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Kaliburn Spirit200a User Manual

High current density plasma cutting system with automatic gas console
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High Current Density Plasma Cutting System
with
Automatic Gas Console
User's Manual - Part Number 718086 Rev J
10/15/2012
R
EVISION
J
This information is subject to the controls of the Export Administration
Regulations [EAR]. This information shall not be provided to non-U.S.
persons or transferred by any means to any location outside the United
States contrary to the requirements of the EAR.

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  • Page 1 High Current Density Plasma Cutting System with Automatic Gas Console User’s Manual - Part Number 718086 Rev J 10/15/2012 EVISION This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
  • Page 2 Spirit200a User’s Manual Rev J EVISION ISTORY ECO# Author Date Description of Change As released 05/08/07 Changed location of coolant level switch Changed 30A mild steel preflow pressure from 30 to 35 05/23//07 • Changed cutting charts to have separate metric and 07/02/07 imperial versions.
  • Page 3 (1) year for the Spirit200a torch and leads and three (3) years for the Spirit200a power supply and automatic gas console. This product is intended for commercial use and is not intended for personal, family, or household purposes.

  • Page 4: Table Of Contents

    Spirit200a User’s Manual Rev J TABLE OF CONTENTS Section 1 Safety General Precautions ....................1-1 Ultraviolet Radiation Protection ................1-1 Noise Protection ...................... 1-1 Toxic Fume Prevention ................... 1-1 Electric Shock Prevention ..................1-2 Fire Prevention ......................1-3 Explosion Prevention ....................1-3 Health Support Equipment ..................
  • Page 5 Spirit200a User’s Manual Rev J Section 4 Operation Power Supply Front Panel Controls ................ 4-1 Automatic Gas Console Keypad ................4-3 Automatic Gas Console Help Prompt ..............4-4 Automatic Gas Console Status Screen ..............4-5 Setting up a Cut or Mark ..................4-6 Torch Consumable Selection ..................
  • Page 6 Spirit200a User’s Manual Rev J Section 7 Maintenance and Troubleshooting Routine Maintenance ....................7-1 Replacing the Torch Coolant .................. 7-4 Microprocessor Status LED’s .................. 7-5 Microprocessor Sequence of Operation ..............7-6 Troubleshooting Using the Control Panel Status LED’s ......... 7-7 Troubleshooting Using the Automatic Gas Console Messages Screen ....

  • Page 7: Section 1 Safety

    Installation, operation, and repairs made to the Spirit200a system should only be performed by qualified personnel. The Spirit system makes use of both A.C.

  • Page 8: Electric Shock Prevention

    Electric Shock Prevention The Spirit200a 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.

  • Page 9: Fire Prevention

    • Preventive maintenance should be performed daily to avoid possible safety hazards. Fire Prevention When using the Spirit200a 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.

  • Page 10: Health Support Equipment

    • Never use any gas hose that is leaking or has other signs of physical damage. Health Support Equipment The Spirit200a 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.

  • Page 11: Safety Standards Booklet Index

    Safety Spirit200a User’s Manual Rev J 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 Safety Spirit200a User’s Manual Rev J 11. OSHA Standard 29CFR 1910.252, Safety 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.

  • Page 13: Section 2 Specifications

    All gas inlets and outlets are connected to the rear of the automatic gas console. For cutting mild steel, the Spirit200a uses oxygen for the plasma gas and either oxygen or air for the shielding gas.

  • Page 14: System Components

    Specifications Spirit200a User’s Manual Rev J System Components The degree of protection provided by the Spirit200a system is IP21S and as such is intended only for indoor use. It is not suitable for use in rain or snow. The Spirit200a system is tested in accordance with CISPR 11, EMC classification –...

  • Page 15: Power Supply Specifications

    Specifications Spirit200a User’s Manual Rev J Power Supply Specifications Stock Number: 208 VAC, 3Ø, 60Hz ........282410 230 VAC, 3Ø, 60Hz ........282411 380 VAC, 3Ø, 50/60Hz ........ 282413 415 VAC, 3Ø, 50/60Hz ........ 282414 460 VAC, 3Ø, 60Hz ........282412 575 VAC, 3Ø, 60Hz ........
  • Page 16 Specifications Spirit200a User’s Manual Rev J Torch Cooling System: Discharge pressure ........150 psi (10.2 bar) Flow rate ............1 gal/min (3.8 liters/min) Coolant fluid ..........Propylene glycol/deionized water Coolant tank capacity ........3.2 gal (12 liters) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to...

