Lincoln Electric SPIRIT II 400, Technical Manual

Page 1: ...nts of the EAR Technical Manual SPIRIT II 400 Register your equipment www lincolnelectric com register Save for future reference Date Purchased Model Number Serial Number THELINCOLNELECTRICCOMPANY BK8053 000095 Rev C Issue Date 23 May 2018 4130 Carolina Commerce Pkwy Ladson SC 29456 U S A Lincoln Global Inc All Rights Reserved Phone 1 843 695 4000 www lincolnelectric com Manual Plasma Cutting Syst...

Page 2: ...ocks Updated coolant pump part number Added pierce capability for 1 25 32mm MS at 150A and 1 5 38mm MS at 275A Removed 220VAC and 240VAC PS models C LAD0426 CAD 23 MAY 2018 Updated parts list Updated Mild Steel kerf widths Gas supply hose fittings optional Added RF EMI guidelines Trademark Notice Spirit is a registered trademark of Lincoln Global Inc FASTON is a trademark of the TE Connectivity Lt...

Page 3: ...pecifications 2 5 Manual Gas Console MGC Specifications 2 6 Gas Supply Requirements 2 7 Arc Starting Console ASC Specifications with RHF 2 8 Arc Starting Console ASC Specifications with CleanStrike 2 9 Torch and 2 Gang Manifold Specifications 2 10 5 Gang Manifold Specifications 2 11 Airborne Noise Emissions 2 12 Electromagnetic Compatibility EMC 2 12 Section 3 Installation Initial Inspection 3 1 C...

Page 4: ...g the Torch Head 5 1 Installing Replacing Consumables 5 3 Maximizing Consumable Life 5 5 Inspecting for Damage 5 6 Selecting Consumables 5 7 Cutting Charts 5 14 Section 6 Maintenance and Troubleshooting Routine Maintenance 6 1 Replacing the Torch Coolant and Filter 6 4 Power Supply Microprocessor DSP Status Indicators 6 5 Power Supply Microprocessor DSP Sequence of Operation 6 6 Error Codes 6 7 Ge...

Page 5: ...tional 7 13 H17 Supply Gas Hose Optional 7 13 Supply Gas Hose Fittings Kit BK300624 Optional 7 14 CII Cable for Optional External Inova 7 15 FII Cable for Optional Internal Inova 7 16 JII Cable for Optional Internal Inova 7 17 PCB Assemblies Component Reference Locations 7 18 Section 8 Internal Inova Console Option Overview 8 1 Plug Identification 8 1 Unique Interconnect Cables 8 1 Grounding 8 2 P...

Page 6: ...les ni des dom mages résultant de l usure des câbles suite à des courbures et à l abra sion L usager final est responsable de l inspection de routine des câbles pour vérifier qu ils ne présentent pas d usure éventuelle et pour y remédier avant la panne du câble 6 Tous les Produits Burny Kaliburn sont garantis par Burny Kaliburn et ne sont pas couverts par cette garantie Email burnykaliburntech lin...

Page 7: ...rnontool com sales product warranty 8 Tous les Produits Arc Products sont garantis par Arc Products et ne sont pas couverts par cette garantie Email service arc products com 8 Tous les Produits ELCo Enterprises Inc sont garantis par ELCo Enter prises Inc et ne sont pas couverts par cette garantie Contacter le 517 782 8040 RESPONSABILITÉ LIMITÉE Garantie actuelle disponible à www lincolnelectric co...

Page 8: ...la panne du câble 6 Tous les Produits Burny Kaliburn sont garantis par Burny Kaliburn et ne sont pas couverts par cette garantie Email burnykaliburntech lincolnelectric com 7 Tous les Produits Vernon Tools sont garantis par Vernon Tool et ne sont pas couverts par cette garantie www vernontool com sales product warranty 8 Tous les Produits Arc Products sont garantis par Arc Products et ne sont pas ...

Page 9: ...ous les Produits Arc Products sont garantis par Arc Products et ne sont pas couverts par cette garantie Email service arc products com 8 Tous les Produits ELCo Enterprises Inc sont garantis par ELCo Enter prises Inc et ne sont pas couverts par cette garantie Contacter le 517 782 8040 RESPONSABILITÉ LIMITÉE Garantie actuelle disponible à www lincolnelectric com warranty Mar 14 THE LINCOLN ELECTRIC ...

Page 10: ...puis l Atelier de Service Agréé par Lincoln LIMITES DE LA GARANTIE LINCOLN N ACCEPTERA AUCUNE RESPONSABILITÉ DANS LE CAS DE RÉPARATIONS EFFECTUÉES HORS D UN ATELIER DE SERVICE AGRÉÉ PAR LINCOLN LA RESPONSABILITÉ DE LINCOLN SELON CETTE GARANTIE NE DÉPASSERA PAS LE COÛT DE LA CORRECTION DU DÉFAUT DU PRODUIT DE LINCOLN LINCOLN NE SERA PAS RESPONSABLE DES DOMMAGES ACCIDENTELS OU CONSÉQUENTS TELS QUE L...

Page 11: ...cise extreme caution while working on the system Ultraviolet Radiation Protection Plasma cutting produces ultraviolet radiation similar to a welding arc This ultraviolet radiation can cause skin and eye burns For this reason it is essential that proper protection be worn The eyes are best protected by using safety glasses or a welding helmet with an AWS No 12 shade or ISO 4850 No 13 shade which pr...

Page 12: ... the system Observe the following guidelines to protect against electric shock A wall mounted disconnect switch should be installed and fused according to local and national electrical codes The disconnect switch should be located as close as possible to the power supply so it can be turned off in case of an emergency The primary power cord should have a 600 volt minimum rating in order to protect...

Page 13: ...sary to exercise good judgment While cutting the arc produces sparks that could cause a fire if they fall on flammable materials Make sure that all flammable materials are a suitable distance away from the cutting area All flammable liquids should be at least 40 feet away from the cutting area preferably stored in a metal cabinet Plasma cutting should never be attempted on containers that contain ...

Page 14: ...epair compressed gas cylinders Keep compressed gas cylinders away from intense heat sparks or flames Clear the compressed gas cylinder connection point by opening the valve momentarily prior to installing a regulator Never lubricate compressed gas cylinder valves or pressure regulators with any type of oil or grease Never use a compressed gas cylinder or pressure regulator for any purpose other th...

Page 15: ...tainers and Piping obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 5 AWS Standard ULR Ultraviolet Reflectance of Paint obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 6 AWS ANSI Standard Z49 1 Safety in Welding Cutting and Allied Processes obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 7 ANSI Standard ...

Page 16: ...ciation 1 Batterymarch Park Quincy MA 02269 15 CGA booklet P 1 Safe Handling of Compressed Gases in Containers obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 16 CGA booklet P 14 Accident Prevention in Oxygen Rich and Oxygen Deficient Atmospheres obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlingto...

Page 17: ...mild steel the system uses oxygen for the plasma gas and either oxygen or air for the shielding gas When cutting stainless steel or other non ferrous materials air or H17 17 5 hydrogen 32 5 argon 50 nitrogen is used for the plasma gas and either air or nitrogen is used for the shielding gas Oxygen and nitrogen are used for the preflow and postflow gases The torch is water cooled and consumables ar...

Page 18: ...mponents Power Supply Cooling System includes torch coolant Cooling System Control Cable Manual Gas Console CAN Cable Arc Starting Console ASC with Remote High Frequency RHF or Arc Starting Console ASC with CleanStrike Technology ASC Control Cable ASC Ground Cable Torch and Handle Assembly Torch Lead Set 5 gang Manifold Assembly 5 gang Manifold Control Cable 2 gang Manifold Assembly 2 gang Manifol...

