Lincoln Electric spirit II 150 Technical Manual
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Lincoln Electric spirit II 150 Technical Manual

Lincoln Electric spirit II 150 Technical Manual

Automatic plasma cutting system with fineline high definition technology
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Technical Manual
SPIRIT II 150
Register your equipment:
http://www.burny.com/warranty
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Date Purchased:
Model Number:
Serial Number:
BK718113 Rev I |
Issue Date: 01-SEP-2015
© Lincoln Global, Inc. All Rights Reserved
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
®
Automatic Plasma Cutting System
with FineLine High Definition Technology
™
4130 Carolina Commerce Pkwy
Phone: +1.843.695.4000
THE LINCOLN ELECTRIC COMPANY
Ladson, SC 29456
www.lincolnelectric.com
U.S.A.

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Summary of Contents for Lincoln Electric spirit II 150

  • Page 1 Technical Manual SPIRIT II 150 Automatic Plasma Cutting System ® with FineLine High Definition Technology ™ Register your equipment: http://www.burny.com/warranty Save for future reference Date Purchased: Model Number: Serial Number: THE LINCOLN ELECTRIC COMPANY BK718113 Rev I | 4130 Carolina Commerce Pkwy Ladson, SC 29456 U.S.A.

  • Page 2: Revision History

    This documentation may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine-readable format without explicit written permission from Lincoln Electric. This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to...

  • Page 3: Table Of Contents

    Spirit II User’s Manual Prologue Table of Contents Section 1: Safety General Precautions ..................1-1 Ultraviolet Radiation Protection ................. 1-1 Noise Protection ....................1-1 Toxic Fume Prevention ..................1-2 Electric Shock Prevention ................. 1-2 Fire Prevention ....................1-3 Explosion Prevention..................1-3 Health Support Equipment ................
  • Page 4 Prologue Spirit II User’s Manual Section 4: Operation Operating the Plasma Console ................. 4-1 Setting up to Cut or Mark .................. 4-3 Verifying Important Parameters ................. 4-4 Viewing the Required Torch Parts ..............4-4 Checking System Status ................... 4-5 Purging Pressure Regulators ................4-6 Making a Cut or Mark ..................
  • Page 5 Spirit II User’s Manual Prologue Section 7: Parts List Power Supply (BK300211 - BK300219) ............7-1 Automatic Gas Console (BK300418)..............7-5 Plasma Console (BK300800) ................7-8 Arc Starting Console (BK300510) with RHF ............7-9 ™ Arc Starting Console (BK300500) with CleanStrike ........

  • Page 6: Limited Warranty

    • All purchased non-expendable replacement parts • Poussoirs magnétiques main (5) Lincoln Electric n’est pas responsable de l’usure des câbles ni des dom- mages résultant de l’usure des câbles suite à des courbures et à l’abra- 90 Jours • All torch valve assemblies sion.

  • Page 7: Section 1: Safety

    Spirit II User’s Manual Section 1: Safety Section 1: Safety General Precautions Whereas plasma cutting has been used safely for years, it does require certain precautions to ensure the safety of the operator and other people around the equipment. The following safety information must be provided to each person who will operate, observe, perform maintenance, or work in close proximity to this piece of equipment.

  • Page 8: Toxic Fume Prevention

    Section 1: Safety Spirit II User’s Manual 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.

  • Page 9: Fire Prevention

    Spirit II User’s Manual Section 1: Safety • Never change torch consumable parts unless the system is switched off at the wall disconnect. • Do not attempt to remove any parts from beneath the torch when cutting. Remember that the workpiece forms the current path back to the power supply. •...

  • Page 10: Health Support Equipment

    Section 1: Safety Spirit II User’s Manual • Compressed gas cylinders should be maintained properly. Never attempt to use a cylinder that is leaking, cracked, or has other signs of physical damage. • All gas cylinders should be secured to a wall or rack to prevent accidental knock over.

  • Page 11: Safety Standards Booklet Index

    Spirit II User’s Manual Section 1: Safety Safety Standards Booklet Index For further information concerning safety practices to be exercised with plasma arc cutting equipment, please refer to the following publications: 1. AWS Standard AWN, Arc Welding and Cutting Noise, obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
  • Page 12 Section 1: Safety Spirit II User’s Manual 12. NFPA Standard 51, Oxygen - Fuel Gas Systems for Welding, Cutting, and Allied Processes, obtainable from the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269. 13. NFPA Standard 51B, Cutting and Welding Processes, obtainable from the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

  • Page 13: Section 2: Specifications

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

  • Page 14: System Components

    Section 2: Specifications Spirit II User’s Manual System Components The Spirit II 150 System consists of the following components: Standard Components • Power Supply • Automatic Gas Console • Plasma Console (Touch Screen) • CAN Cables • CAN Termination Plug •...

  • Page 15: Power Supply Specifications

    Spirit II User’s Manual Section 2: Specifications Power Supply Specifications Input Current at Power Supply Description Part Number Maximum Output 208 VAC, 3Ø, 60Hz BK300211 99 amps 220 VAC, 3Ø, 60Hz BK300212 94 amps 240 VAC, 3Ø, 60Hz BK300213 86 amps 380 VAC, 3Ø, 50/60Hz BK300214 54 amps...

  • Page 16: Torch Coolant Specifications

    Section 2: Specifications Spirit II User’s Manual Torch Coolant Specifications Note: Refer to the supplier’s most current Material Safety Data Sheet for information regarding safety, handling, and storage of torch coolant. The Spirit system is shipped without torch coolant in the reservoir. Coolant must be added before applying power to the system.