  • Page 17: Automatic Gas Console Specifications

    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.

  • Page 18: Remote High Frequency Console Specifications

    Specifications Spirit200a User’s Manual Rev J Remote High Frequency Console Specifications Stock Number ........... 205500 Height ..............5.35 in (136 mm) Width ..............13.5 in (343 mm) Depth ..............10 in (25 mm) Weight ............... 22 lb (10 kg) Spark gap distance ..........015 in (.381 mm) This information is subject to the controls of the Export Administration Regulations [EAR].

  • Page 19: Torch Specifications

    Specifications Spirit200a User’s Manual Rev J Torch Specifications Stock Number: 2-Gang Manifold Assembly........260214 Torch Handle ............820134 Torch Base ............. 279050 Torch Head (Copper Electrode) ......279150 Torch Head (Silver Electrode) ........ 279160 Weight: Manifold/Bracket, Handle, Base and Head ..... 7.3 lbs (3.3 kg) Manifold 3.38 [86]...

  • Page 20: 5-Gang Manifold Specifications

    Specifications Spirit200a User’s Manual Rev J 5-Gang Manifold Specifications Stock Number ........... 280022 Height ..............3.035 in (77 mm) Width ..............8.35 in (212 mm) Depth ..............7 in (178 mm) Weight ............... 6 lb (2.7 kg) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to...

  • Page 21: Airborne Noise Emissions

    Spirit200a User’s Manual Rev J Airborne Noise Emissions The Spirit200a 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.

  • Page 22: Specifications

    Specifications Spirit200a User’s Manual Rev J 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.

  • Page 23: Section 3 Installation

    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 Spirit200a system.

  • Page 24: Power Supply Installation

    See Section 2 for 5-gang manifold mounting dimensions. Torch Installation The Spirit200a 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.

  • Page 25: Primary Power Connection

    Installation Spirit200a User’s Manual Rev J 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.
  • Page 26 Installation Spirit200a User’s Manual Rev J     TB5 Location This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 27: Power Supply Output Connections

    Installation Spirit200a User’s Manual Rev J 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.

  • Page 28: Rhf Console Ground Connection

    Installation Spirit200a User’s Manual Rev J 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.
  • Page 29 Installation Spirit200a User’s Manual Rev J            This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 30: Torch Leads To Rhf Console Connections

    Installation Spirit200a User’s Manual Rev J 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.
  • Page 31 Installation Spirit200a User’s Manual Rev J This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 32: Torch Leads To Torch Base Connections

    Installation Spirit200a User’s Manual Rev J 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 33: Torch Gas Connections

    Installation Spirit200a User’s Manual Rev J Torch Gas Connections Perform the following steps to connect the torch gas hoses to the automatic gas console, torch base, and torch valve assemblies. figure below. Note: When making hose connections, only tighten the brass fittings enough to make gas seals.
  • Page 34 Installation Spirit200a User’s Manual Rev J 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.
  • Page 35 Installation Spirit200a User’s Manual Rev J This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 36: Torch Head Connection

    Installation Spirit200a User’s Manual Rev J 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.

  • Page 37: Automatic Gas Console Input Connections

    Installation Spirit200a User’s Manual Rev J 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.

  • Page 38: Cnc Machine Interface Connections

    CNC cutting machine. See the system schematic for additional information. Plasma Start Input • The Spirit200a requires a contact closure between P8 pins 3 and 4 to commence the cutting or marking sequence. The sequence is terminated when the contacts are opened. The contacts should be rated for 12VDC - 10mA.
  • Page 39 Installation Spirit200a User’s Manual Rev J RS-422 Serial Communication Link • 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.

  • Page 40: Torch Coolant Requirements

    The Spirit200a 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.

  • Page 41: Initial Filling Of The Torch Coolant Reservoir

    Installation Spirit200a User’s Manual Rev J 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.
  • Page 42 Installation Spirit200a User’s Manual Rev J 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.

  • Page 43: Section 4 Operation

    Operation Spirit200a User’s Manual Rev J 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.
  • Page 44 Operation Spirit200a User’s Manual Rev J • Coolant Level Indicator Illuminates when the coolant level inside the reservoir is satisfactory. Remains extinguished when coolant must be added to the system. • Coolant Temperature Indicator Illuminates when the torch coolant temperature is satisfactory.