Page 19: ...y Specifications Power Supply Description Part Number Input Current at Maximum Output 380 VAC 3Ø 50 60Hz BK300234 152 amps 400 VAC 3Ø 50 60Hz BK300235 144 amps 415 VAC 3Ø 50 60Hz BK300236 140 amps 440 VAC 3Ø 50 60Hz BK300237 131 amps 480 VAC 3Ø 60Hz BK300238 120 amps 600 VAC 3Ø 60Hz BK300239 96 amps Open Circuit Voltage 370 VDC Output Current drooping characteristic 10 400 amps Maximum Output Volt...

Page 20: ...persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 4 Cooling System Specifications Part Number BK300275 Discharge pressure 150 psi 10 2 bar Flow rate 2 1 gal min 7 9 liters min Coolant fluid Propylene glycol solution Coolant tank capacity 3 2 gal 12 liters Weight 141 lbs 64 kg without coolant 36 0 914 23 0 584 15 8 401 ...

Page 21: ...tion for optimal system performance as commercially available antifreeze contains corrosion inhibitors that will damage the cooling system The standard coolant solution consists of 25 industrial grade propylene glycol and provides freezing protection down to 13º C 9º F The standard solution can be ordered in one gallon containers PN BK500695 For operating temperatures below 13º C a 50 solution of ...

Page 22: ...ation shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 6 Manual Gas Console MGC Specifications Part Number BK300610 Weight 43 lbs 19 5 kg 4 300 7 6 13 7 348 2 4 315 12 0 305 10 9 277 7 0 178 12 4 315 12 0 305 13 6 348 10 9 277 7 0 178 4 Ø 300 7 6 ...

Page 23: ...ar Minimum Inlet gas pressure 105 psi 7 2 bar Maximum Inlet gas pressure 145 psi 10 0 bar Oxygen and nitrogen should be supplied with a purity of at least 99 5 H17 should be supplied with a purity of at least 99 995 A potential fire hazard exists when cutting with oxygen It is recommended that an exhaust ventilation system be used when cutting with oxygen Flashback arrestors must be supplied unles...

Page 24: ...means to any location outside the United States contrary to the requirements of the EAR 2 8 Arc Starting Console ASC Specifications with Remote High Frequency RHF Part Number BK284500 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 CleanStrike Technology but not both 12 75 324 8 00 203 12 00 305 13 50 343 10 00 254...

Page 25: ...nited States contrary to the requirements of the EAR 2 9 Arc Starting Console ASC Specifications with CleanStrike Technology Part Number BK300505 Weight 22 lbs 10 kg Note The Spirit II system requires either an ASC with RHF or an ASC with CleanStrike Technology but not both Systems containing an ASC with CleanStrike Technology are only recommended for use with downdraft cutting tables 12 75 324 8 ...

Page 26: ... EAR 2 10 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 8 3 lbs 3 8 kg Torch Head 5 08 129 Torch Base 1 87 47 Torch Handle BK278001 9 46 240 BK27801...

Page 27: ...his information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 11 5 Gang Manifold Specifications Part Number BK300075 Weight 6 lbs 2 7 kg 4 20 107 3 80 97 6 18 157 0 327 8 3 0 25 6 4 1 18 30 8 35 212 3 035 77 4 0 187 4 8 Mounting Holes ...

Page 28: ...y local or national codes The following chart gives the noise levels generated by the system when operating at 400 amps 205 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound Pressure Level C Weighted Sound Pressure Level 1 meter horizontal 1 6 meters above the workpiece 120 dB 115 dB The maximum noise level is 131 dB at a distance of 3 inches 76 2 m...

Page 29: ...If lifting with a sling lifting straps ensure the following Sling and material handling equipment must comply with local and national laws and regulations The personnel involved in the move must be properly trained and qualified to use such equipment All power supply covers must be securely installed Two slings are required Each sling should pass through all three 3 structural members on the botto...

Page 30: ...ction 2 for mounting dimensions 5 Gang Manifold The 5 gang manifold assembly must be mounted within 6 feet 1 8 m of the torch See Section 2 for mounting dimensions 2 Gang Manifold The 2 gang manifold assembly must be mounted to the torch See Section 2 for mounting dimensions Torch The torch must be installed on the positioner of an arc voltage control height control capable of maintaining the cutt...

Page 31: ...controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 3 Figure 1a Spirit II System MGC Internal Inova ASC with RHF ...

Page 32: ...controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 4 Figure 1b Spirit II System MGC External Inova ASC with RHF ...

Page 33: ...f the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 5 Figure 1c Spirit II System MGC Internal Inova ASC with CleanStrike Technology ...

Page 34: ...f the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 6 Figure 1d Spirit II System MGC External Inova ASC with CleanStrike Technology ...

Page 35: ...to prevent a shock hazard with respect to the plasma equipment and work table It represents the service ground connected to the plasma power supply and all other system components such as drive amplifiers and CNC The PE or Service ground must be connected to each piece of equipment per local and national codes 2 DC power ground This is the work lead of the power supply and is connected to the cutt...

Page 36: ... to the star ground point even if bolted to the gantry or power supply Grounds are not to be daisy chained 6 For components mounted to the cutting table gantry it is acceptable to create a star ground at the gantry with a single ground cable connecting the gantry star ground with the cutting table star ground The exception is the Arc Starting Console this should always have a separate ground cable...

Page 37: ...r equivalent is recommended if time delay fuses are not used or allowed by local or national codes The main feed device breaker or fuse and any branch protection breaker or fuse upstream of the power supply must be sized to handle all branch loads for both steady state and inrush current The disconnect switch should be sized according to local and national codes The rating must meet or exceed the ...

Page 38: ...B5 is located on the rear of the power supply and is accessible with the right side cover removed Be sure to connect the primary ground cable to the ground stud on the input terminal block Under no circumstances are the supply cables to be routed through the opening in the power supply cabinet without conduit or an appropriate strain relief as per local and national codes Strain Relief Disconnect ...

Page 39: ...llips head screw For systems that include ACS with CleanStrike Technology connect it to the angled bracket on the red standoff using the provided Phillips head screw Power Supply CTP Sensor Lead 1 Route the ring terminal end of the 14AWG power supply CTP sensor lead through the bushing on the rear of the power supply and connect it to the CTP terminal 2 Route the FASTON end of the power supply CTP...

Page 40: ...Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 12 ASC with RHF ASC with CleanStrike Technology 4 1 3 2 Strain Relief 1 3 2 Figure 4 Power Supply Output Connections Strain Relief 1 3 2 ...

Page 41: ...oolant out fitting on the rear of the cooling system Note that the coolant out fitting has right hand threads 2 Connect the other end of the coolant supply hose to the coolant in fitting on the arc starting console Note that the coolant in fitting has right hand threads Coolant Return Hose 1 Connect one end of the coolant return hose to the coolant in fitting on the rear of the cooling system Note...

Page 42: ...dministration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 14 ASC with RHF ASC with CleanStrike Technology Figure 5 Cooling System Connections 7 8 10 9 8 7 5 6 6 5 7 8 ...

Page 43: ...e of the arc starting console in order to help reduce high frequency noise emission Using an ohmmeter measure for zero ohms between the braided shield and the ground stud located on the outside of the arc starting console Torch Electrode Coolant Supply Lead Connect the torch electrode coolant supply lead to the brass cathode manifold Note that the torch electrode coolant supply lead has right hand...