  • Page 17: Automatic Gas Console (Agc) Specifications

    Spirit II User’s Manual Section 2: Specifications Automatic Gas Console (AGC) Specifications Part Number ............. BK300418 Weight .............. 53 lbs (24 kg) 12.4" [315] 13.7" [348] 12.0" [305] (4) Ø .300 [7.6] 10.9" [277] 7.0" [178] This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 18: Gas Supply Requirements

    Section 2: Specifications Spirit II User’s Manual Gas Supply Requirements Plasma gas types: Mild Steel ............. Oxygen Stainless Steel ..........Air or H17 Aluminum ............ Air Shield gas types: Mild Steel ............. Oxygen or Air Stainless Steel ..........Air or Nitrogen Aluminum ............

  • Page 19: Plasma Console Specifications

    Spirit II User’s Manual Section 2: Specifications Plasma Console Specifications Part Number ............. BK300800 Weight .............. 10 lbs (4.5 kg) 9.2" [234] 13.4" [340] 3.6" [91] (4) Ø.180 [5] 3.2" [81] 10.1" [257] This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 20 Section 2: Specifications Spirit II User’s Manual Arc Starting Console (ASC) Specifications with Remote High Frequency (RHF) Part Number ............ BK300510 Weight ............... 24 lbs (10.9 kg) Spark gap distance .......... 0.015 in (0.381 mm) Note: The Spirit II system requires either an ASC with RHF or an ASC with ™...

  • Page 21: Arc Starting Console (Asc) Specifications With Cleanstrike

    Spirit II User’s Manual Section 2: Specifications Arc Starting Console (ASC) Specifications ™ with CleanStrike Technology Part Number ............ BK300500 Weight ............... 22 lbs (10 kg) Note: The Spirit II system requires either an ASC with RHF or an ASC with ™...

  • Page 22: Torch And 2-Gang Manifold Specifications

    Section 2: Specifications Spirit II User’s Manual Torch and 2-Gang Manifold Specifications Part Number: 2-Gang Manifold Assembly ..........BK284214 Torch Handle (standard) ............BK278001 Torch Handle (short) ............BK278018 Torch Base................BK279000 Torch Head (Copper Electrode) ........... BK279100 Torch Head (Silver Electrode) ..........BK279060 Max Weight: Manifold/Bracket, Handle (BK278001), Base and Head ..

  • Page 23: 5-Gang Manifold Specifications

    Spirit II User’s Manual Section 2: Specifications 5-Gang Manifold Specifications Part Number ............ BK300075 Weight .............. 6 lbs (2.7 kg) 6.18" [157]  0.327" [8.3]  0.25" [6.4]  (4) 0.187" [4.8] Mounting Holes   1.18" [30] 3.80" 4.20" ...

  • Page 24: Airborne Noise Emissions

    Section 2: Specifications Spirit II User’s Manual Airborne Noise Emissions The system generates high noise levels while cutting. Depending on the size of the cutting area, distance from the cutting torch, and arc current cutting level, acceptable noise levels may be exceeded. Proper ear protection should be used as defined by local or national codes.

  • Page 25: Section 3: Installation

    Spirit II User’s Manual Section 3: Installation Section 3: Installation Initial Inspection All systems undergo full testing before being shipped from the factory. In the unlikely event that one of the components is defective or missing, please contact customer service so that a replacement can be sent. Also, special care has been taken in the packaging of the system.

  • Page 26: System Interconnection

    Section 3: Installation Spirit II User’s Manual 2-Gang Manifold The 2-gang manifold assembly must be mounted to the torch. See Section 2 for mounting dimensions. Torch The torch must be installed on the positioner of an arc voltage control (height control) capable of maintaining the cutting arc voltage within 1 arc volt.
  • Page 27 Spirit II User’s Manual Section 3: Installation Figure 1a: Spirit II System (AGC, Internal Inova, ASC with RHF) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
  • Page 28 Section 3: Installation Spirit II User’s Manual Figure 1b: Spirit II System (AGC, External Inova, ASC with RHF) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
  • Page 29 Spirit II User’s Manual Section 3: Installation ™ Figure 1c: Spirit II System (AGC, Internal Inova, ASC with CleanStrike Technology) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 30 Section 3: Installation Spirit II User’s Manual ™ Figure 1d: Spirit II System (AGC, External Inova, ASC with CleanStrike Technology) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 31: Power Supply Primary Power Connections

    Spirit II User’s Manual Section 3: Installation Power Supply Primary Power Connections ** Before connecting primary power, check the data plate on the power supply to verify the voltage required ** A primary disconnect switch, switching all ungrounded supply conductors, should be provided for each Spirit system.
  • Page 32 Section 3: Installation Spirit II User’s Manual cover removed. Be sure to connect the primary ground cable to the ground stud on the input terminal block. Under no circumstances are the supply cables to be routed through the opening in the power supply cabinet without conduit or an appropriate strain relief as per local and national codes.