  • Page 45: Automatic Gas Console Keypad

    Operation Spirit200a User’s Manual Rev J 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. Menu Key The Menu key is used to select the bottom portion of a split-level key.

  • Page 46: Automatic Gas Console Help Prompt

    Operation Spirit200a User’s Manual Rev J Arrow Keys The Arrow keys are used to scroll up and down in order to edit or select a particular item. Function Keys The Function keys are used for various purposes in the editing and maintenance modes.

  • Page 47: Automatic Gas Console Status Screen

    Operation Spirit200a User’s Manual Rev J 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.

  • Page 48: Setting Up A Cut Or Mark

    Operation Spirit200a User’s Manual Rev J 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.
  • Page 49 Operation Spirit200a User’s Manual Rev J 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.
  • Page 50 Operation Spirit200a User’s Manual Rev J Selecting Process 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.
  • Page 51 Also, the height control should be set to the proper pierce (initial) height, cutting (marking) height and arc voltage. If a 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.
  • Page 52 Operation Spirit200a User’s Manual Rev J 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.

  • Page 53: Torch Consumable Selection

    Operation Spirit200a User’s Manual Rev J Torch Consumable Selection Mild Steel Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 277154 277145 277153 277120 277140 277130 279150 277140/ 277154 277115 277153 277122 277142...
  • Page 54 Operation Spirit200a User’s Manual Rev J Mild Steel Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 279440 277154 277274 277266 279489 279443 279160 (yellow o-ring) 200A This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 55 Operation Spirit200a User’s Manual Rev J Stainless Steel - H17 Plasma Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 277154 277150 277113 277124 277140 277132 279150 277154 277146 277113 277126 277141 277133...
  • Page 56 Operation Spirit200a User’s Manual Rev J Stainless Steel - Air or Nitrogen Plasma Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 277154 277144 277110 277121 277138 277137 279150 277154 277149 277110 277123...
  • Page 57 Operation Spirit200a User’s Manual Rev J Stainless Steel - Air or Nitrogen Plasma Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 279440 277154 277274 277266 279489 279443 279160 (yellow o-ring) 200A This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 58 Operation Spirit200a User’s Manual Rev J Aluminum Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 277154 277145 277153 277120 277140 277130 279150 277154 277150 277153 277122 277142 277131 279150 277154 277150 277153...
  • Page 59 Operation Spirit200a User’s Manual Rev J Aluminum Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 279440 277154 277274 277266 279489 279443 279160 (yellow o-ring) 200A This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 60: Installing Or Removing Torch Consumables

    Operation Spirit200a User’s Manual Rev J Installing or Removing Torch Consumables 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.

  • Page 61: Making A Cut Or Mark

    Operation Spirit200a User’s Manual Rev J 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.

  • Page 62: Piercing Thick Materials

    Operation Spirit200a User’s Manual Rev J 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 63: Cut Quality

    Operation Spirit200a User’s Manual Rev J 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 64: Changing Consumable Parts

    Operation Spirit200a User’s Manual Rev J 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, debris, and excess o-ring lubricant and clean as necessary.

  • Page 65: Consumable Life

    Operation Spirit200a User’s Manual Rev J 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 66: Cutting Charts