Page 44: ... Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 16 ASC with RHF ASC with CleanStrike Technology 15 12 14 13 11 15 13 12 14 11 Figure 6 Torch Leads to Arc Starting Console Connections ...

Page 45: ...ned Also use two wrenches when tightening the torch fittings to avoid damaging the torch base Torch Lead through Torch Handle Installation Route the torch leads through the torch handle Note that the threaded end of the torch handle mates with the torch base Torch Electrode Coolant Supply Lead Connect the torch electrode coolant supply lead to the torch base as shown Torch Coolant Return Lead Conn...

Page 46: ...as hose through the torch handle and connect to the plasma gas fitting on the torch base 2 Thread the torch handle onto the torch base being careful not to twist the torch leads and gas hoses when tightening the torch handle 3 Tighten the base to the handle using a pin style adjustable spanner wrench fits 2 diameter with diameter pin 4 Attach the 2 gang manifold assembly to the torch handle The to...

Page 47: ...ifold Shield Gas Hose 1 Connect one end of the shield hose to the shield outlet on the rear of the MGC 2 Connect the other end of the shield hose to the shield inlet on the 5 gang manifold Preflow Gas Hose 1 Connect one end of the preflow hose to the preflow outlet on the rear of the MGC Note that the preflow hose fittings have left hand threads 2 Connect the other end of the preflow hose to the p...

Page 48: ...ions EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 20 Figure 8 Torch Gas Connections Manual Gas Console 25 22 26 22 21 30 RED GREEN REAR PORT REAR PORT BLUE 27 21 20 20 28 29 BLUE GREEN RED 27 25 28 26 ...

Page 49: ...ittings are subject to damage if over tightened WARNING IMPROPER GAS USAGE can cause explosion and or fire The combination of Preflow Postflow Plasma and Shield input gases should always adhere to the types specified in the cut charts for a given material type When changing to a different type of gas oxidizing or oxygen containing to combustible or vice versa a purge of the gas lines 30 second min...

Page 50: ...by any means to any location outside the United States contrary to the requirements of the EAR 3 22 CAN Communication Connections Perform the following steps to connect the plasma power supply to the MGC CAN Cable Connect the male end of the CAN cable to the connector labeled P4 on the rear of the plasma power supply Connect the female end of the CAN cable to the top connector on the rear of the M...

Page 51: ...he arc is initiated This feature is used to decrease cycle time by allowing pre cut gas and contact sequencing to occur simultaneously with initial torch height positioning The contacts should be rated for 24VDC 7 3mA Motion Output The power supply provides a maintained contact closure output between P8 pins 12 and 14 as long as an arc is maintained between the torch and the workpiece The motion c...

Page 52: ...ure the coolant filter housing is tightened securely 6 Ensure the drain petcock on the bottom of the reservoir is tightened securely 7 Fill the reservoir with approximately 2 gallons of approved coolant 8 Apply primary power to the Spirit system and enable it by releasing turn right the OFF Button on the MGC 9 On the MGC main menu move the pointer to On Press the select button to start the coolant...

Page 53: ... well as the adjustment regulator knobs used to manually adjust the gas pressures necessary for cutting and marking OFF Button Push in to disable the Spirit II system Release turn to the right to enable the system Display The display turns on automatically when AC power is applied to the Spirit II system It displays the menu tree which is navigated using the Up Down Select buttons Up Down Select B...

Page 54: ...e pointer to Setup Press the select button Press the select button until Cutting is displayed Move the pointer to Current Press the select button to cycle through the list until the required amperage from the cutting chart is displayed Move the pointer to Select Gas Press the select button Press the select button until the proper Plasma gas is displayed Move the pointer and select the proper Shiel...

Page 55: ...re not used for marking and then follow the steps below NOTE When the Process is set to Marking the Current value is internally set to the proper value even though the cutting current is displayed Push the OFF Button on the MGC to disable the system On the main menu move the pointer to Setup Press the select button Press the select button until Marking is displayed Move the pointer to Adjust Gas P...

Page 56: ...ve the pointer to Input Gas Press the select button Verify that all connected gas pressures are at least 115 psi 7 9 bar The maximum input gas pressure is 145 psi 10 0 bar Press the select button to return to the main menu Input Gas Pressure Error Messages The following error messages are displayed when the associated input gas pressure drops below the minimum of 105 psi 7 2 bar To correct this er...

Page 57: ...ol are properly configured the system is ready to cut or mark Release the OFF Button turn to the right on the MGC On the main menu move the pointer to On Press the select button The MGC starts to purge the gas hoses The purge icon is displayed during this process Once purging is complete the ready icon is displayed The system is now ready to cut or mark When the system receives a start signal from...

Page 58: ... does not move from the pierce height down to the cutting height and come into contact with this solidified metal The torch should not move from the pierce height down to the cutting height until the X Y controller has moved the torch away from the pierce point One way to accomplish this may be to program the pierce time on the torch height control system to a value that is longer than the X Y con...

Page 59: ...o cut a given plate thickness 2 A negative cut angle top dimension of piece larger than the bottom dimension usually occurs when the torch standoff distance is too low or when the cutting speed is too slow 3 Top dross usually occurs when the torch standoff distance is too high 4 Bottom dross usually occurs when the cutting speed is either too slow slow speed dross or too fast high speed dross Low ...

Page 60: ...ough the last ten 10 error codes See Section 6 in this manual for details on the error codes Simultaneously pressing the down button and the select button will erase all ten error codes Move the pointer to Return and press the select button to return to the main menu Checking the Version Number The hardware version and software version for the Power Supply and Gas Console can be displayed as descr...

Page 61: ...ress the select button Press the select button on Languages Move the pointer to the desired language and then press the select button The display changes immediately to the selected language Move the pointer to Return and press the select button to return to the previous screen Repeat to return to the main menu Adjusting the Screen Contrast The contrast of the display on the MGC can be adjusted as...

Page 62: ... This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 10 BLANK ...

Page 63: ...rch Each time the torch head is connected to the torch base use a cotton swab to apply a small amount of o ring lubricant on each of the seven o rings on the top of the torch head Reminder do not use an excessive amount of o ring lubricant 1 Align the indicator on the torch head circle with the one on the torch base slot 2 Apply enough upward force to engage the threads while tightening the attach...

Page 64: ...ormation shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 2 YES NO To remove the torch head turn the attachment ring to the LEFT There is no gap between o ring and attachment ring Gap is visible between o ring and attachment ring O ring O ring Torch Base Torch Head ...

Page 65: ...lling the consumables do not use an excessive amount of o ring lubricant Also ensure that the lubricant is placed only on the o rings Excess lubricant can interfere with gas flow which can cause starting problems poor cut quality and short consumable life 1 Unthread the torch head from the torch base by turning the attachment ring to the LEFT Verify the torch base doesn t unthread from the torch h...

Page 66: ...emoval tool P N BK260105 to remove the swirl ring from the nozzle 7 Remove the electrode from the torch head using the appropriate tool 400A copper electrodes use socket P N BK284052 driver P N BK277086 All other copper electrodes use socket P N BK277087 driver P N BK277086 All silver electrodes use P N BK279061 8 Inspect all consumables and o rings for damage and excess wear Replace with new cons...

Page 67: ...tting current are changed to optimum values for extinguishing the arc Ideally the x y machine controller should provide a plasma stop signal prior to the end of the cut path so the gases and current reach the shut off values at the same time that the part has been completely cut The shutdown times are different for each current and are given below Arc Shutdown Times Current A Time ms 30 490 50 390...