  • Page 33: Power Supply Output Connections

    Spirit II User’s Manual Section 3: Installation Power Supply Output Connections Perform the following steps to connect the output of the power supply to the arc starting console and the work table. See Figure 4 on the next page. Power Supply Electrode Lead 1.
  • Page 34 Section 3: Installation Spirit II User’s Manual Strain Relief ™ ASC with RHF ASC with CleanStrike Technology Strain Relief Strain Relief Figure 4: Power Supply Output Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 35: Asc Control Cable And Asc Ground Connections

    Spirit II User’s Manual Section 3: Installation ASC Control Cable and ASC Ground Connections Perform the following steps to connect the ASC control cable and ASC ground. See Figure 5 on the next page. ASC Control Cable 1. Connect the ASC control cable plug labeled P16 to the connector labeled P16 on the rear of the power supply.
  • Page 36 Section 3: Installation Spirit II User’s Manual ™ ASC with RHF ASC with CleanStrike Technology Figure 5: Cooling System Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 37: Torch Leads To Arc Starting Console Connections

    Spirit II User’s Manual Section 3: Installation Torch Leads to Arc Starting Console Connections Perform the following steps to connect the torch leads to the arc starting console. See Figure 6 on the next page. Note: When making hose connections, only tighten the brass fittings enough to make water or gas seals.
  • Page 38 Section 3: Installation Spirit II User’s Manual ™ ASC with RHF ASC with CleanStrike Technology Figure 6: Torch Leads to Arc Starting Console Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 39: Torch Leads To Torch Base Connections

    Spirit II User’s Manual Section 3: Installation Torch Leads to Torch Base Connections Perform the following steps to connect the torch leads to the torch base. Note: When making hose connections, only tighten the brass fittings enough to make water or gas seals. The fittings are subject to damage if over tightened.

  • Page 40: Torch Gas Connections

    Section 3: Installation Spirit II User’s Manual Torch Gas Connections Perform the following steps to connect the torch gas hoses to the automatic gas console, torch base, and manifold assemblies. See Figure 8. Note: When making hose connections, only tighten the brass fittings enough to make gas seals.
  • Page 41 Spirit II User’s Manual Section 3: Installation Marking Plasma Gas Hose 1. Connect one end of the marking plasma gas hose to the marking plasma outlet on the rear of the AGC. 2. Connect the other end of the marking plasma hose to the marking plasma inlet on the 5-gang manifold.
  • Page 42 Section 3: Installation Spirit II User’s Manual Automatic Gas Console BLACK GREEN BLACK BLUE GREEN REAR PORT REAR PORT BLUE BLACK Figure 8: Torch Gas Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 43: Gas Supply Connections

    Spirit II User’s Manual Section 3: Installation Gas Supply Connections Perform the following steps to connect the gas supply lines to the AGC. See Section 2 for gas supply requirements. Connectors 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.

  • Page 44: Plasma Console Connections

    Section 3: Installation Spirit II User’s Manual Plasma Console Connections Perform the following steps to connect the plasma console to the Spirit system. CAN Communications • Insert the male end of the CAN communication cable. See "CAN Communication Connections" for more details. CAN Communications •...

  • Page 45: Can Communication Connections

    Spirit II User’s Manual Section 3: Installation CAN Communication Connections Choose one of the schemes below to connect the Spirit system for CAN communications. Both schemes require two CAN cables and a CAN termination plug. This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 46: Cnc Machine Interface Connections

    Section 3: Installation Spirit II User’s Manual CNC Machine Interface Connections Perform the following steps to properly interface the Spirit system with a CNC cutting machine. See the system schematic for additional information. Plasma Start Input The power supply requires a contact closure between P8 pins 3 and 4 to commence the cutting or marking sequence.

  • Page 47: Filling The Cooling System

    Spirit II User’s Manual Section 3: Installation Filling the Cooling System WARNING: Do not touch the fans inside the power supply. Important: Never turn on the system when the coolant reservoir is empty. Important: When handling coolant, wear nitrile gloves and safety glasses. Important: Only use approved coolant.
  • Page 48 Section 3: Installation Spirit II User’s Manual BLANK This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 3-24...

  • Page 49: Section 4: Operation

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Section 4: Operation Operating the Plasma Console The Plasma Console is the touch screen interface to the entire Spirit system when the Automatic Gas Console (AGC) is used instead of the Manual Gas Console (MGC). OFF Button Push to disable the Spirit system.
  • Page 50 Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Important Messages and Icons Messages and icons at the top of the screen provide additional important information. Messages and Icons Edge start is required The power supply is ON The power supply is OFF A valve is open Warning message - see Error Log...

  • Page 51: Setting Up To Cut Or Mark

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Setting up to Cut or Mark Press the Material navigation button to setup a cut or mark. Material type, material thickness, and process (cut or mark) are the only parameters that must be selected. All other parameters are adjusted automatically;...

  • Page 52: Verifying Important Parameters

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Verifying Important Parameters Prior to making a cut or mark with the system, the torch height control and the X/Y controller must be configured properly. To view the recommended cutting data, press the Parameters navigation button.

  • Page 53: Checking System Status

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Checking System Status To view the system status indicators, press the Status navigation button. Each indicator will be either Green or Red. DC Power Indicator Green when the main contactor has been energized and D.C.

  • Page 54: Purging Pressure Regulators

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Purging Pressure Regulators Press the Purge navigation button to access the screen described below. The background color of the actual pressure reading will change; • Green for pressures at the set point •...

  • Page 55: Making A Cut Or Mark

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Making a Cut or Mark Once the material type, material thickness, and process have been selected; the correct torch parts (consumables) installed; and the X/Y controller and torch height control are properly configured;...

  • Page 56: Piercing Thick Materials

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Piercing Thick Materials Care must be taken when piercing thick materials in order to prevent damage to the shield cap and nozzle. As with all thicknesses, the pierce height must be set high enough so the metal ejected while piercing does not come into contact with the shield cap.