    Operation Spirit200a User’s Manual Rev J 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.
  • Page 67 Operation Spirit200a User’s Manual Rev J 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...
  • Page 68 Operation Spirit200a User’s Manual Rev J Mild Steel - 50 Amps - Oxygen Plasma / Oxygen or Air Shield Copper Electrode Shield Cap Nozzle Electrode 277115 277122 277131 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277140 / 277142...
  • Page 69 Operation Spirit200a User’s Manual Rev J Mild Steel - 70 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277142 279150 Imperial Material...
  • Page 70 Operation Spirit200a User’s Manual Rev J Mild Steel - 100 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277151 277283 279150 Imperial Material...
  • Page 71 Operation Spirit200a User’s Manual Rev J Mild Steel - 150 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277117 277293 277292 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277151 / 277152 277139 279150...
  • Page 72 Operation Spirit200a User’s Manual Rev J Mild Steel - 200 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 277143 279150 Imperial Material...
  • Page 73 Operation Spirit200a User’s Manual Rev J Stainless Steel - 30 Amps - Air Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277144 277121 277137 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277110 277138 279150 Imperial Material...
  • Page 74 Operation Spirit200a User’s Manual Rev J Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277149 277123 277137 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277110 277142 279150 Imperial Material...
  • Page 75 Operation Spirit200a User’s Manual Rev J 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 Outer Cap...
  • Page 76 Operation Spirit200a User’s Manual Rev J 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 Outer Cap Retaining Cap...
  • Page 77 Operation Spirit200a User’s Manual Rev J 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 Outer Cap...
  • Page 78 Operation Spirit200a User’s Manual Rev J 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 277286 277284 277282 Outer Cap Retaining Cap...
  • Page 79 Operation Spirit200a User’s Manual Rev J 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...
  • Page 80 Operation Spirit200a User’s Manual Rev J 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 277117 277293 277292 Outer Cap Retaining Cap...
  • Page 81 Operation Spirit200a User’s Manual Rev J Stainless Steel - 200 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen) This gas combination gives the good cut quality and minimum dross levels...
  • Page 82 Operation Spirit200a User’s Manual Rev J Stainless Steel - 200 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap...
  • Page 83 Operation Spirit200a User’s Manual Rev J Aluminum - 30 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277130 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277140 279150 Imperial Material Travel...
  • Page 84 Operation Spirit200a User’s Manual Rev J Aluminum - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277150 277122 277131 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277142 279150 Imperial Material Travel...
  • Page 85 Operation Spirit200a User’s Manual Rev J Aluminum - 70 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277142 279150 Imperial Material Travel...
  • Page 86 Operation Spirit200a User’s Manual Rev J Aluminum - 100 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277151 277283 279150 Imperial Material Travel...
  • Page 87 Operation Spirit200a User’s Manual Rev J Aluminum - 150 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277117 277293 277292 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277139 279150 Imperial Material Travel...
  • Page 88 Operation Spirit200a User’s Manual Rev J Aluminum - 200 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 277143 279150 Imperial Material Travel...
  • Page 89 Operation Spirit200a User’s Manual Rev J Mild Steel - 200 Amps - Oxygen Plasma / Air Shield Silver Electrode Shield Cap Nozzle Electrode 277274 279489 279440 (yellow o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 279443 279160...
  • Page 90 Operation Spirit200a User’s Manual Rev J Stainless Steel - 200 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode 277274 279489 279440 (yellow o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 279443 279160...
  • Page 91 Operation Spirit200a User’s Manual Rev J Aluminum - 200 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode 277274 279489 279440 (yellow o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 279443 279160 Imperial...
  • Page 92 Operation Spirit200a User’s Manual Rev J 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.

  • Page 93: Section 5 Automatic Gas Console Advanced Functions

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J Section 5 Automatic Gas Console 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.

  • Page 94: Setting The Pierce Time

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J Setting the Pierce Time After the Spirit cutting or marking arc transfers to the workpiece, a motion signal (ok to move signal) is sent to the x/y controller or torch height control.

  • Page 95: Altering Gas Types

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 96: Altering Gas Pressures

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 97: Altering Arc Voltage Control And X/Y Machine Parameters

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 98: Saving A User Created Cutting Or Marking Condition

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 99: Maintenance Screen

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 100: Viewing Messages

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 101: Viewing Cut Errors

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.
  • Page 102 Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.
  • Page 103 Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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. When any of the errors listed on the actual cut errors screen occur, measures should be taken to avoid further errors.
  • Page 104 Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J • 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.

  • Page 105: Pressure Diagnostics

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 106: Restoring Factory Default Cutting Or Marking Conditions

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 107: Measurement System

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 108: Communication Node

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 109: Inova Parameter Transmit

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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...

  • Page 110: Viewing Serial Communication

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 111: Configuring Hydrogen Cutting

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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 the use of H17, hydrogen cutting must be disabled.

  • Page 112: Setting An Arc Off Delay

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 113: Switching Between Cutting And Marking

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 114: Software Updates

    Automatic Gas Console Advanced Functions Spirit200a User’s Manual Rev J 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.

  • Page 115: Section 6 Serial Communication

    Serial Communication Spirit200a User’s Manual Rev J 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.

  • Page 116: Communication Error Checking

    Serial Communication Spirit200a User’s Manual Rev J 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.