Page 68: ...ged o ring Replace shield cap Replace shield cap Apply a thin film of o ring lubricant Replace shield cap Retaining Cap Center hole out of round Dents cracks Dry o ring Damage o ring Replace retaining cap Replace retaining cap Apply a thin film of o ring lubricant Replace retaining cap Nozzle Center hole out of round Erosion or arcing Dry o rings Damaged o rings Replace nozzle Replace nozzle Apply...

Page 69: ... Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 30A BK284150 BK277115 BK277153 BK277122 BK277140 BK277142 BK277131 BK279100 50A BK284150 BK277150 BK277153 BK277125 BK277142 BK277131 BK279100 70A BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100 100A BK284150 BK277117 BK277151 BK277152 BK277293 BK277139 BK27729...

Page 70: ...ld Steel Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode Torch Head BK284150 BK277286 BK277151 BK279484 BK279483 BK279410 brown o ring BK279060 100A BK284150 BK277117 BK277151 BK277152 BK279493 BK279439 BK279420 green o ring BK279060 150A BK284150 BK277274 BK277266 BK279489 BK279443 BK279440 yellow o ring BK279060 200A BK284150 BK277263 BK2772...

Page 71: ...ss Steel H17 Plasma Copper Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head BK284150 BK277150 BK277113 BK277124 BK277140 BK277132 BK279100 70A BK284150 BK277146 BK277113 BK277126 BK277141 BK277133 BK279100 100A BK284150 BK277298 BK277266 BK277297 BK277139 BK277135 BK279100 150A BK284150 BK277274 BK277266 BK277287 BK277259 BK277135 BK279100 ...

Page 72: ...eld Cap Inner Retaining Cap Nozzle Swirl Ring Copper Electrode Torch Head BK284150 BK277144 BK277110 BK277121 BK277138 BK277137 BK279100 30A BK284150 BK277149 BK277110 BK277123 BK277142 BK277137 BK279100 50A BK284150 BK277150 BK277153 BK277125 BK277142 BK277131 BK279100 70A BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100 100A BK284150 BK277117 BK277152 BK277293 BK277139 BK277292 BK2...

Page 73: ...tside the United States contrary to the requirements of the EAR 5 11 Stainless Steel Air or Nitrogen Plasma Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode Torch Head BK284150 BK277286 BK277151 BK279484 BK279483 BK279410 brown o ring BK279060 100A BK284150 BK277117 BK277152 BK279493 BK279439 BK279420 green o ring BK279060 150A BK284150 BK27727...

Page 74: ...etaining Cap Nozzle Swirl Ring Copper Electrode Torch Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 30A BK284150 BK277150 BK277153 BK277122 BK277142 BK277131 BK279100 50A BK284150 BK277150 BK277153 BK277125 BK277142 BK277131 BK279100 70A BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100 100A BK284150 BK277117 BK277152 BK277293 BK277139 BK277292 BK279100 150A BK28...

Page 75: ...contrary to the requirements of the EAR 5 13 Aluminum Silver Electrode Outer Retaining Cap Shield Cap Inner Retaining Cap Nozzle Swirl Ring Silver Electrode Torch Head BK284150 BK277286 BK277151 BK279484 BK279483 BK279410 brown o ring BK279060 100A BK284150 BK277117 BK277152 BK279493 BK279439 BK279420 green o ring BK279060 150A BK284150 BK277274 BK277266 BK279489 BK279443 BK279440 yellow o ring BK...

Page 76: ...e 5 25 Stainless Steel 70 Amps Air Air Nitrogen Page 5 26 Stainless Steel 100 Amps Nitrogen H17 Nitrogen Page 5 27 Stainless Steel 100 Amps Air Air Nitrogen Page 5 28 Page 5 50 Stainless Steel 150 Amps Nitrogen H17 Nitrogen Page 5 29 Stainless Steel 150 Amps Air Air Nitrogen Page 5 30 Page 5 51 Stainless Steel 200 Amps Nitrogen H17 Nitrogen Page 5 31 Stainless Steel 200 Amps Air Air Nitrogen Page ...

Page 77: ...100 062 18 048 121 97 090 16 060 125 78 105 200 065 14 075 126 65 12 105 127 55 070 11 120 129 50 120 125 300 10 135 131 40 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 1 35 77 6 75 120 2615 2 0 2 8 100 1 5 1 5 124 2020 2 6 200 1 6 2 126 1615 2 7 1 7 2 5 1455 3 128 1...

Page 78: ...14 075 25 74 19 72 106 200 100 135 100 050 12 105 190 125 180 200 10 135 110 170 110 3 16 113 105 140 200 300 053 1 4 117 75 225 400 060 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm Cold Rolled Steel Oxygen Shield Swirl Ring BK277140 2 5 25 74 12 72 121 1895 2 9 3 4 ...

Page 79: ...35 74 110 190 100 150 100 056 3 16 40 113 130 200 200 057 1 4 116 120 110 225 300 059 3 8 122 75 140 250 400 065 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 3 25 76 35 74 109 4995 2 5 3 6 100 1 4 5 40 113 3265 5 1 300 1 5 6 115 3105 2 7 5 5 Marking For All Material ...

Page 80: ... 100 130 250 400 0 078 1 2 65 155 300 500 0 085 5 8 143 47 185 325 800 0 092 3 4 145 35 350 1000 0 098 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 83 26 81 124 3950 2 1 4 9 300 1 8 10 130 2405 3 3 6 5 500 2 0 12 1850 3 7 7 3 2 1 16 143 1180 4 7 8 3 1000 2 3 20 ...

Page 81: ... 0 104 1 134 40 150 400 1500 0 115 1 25 145 25 200 700 3000 0 126 1 50 155 15 225 350 1500 0 139 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm Retaining Cap BK277151 6 20 71 30 69 117 4305 2 6 4 9 300 2 2 10 123 3040 3 4 6 5 500 2 3 12 124 2485 3 5 7 3 2 4 Retaining C...

Page 82: ... 240 500 1500 0 160 1 50 165 17 300 350 0 189 1 75 175 12 350 0 222 2 00 185 7 500 500 0 260 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 74 58 72 124 6100 8 4 9 300 2 3 10 130 3480 2 3 6 5 500 2 4 12 132 3160 2 7 7 3 2 5 16 137 2515 3 3 8 9 800 2 7 20 141 1810 ...

Page 83: ... 290 350 1500 0 192 2 00 180 15 350 0 210 2 25 185 13 375 375 0 227 2 50 190 9 385 385 0 246 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 12 20 81 70 79 139 3290 3 6 7 4 500 3 0 16 138 2650 3 3 8 3 800 3 2 20 2190 3 1 9 0 1000 3 4 25 143 1690 4 0 10 1 3 7 32 150 1120...

Page 84: ...182 15 300 350 1300 0 234 2 75 185 12 325 350 1500 0 253 3 00 195 8 350 350 2000 0 273 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 12 30 79 70 76 138 4205 3 6 7 3 500 3 5 16 145 3405 3 3 8 9 800 3 6 20 2700 3 4 10 5 1000 3 7 25 149 2200 4 0 12 5 3 9 32 155 1500 4 4 ...

Page 85: ... in in msec in 20 036 35 81 30 85 71 200 020 050 100 065 18 048 165 035 16 060 74 125 200 068 14 075 75 90 025 070 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 1 35 81 30 85 71 4855 0 6 1 3 100 1 7 1 5 73 3260 0 9 200 Marking For All Material Thicknesses Type of Gas ...