  • Page 57: Cut Quality

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Cut Quality Before the optimum cutting condition can be achieved on a particular material type and thickness, the machine operator must have a thorough understanding of the cutting characteristics of the Spirit system. When the cut quality is not satisfactory, the cutting speed, torch height, or gas pressures may need to be adjusted in small increments until the proper cutting condition is obtained.

  • Page 58: Customizing Cutting Or Marking Settings

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Customizing Cutting or Marking Settings Changes to any of these factory default settings will cause the Setup message at the top of the screen to change from Setup: Optimum Setup: Custom - Not Saved.

  • Page 59: Saving Customized Settings

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Altering Important Parameters With the RS422 Parameter Control set to Manual, certain values on the Parameters Screen can be changed manually. Press the corresponding data entry button and enter the desired value.

  • Page 60: Restoring Or Deleting Customized Settings

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Restoring or Deleting Customized Settings If a new setup configuration was saved for later use, it can be restored at any time or deleted permanently from the list. Press the Manage Custom Setups button on the Parameters Screen.

  • Page 61: Configuration Tab

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Configuration Tab Press the Config navigation button followed by the Configuration tab to access the screen described below. RS422 Parameter Control Controls how the Spirit communicates with the X/Y controller and height control system. With the RS422 Parameter Control set to Automatic, the Inova is automatically updated with the correct arc voltage, pierce (initial) height, and cutting (marking) height any time a new condition is loaded, the process (cutting or marking) is changed, or when the arc...

  • Page 62: Advanced Config Tab

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Advanced Config Tab Press the Config navigation button followed by the Advanced Config tab to access the screen described below. Set RS422 Node When multiple Spirit systems are being used together on an RS-422 serial communication link, each system must have a unique identification number (node number) to identify itself to the network.

  • Page 63: Network Settings Tab

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Network Settings Tab Press the Config navigation button followed by the Network Settings tab to access the screen described below. To enable networking, press the red exclamation graphic next to Network Disabled.

  • Page 64: Software Updates Tab

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Software Updates Tab Press the Config navigation button followed by the Software Updates tab to update the Spirit system software. See the next page for details on updating the software. This information is subject to the controls of the Export Administration Regulations [EAR].
  • Page 65 Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Updating the Software 1. Copy the file Installer.exe onto a USB thumbdrive. This file will be emailed or an ftp address will be provided for download. 2. Turn the Plasma Console off. 3.

  • Page 66: System Info Tab

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual System Info Tab Press the Config navigation button followed by the System Info tab to access the screen described below. This screen displays the hardware, software and serial number for each of the components in the Spirit system.

  • Page 67: Pressures/Coolant Tab

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Pressures/Coolant Tab Press the Diagnostics navigation button followed by the Pressures/Coolant tab to access the screen described below. Pressing any of the Output Pressure buttons will cause the corresponding valve to open or close.

  • Page 68: Rs422 Tab

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual RS422 Tab Press the Diagnostics navigation button followed by the RS422 tab to access the screen described below. Note that incoming data is appended to show an “R” before the data and outgoing transmissions are appended to show a “T”...

  • Page 69: Cut Info Tab

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Cut Info Tab Press the Diagnostics navigation button followed by the Cut Info tab to access the screen described below. Press the Save to History button to add the Present Cut Errors to the History list for future reference.
  • Page 70 Section 4: Operation with Automatic Gas Console Spirit II User’s Manual When any of the following errors occur, measures should be taken to avoid further errors. The following is a description of the errors and possible causes: • Transferred arc not established This error occurs when the arc fails to transfer to the workpiece.

  • Page 71: Power Supply Tab

    Spirit II User’s Manual Section 4: Operation with Automatic Gas Console Power Supply Tab Press the Diagnostics navigation button followed by the Power Supply tab to access the screen described below. Error Log Tab Press the Diagnostics navigation button followed by the Error Log tab to access the screen described below.

  • Page 72: Messages Tab

    Section 4: Operation with Automatic Gas Console Spirit II User’s Manual Messages Tab Press the Diagnostics navigation button followed by the Messages tab to access the screen described below. This screen displays all power supply and gas console messages, sequencing, and errors.

  • Page 73: Section 5: Torch Consumables And Cutting Charts

    Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Section 5: Torch Consumables and Cutting Charts Installing / Removing the Torch Head DANGER! Electric Shock Can Kill. • Remove primary power from the Spirit system before installing or removing the torch head.
  • Page 74 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual O-ring O-ring Torch Base Torch Head Gap is visible There is no gap between between o-ring and o-ring and attachment attachment ring ring To remove the torch head, turn the attachment ring to the LEFT. This information is subject to the controls of the Export Administration Regulations [EAR].

  • Page 75: Installing / Replacing Consumables

    Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Installing / Replacing Consumables DANGER! Electric Shock Can Kill. • Remove primary power from the Spirit system before installing or removing the torch head. WARNING! Hot Parts Can Burn Skin. •...
  • Page 76 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual PULL PULL 6. Use the swirl ring removal tool (P/N BK260105) to remove the swirl ring from the nozzle. 7. Remove the electrode from the torch head using the appropriate tool: •...

  • Page 77: Maximizing Consumable Life

    Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Maximizing Consumable Life Use the following guidelines to maximize consumable parts life: 1. The Spirit system utilizes the latest advancement in technology for extending the life of the torch consumable parts. To maximize the life of the consumable parts, it is imperative that the shutdown procedure of the arc is carried out properly.

