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Kaliburn
Welding System
Spirit150a
Kaliburn Spirit150a User Manual
164 pages
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High Cur
rent D
ensit
y Plasma
Cutti
ng S
ystem
w
ith
Automatic Gas Console
User’
s Manual
-
P
art N
umber
718086
Rev
J
10
/
15
/2012
J
R
EVISION
This inf
ormation
is subjec
t to the
contro
ls of the
Export
Administr
ation
Regulations
[EAR
]. This i
nform
ation shal
l not be pr
ovided t
o non
-
U
.S.
persons or
trans
ferred b
y an
y means to a
ny locati
on outside
the Un
ited
States
c
ontrary to t
he requ
irem
ents of
the EAR.
2
Table of Contents
Default Chapter
4
Table of Contents
4
Section 1 Safety
7
General Precautions
7
Ultraviolet Radiation Protection
7
Noise Protection
7
Toxic Fume Prevention
7
Electric Shock Prevention
8
Fire Prevention
9
Explosion Prevention
9
Health Support Equipment
10
Safety Standards Booklet Index
11
Section 2 Specifications
13
System Description
13
System Components
14
Power Supply Specifications
15
Automatic Gas Console Specifications
17
Remote High Frequency Console Specifications
18
Torch Specifications
19
5-Gang Manifold Specifications
20
Airborne Noise Emissions
21
Specifications
22
Section 3 Installation
23
Initial Inspection
23
System Interconnection
23
Power Supply Installation
24
Remote High Frequency Installation
24
5-Gang Manifold Installation
24
Torch Installation
24
Primary Power Connection
25
Power Supply Output Connections
27
RHF Console Ground Connection
28
Torch Leads to RHF Console Connections
30
Torch Leads to Torch Base Connections
32
Torch Gas Connections
33
Torch Head Connection
36
Automatic Gas Console Input Connections
37
CNC Machine Interface Connections
38
Torch Coolant Requirements
40
Initial Filling of the Torch Coolant Reservoir
41
Section 4 Operation
43
Power Supply Front Panel Controls
43
Automatic Gas Console Keypad
45
Automatic Gas Console Help Prompt
46
Automatic Gas Console Status Screen
47
Setting up a Cut or Mark
48
Torch Consumable Selection
53
Installing or Removing Torch Consumables
60
Making a Cut or Mark
61
Piercing Thick Materials
62
Cut Quality
63
Changing Consumable Parts
64
Consumable Life
65
Cutting Charts
66
Section 5 Automatic Gas Console Advanced Functions
93
Altering the Current Set Point
93
Setting the Pierce Time
94
Altering Gas Types
95
Altering Gas Pressures
96
Altering Arc Voltage Control and X/Y Machine Parameters
97
Saving a User Created Cutting or Marking Condition
98
Gas Purge
98
Maintenance Screen
99
Viewing Messages
100
Viewing Cut Errors
101
Pressure Diagnostics
105
Restoring Factory Default Cutting or Marking Conditions
106
Measurement System
107
Communication Node
108
Inova Parameter Transmit
109
Viewing Serial Communication
110
Configuring Hydrogen Cutting
111
Setting an Arc off Delay
112
Switching between Cutting and Marking
113
Software Updates
114
Section 6 Serial Communication
115
Initializing the Spirit System
115
Transmitting Parameters to the Spirit System
115
Communication Error Checking
116
Default Cutting Parameters
117
Troubleshooting Serial Communication
117
RS-422 Serial Commands
118
Section 7 Maintenance and Troubleshooting
123
Routine Maintenance
123
Replacing the Torch Coolant
126
Microprocessor Status Led's
127
Microprocessor Sequence of Operation
128
Troubleshooting Using the Control Panel Status Led's
129
Troubleshooting Using the Automatic Gas Console Messages Screen
130
General Troubleshooting
131
Chopper Test Procedure
134
Section 8 Parts List
137
Power Supply
137
Automatic Gas Console
143
Remote High Frequency Console
146
Torch and Manifold Assemblies
147
Shielded Torch Leads
148
Gas Hose Package
149
Coolant and Power Leads
150
Work Ground Cable
151
Oxygen Supply Gas Hose (Optional)
152
Nitrogen Supply Gas Hose (Optional)
152
Air Supply Gas Hose (Optional)
152
H17 Supply Gas Hose (Optional)
152
Power Supply Microprocessor P.C. Board
153
A.C. Detect P.C. Board
154
Relay P.C. Board
155
Power Supply I/O P.C. Board
156
Automatic Gas Console I/O P.C. Board
157
Consumable Spare Parts Kit
158
Appendix A Electromagnetic Compatibility (EMC)
161
Background
161
Installation and Use
161
Assessment of Area
162
Methods of Reducing Emissions
162
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Kaliburn Spirit150a Specifications
General
Brand
Kaliburn
Model
Spirit150a
Category
Welding System
Language
English
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