  • Page 117: Default Cutting Parameters

    Serial Communication Spirit200a User’s Manual Rev J 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 118: Rs-422 Serial Commands

    Serial Communication Spirit200a User’s Manual Rev J 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” should be set to C8 hex (200 decimal).
  • Page 119 Serial Communication Spirit200a User’s Manual Rev J Command Hex String Additional Information Torch Body Part AA nn FA 10 -- -- 0D If requested in command #30, the AGC Number (msw) will transmit the most significant word of the torch body part number.
  • Page 120 Serial Communication Spirit200a User’s Manual Rev J Command Hex String Additional Information Torch Outer Cap AA nn FA 1D -- -- 0D If requested in command #30, the AGC Part Number (lsw) will transmit the least significant word of the outer cap part number.
  • Page 121 Serial Communication Spirit200a User’s Manual Rev J Command Hex String Additional Information Cutting Chart AA nn FA 22 00 -- 0D If requested in command #30, the AGC Version will transmit the cutting chart version x 10. Number of Pierces...
  • Page 122 Serial Communication Spirit200a User’s Manual Rev J Command Hex String Additional Information Restore Factory AA nn FA 2F 00 01 0D Restores the factory cutting condition for Condition the present material type and thickness. Cutting Condition AA nn FA 30 00 -- 0D...

  • Page 123: Section 7 Maintenance And Troubleshooting

    Maintenance and Troubleshooting Spirit200a User’s Manual Rev J Section 7 Maintenance and 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.
  • Page 124 Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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.
  • Page 125 Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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.

  • Page 126: Replacing The Torch Coolant

    Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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.

  • Page 127: Microprocessor Status Led's

    Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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...

  • Page 128: Microprocessor Sequence Of Operation

    Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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 •...

  • Page 129: Troubleshooting Using The Control Panel Status Led's

    Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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.

  • Page 130: Troubleshooting Using The Automatic Gas Console Messages Screen

    Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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).

  • Page 131: General Troubleshooting

    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.
  • Page 132 Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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.
  • Page 133 Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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.

  • Page 134: Chopper Test Procedure

    Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 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.
  • Page 135 Maintenance and Troubleshooting Spirit200a User’s Manual Rev J 8. If 300 VDC is not present at the output terminal block, install a jumper wire between P28-7 & P28-8 (ILK1). With a start signal applied, check for 300 VDC at the Spirit output terminal block between Electrode and Work.
  • Page 136 Maintenance and Troubleshooting Spirit200a User’s Manual Rev J This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 137: Section 8 Parts List

    Parts List Spirit200a User’s Manual Rev J Section 8 Parts List Power Supply (See Figures Below) Item Number Part Number Quantity Description 708088 Off switch, red 708111 Off actuator, red 708090 On switch, green 708089 On actuator, green / illuminated...
  • Page 138 Parts List Spirit200a User’s Manual Rev J Item Number Part Number Quantity Description 500511 Coolant pump, 70 gph 708061 Solenoid valve, 220/240VAC 715084 Check valve, coolant return 708068 CR2/CR5 relay 708059 FS1 coolant flow switch 500516 Fan, heat exchanger / front panel...
  • Page 139 Parts List Spirit200a User’s Manual Rev J Power Supply – 1 of 4 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...
  • Page 140 Parts List Spirit200a User’s Manual Rev J Power Supply – 2 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.
  • Page 141 Parts List Spirit200a User’s Manual Rev J Power Supply – 3 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.
  • Page 142 Parts List Spirit200a User’s Manual Rev J 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.

  • Page 143: Automatic Gas Console

    Parts List Spirit200a User’s Manual Rev J Automatic Gas Console (Assembly 282002) Note: See Figures Below Item Number Part Number Quantity Description 280005 AGC decal / membrane switch 501146 AGC aluminum display panel 500860 AGC display window 710199 Aluminum standoff...
  • Page 144 Parts List Spirit200a User’s Manual Rev J Automatic Gas Console – 1 of 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.
  • Page 145 Parts List Spirit200a User’s Manual Rev J Automatic Gas Console – 2 of 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.

  • Page 146: Remote High Frequency Console

    Parts List Spirit200a User’s Manual Rev J Remote High Frequency Console (Assembly 205500) Item Number Part Number Quantity Description 715051 Coolant return fitting (left hand) 715050 Coolant supply fitting (right hand) 709227 Strain relief 709001 4 pin receptacle 707001 Line filter 706109 Transformer –...