  • Page 78: Inspecting For Damage

    Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Inspecting for Damage When the cut quality is not satisfactory, use the following guidelines for determining which consumable parts need to be changed. Inspect all parts for dirt, debris, and excess o-ring lubricant and clean as necessary. Part Inspect For Corrective Action...

  • Page 79: Selecting Consumables

    Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Selecting Consumables Mild Steel Copper Electrode Inner Outer Shield Swirl Copper Torch Retaining Nozzle Retaining Cap Ring Electrode Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 BK277140/ BK284150 BK277115 BK277153 BK277122 BK277142 BK277131...
  • Page 80 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel Silver Electrode Inner Outer Shield Swirl Silver Torch Retaining Nozzle Retaining Cap Ring Electrode Head BK279410 BK284150 BK277286 BK277151 BK279484 BK279483 BK279060 (brown o-ring) 100A BK277151/ BK279420 BK284150 BK277117 BK277152...
  • Page 81 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - H17 Plasma Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK284150 BK277150 BK277113 BK277124 BK277140 BK277132 BK279100 BK284150 BK277146 BK277113 BK277126 BK277141 BK277133...
  • Page 82 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - Air or Nitrogen Plasma Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK284150 BK277144 BK277110 BK277121 BK277138 BK277137 BK279100 BK284150 BK277149...
  • Page 83 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - Air or Nitrogen Plasma Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK279410 BK284150 BK277286 BK277151 BK279484 BK279483 BK279060 (brown o-ring) 100A...
  • Page 84 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 BK284150 BK277150 BK277153 BK277122 BK277142 BK277131 BK279100 BK284150 BK277150...
  • Page 85 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK279410 BK284150 BK277286 BK277151 BK279484 BK279483 BK279060 (brown o-ring) 100A BK279420 BK284150 BK277117 BK277152 BK279493 BK279439...

  • Page 86: Cutting Charts

    Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual 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.
  • Page 87 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield Copper Electrode Shield Cap Nozzle Electrode BK277145 BK277120 BK277130 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK279100...
  • Page 88 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 50 amps - Oxygen Plasma / Oxygen or Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277115 BK277122 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140/BK277142...
  • Page 89 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 70 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100...
  • Page 90 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 100 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277283 BK279100...
  • Page 91 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 150 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151/BK277152 BK277139 BK279100...
  • Page 92 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 30 Amps - Air Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277144 BK277121 BK277137 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277110 BK277138 BK279100...
  • Page 93 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277149 BK277123 BK277137 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277110 BK277142 BK279100...
  • Page 94 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen) This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode...
  • Page 95 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts 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 BK277150 BK277125 BK277131 Outer Cap...
  • Page 96 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 100 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen) This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode...
  • Page 97 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 Outer Cap...
  • Page 98 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 150 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen) This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode...
  • Page 99 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 Outer Cap...
  • Page 100 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 30 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277145 BK277120 BK277130 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK279100 Imperial*...
  • Page 101 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277122 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial*...
  • Page 102 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 70 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial*...
  • Page 103 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 100 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277283 BK279100 Imperial*...
  • Page 104 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 150 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK277139 BK279100 Imperial*...
  • Page 105 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 100 Amps - Oxygen Plasma / Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 (brown o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483...
  • Page 106 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 150 Amps - Oxygen Plasma / Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 (green o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151/BK277152 BK279439...
  • Page 107 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 (brown o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483...
  • Page 108 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 (green o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK279439...
  • Page 109 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 100 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 (brown o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483...
  • Page 110 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 150 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 (green o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK279439...

  • Page 111: Section 6: Maintenance And Troubleshooting

    Spirit II User’s Manual Section 6: Maintenance &Troubleshooting Section 6: Maintenance & Troubleshooting WARNING: Only qualified maintenance personnel should perform maintenance on the Spirit system. The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance should be performed with safety in mind. Use extreme caution when working near the power conversion module (i.e., chopper).
  • Page 112 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Automatic Gas Console (AGC) 1. Remove the cover of the automatic gas console. Using clean, dry, compressed air, blow out all accumulated dust inside the unit. In an excessively dirty environment, blow out the unit on a weekly basis. 2.
  • Page 113 Spirit II User’s Manual Section 6: Maintenance &Troubleshooting 8. With the electrode removed, inspect the cooling tube in the torch head for damage. If using the copper electrode, the torch head uses cooling tube P/N BK277007. If replacement is required, use tool P/N BK200109. If using the silver electrode, the torch head uses cooling tube holder assembly P/N BK279216.

  • Page 114: Replacing The Torch Coolant And Filter

    Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Replacing the Torch Coolant and Filter WARNING: Do not touch the fans inside the power supply. Important: Never turn on the system when the coolant reservoir is empty. Important: When handling coolant, wear nitrile gloves and safety glasses. Important: Only use approved coolant.

  • Page 115: Power Supply Microprocessor (Dsp) Status Indicators

    Spirit II User’s Manual Section 6: Maintenance &Troubleshooting Power Supply Microprocessor (DSP) Status Indicators The microprocessor DSP board controls all of the functions of the Spirit power supply. It contains diagnostic LEDs and OPTO LEDs which aid in troubleshooting the system. These indicators illuminate when a particular event occurs.

  • Page 116: Power Supply Microprocessor (Dsp) Sequence Of Operation

    Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Power Supply Microprocessor (DSP) Sequence of Operation The following DSP Indicators should illuminate after primary power is applied:  D77 ........3.3V Supply  D78 ........1.8V Supply  D50 ........ASC (Door) ...