Page 86: ...35 070 100 105 12 105 88 75 11 120 89 65 200 10 135 90 55 110 3 16 94 50 040 080 300 1 4 100 40 060 125 400 115 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 2 25 66 40 67 87 2565 9 1 8 100 2 7 2 5 2080 3 88 1685 200 5 94 1235 1 0 2 1 400 2 8 6 98 1075 1 3 2 9 2 9 Mar...

Page 87: ...oltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 3 16 35 65 30 60 135 80 100 200 300 090 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 5 35 65 30 60 135 2030 2 5 5 1 300 2 3 Marking For All Material Thi...

Page 88: ...i psi volts ipm in in msec in 10 135 25 76 25 76 132 120 060 150 200 085 3 16 134 100 070 200 300 1 4 140 75 090 225 400 090 3 8 148 50 120 250 500 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 3 25 76 25 76 131 3210 1 4 3 3 200 2 2 5 134 2445 1 8 5 1 400 6 138 2050 2...

Page 89: ...erce Height Pierce Time Kerf Width in psi psi psi psi volts ipm in in msec in 3 16 28 72 40 67 138 115 105 200 300 100 1 4 140 100 125 225 400 105 3 8 152 65 180 250 500 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 5 28 72 40 67 138 2865 2 7 5 1 400 2 5 6 139 2625 3 ...

Page 90: ...n psi psi psi psi volts ipm in in msec in 1 4 25 80 35 80 141 100 135 225 400 092 3 8 147 80 170 250 500 095 1 2 154 55 210 300 600 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 80 35 80 140 2595 3 2 5 6 400 2 3 10 148 1935 4 4 6 5 600 2 4 12 152 1540 5 0 7 3 Mar...

Page 91: ...si psi psi psi volts ipm in in msec in 1 4 25 77 75 81 165 95 250 250 400 135 3 8 75 150 275 500 1 2 60 165 300 600 140 5 8 50 185 325 800 3 4 40 250 350 1200 145 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 10 25 77 75 81 155 1845 3 8 7 0 600 3 4 12 1610 4 1 7 4 3 6...

Page 92: ...70 69 145 150 160 250 400 125 3 8 150 115 180 275 500 1 2 155 85 210 300 600 130 5 8 160 60 220 325 800 3 4 168 45 240 350 1200 135 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 71 70 69 144 3910 4 0 6 3 400 3 2 10 150 2805 4 7 7 0 600 12 153 2330 5 1 7 4 3 3 16 ...

Page 93: ... in in msec in 3 8 37 72 79 68 156 80 195 250 500 150 1 2 148 75 130 300 600 5 8 155 60 190 350 800 155 3 4 160 50 200 400 1200 1 0 170 35 240 450 1500 160 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 10 37 72 79 68 154 2010 4 7 6 5 600 3 8 12 149 1935 3 6 7 3 16 155...

Page 94: ...146 75 150 350 800 155 3 4 153 60 190 400 1200 1 0 158 40 210 450 1500 160 1 25 170 20 250 350 165 1 50 180 10 275 350 175 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 74 58 72 129 5220 1 8 4 9 400 3 8 10 134 3655 1 9 6 5 600 12 138 3020 2 6 7 3 3 9 16 146 1890 ...

Page 95: ...85 160 250 500 190 1 2 142 80 140 300 600 5 8 145 65 185 350 800 195 3 4 150 55 225 400 1200 1 0 160 33 250 450 1500 200 1 25 170 26 280 350 205 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 10 40 63 64 63 144 2140 4 0 6 5 600 4 8 12 142 2060 3 7 7 3 16 145 1640 4 7 8...

Page 96: ... 5 8 148 90 140 350 800 3 4 152 80 180 400 1200 170 1 0 165 55 210 450 1500 1 25 175 35 250 350 180 1 50 185 25 300 350 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 12 20 73 70 75 141 3220 3 1 7 3 600 4 2 16 148 2275 3 6 8 9 800 20 153 1940 4 7 10 3 1500 4 3 25 164 1...

Page 97: ...70 400 1200 200 1 170 50 185 500 1500 1 25 175 40 210 700 2000 1 5 185 30 270 800 2500 225 1 75 193 23 300 350 1500 235 2 00 200 18 350 250 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 12 30 80 82 96 165 2750 4 8 7 3 600 4 2 16 2270 4 5 8 9 800 4 4 20 1810 4 3 10 5 1...

Page 98: ...00 1 170 65 150 500 1500 1 25 175 45 160 700 2000 1 5 180 35 170 800 2500 205 1 75 190 25 190 350 1500 2 00 205 15 210 350 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 12 30 85 63 96 176 3415 5 5 7 3 600 4 2 16 169 2775 4 2 8 9 800 20 165 2190 3 8 10 5 1500 5 1 25 16...

Page 99: ...i psi volts ipm in in msec in 040 35 81 20 85 135 150 030 100 100 065 050 120 063 90 150 200 070 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 1 35 81 20 85 135 3885 0 8 2 5 100 1 7 1 5 2520 3 4 200 1 8 Marking For All Material Thicknesses Type of Gas Preflow Plasma S...

Page 100: ...n in msec in 050 25 66 19 67 135 180 050 100 100 080 063 138 140 065 150 082 080 143 90 075 150 200 085 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 1 5 25 66 19 67 137 3870 1 5 2 5 150 2 1 2 0 142 2360 1 8 3 7 200 2 2 Marking For All Material Thicknesses Type of Gas...

Page 101: ...16 145 80 100 200 200 085 1 4 150 50 060 250 300 3 8 155 40 075 275 400 090 1 2 162 30 115 300 500 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 2 25 76 25 76 129 6400 1 2 3 7 100 2 0 3 134 4420 1 7 4 3 5 145 1920 2 3 5 2 300 2 2 6 148 1440 1 7 6 1 10 156 975 2 0 7 0 ...

Page 102: ... in 1 4 25 80 26 80 158 105 155 250 300 095 3 8 162 90 180 275 400 098 1 2 165 70 195 300 500 100 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 80 26 80 158 2710 3 8 6 3 300 2 4 10 162 2210 4 6 7 0 500 2 5 12 165 1890 4 9 7 4 Marking For All Material Thicknesses ...

Page 103: ...8 155 115 185 275 500 1 2 165 90 230 300 600 130 5 8 170 65 250 325 800 135 3 4 45 350 1200 140 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 71 50 69 143 3770 3 1 6 3 400 3 2 10 156 2825 4 8 7 0 600 12 162 2430 5 5 7 4 3 3 16 170 1630 6 4 8 3 1200 3 4 20 170 990...

Page 104: ...0 135 300 500 155 5 8 160 95 350 600 3 4 65 150 400 800 160 1 0 175 35 200 1000 170 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 74 58 72 149 4955 3 3 6 3 300 3 8 10 155 3545 3 5 7 0 500 12 2995 3 4 7 4 3 9 16 160 2380 8 9 800 20 162 1575 3 9 10 2 1000 4 1 25 17...

Page 105: ...5 3 4 172 85 200 400 800 1 00 180 60 240 1000 170 1 25 185 45 260 1 50 190 25 270 180 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 10 20 73 65 75 160 3930 4 1 7 1 500 4 1 12 163 3375 4 4 7 4 16 168 2645 4 8 8 9 800 4 2 20 173 2055 5 3 10 2 25 179 1565 6 0 1000 4 3 32...

Page 106: ...205 500 800 210 1 190 75 215 600 1200 1 25 200 55 220 700 1500 225 1 5 205 35 225 800 2000 240 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 12 30 85 63 96 173 3950 4 1 7 0 600 5 1 16 180 3150 4 8 10 3 800 5 2 20 185 2445 5 2 13 0 1200 5 3 25 189 1945 5 4 15 0 32 200 ...