  • Page 147: Torch And Manifold Assemblies

    Parts List Spirit200a User’s Manual Rev J Torch and Manifold Assemblies Item Number Part Number Quantity Description 260214 2-gang manifold assembly (includes bracket) 277195 2-gang manifold bracket 820134 Torch handle 279050 Torch Base 279150 Torch Head (Copper Electrode) 279160 Torch Head (Silver Electrode)

  • Page 148: Shielded Torch Leads

    Parts List Spirit200a User’s Manual Rev J Shielded Torch Leads Part Number Length 200304-10 10 ft. (3.0 m) 200304-15 15 ft. (4.6 m) 200304-20 20 ft. (6.1 m) 200304-25 25 ft. (7.6 m) 200304-30 30 ft. (9.1 m) 200304-35 35 ft. (10.7 m) 200304-40 40 ft.

  • Page 149: Gas Hose Package

    Parts List Spirit200a User’s Manual Rev J 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.

  • Page 150: Coolant And Power Leads

    Parts List Spirit200a User’s Manual Rev J Coolant and Power Leads Part Number Part Number Length (Non-CSA Systems) (CSA Systems) 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) 280306-20 288306-20 20 ft.

  • Page 151: Work Ground Cable

    Parts List Spirit200a User’s Manual Rev J Work Ground Cable Part Number Part Number Length (Non-CSA Systems) (CSA Systems) 280318-10 288318-10 10 ft. (3.0 m) 280318-15 288318-15 15 ft. (4.6 m) 280318-20 288318-20 20 ft. (6.1 m) 280318-25 288318-25 25 ft. (7.6 m)

  • Page 152: Oxygen Supply Gas Hose (Optional)

    Parts List Spirit200a User’s Manual Rev J Oxygen Supply Gas Hose (Optional) Part Number Length 200362-25 25 ft. (7.6 m) 200362-50 50 ft. (15.2 m) BLUE BLUE Nitrogen Supply Gas Hose (Optional) Part Number Length 200365-25 25 ft. (7.6 m) 200365-50 50 ft.

  • Page 153: Power Supply Microprocessor P.c. Board

    Parts List Spirit200a User’s Manual Rev J Power Supply Microprocessor P.C. Board (Assembly 282275) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 154: A.c. Detect P.c. Board

    Parts List Spirit200a User’s Manual Rev J A.C. Detect P.C. Board (Assembly 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.

  • Page 155: Relay P.c. Board

    Parts List Spirit200a User’s Manual Rev J Relay P.C. Board (Assembly 500348) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 156: Power Supply I/O P.c. Board

    Parts List Spirit200a User’s Manual Rev J Power Supply I/O P.C. Board (Assembly 277452) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 157: Automatic Gas Console I/O P.c. Board

    Parts List Spirit200a User’s Manual Rev J Automatic Gas Console I/O P.C. Board (Assembly 200288) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided 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 158: Consumable Spare Parts Kit

    Parts List Spirit200a User’s Manual Rev J Consumable Spare Parts Kit (Part Number 282267) Part Number Quantity Description 277130 Electrode 30A Mild Steel - 30A Aluminum 277137 Electrode 30/50A Stainless (Air) 277131 Electrode 50/70A Mild Steel - 70A Stainless (Air) - 50/70A Aluminum...
  • Page 159 Parts List Spirit200a User’s Manual Rev J Part Number Quantity Description 277287 Nozzle 200A Stainless (H17) 277145 Shield Cap 30A Mild Steel - 30A Aluminum 277144 Shield Cap 30A Stainless (Air) 277149 Shield Cap 50A Stainless (Air) 277115 Shield Cap...
  • Page 160 Parts List Spirit200a User’s Manual Rev J Part Number Quantity Description 277151 Inner Retaining Cap 100A Mild Steel - 100A Stainless (Air) - 100A Aluminum 150A Mild Steel – 1/2” and below 277152 Inner Retaining Cap 150A Mild Steel – 5/8” and above – 150A Stainless (Air)

  • Page 161: Appendix A Electromagnetic Compatibility (Emc)

    Appendix A Electromagnetic Compatibility (EMC) Background The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit200a 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

    Electromagnetic Compatibility (EMC) Spirit200a User’s Manual Rev J 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;...
  • Page 163 Electromagnetic Compatibility (EMC) Spirit200a User’s Manual Rev J 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.
  • Page 164 Electromagnetic Compatibility (EMC) Spirit200a User’s Manual Rev J 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.

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