  • Page 117: Error Codes

    Spirit II User’s Manual Section 6: Maintenance &Troubleshooting Error Codes The following is a comprehensive list of error codes for the Spirit system. When the system uses a Manual Gas Console, only the numeric error code is displayed. When an Automatic Gas Console is used, the text description is also displayed.
  • Page 118 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Gas Console Code Short Description Long Description 20100 Plasma Adjust Could not adjust Plasma Gas 20110 Shield Adjust Could not adjust Shield Gas 20120 Preflow Adjust Could not adjust Preflow Gas 20130 Postflow Adjust Could not adjust Postflow Gas 20140...

  • Page 119: General Troubleshooting

    Spirit II User’s Manual Section 6: Maintenance &Troubleshooting General Troubleshooting The following contains general troubleshooting guidelines for the Spirit system. Please contact technical support for any issues not covered in this section. Before any tests are performed, make sure that all system fuses are good; remove top cover of power supply to check these fuses.
  • Page 120 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Problem Possible Cause Primary power has been 1. Check power/communications CAN cable applied to the system, but connection on back of plasma console. the plasma console screen is 2. Check for blown DIN rail fuse. blank 3.

  • Page 121: Chopper Test Procedure

    Spirit II User’s Manual Section 6: Maintenance &Troubleshooting Chopper Test Procedure WARNING: Only qualified maintenance personnel should perform the chopper test procedure. The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance should be performed with safety in mind. Use extreme caution when working near the power conversion module (i.e., chopper).
  • Page 122 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual 4. Remove the Electrode, Work and Nozzle leads from the output terminal block, which is located on the left side of the unit. 5. Ensure the torch head (with a full set of consumables) is properly installed onto the torch base.
  • Page 123 Spirit II User’s Manual Section 6: Maintenance &Troubleshooting 9. With a start signal applied, check for the proper DC voltage (refer to TABLE 1) at the output terminal block between Electrode and Work, which is located on the left side of the unit.
  • Page 124 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual 13. Remove primary power from the Spirit system. Check cable continuity between the chopper PCB and DSP PCB. Use a digital voltmeter set up to read resistance (ohms) and make the following measurements: Chopper (1) J1-1 to DSP J7-1 Chopper (1) J1-2 to DSP J7-2 Chopper (1) J1-3 to DSP J7-3...

  • Page 125: Power Supply (Bk300211 - Bk300219)

    Spirit II User’s Manual Section 7: Parts List Section 7: Parts List Power Supply (BK300211 - BK300219) Right Side View Item Part Number Quantity Description BK707155 L1 Inductor BK706409 T2 Control Transformer, 200-480 V / 60 Hz BK706410 T2 Control Transformer, 600 V / 60 Hz BK706405 T1 Main Transformer, 200-480 V / 60 Hz / 3Ø...
  • Page 126 Section 7: Parts List Spirit II User’s Manual Power Supply (BK300211 - BK300219) Left Side View Item Part Number Quantity Description BK300101 Printed Circuit Board (PCB), Microprocessor (DSP) BK300112 Printed Circuit Board (PCB), A.C. Detect BK708118 CR3/PAR Relay BK705011 PAT IGBT BK702075 PAT IGBT Filter Capacitor BK300108...
  • Page 127 Spirit II User’s Manual Section 7: Parts List Power Supply (BK300211 - BK300219) Top View Item Part Number Quantity Description BK501163 Light Housing BK501164 Bulb BK501162 White Lens BK706409 T2 Control Transformer, 200-480 V / 60 Hz BK706410 T2 Control Transformer, 600 V / 60 Hz BK709359 F3 Fuse, 5A, Slow Blow BK709358...
  • Page 128 Section 7: Parts List Spirit II User’s Manual Power Supply (BK300211 - BK300219) Cooling Section View Item Part Number Quantity Description BK709105 Strain Relief BK200092 Coolant Reservoir, without Fittings or Cap BK500518 Coolant Reservoir Cap/Level Gauge BK300135 Coolant Level Switch BK505024 Coolant Temperature Switch BK500052...

  • Page 129: Automatic Gas Console (Bk300418)

    Spirit II User’s Manual Section 7: Parts List Automatic Gas Console (BK300418) Front View Item Part Number Quantity Description BK300412 Power Supply, 24VDC, 8.3A BK300301-AGC Printed Circuit Board (PCB), Gas Console DSP BK280030 Fan, 24VDC BK260109 Nitrogen, Regulator Valve BK300415 Nitrogen, Regulator Valve Amplifier (Programmed) BK260109 Oxygen, Regulator Valve...
  • Page 130 Section 7: Parts List Spirit II User’s Manual Automatic Gas Console (BK300418) Right Side View Item Part Number Quantity Description BK300412 Power Supply, 24VDC, 8.3A BK300301-AGC Printed Circuit Board (PCB), Gas Console DSP BK280030 Fan, 24VDC BK260109 Shield, Regulator Valve BK300415 Shield, Regulator Valve Amplifier (Programmed) BK260109...
  • Page 131 Spirit II User’s Manual Section 7: Parts List Automatic Gas Console (BK300418) Left Side View Item Part Number Quantity Description BK300412 Power Supply, 24VDC, 8.3A BK300301-AGC Printed Circuit Board (PCB), Gas Console DSP BK280030 Fan, 24VDC BK260109 Nitrogen, Regulator Valve BK300415 Nitrogen, Regulator Valve Amplifier (Programmed) BK260109...

