Iluminates when the torch coolant temperature is satisfactory Remains extinguished when the coolant temperature is too hot If the torch coolant indicat
197. xdale 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 Specifications Spirit275a User s Manual Rev K Section 2 Specifications System Description The Spirit275a is a 275 amp microprocessor controlled 100 duty cycle high current density plasma cutting and marking system It utilizes a precision dual gas torch that is capable of cutting mild steel up to 2 thick and stainless steel up to 1 1 2 thick The Spirit275a is equipped with a computer controlled automatic gas console with VGA display All cutting parameters are controlled from the automatic gas console Setting up a cut is as simple as entering the material type material thickness and process cutting or marking All gas types and pressures are set automatically and the cutting parameters are transmitted to the Spirit power supply Switching to a different screen on the gas console gives the operator a pictorial view of the torch parts required to make the cut Another screen shows the recommended cutting speed and torch height for making the cut These parameters can even be transmitted to an x y machine controller or an arc voltage control system via RS 422 serial communication The RS 422 port also allows for fu

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