Page 107: ... 8 130 100 130 250 400 0 078 1 2 65 155 300 500 0 085 5 8 143 47 185 325 800 0 092 3 4 145 35 350 1000 0 098 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 83 26 81 124 3950 2 1 4 9 300 1 8 10 130 2405 3 3 6 5 500 2 0 12 1850 3 7 7 3 2 1 16 143 1180 4 7 8 3 1000 2...

Page 108: ...50 1000 0 104 1 134 40 150 400 1500 0 115 1 25 145 25 200 700 3000 0 126 1 50 155 15 225 350 1500 0 139 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm Retaining Cap BK277151 6 20 71 30 69 117 4305 2 6 4 9 300 2 2 10 123 3040 3 4 6 5 500 2 3 12 124 2485 3 5 7 3 2 4 Reta...

Page 109: ... 155 25 240 500 1500 0 160 1 50 165 17 300 350 0 189 1 75 175 12 350 0 222 2 00 185 7 500 500 0 260 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 74 58 72 124 6100 8 4 9 300 2 3 10 130 3480 2 3 6 5 500 2 4 12 132 3160 2 7 7 3 2 5 16 137 2515 3 3 8 9 800 2 7 20 14...

Page 110: ...170 20 290 350 1500 0 192 2 00 180 15 350 0 210 2 25 185 13 375 375 0 227 2 50 190 9 385 385 0 246 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 12 20 81 70 79 139 3290 3 6 7 4 500 3 0 16 138 2650 3 3 8 3 800 3 2 20 2190 3 1 9 0 1000 3 4 25 143 1690 4 0 10 1 3 7 32 15...

Page 111: ... 2 50 182 15 300 350 1300 0 234 2 75 185 12 325 350 1500 0 253 3 00 195 8 350 350 2000 0 273 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 12 30 79 70 76 138 4205 3 6 7 3 500 3 5 16 145 3405 3 3 8 9 800 3 6 20 2700 3 4 10 5 1000 3 7 25 149 2200 4 0 12 5 3 9 32 155 150...

Page 112: ...n in msec in 1 4 25 80 35 80 141 100 135 225 400 092 3 8 147 80 170 250 500 095 1 2 154 55 210 300 600 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 80 35 80 140 2595 3 2 5 6 400 2 3 10 148 1935 4 4 6 5 600 2 4 12 152 1540 5 0 7 3 Marking For All Material Thickne...

Page 113: ... 3 8 150 115 180 275 500 1 2 155 85 210 300 600 130 5 8 160 60 220 325 800 3 4 168 45 240 350 1200 135 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 71 70 69 144 3910 4 0 6 3 400 3 2 10 150 2805 4 7 7 0 600 12 153 2330 5 1 7 4 3 3 16 160 1510 5 6 8 3 800 20 170 1...

Page 114: ...3 60 190 400 1200 1 0 158 40 210 450 1500 160 1 25 170 20 250 350 165 1 50 180 10 275 350 175 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 74 58 72 129 5220 1 8 4 9 400 3 8 10 134 3655 1 9 6 5 600 12 138 3020 2 6 7 3 3 9 16 146 1890 3 8 8 9 800 20 153 1450 4 8 1...

Page 115: ...n msec in 1 4 25 80 26 80 158 105 155 250 300 095 3 8 162 90 180 275 400 098 1 2 165 70 195 300 500 100 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 25 80 26 80 158 2710 3 8 6 3 300 2 4 10 162 2210 4 6 7 0 500 2 5 12 165 1890 4 9 7 4 Marking For All Material Thickn...

Page 116: ...125 3 8 155 115 185 275 500 1 2 165 90 230 300 600 130 5 8 170 65 250 325 800 135 3 4 45 350 1200 140 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 71 50 69 143 3770 3 1 6 3 400 3 2 10 156 2825 4 8 7 0 600 12 162 2430 5 5 7 4 3 3 16 170 1630 6 4 8 3 1200 3 4 20 1...

Page 117: ... 1 2 110 135 300 500 155 5 8 160 95 350 600 3 4 65 150 400 800 160 1 0 175 35 200 1000 170 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 6 20 74 58 72 149 4955 3 3 6 3 300 3 8 10 155 3545 3 5 7 0 500 12 2995 3 4 7 4 3 9 16 160 2380 8 9 800 20 162 1575 3 9 10 2 1000 4 ...

Page 118: ...600 165 3 4 172 85 200 400 800 1 00 180 60 240 1000 170 1 25 185 45 260 1 50 190 25 270 180 Metric Material Thickness Preflow Plasma Shield Postflow Arc Voltage Travel Speed Cutting Height Pierce Height Pierce Time Kerf Width mm psi psi psi psi volts mm m mm mm msec mm 10 20 73 65 75 160 3930 4 1 7 1 500 4 1 12 163 3375 4 4 7 4 16 168 2645 4 8 8 9 800 4 2 20 173 2055 5 3 10 2 25 179 1565 6 0 1000 ...

Page 119: ...roubleshooting requires the system to be powered with the enclosure panels removed remain clear of the capacitors Failure of a capacitor can result in a sudden release of stored energy causing rupture of the capacitor case Routine Maintenance Note At minimum these checks should be performed on a monthly basis In excessively dirty environments or in heavy usage situations the checks should be perfo...

Page 120: ...o make sure the shield adapter is secured tightly to the arc starting console enclosure 3 Inspect the braided shield for nicks or cuts and replace if necessary 4 Remove the torch handle and verify that the connections at the torch base are tightened securely Only tighten the fittings enough to make a coolant or gas seal The fittings are subject to damage if over tightened Coolant leaking from the ...

Page 121: ...nsole and verify that all leads and hoses are tightened securely Only tighten the fittings enough to make a coolant or gas seal The fittings are subject to damage if over tightened 2 For systems that include ASC with RHF check the spark gap electrodes for signs of wear Replace electrodes that have rounded faces Use a clean feeler gauge and set the spark gap to 015 38 mm Work Ground 1 Verify that t...

Page 122: ...and out hoses are properly installed 4 Remove the coolant reservoir cap level gauge 5 Remove the cover from the cooling system 6 Connect a 3 8 ID hose and bucket to the drain petcock on the bottom of the reservoir Unscrew the petcock to drain the reservoir Leave the hose and bucket in place after the coolant drains out 7 Remove the coolant supply hose coolant out from the rear of the cooling syste...

Page 123: ...LASMA START Plasma start signal applied to Spirit D37 ARC HOLD Arc hold input enabled D38 MARKING Marking input enabled D39 CORNER Corner current input enabled D40 EOFF Off button disengaged D41 MOTION Motion output signal activated D42 PLASMA READY Power supply ready output signal activated D43 PAT Pilot arc transistor energized D48 RMT ON OFF Remote On Off input enabled D50 ASC DOOR ASC door is ...

Page 124: ...en the OFF Button is released D40 OFF Button The following DSP Indicators should illuminate when the ON Button is activated Opto U21 Motor Solenoid Opto U19 Solenoid not used Opto U26 Fan D42 Plasma Ready The following DSP Indicators should illuminate when a START signal is applied begin cut cycle D36 Start Opto U27 Preflow Opto U29 Shield Opto U24 Surge only over 100 amps Opto U23 Contactor D24 P...