  • Page 132: Plasma Console (Bk300800)

    Section 7: Parts List Spirit II User’s Manual Plasma Console (BK300800) Item Part Number Quantity Description BK300712 Power Supply, 12VDC BK300701 Printed Circuit Board (PCB), RS422 Isolation BK300706 Printed Circuit Board (PCB), Computer BK300707 10.4" LCD Touchscreen BK708111 Switch, Pushbutton (OFF Button) This information is subject to the controls of the Export Administration Regulations [EAR].
  • Page 133 Spirit II User’s Manual Section 7: Parts List Arc Starting Console (BK300510) with Remote High Frequency (RHF) Item Part Number Quantity Description BK715051 Coolant return fitting (left hand) BK715050 Coolant supply fitting (right hand) BK709227 Strain relief BK709001 4 pin receptacle BK707001 Line filter BK706109...

  • Page 134: Arc Starting Console (Bk300500) With Cleanstrike

    Section 7: Parts List Spirit II User’s Manual Arc Starting Console (BK300500) ™ with CleanStrike Technology Item Part Number Quantity Description BK715051 Coolant Return Fitting (left hand) BK715050 Coolant Supply Fitting (right hand) BK715021 Coolant Supply Fitting (right hand) BK709001 4 pin Receptacle BK708057 Door Interlock Switch...

  • Page 135: Torch And Manifold Assemblies

    Spirit II User’s Manual Section 7: Parts List Torch and Manifold Assemblies Item Part Number Quantity Description BK284214 2-gang Manifold (includes Bracket) BK277195 2-gang Manifold Bracket BK278001 Torch Handle – Standard BK278018 Torch Handle – Short BK279000 Torch Base BK279100 Torch Head (Copper Electrode) BK279060 Torch Head (Silver Electrode)

  • Page 136: Shielded Torch Leads

    Section 7: Parts List Spirit II User’s Manual Shielded Torch Leads Part Number Length BK284304-XX Where -XX is the length in feet. 4-10 ft lengths available in 1 ft increments. 15-150 ft lengths available in 5 ft increments. CAN Communication Cable and Termination Plug Item Part Number Length...

  • Page 137: Gas Hose Package With Agc

    Spirit II User’s Manual Section 7: Parts List Gas Hose Package with AGC Part Number Length* BK300080-XX Where -XX is the length in feet. 10-150 ft lengths available in 10 ft increments. *Custom lengths are available. Contact factory.   ...

  • Page 138: Coolant And Power Leads

    Section 7: Parts List Spirit II User’s Manual Coolant and Power Leads Part Number Part Number Length (Non-CSA Systems) (CSA Systems) BK300306-XX BK388306-XX Where -XX is the length in feet. 10-150 ft lengths available in 10 ft increments.   ...

  • Page 139: Oxygen Supply Gas Hose (Optional)

    Spirit II User’s Manual Section 7: Parts List Oxygen Supply Gas Hose (Optional) Part Number Length BK200362-XX Where -XX is the length in feet. 25-100 ft lengths available in 25 ft increments. BLUE BLUE Nitrogen Supply Gas Hose (Optional) Part Number Length BK200365-XX Where -XX is the length in feet.

  • Page 140: Cii" Cable (For Optional External Inova)

    Section 7: Parts List Spirit II User’s Manual “CII” Cable (for Optional External Inova) Part Number Length BK300902-XX Where -XX is the length in feet. 5-150 ft lengths available in 5 ft increments. STRAIN RELIEF BK709015 CABLE BK711001 PLUG BK709016 PLUG BK709364 STRAIN RELIEF BK709025 BK709365 PIN...

  • Page 141: Fii" Cable (For Optional Internal Inova)

    Spirit II User’s Manual Section 7: Parts List “FII” Cable (for Optional Internal Inova) Part Number Length BK300903-XX Where -XX is the length in feet. 5-150 ft lengths available in 5 ft increments. CABLE BK711002 PLUG BK709364 PLUG BK709095 STRAIN RELIEF BK709025 STRAIN RELIEF BK709021 BK709018 SOCKET BK709365 PINS...

  • Page 142: Jii" Cable (For Optional Internal Inova)

    Section 7: Parts List Spirit II User’s Manual “JII” Cable (for Optional Internal Inova) Part Number Length BK300904-XX Where -XX is the length in feet. 5-50 ft lengths available in 5 ft increments. STRAIN RELIEF BK709025 STRAIN RELIEF BK709021 PLUG BK709364 PLUG BK709020 CABLE BK711049 BK709365 PIN...

  • Page 143: Pcb Assemblies - Component Reference Locations

    Spirit II User’s Manual Section 7: Parts List PCB Assemblies – Component Reference Locations Power Supply, Microprocessor DSP (BK300101) – Quadrant 1 PCB Quadrant Map U37 - RHF U36 – Impulse Start U32 - Marking U31 – Postflow U30 - Vent U29 - Shield This information is subject to the controls of the Export Administration Regulations [EAR].
  • Page 144 Section 7: Parts List Spirit II User’s Manual Power Supply, Microprocessor DSP (BK300101) – Quadrant 2 PCB Quadrant Map U28 - Plasma U27 - Preflow U19 – Solenoid (not used) U21 – Mtr / Sol U22 - PAR U24 - Surge U26 - Fan U23 - Con This information is subject to the controls of the Export Administration Regulations [EAR].
  • Page 145 Spirit II User’s Manual Section 7: Parts List Power Supply, Microprocessor DSP (BK300101) – Quadrant 3 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-21...
  • Page 146 Section 7: Parts List Spirit II User’s Manual Power Supply, Microprocessor DSP (BK300101) – Quadrant 4 PCB Quadrant Map J4-1 J4-2 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 147 Spirit II User’s Manual Section 7: Parts List Power Supply, Output (BK300108) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-23...
  • Page 148 Section 7: Parts List Spirit II User’s Manual Power Supply, A.C. Detect (BK300112) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-24...
  • Page 149 Spirit II User’s Manual Section 7: Parts List Gas Console, Microprocessor DSP (BK300301-AGC) – Quadrant 1 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-25...
  • Page 150 Section 7: Parts List Spirit II User’s Manual Gas Console, Microprocessor DSP (BK300301-AGC) – Quadrant 2 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-26...
  • Page 151 Spirit II User’s Manual Section 7: Parts List Gas Console, Microprocessor DSP (BK300301-AGC) – Quadrant 3 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-27...
  • Page 152 Section 7: Parts List Spirit II User’s Manual Gas Console, Microprocessor DSP (BK300301-AGC) – Quadrant 4 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-28...
  • Page 153 Spirit II User’s Manual Section 7: Parts List Chopper, Gate Driver (BK300106) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-29...
  • Page 154 Section 7: Parts List Spirit II User’s Manual Plasma Console, RS422 Isolation (BK300701) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-30...

  • Page 155: Section 8: Internal Inova Console Option

    RS-422 MACHINE RS-422 IN RS-422 OUT Spirit II 150/275 Spirit II 400 Unique Interconnect Cables Two unique interconnect cables are required for this option with the Spirit II system. The FII cable is used to connect the Spirit II internal Inova console (IP4) to the X/Y Machine (CNC controller).

  • Page 156: Grounding

    Use a minimum of #8AWG (10 mm ) wire. Note: the customer must supply the ground cable. Direct to star ground: Ground Ground Point Point Spirit II 150/275 Spirit II 400 Jumper to the work ground lead: Ground Ground Point Point Spirit II 150/275 Spirit II 400 This information is subject to the controls of the Export Administration Regulations [EAR].

  • Page 157: Parts List

    Printed Circuit Board (PCB), Voltage Divider BK709276 Power Distribution Block,1 Pole Location in Spirit II 150 & 275 (pos A) (pos B) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to...
  • Page 158 Section 8: Internal Inova Console Option Spirit II User’s Manual Location in Spirit II 150 & 275 - Continued This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
  • Page 159 Spirit II User’s Manual Section 8: Internal Inova Console Option Location in Spirit II 400 (pos A) (pos B) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
  • Page 160 Section 8: Internal Inova Console Option Spirit II User’s Manual Location in Spirit II 400 - Continued This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

  • Page 161: Appendix A: Electromagnetic Compatibility (Emc)

    Spirit II User’s Manual Appendix A: Electromagnetic Compatibility (EMC) Appendix A: Electromagnetic Compatibility (EMC) Background The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit 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 –...

  • Page 162: Assessment Of Area

    Appendix A: Electromagnetic Compatibility (EMC) Spirit II User’s Manual Assessment of Area Before installing plasma cutting equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the plasma cutting equipment;...
  • Page 163 Spirit II User’s Manual Appendix A: Electromagnetic Compatibility (EMC) 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 receive a shock by touching these metallic components and the electrode at the same time.
  • Page 164 Appendix A: Electromagnetic Compatibility (EMC) Spirit II User’s Manual BLANK This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

  • Page 165: Appendix B: Serial Communication

    Spirit II User’s Manual Appendix B: Serial Communication Appendix B: Serial Communication Initializing the Spirit System The Spirit system uses an RS-422 serial communication port located on the rear of the plasma console to receive and respond to commands that are transmitted from an x/y controller.

  • Page 166: Communication Error Checking

    Appendix B: Serial Communication Spirit II User’s Manual 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 AA nn FA 04 -- -- 0D Time in mS (seconds / 1000) Valid range: 0 to 5000 Once again, AA hex signifies the start of the command, “nn”...

  • Page 167: Default Cutting Parameters

    Spirit II User’s Manual Appendix B: Serial Communication 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.

  • Page 168: Rs-422 Serial Commands

    Appendix B: Serial Communication Spirit II User’s Manual RS-422 Serial Commands Note: 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”...
  • Page 169 Spirit II User’s Manual Appendix B: Serial Communication Command Hex String Additional Information Torch Body Part AA nn FA 10 -- -- 0D If requested in command #30, the system will Number (msw) transmit the most significant word of the torch body part number.
  • Page 170 Appendix B: Serial Communication Spirit II User’s Manual Command Hex String Additional Information Torch Outer Cap AA nn FA 1D -- -- 0D If requested in command #30, the system will Part Number (lsw) transmit the least significant word of the outer cap part number.
  • Page 171 Spirit II User’s Manual Appendix B: Serial Communication Command Hex String Additional Information Cutting Chart AA nn FA 22 00 -- 0D If requested in command #30, the system will Version transmit the cutting chart version x 10. Number of Pierces AA nn FA 23 00 -- 0D If requested in command #30, the system will transmit the number of pierces.
  • Page 172 Appendix B: Serial Communication Spirit II User’s Manual Command Hex String Additional Information Restore Factory AA nn FA 2F 00 01 0D Restores the factory cutting condition for the Condition present material type and thickness. Cutting Condition AA nn FA 30 00 -- 0D If requested in command #30, the system will Type transmit whether the present cutting condition is a...

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