Page 125: ...ant temperature is high 10290 GC Quiet Lost CAN communication with Gas Console 10300 PC Quiet Lost CAN communication with Plasma Console 10320 FCC Invalid Using default current remove start 10330 PAC Invalid Pilot Arc Current invalid 10340 AH IHS Timeout Arc Hold for Initial Height Sense has timed out 10350 PAT Not Established Pilot Arc Current not established within 2 seconds 10360 TAC Not Establ...

Page 126: ... EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 8 Gas Console Code Short Description Long Description 20200 Low Plasma Input Pressure is low 20210 Shield Low Input Pressure is low 20230 Low Pre Post Input Pressure is low ...

Page 127: ...ansformer or associated wiring bad Power Supply will not energize after moving the pointer to ON and then pressing the select button on the MGC 1 ASC door open 2 Low coolant level 3 Fuse is blown F1 F6 4 Faulty Off Button or associated wiring 5 Off Relay faulty Power Supply will not stay on after moving the pointer to ON and then pressing the select button on the MGC 1 Faulty DSP board 2 Off Relay...

Page 128: ...imary power to the Spirit system 2 Check the connection of the ribbon cable that connects the keypad to the DSP PCB in the manual gas console Gas pressures will not adjust properly 1 Wrong consumables installed in torch 2 Loose pressure transducer cable on PC board in the MGC 3 Check connectors on the MGC valve associated with the malfunction Low pressure error 1 Supply gas pressure s less than 12...

Page 129: ...e power conversion module Capacitor failure can injure and or cause property damage If troubleshooting requires the system to be powered with the enclosure panels removed remain clear of the capacitors Failure of a capacitor can result in a sudden release of stored energy causing rupture of the capacitor case IMPORTANT Depending upon the system there are one two or three chopper assemblies in the ...

Page 130: ...Spirit system 7 Release the OFF Button on the Manual Gas Console to enable the system Move the pointer to ON and then press the select button to energize the system After the gases set prepare to apply a start signal to the unit 8 With a start signal applied check the three phase voltage input to each chopper at the diode bridge terminals three screws on the left side of each chopper Refer to TABL...

Page 131: ...pirit II 150 Amp 208 300 N A N A N A N A 10 If the proper DC voltage is not present at the output terminal block check the 200 amp fuse F9 chopper 1 fuse F10 chopper 2 or fuse F11 chopper 3 located on the bottom right of the output bus bars If the fuse is open replace chopper and fuse 11 If the fuse s is good check if the chopper PWM LED illuminates when a start signal is applied a check D24 on th...

Page 132: ...m 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 Chopper 1 J1 5 to DSP J7 4 Chopper 2 J1 1 to DSP J8 1 Chopper 2 J1 2 to DSP J8 2 Chopper 2 J1 3 to DSP J8 3 Chopper 2 J1 5 to DSP J8 4 Chopper 3 J1 1...

Page 133: ...e requirements of the EAR 7 1 Section 7 Parts List Power Supply BK300234 BK300239 Right Side View Item Part Number Quantity Description 4 BK707155 3 L1 L2 L3 Inductor 15 BK709296 1 Strain Relief 30 BK708120 1 CON 1 Main Contactor 31 BK702080 1 EMI Filter 380 400 415 V units only 35 BK709251 2 TB5 3 Phase Input Power Terminal Block 38 BK300250 3 Chopper Assembly 44 BK200204 3 Fan 4 7 59 BK284031 2 ...

Page 134: ...5011 1 PAT IGBT 34 BK702075 2 PAT IGBT Filter Capacitor 36 BK300108 1 Printed Circuit Board PCB I O 37 BK301200 1 Optional Printed Circuit Board PCB Voltage Divider 39 BK709378 1 I O Terminal Block small 40 BK280003 2 Power Supply 24VDC 43 BK708105 2 Relay Hold Down Clip 44 BK200204 1 Fan 4 7 46 BK709379 1 I O Terminal Block large 47 BK709253 2 Strain Relief 50 BK284029 4 Current Sensor 51 BK30013...

Page 135: ...tion 1 BK501163 1 Light Housing 2 BK501164 1 Bulb 3 BK501162 1 White Lens 7 BK709359 1 F3 Fuse 5A Slow Blow 8 BK709358 1 F4 Fuse 5A Medium Blow 9 BK709358 1 F5 Fuse 5A Medium Blow 10 BK709360 1 F6 Fuse 6 3A 11 BK709360 1 F7 Fuse 6 3A 13 BK709061 4 F1A F1B and F2A F2B Fuse Holder 14 BK709128 4 F1A F1B and F2A F2B Fuse FNM 6 25A 38 BK300250 3 CA1 CA2 CA3 Chopper Assembly 41 BK708103 1 Fan Relay 42 B...

Page 136: ...t Level Switch 4 BK505024 1 Coolant Temperature Switch 5 BK500058 1 Pump Motor 1 2hp 230V 50 60 Hz 6 BK500513 1 V Band Clamp 7 BK300193 1 Coolant Pump 125 gph 8 BK708061 1 Solenoid Valve 220 240VAC 9 BK715118 1 Check Valve Coolant Return 10 BK708068 1 CR5 Relay 11 BK300134 1 Coolant Flow Sensor 12 BK284031 2 Fan 10 Aluminum 13 BK500514 2 Heat Exchanger 14 BK500509 1 Coolant Filter Housing 15 BK500...

Page 137: ...of the EAR 7 5 Manual Gas Console BK300610 Right Side View Item Part Number Quantity Description 1 BK300613 1 Power Supply 24VDC 1 04A 2 BK300301 PMGC 1 Printed Circuit Board PCB Gas Console DSP 3 BK300606 1 Keypad Membrane 4 BK300604 1 LCD Display Assembly 5 BK708111 1 Switch Pushbutton OFF Button 6 BK500570 3 Plasma Shield Regulator 0 125 PSI 7 BK500562 1 Preflow Regulator 0 60 PSI 8 BK300618 7 ...

Page 138: ... States contrary to the requirements of the EAR 7 6 Manual Gas Console BK300610 Left Side View Item Part Number Quantity Description 1 BK300613 1 Power Supply 24VDC 1 04A 2 BK300301 PMGC 1 Printed Circuit Board PCB Gas Console DSP 5 BK708111 1 Switch Pushbutton OFF Button 6 BK500570 3 Postflow Regulator 0 125 PSI 7 BK500562 1 Preflow Regulator 0 60 PSI 8 BK300618 7 Manifold Block Gas Outputs 9 BK3...

Page 139: ...0 1 Coolant supply fitting right hand 3 BK709253 1 Strain relief 5 BK709001 1 4 pin receptacle 6 BK707001 1 Line filter 7 BK706109 1 Transformer 5000V 20 mA 8 BK702069 1 Capacitor 15 kV 9 BK708057 1 Door interlock switch 10 BK500014 1 Spark gap assembly 11 BK740039 3 Spark gap electrode 12 BK505043 1 High frequency inductor 13 BK740072 2 Standoff 14 BK800041 1 Busbar 15 BK500505 1 Printed Circuit ...

Page 140: ... the requirements of the EAR 7 8 Arc Starting Console BK300505 with CleanStrike Technology Item Part Number Quantity Description 1 BK715051 2 Coolant Return Fitting left hand 2 BK715050 1 Coolant Supply Fitting right hand 3 BK715021 1 Coolant Supply Fitting right hand 4 BK709001 1 4 Pin Receptacle 5 BK708057 1 Door Interlock Switch 6 BK500503 1 Cathode Manifold 7 BK300506 1 Printed Circuit Board P...

Page 141: ...ase 5 BK279100 BK279060 1 Torch Head Copper Electrode Torch Head Silver Electrode 6 BK820209 1 O ring red 7 BK500024 1 O ring blue 8 BK500018 1 O ring red 9 BK279013 1 O ring red indicator only not a seal 10 BK279112 2 O ring red 11 BK279113 6 O ring red 12 BK284039 1 17 Torch Solenoid Plasma Hose 13 BK300075 1 5 Gang Manifold Not shown BK716012 1 O ring Lubricant Not shown BK277056 1 Nozzle Remov...

Page 142: ...Torch Leads Part Number Length BK284304 XX Where XX is the length in feet 4 10 ft lengths available in 1 ft increments 15 50 ft lengths available in 5 ft increments CAN Communication Cable and Termination Plug Item Part Number Length CAN Cable BK300177 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Manifold Control Cables Item Part Number Length 2 Gang Manifold B...

Page 143: ... U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 11 Gas Hose Package with MGC Part Number Length BK300086 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Custom lengths are available Contact factory Cooling System Control Cable Part Number Length BK300276 10 10 ft 3 0 m ...

Page 144: ...es contrary to the requirements of the EAR 7 12 Coolant and Power Leads Part Number Non CSA Systems Part Number CSA Systems Length BK284306 XX BK288406 XX Where XX is the length in feet 10 150 ft lengths available in 10 ft increments Work Ground Lead Part Number Non CSA Systems Part Number CSA Systems Length BK284318 XX BK288418 XX Where XX is the length in feet 10 100 ft lengths available in 5 ft...

Page 145: ...th BK200362 XX Where XX is the length in feet 25 100 ft lengths available in 25 ft increments Nitrogen Supply Gas Hose Optional Part Number Length BK200365 XX Where XX is the length in feet 25 100 ft lengths available in 25 ft increments Air Supply Gas Hose Optional Part Number Length BK200364 XX Where XX is the length in feet 25 100 ft lengths available in 25 ft increments H17 Supply Gas Hose Opt...

Page 146: ...outside the United States contrary to the requirements of the EAR 7 14 Supply Gas Hose Fittings Kit BK300624 Optional This kit contains the components shown below Hose and ferrule clamp are not supplied Supply Gas Hose Assembled Fittings Oxygen Nitrogen Air H17 Barbed Nipple for 3 8 ID Hose 9 16 Nut RH 5 8 Male Nut RH 5 8 Male Nut LH 9 16 Nut LH Barbed Nipple for 3 8 ID Hose Barbed Nipple for 3 8 ...

Page 147: ...d by any means to any location outside the United States contrary to the requirements of the EAR 7 15 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 STRAIN RELIEF BK709025 PLUG BK709364 PLUG BK709016 BK709018 SOCKET BK709018 SOCKET BK709019 KEY BK709365 PIN BK709...

Page 148: ...to any location outside the United States contrary to the requirements of the EAR 7 16 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 STRAIN RELIEF BK709021 CABLE BK711002 STRAIN RELIEF BK709025 PLUG BK709095 PLUG BK709364 BK709365 PINS BK709365 PINS BK709018 SOCKET BK709018 SOCKET BK709018 SOCKET BK...

Page 149: ...d by any means to any location outside the United States contrary to the requirements of the EAR 7 17 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 BK709021 STRAIN RELIEF BK709025 CABLE BK711049 PLUG BK709364 PLUG BK709020 BK709018 SOCKET BK709018 SOCKET BK709019 KEY BK709365 PIN BK7093...

Page 150: ...e provided 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 18 PCB Assemblies Component Reference Locations Power Supply Microprocessor DSP BK300101 Quadrant 1 J17 J13 U37 RHF U36 Arc Starting U35 U34 U32 Marking U31 Postflow U30 Vent U29 Shield J20 J22 J19 PCB Quadrant Map 1 3 4 2 ...

Page 151: ...tion shall not be provided 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 19 Power Supply Microprocessor DSP BK300101 Quadrant 2 J15 U28 Plasma U27 Preflow U19 Solenoid not used U21 Mtr Sol U22 PAR U24 Surge U26 Fan U23 Con J16 J12 J14 J1 PCB Quadrant Map 1 3 4 2 ...

Page 152: ...Export Administration Regulations EAR This information shall not be provided 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 20 Power Supply Microprocessor DSP BK300101 Quadrant 3 J18 J11 J3 PCB Quadrant Map 1 3 4 2 ...

Page 153: ...inistration Regulations EAR This information shall not be provided 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 PCB Quadrant Map Power Supply Microprocessor DSP BK300101 Quadrant 4 J3 J4 2 J4 1 J10 J7 J8 J9 J21 1 3 4 2 ...

Page 154: ...bject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 22 Power Supply Output BK300108 ...

Page 155: ...ect to the controls of the Export Administration Regulations EAR This information shall not be provided 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 Power Supply A C Detect BK300112 ...

Page 156: ...port Administration Regulations EAR This information shall not be provided 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 Gas Console Microprocessor DSP BK300301 PMGC Quadrant 1 PCB Quadrant Map 1 3 4 2 J25 J19 J4 ...

Page 157: ...rt Administration Regulations EAR This information shall not be provided 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 Gas Console Microprocessor DSP BK300301 PMGC Quadrant 2 J6 PCB Quadrant Map 1 3 4 2 J5 J31 J28 ...

Page 158: ...Administration Regulations EAR This information shall not be provided 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 Gas Console Microprocessor DSP BK300301 PMGC Quadrant 3 J19 PCB Quadrant Map 1 3 4 2 J20 J21 J17 J13 ...

Page 159: ...port Administration Regulations EAR This information shall not be provided 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 PCB Quadrant Map Gas Console Microprocessor DSP BK300301 PMGC Quadrant 4 J13 1 3 4 2 J9 J18 ...

Page 160: ...bject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 7 28 Chopper Gate Driver BK300106 ...

Page 161: ...nova console See the standard Inova manual for all other Inova information Plug Identification Connections for the internal Inova console option are distinguished from other connections on the back of the power supply by the addition of the letter I before the plug number The function of each plug e g IP1 is the same as the corresponding plug found on the external Inova console e g P1 Spirit II 15...

Page 162: ...y to the requirements of the EAR 8 2 Grounding The internal Inova console must be connected to the same protective earth ground as the plasma power supply and in accordance with national or local codes The figures below describe two methods Use a minimum of 8AWG 10 mm2 wire Note the customer must supply the ground cable Direct to star ground Spirit II 150 275 Spirit II 400 Jumper to the work groun...

Page 163: ...ntrary to the requirements of the EAR 8 3 Parts List Item Part Number Quantity Description 1 BK110200 1 Printed Circuit Board PCB Microprocessor 2 BK110705 1 Printed Circuit Board PCB Power Distribution 3 BK110900 1 Printed Circuit Board PCB H Bridge 4 BK706003 1 Transformer 5 BK709360 1 F7 Fuse 6 3A 6 BK709370 1 F8 Fuse 3A 7 BK301200 1 Printed Circuit Board PCB Voltage Divider 8 BK709276 1 Power ...

Page 164: ... subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 4 Location in Spirit II 150 275 Continued 8 7 ...

Page 165: ...ct to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 5 Location in Spirit II 400 1 5 6 3 4 2 F7 F8 pos A pos B ...

Page 166: ...is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 8 6 Location in Spirit II 400 Continued 7 8 ...

Page 167: ...ieved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installation and Use The user is responsible for installing and using the plasma cutting equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the ...

Page 168: ... activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Plasma cutting equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be give...

Page 169: ...thing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other ele...

Page 170: ...l This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 4 BLANK ...